Part 3 of 3
The process of transforming the cacao bean into mouth-watering chocolate is as much a blend of art and science as coaxing a ripe, flavorful bean out of Mother Nature. The process is secretive to each manufacturer as this is how they keep a competitive edge. But generally speaking this is the basic process.
Once grown, picked, dried, culled, and packed in 130-200 lbs. jute, sisal or burlap bags, the cacao beans arrive from many countries on four continents at various ports. Quality control begins at the pier, with samples taken randomly from each lot for analysis. The principal test in the judging of cocoa beans is the cut test. After careful evaluation of the cocoa bean halves conclusions are made as to the degree of fermentation and flavor development of the raw cocoa. Additional analysis will include testing the beans for size (100 gram bean count), moisture, and foreign matter. If all of the test results are within the specifications, delivery is accepted and the beans are shipped to the chocolate plant. Upon arrival at the plant, samples are taken and retested for comparison with the pre-shipment test results. A small test batch of chocolate is made and tasted before final approval is granted for the lot of beans to be used in manufacturing.
Only after the final approval does the manufacturing process begin. The beans are dumped onto a grate and go through a series of screening steps to remove foreign matter such as stones, twigs, pod fragments, sack threads, dust, etc. They are scanned by an electro-magnet to remove any metallic particles. Each type of bean, because of varying size, is roasted individually to ensure uniformity.
Roasting is done slowly in continuous roasters for approximately 30 minutes at temperatures ranging from 100° F to 150° F, depending upon the bean. During the process, the heat swells the bean, bursting the shell.
The roasted cacao bean then goes into a winnowing machine, where it is cracked into small pieces and the fragments of shell removed. The husked and winnowed beans are now called “nibs.” It is at this point in the process that the nibs of many varieties are blended. It is a test of the chocolate maker’s skill to achieve the subtle (and secret) mixtures that ensure the quality and flavor consistency that are the hallmarks of each manufactor’s product.
The roasted nibs undergo a grinding process and then pass through mills, which transform them into a fine paste. The heat generated by the friction of the milling process melts the cocoa butter in the paste, constituting 50-60 percent of the bean, and produces a thick, liquid mixture called chocolate liquor.
From here the process becomes even more secretive as each manufacturer has their own precise process to yield exactly the type of chocolate they are famous for.
