The Insane Process of How Chocolate Is Actually Made

1. Finding the right climate for cocoa

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Before cocoa growing can get underway, the first step is the find a suitable place to plant cacao. Cacao, also known as Theobroma Cacao, is the plant that produces cocoa beans, and is a native plant of South America. However, it can also be cultivated in tropical countries like Ghana, Cameroon and Nigeria. In fact, these African countries are now some of the highest producers of cacao, and account for 70% of the world’s cocoa beans. Cacao plants need plenty of high humidity and rainfall to thrive, and will tend to do best when they’re given some shade.

2. Clearing land for cacao plants

The best way to prepare land for high-yielding cocoa is to clear land between December and February in tropical climates, as this avoids the rainy season. Cocoa growers will usually remove a few trees during this process, but will be selective about which ones they get rid of. Some trees can harbour what’s known as ‘the cocoa swollen root shoot virus’, so they will need to be chopped down asap. But as cacao plants thrive in shade, they will rely on trees to provide a sanctuary for them as they grow.

3.  Selecting different types of cocoa beans

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The general consensus among chocolate producers is that there are three different types of Theobroma Cacao.

That being said, there are actually over ten varieties of cacao, but only three are usually used in chocolate production, which all thrive in the equatorial region. Criollo are the original cocoa plants that were first found in the Amazon basin, so they’re considered the highest quality ones. However, they only make up 1-2% of the world’s cocoa production. The other varieties include Forastero, which is a super hardy breed of cocoa, and makes up the bulk of cocoa production. There’s also Trinitario, which has a deep and complex flavor.

4. Planting cacao

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Once growers have selected which breeds of cacao plants they want to use, they get to work with planting. Producers need seeds that are still in their pod, or have been kept moist since they’ve been removed from the pod. The seeds won’t go if they’ve already dried out. The seeds are placed vertically in the ground, and are covered with soil just to the top of the seed, and should start to sprout in around 5-10 days. Cacao plants only flower at 4-6 years old when they’re around 5 feet tall, and it then takes 5-6 months for the cacao pods to ripen from the flowers.

5. Harvesting

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Once the cocoa pods have ripened, they can then be harvested. And while many crops are cultivated using machinery and equipment, cocoa harvesting is actually done by hand even today. This is because these plants need to be treated with care to ensure the bark of the tree isn’t damaged in any way. If the tree does become damaged, it can end up limiting the number of flowers the tree can produce in the future. When the pods are collected and harvested, they are then cut open to remove the beans and the pulp from the inside. Each cocoa pod typically holds around 30 to 50 cocoa beans.

6. Fermentation

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The fermentation process basically involves exposing the beans and pulp to oxygen, which means they start to ferment as soon as the oxygen hits them. This is super important because the oxygen breaks down the tough coating of the beans. It also kills germs and bacteria too. And just like beer and wine, the fermentation process with cocoa beans is critical in developing flavor! Cocoa producers typically place the beans and the pulp in large fermentation boxes for around 5 to 8 days, and are turned and mixed every couple of days or so.

7. Drying

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When the cocoa has finished fermenting, the beans contain a pretty high level of moisture, so the beans need to be dried out to stop them from fermenting any further. Most cacao farmers decide to lie the cocoa beans out in the sun to dry for several days. And just like in the fermentation process, the beans are turned regularly. This is to ensure they dry evenly. However, in wetter climates, or during rainy season, this isn’t possible, so farmers use alternative methods. For example, in the likes of Papua New Guinea, the beans are dried out on open fires, which gives them a unique, smoky flavor.

8. Bagging

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When the cocoa beans are finally dry, they will then be bagged up in sacks by the cacao plant producers. These sacks need to be airtight to ensure the cocoa stays fresh and dry during transit. These sacks also stop spillages, and ensure no nasty bugs or rodents get into the sacks and spoil the beans. The sacks and liner bags are much more cost-effective for cocoa producers too! They are then put in containers, which are kept at a water content level of 12%. This ensures the cocoa cargo doesn’t let in any damp.

9. Shipping

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Shipping cocoa beans can sometimes be a delicate process. When it comes to handling the sacks, it’s really important that cargo handlers don’t use any hooks during the freight forwarding process, as this could cause serious damage to the sacks of cocoa. Weather can also play a part in the freight forward process, as the cocoa beans need to be protected from moisture at all times. This ensures no mold grows in the sacks. When in their shipment, the bags of cocoa are stored in a cool, dry place with good ventilation.

10. Roasting

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When the cocoa beans have been bagged and shipped to chocolate makers, the real fun begins. Chocolate makers will roast the beans to give them a unique flavor, but before they can do so, they need to make sure the beans and clean. Small twigs, rocks and general debris will be removed from the bags, along with any beans that have gone moldy during transit. Only then are the beans roasted in huge ovens. The temperature and the length of time the beans spend in the oven will depend on their variety.

