How is chocolate made

How Exactly Is Chocolate Made?

Chocolate is enjoyed by millions of people around the world. But how many stop to consider how chocolate is made?

If you were ever considering of becoming a chocolate master yourself, you’re going to love learning all about the cocoa bean’s journey from plant to your palate.

How chocolate is made (step by step)

The whole process starts with the cocoa beans themselves. Their journey to your mouth begins with the Theobroma cacao tree.

These are small trees, around 4-8 meters tall, of the family Malvaceae that are native to the deep tropical regions of Mexico. They have been extensively harvested in Mesoamerica since antiquity with evidence of cacao residues found in artifacts dating back to the Early Formative period (1900-900 BC).

The beans are contained within pods, an oval-shaped fruit, that is around 5-12 inches (13-30 cm) long. Each pod contains anywhere between 30 and 50 beans. Each bean is roughly the size of a typical olive.

A little off-topic, but do you know what the difference between cocoa and cacao is? Well.

The process begins with collecting the beans

Today, just like then, the beans first need to be collected. Cocoa beans are contained within large seed pods that, once ripe, are readily harvested.

Unripe pods tend to yield beans with low cocoa butter content and low sugar content. This is very important for the creation of chocolate as the natural sugars within cocoa beans help fuel the fermentation process later down the line.

How is chocolate fermented?

In their natural state, cocoa beans are quite bitter to the taste. This is removed by fermenting the beans to give chocolate its highly desirable flavor.

Fermentation, like with alcohol, is achieved using natural yeast and bacteria that are already present in the beans. The process is fairly simple with the beans being allowed to ferment naturally in a warm and moist environment for about seven days.

Once the fermentation process is complete, the beans are removed and allowed to dry out to prevent mold growth and rot.

Next, the beans must be roasted

Once desiccated, the beans are thoroughly cleaned and any contaminants like sticks, stones or other debris are removed. The beans are then roasted typically using a dry roast method.

The beans are constantly stirred to ensure that the entire crop is evenly heated. No extra oils or fats are added which preserves the cocoa beans flavor.

Once complete, the classic flavor we all know and love about chocolate is achieved and ready to be processed.

Once roasted, the beans can be processed

With the beans nicely, and evenly roasted, the beans then have their hull and inner nibs removed. This is usually achieved through cracking and winnowing (deshelling).

The hull is a thin, papery skin that surrounds the whole cocoa bean. Nibs, on the other hand, are simply small pieces of the cocoa bean body that are broken up during the winnowing process.

These nibs are then ground into a fine powder that is rich in cocoa solids and cocoa butter. The butter usually liquifies from the frictional heat while the nibs are ground.

The resultant cocoa liquor is then poured into molds and allowed to cool. Once solidified, the chocolate is almost ready to be eaten.

But there is one final step required prior to chocolate arriving at the shop’s shelves.

The final step is to blend the chocolate

While baker’s or unsweetened chocolate can be used as-is, most confectionary requires some form of blending.

The production of chocolate candies, that you are obviously very familiar with, requires cocoa liquor to be combined with extra cocoa butter, sugar, milk, emulsifiers and/or stabilizers and other ingredients like vanilla. These ingredients add extra smoothness and sweetness to the chocolate.

The amount of sugar and milk added to the cocoa creates different degrees of chocolate from milk to dark chocolate. Each chocolate brand will also have its own ingredients and ingredient ratios that determine its specific signature recipes too.

Interestingly, for something to be actually considered chocolate, it must be made with real cocoa liquor. If it contains hydrogenated vegetable oils, milk substitutes, or artificial flavors, the United States Department of Agriculture (USDA) does not allow companies to call it chocolate.

Chocolate is also not the only use of cocoa beans. They can, and often are, used to make a variety of savory dishes as well as many skin products.

Another fun fact is that Cocoa beans were also used as currency for a time by the Aztecs who believed they were a gift from the «God of Wisdom» Quetzalcoatl. I mean, who can blame them?

Is chocolate made from hair?

You may not have heard of this rumor, but there appear to be people who actually believe, or spread it. The confusion over the issue may have arisen due to the presumed presence of L-C ysteine (E-920) in some chocolate products.

The problem is, as we have seen, that human hair is not used, or required, during any part of the chocolate-making process. It could, in theory, be added by confectioners during the blending process but this is usually forbidden by many food standards agencies around the world.

It is not, for example, listed on the Codex General Standard for Food Additive (GSFA) of permissible levels of food additives in various food groups.

Still, it is possible that some human or other animal hair can find its way into a batch of chocolate by accident, but this is very rare. In fact, contamination of any food product is nye on impossible to avoid.

For this reason, many food standard agencies have tolerance levels for maximum amounts of contaminants in many food groups.

Where exactly this myth originated from is anybody’s guess, but rest assured your favorite chocolate bar has undergone various stages of careful and thorough preparation. After all, the last thing a chocolate producer would ever want is the bad press associated with defective products.

They could also face serious legal actions by authorities and consumers.

