How Its Made - Chocolate

8/9/2019 How Its Made - Chocolate

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INSTITUT PENDIDIKAN GURU

KAMPUS DATO RAZALI ISMAIL

KUALA TERENGGANU

TERENGGANU

Prepared by :


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Fermentation

Fermenting and drying are the first crucial

steps in transforming cacao beans

into the flavor of chocolate as we know it.

After harvesting, the cacao pod

fruits are cut open and the beans(technically seeds) are scooped out.

Covered with a delicious, sweet whitish

pulp, the cacao beans are placed

in large, wooden boxes or, in the case of

Ghana (origin of our Chocolatey)

and much of West Africa, the wet cacao is

heaped in piles and covered with banana

leaves.

STEP 1 : FERMENTING

HOW ITS MADE

Chocolate


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Once the fermentation is complete, the

cacao beans have little or no pulp left on

them. The beans are transferred to

expansive cement patios or elevated

wooden or bamboo beds to be dried in

the sun. Constant turning by rake or byhand ensures even drying throughout. On

larger plantations, or at cooperatives,

during inclement weather beans can be

dried using artificial gas driers. In terms of

optimum flavor development, artificial

drying is never as good as slow sun drying

and great care must be taken.

STEP 2 : DYING

HOW ITS MADE

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Proper roasting is vital to crafting great

tasting chocolate. Different temperatures

and roast times bring out different flavors

and characteristics in the cacao. We have

to pay extraordinary attention to our

roasts. Unlike coffee, which roasts at

relatively high temperatures anywhere

from 400-460 F cacao beans need moregentle treatment. Cacao beans can be

roasted at 250 to 350 degrees for thirty

minutes to two hours depending on the

variety of cacao. Generally speaking, the

milder criollo beans are roasted at a lower

temperature than the stronger-tasting

forestero and trinitario cacao varieties.

STEP 3 : ROASTING

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After roasting, the beans are transferred to

a winnower that removes the shells of

the beans and leaves the nibsthe

essence of the cacao bean thats full of

cocoa solids and cocoa butter. The roasted

beans are first cracked open, then vibrated

in large vibrating machines and set over a

series of flat screens that haveprogressively smaller openings, so the

larger pieces of shell and debris are

removed, while the just nibs are collected

for the next step in the process.

After winnowing, the nibs are transferred

to the mlangeur or grinder, where they

are ground to a thick, rich paste called

chocolate liquor.

STEP 4 : WINNOWING

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After winnowing, the freshly roasted cacao

nibs are transformed into a liquid state

through a series of grinding steps utilizing

gentle heat and pressure. The resultingunsweetened liquid is commonly called

"cocoa mass" or "cocoa liquor" (although it

does not contain alcohol). The cocoa liquor

is then poured and cooled into block forms

for shipping, soon to become the core

ingredient of chocolate.

STEP 5 : GRINDING

HOW ITS MADE

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Here, the cocoa liquor (made from grinding

the nibs) is pumped in and mixed with

other all-natural ingredients : cane sugar,

cocoa butter, vanilla beans, and lecithin.

Depending on the raw materials, refining

can take 4-12 hours. Using the powerful

shear forces of the MacIntyres numerous

hardened steel blades, we refine these

ingredients until we reach a particle size of

about 16-18 microns. In addition to intense

pressure, heating and cooling cycles inside

the MacIntyre also help impact the finalproduct.

STEP 6 : REFINING

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Conching is a crucial step in making fine

quality chocolate. During this step, the

blended ingredients are agitated in a

folding or wave motion by a machine for

several hours or even days. This removes

excess moisture and astringency while

volatilizing certain undesirable organicacids that still remain from the

fermentation process. When done

properly, conching fully evolves the desired

flavors of the beans. The refined and

blended chocolate mass is kept in a liquid

state by frictional heat. During the

conching process, the fully refined particles

become evenly distributed, improving the

flow properties of the liquid chocolate.

STEP 7 : CONCHING

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There are three main components involved

with the tempering process: time,

temperature, and agitation. The best

quality chocolate begins by heating the

cacao to about 118 degrees Fahrenheit.

After the initial heat the chocolate is then

slightly cooled so that cacao crystals beginto form. While still being agitated the

temperature is increased a second time to

capture the most desirable crystal

formations that create the smooth surface

of the chocolate bar. The ideal crystals are

those that fit tightly together and disperse

flavors evenly. If the chocolate develops

the expected glossy finish and snap, its

properly tempered and ready for the next

stage.

STEP 8 : TEMPERING

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After the tempering process is completed,

the warm, molten chocolate is depositedinto molds to form signature square bars.

The molds run under the depositor in an

assembly line fashion. After depositing,

vibration in the assembly line helps work

out the air bubbles in the chocolate as the

chocolate settles into its future shape.Next, the mechanized conveyor belt brings

the molded chocolate through a cooling

tunnel, where the chocolate cools and

hardens. Depending on the size of the

chocolate bar being molded, the cooling

cycle takes between 20 minutes and two

hours. After cooling, the conveyor belt

moves the chocolate through a de-molding

mechanism that flips the bars out of their

molds. Now the bars are ready to be

wrapped.

STE 9 : L I

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After chocolate bars come off the molding

line and go through de-molding, the bars

are transferred to racks where theyre held

until being fed through the wrapping

machine. There are two wrapping

machines; one for 5g and 8g bars and theother is the 58g bar. Usually this machines

were imported from Europe. To wrap 58g

bars they are first machine-wrapped in

paper-backed foil then placed in a

paperboard carton. The 5g and 8g bars are

wrapped in die-fold process, whichcombines the foil with the paper wrapper

to complete wrapping simultaneously.

STEP 10 : WRAPPING

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HOW ITS MADE

Variety of Chocolate

Baby Chocolate

Variety of

Chocolate

F1 Chocolate

Hot Chocolate


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HOW ITS MADE

Variety of Chocolate

Keyboard

Chocolate

House

Chocolate

Chocolate

Fountain

Shoes

Chocolate


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How Its Made - Chocolate