11. Winnowing

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Winnowing is the process that removes the thin, crusty outer shell of the beans from the cacao nibs inside. The nibs are the part of the cacao bean that’s essential for chocolate making, so they need to be carefully winnowed from their outer shells. These shells are separated from the nibs using subtle jets of air, which doesn’t cause any damage to the precious nibs. The shells of the beans aren’t discarded though; they can be used for other things like smooth cacao tea, as well as garden fertilizer!

12. Grinding

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The cacao nibs then need to be ground down with a machine called a mélangeur grinder. This grinder is made up of two big stone slabs that spin, which gradually grind down the cacao nibs. Nibs consist of both cocoa solids and cocoa butter, so they first turn into a super thick paste. However, as the machine continues to spin, the consistency of the nibs change. The cocoa butter in the nibs gradually melts, which makes the paste nice and smooth. Some chocolate producers will spin their machines for longer to create a creamy texture.

13. Extra ingredients

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When chocolate producers grind down the cocoa nibs, they also begin to add their chosen ingredients to the paste. These ingredients will typically consist of sugar and milk powder, as well as vanilla (which can either be an extract or straight from the vanilla pod). However, some producers go the extra mile and even add more cocoa butter to their nib mix. This extra cocoa butter gives the chocolate a super creamy mouthfeel. This isn’t strictly necessary though; only the more luxurious chocolate producers tend to do this.

14. Conching

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The conching stage is the final point where the taste and texture of the chocolate are determined. But not every chocolate producer will follow this particular process; it’s usually reserved for gourmet chocolate companies! Conching is a delicate process that involves rolling, kneading and heating the chocolate, as well as aeration. The ‘conch’ is just a large agitator that smooths and stirs the chocolate while it heats. This helps create a fine, luxurious consistency. Some producers will add yet more cocoa butter or soy lecithin at this point for more fluidity.

15. Cooling

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After chocolate producers have added their final few ingredients to the cocoa paste mix, they will check whether they are happy with the taste and consistency before allowing the chocolate to cool. The mixture is poured into large containers or molds to reduce temperature and develop in taste. Some chocolate producers actually let their chocolate cool and age for weeks, as this creates a deeper, richer flavor. Again, this is something that’s generally practiced by the more luxurious chocolate makers on the market.

16. Setting

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The large containers and molds used by chocolate producers also set the chocolate mix, ensuring the mix is ready to be tempered. Some of the largest mass-produced chocolate makers generally set their chocolate between two and eight days depending on the cocoa bean variety, while smaller, gourmet-style producers can leave their chocolate to set for much longer to develop even more flavor and richness. The texture of the chocolate at this stage isn’t great though; it’s crumbly, and dull, and lacks that sharp snap that you find with your chocolate bars.

17. Tempering

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Tempering chocolate basically means slowly raising and lowering the temperature of the chocolate to alter all of the fatty acids and crystals inside it. It’s been traditionally done by hand for centuries, but the biggest chocolate producers will naturally use machines to do this. Not only can machines temper higher volumes of chocolate, but they can also do it much more quickly too. This process makes the chocolate nice and smooth, and transforms the texture from dull and crumbly to sharp and shiny.

18. Molding

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After the chocolate has been tempered, it’s ready to be molded into specific shapes. Some of the biggest chocolate companies will create everything from bars and blocks to individual chocolates and ‘buttons’. The molds will be shaken or tapped against a hard surface by assembly line workers to remove the air bubbles from the chocolate. The molds are then allowed to cool and set. As they cool, the chocolate solidifies, and has a shiny, glossy look. Chocolate makers will carry out one final quality control inspection on the chocolate before it’s ready to be wrapped.

19. Wrapping

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The chocolate will then be wrapped and ready to be sold at a store near you! While some companies (including independent gourmet chocolate producers) will wrap chocolate by hand on the assembly line, the vast majority of global chocolate makers will use machines to make this process quicker and easier. Most chocolates will be placed in an airtight foil wrapper or bags to keep the chocolate fresher and richer for longer, but some suppliers will use cardboard boxes, which are then wrapped into plastic.

20. Distribution

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When the chocolate has been wrapped and spot-checked, it’s then packed up and shipped to stores across the globe. Large chocolate companies will tend to have a fair few distribution strategies in place, and will sometimes partner with specific supermarkets and vending machine companies. Regardless though, there’s an army of people quietly working behind the scenes to deliver your favorite chocolate to your local store – which is definitely something to think about when you bite into your next bar!