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How is chocolate made? From bean to bar…

Ever wondered, “how is chocolate made?” Let’s pick up with the arrival of the cacao beans at the factory (or click here to learn about how cacao is grown).

At the factory, the cacao beans are first sifted for foreign objects- you know, rocks, machetes, whatever got left in the bag. The cacao is weighed and sorted by type so that the manufacturer knows exactly what type of cacao is going into the chocolate. Some manufacturers use up to twelve types of cacao in their recipes, and they must carefully measure so that the flavor is consistent time after time.

Next, the cacao beans are roasted in large, rotating ovens, at temperatures of about 210-290F. Roasting lasts from half an hour up to two hours. The heat brings out more flavor and aroma, and it dries and darkens the beans.

Then the cacao beans are cracked and winnowed, that is, their outer shells are cracked and blown away, leaving the crushed and broken pieces of cacao beans, called “nibs.” At this point, we have something edible and really chocolatey, but they’re also really bitter. You might try some cacao nibs on a salad. Mmm.

But how is chocolate made? We’ve gone through all these steps and we still don’t have a chocolate bar! Be patient, it can take up to a week!

The cacao nibs must now be crushed and ground into a thick paste called chocolate liquor (there is no alcohol in it). What happens next, though, depends on what type of chocolate we’re making.

Let’s pretend that in addition to knowing, “how is chocolate made?” you also want to know how cocoa is made. Say the manufacturer divides our chocolate liquor in two. We’ll make cocoa with half, and use the other half to make some chocolate bars.

To make cocoa, the powdery stuff you mix up into hot chocolate, the cocoa liquor is slammed by a giant hydraulic press. This removes much of the fat, or cocoa butter. The cocoa butter will be used in making chocolate, but it is also used in cosmetics and medicines. What’s left of the slammed chocolate liquor is very dry and can be ground into cocoa.

Now, on to the chocolate, which we’ll make with the other half of our chocolate liquor. Chocolate liquor by itself is bitter and not very smooth and creamy. To sweeten it up and improve the texture, the manufacturer will add things like sugar, cocoa butter, vanilla, and milk.

You could eat this now, and it would taste pretty good, but it wouldn’t have the texture you associate with a chocolate bar, and you still wouldn’t be able to answer the question, “how is chocolate made?” The cacao and the sugar are still pretty grainy at this point, so the manufacturer runs the mixture through a series of steel rollers to refine the texture.

To further refine the texture, and to really bring out the flavor, the mixture is then “conched.” That is, it’s run through a chocolate making machine (a conch – so named because the first such machine looked kind of like a conch shell) that mixes and mashes and swirls and aerates the chocolate. At this point we will probably add some more cocoa butter and maybe some soy lecithin – these will give the chocolate its silky smooth texture. Conching can last a few hours for cheaper chocolates, and up to six days for the expensive stuff!

The chocolate is then tempered by stirring it, letting it cool, heating it back up slowly, and repeating the process several times. This will give our chocolate that nice glossy look, and it will help it melt properly.

Finally, we have chocolate! Some people might use the liquid chocolate in candies or cookies or ice cream, but let’s pour our lovely mixture into a mold (how about in the shape of a bunny rabbit?), let it harden, then chomp its ears off!

Mmmm! You are now a chocolate smarty-pants.

How is chocolate made

As a chocolate lover, you already know that chocolate comes from the cocoa bean. Perhaps you’ve read our guide to cocoa plants and you know all about the ideal climate, different cocoa varieties and the fascinating non-edible uses of cocoa beans. But do you really know how that reddish-yellow fruit dangling from a tree in some tropical country turns into the delicious bar of chocolate you’ve got stashed in your cupboard?

At Hotel Chocolat, we directly grow some of our beans ourselves on our St Lucia plantation, so we know the intricacies of every step of how chocolate is made, from bean to bar – or, as we like to put it – from roots to wrapper. In this blog, we explain each step of the chocolate making process, and how it affects the end flavour of the chocolate you eat.

1. Harvesting

Cocoa plants don’t just bear fruit once a year; instead they can produce fruit intermittently. The main harvesting periods coincide with the rainy seasons of that country, so Colombian beans are often harvested in November and April, whereas the Ghanain cocoa bean harvest will depend on where you are in the country.

However, in some climates, including in the Amazon basin, cocoa beans can be harvested at any time of year. This process is always done by hand, as the beans must be harvested without harming the flower buds, immature cocoa pods or stem area, which could damage the cocoa plant.

The cocoa pods are deemed ripe according to their colour – which can be anywhere from red to yellow depending on the type of cocoa plant. Once the beans are harvested, our cocoa farmers cut the pods open and scoop out the beans inside, which are encased in a white, sweet pulp.

2. Fermentation

The second stage involves putting these beans – still covered in their sticky fruit – in piles and covering them with banana leaves. The warm tropical temperatures cause the pulp to break down yeast in the air and turn into alcohol. Then, the beans are mixed gently to expose the beans to oxygen, which then breaks the alcohol down into acetic and lactic acid.

