Believe it or not, your favourite candy bar started out as a fruit. More specifically, it began as a cocoa pod, the fruit of the cacao tree. Cultivated only in countries located within 20 degrees north or south of the equator, Theobroma cacoa is a tropical plant that thrives in rainy climates. Because it needs protection from the sun adn wind, the cacao tree is generally planted under as canopy of leafy, taller trees such as banana trees and stands between 15 and 25 feet (4.6 and 7.6 m) tall at maturity The oval pods that become the cocoa bean start off as pink and white flowers that grow from the branches of the tree. A mature tree is covered in thousands of flowers, but only about 10 percent of these will develop into mature fruit for harvesting.
Harvesting
Nearly all of the world's cocoa supply is grown on small family farms and harvested by and. Pods ripen throughout the year. allowing for a continuous growing cycle. Experienced farmers select the cacao pods that are ready for harvesting and cut them away from the tree, using a machete or a long pole knife. Machete are also used to prune the trees, keeping them healthy and productive and reducing the need pods are split open. Mature pods contain forty to fifty light yellow seeds.
Fermentation
The seeds, contained in a gelatinous, pod, placed in wooden crates, covered with banana leaves or other leafy greens specific to the region, and allowed to ferment for up to five days. During fermentation, the flavor of the seeds begins to develop, the bitterness subsides, and the seeds become a rich brown colour. The cacao seeds are now referred to as cocoa beans.
Drying
The process of drying the cocoa beans takes place either on the farm or at a processing plant. The fermented beans are spread out onto mats and turned frequently during the next five to seven days. The dried cocoa beans, now known as raw cocoa, are bagged, taken to market, and shipped to manufacturers worldwide.
Destoning and Cleaning
Upon arrival at its specific factory, the raw cocoa is inspected and tested for bacteria and other noncocoa particles. It is then cleaned and blended to create specific flavor characteristics before going into the roaster.
Roasting
Roasting, a crucial part of chocolate making, takes place in large rotationg cylinders. Chocolate manufacturers vary on how long they roast their beans. Some roast at a lower temperature for a longer amount of time, while others use higher temperatures for a shorter time. Generally speaking, roasting can take between thirty minutes and two hours. Carefully controlled heat turns the beans a deep brown colour and allows the characteristic chocolate aroma to develop. After roasting, the raw cocoa goes to the cracker and fanner. Using high force, the cracker throws the beans against the inside wall of the machine to crack off the shell. A fan then blows the bean one way and the shell. or husk, another. The husks are no longer needed for chocolate production and are either thrown out or sold to farmers for compost. The cracked beans are now called cocoa nibs.
Nib Roasting
Like many of the steps that go into manufacturing chocolate, each company roasts their nibs differently. Cocoa nibs can be roasted with or without their shells. The process fo roasting nibs without their shells is known as nib roasting. This process is not ideal because the bean particles are often not the same size, so smaller particles burn before the rest of the batch is fully roasted. and may give off a burnt flavor to the chocolate.
Grinding
A series for heavy steel rollers or grinding stones crush and liquefy the cocoa nibs into a shiny brown liquid called chocolate liquor (even though it does not contain any alcohol). At this point the chocolate liquor is either made into cocoa powder or turned into eating chocolate.
Cocoa Powder
Cocoa powder is created when chocolate liquor is pumped into giant hydraulic presses whose intense pressure forces out the cocoa butter. which is then removed by filters. The remaining pressed cake is cooled, further pulverized, and then sifted into cocoa powder.
Conching
This flavor-development process is the next crucial step in making eating chocolate, and can vary in length of time from manufacturer to macufacturer. At this point, cocoa butter is also added. Conching can last from several hours to several days, depending on the desired outcome. During this step, heavy rollers continuously knead the mixture, developing complex flavors and creating a smooth texture; most chocolate manufacturers conch their chocolate between ten and seventy hours. After conching, the mixture is cooled and tempered before being deposited into molds or blocks, or formed into chips or drops. After a quick trip through a cooling tunnel, the solid chocolate is packaged and shipped to a distributor or gourmet store for use and resale.
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