Ten cool facts about chocolate... It's national chocolate day on July 7

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Did you know that July 7 is National Chocolate Day? Yes, really! This is to commemorate the day that chocolate treats were originally distributed across the world, which happened way back in 1550. While we don’t think we need a specific occasion to tuck into our all-time favorite chocolate bars, it’s quite a nice opportunity to have a special day in chocolate history to look back on. However, if you’re a serious chocoholic, you might well think that every day is National Chocolate Day (us included).

Switzerland eats more chocolate than any other country

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The most hardcore chocolate fans in the world belong to Switzerland – a country renowned for its high-quality chocolate production. The Swiss have been shown to regularly eat more chocolate than any other country, which is an impressive feat! While global chocolate consumption is estimated at around 7.5 million tons of chocolate per year, Switzerland has ranked highest per capita with 8.8 kilos of chocolate consumption per person. The United States has been estimated to eat 4.4 kilograms per person, and ranks 19th

in the world for chocolate consumption.

Hershey’s made their first million producing caramel candies

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The chocolate brand we know and love today almost never happened. Back in 1886, Milton S. Hershey had opened an unsuccessful confectionary business. He was broke, but decided to give things one last try before he went bankrupt. He somehow managed to secure a loan from the Lancaster National Bank to fund a huge order of “Hershey’s Crystal A” caramel candy, which had come from a popular English candy importer. As he gained confidence and cash, he decided to pivot into chocolate after he visited a world chocolate fair in Chicago – and the rest is history!

The first chocolate consumed was hot chocolate

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It took a long time for chocolate to be turned into bars. Chocolate was originally consumed as a bitter drink by ancient Mayan people in South America in 1500BC, which is around 1,500 years earlier than previously thought. Mayans typically worshipped xocolatl (a kind of bitter water) made with crushed cocoa, cornmeal and lashings of chili pepper. The cocoa was mixed into a thick paste after the cocoa beans were fermented, cured and roasted. The Mayan people also added botanicals to this drink for special occasions.

Milk chocolate comes from Jamaica

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Did you know that milk chocolate comes from Jamaica? The official discovery of milk chocolate is credited to a guy called Hans Sloane, who decided to sail from England to a British-owned colony in Jamaica in 1687. He was a physician, and spent his time during his 15-month stay at the colony observing locals. He saw they were consuming a milk chocolate drink, and quizzed them about how they made it. History tells us that Jamaicans have been making milky hot chocolate from as early as 1494, and have used everything from oat to cow milk.

Milk chocolate bars were created by Nestle

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While milk chocolate originally came from Jamaica, it was confectionery conglomerate Nestle that made the first-ever milk chocolate bar. A guy called Daniel Peter was trying to create a process that allowed him to mix milk into a chocolate bar back in 1857, but he had a lot of problems with getting rid of water from the milk. So he asked his neighbor for help – who happened to be Henri Nestle. Henri helped him create a milk condensation technique that made powdered milk, and Daniel Peter launched his milk chocolate bar seven years later.

White chocolate isn't real chocolate

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White chocolate can’t legally be declared chocolate. While it’s generally thought of as the third variety of chocolate after dark and milk, it’s technically not a chocolate because it doesn’t contain any solid cocoa. Instead, it only contains cocoa butter, milk solids and additional sweeteners. And it’s these sweeteners that give it such a distinct taste. It’s also worth bearing in mind that natural white chocolate isn’t actually white, because cocoa butter has a creamy, almost yellowish color. If you do come across chocolate that is completely white, then you can guarantee it’s got food coloring in it.

A pinch of salt enhances the flavor of chocolate

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It might be a bit of a new trend where chocolate’s concerned, but adding a teeny tiny amount of salt to your chocolate has been found to improve taste. Salt is really good at neutralizing any bitterness in chocolate (especially in dark chocolate) and can emphasize the sweeter notes that are found in cocoa. It’s also good at adding a little bit of crunch and texture to smooth chocolate, which adds to the sensory experience. You’ll usually find salted chocolate from more gourmet chocolate producers.

It's thought to contain the 'love' molecule

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Studies are still been carried out, but scientists believe that chocolate can promote chemicals in the brain that are similar to those produced when we fall in love. To put it in basic terms, chocolate contains the compound phenylethylamine, which can also be found in cannabis. Phenylethylamine has been found to improve your mood and ability to pay attention, and produce feelings of euphoria in some cases. It’s also thought to have antidepressant effects. However, more tests still need to be carried out to investigate this further.

One pound of chocolate contains 400 cacao beans

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While this can depend on the type of cacao plant, one single fruit can hold 20-30 beans on average. But as one pound of chocolate needs a whopping 400 beans, you can see why so much land is needed to meet demand. Over the course of a year, a cacao plant can bear 50,000 to 100,000 cacao blossoms, but just 10-30% of these blossoms will actually develop into fruit. Farming these plants is also fairly labor intensive, so chocolate producers are trying to find new ways to make this process a lot easier.