The liquid drains away and you are left with a pile of cocoa beans that have plumped up due to the moisture in the environment, and whose bitter flavours have been tempered by the acid. This can take up to eight days and is the first stage of developing the well-known chocolate flavours from the naturally bitter, hard cocoa bean.

3. Drying

To dry the beans, our cocoa farmers spread them out in a single layer and dry them naturally in the sun – depending on the weather, this takes around seven days. This makes sure that there is no more moisture in the beans, which is important as after this stage they are transported to the UK, where we finish the chocolate-making process. We always transport our beans by sea freight, rather than air, because it has a smaller carbon footprint. Our Engaged Ethics programme means we work to be as environmentally sustainable as possible, in every aspect of our business.

Cocoa farmers in Ghana dry cocoa beans in the sun. Photo courtesy of Francesco Veronesi, Flickr.

4. Cleaning

Once the beans arrive with us at our factory, we run them through a cleaning machine, which gets rid of any remaining dried cocoa pulp or pod that might be attached. This ensures that the flavour isn’t impaired, as small impurities could burn during the roasting process.

5. Roasting

Roasting is one of the most important stages to help bring out the flavour in the cocoa beans. To develop the characteristic cocoa aroma, we rely on our in-depth knowledge of the cocoa beans we use; each type of bean needs a different temperature and a different duration of roasting. We roll the beans over constantly during roasting so that they develop a rich colour and start giving off a delectable chocolatey smell!

6. Shell removal

Once the roasting process has finished, it’s time to remove the bean’s thin outer shell. Roasting makes them brittle, so when we pass the beans through a winnowing machine, they easily crack open.

Cocoa shells after the winnowing process. Photo courtesy of PSNH

The outer shell is lighter than the beans, so we can use fans to blow them away and separate them from the beans themselves. What’s left are the cocoa nibs, which we use to make our chocolate. However, they can be enjoyed in their own natural right: our cocoa nibs can be enjoyed sprinkled on top of foods for a fruity crunch, mixed into homemade granola or stirred into chilli con carne for a deep cocoa taste.

We are committed to minimising our waste, which is why we even use the discarded cocoa shells in our beauty products, or distil them into drinks like our Cocoa Gin or Cocoa beer.

Before the next step, we mix the nibs according to the flavour we want to achieve; smooth and mellow like our 40% milk chocolate, or rich and fruity like our Supermilk. For our Single Origin chocolates we just use one type of cocoa bean grown in a particular region, so you can taste how a single climate and plant variety creates a unique flavour.

7. Grinding

We process our cocoa nibs by grinding them continuously between two discs until they break down into small pieces and form a paste. Because of the naturally occurring fats in the product, it forms a paste rather than a powder in the same way that grinding peanuts turns into peanut butter rather than dry peanut flour.

Cocoa nibs are just over 53% cocoa butter, and the friction of grinding heats the mixture up, causing the cocoa butter to melt and turn the mixture into a paste, called chocolate liquor. This chocolate liquor can be poured into moulds at this stage and be sold as unsweetened, bitter chocolate – but we think it tastes a lot better after a couple more stages!

8. Separating the cocoa butter from the cocoa.

Cocoa butter is an important part of the chocolate-making process, but we separate it from the cocoa so we can have more control over how much we add to each chocolate bar, as well as using it for our white chocolate.

Using a hydraulic press, we subject the chocolate liquor to large amounts of pressure, which squeezes out the cocoa butter. At this stage it is still melted, so it drains away as a yellow liquid which is then collected and filtered for later use.

Cocoa butter is what makes chocolate melt; solid at room temperature but with a melting point between 34 and 37℃, it means chocolate melts perfectly on the tongue. When tempered correctly, the cocoa butter also gives the chocolate its lustrous shine.

After pressing, we are left with compacted cocoa beans. We can go two ways with this; either we start making chocolate by adding ingredients directly to the compacted chocolate liquor, or we can grind it down further to make cocoa powder. The grinding is important as we need to get the cocoa into miniscule pieces so that they make sumptuously smooth hot chocolate!

9. Adding to the chocolate liquor

This is where we’re going to get a bit vague – we don’t want to give away our secrets! The recipe varies for each chocolate that we make.

For milk chocolate, we add milk powder, sugar and cocoa butter. We use various amounts depending on which chocolate we make, from our classic 40% milk, our not-too-sweet 50%, or our revolutionary cocoa-rich but still creamy 65% Supermilk chocolate.

For dark chocolate, we skip the milk and up the cocoa butter content a little, depending on the percentage of cocoa we’re using. For a strong 90% we add very little sugar, relying on the natural mellow flavours in our chosen cocoa beans and the cocoa butter to give it a well-rounded taste and a smooth melt. For a 70% chocolate, we use slightly more sugar for a rich but decadent treat.

We mix all of these ingredients thoroughly until they are completely blended, but the mixture is still a little gritty.

10. Conching

Conching is a word directly associated with chocolate-making, but what does it actually mean? It’s the process used to turn the tasty-but-grainy mixture into delectably smooth melted chocolate. Conching is important because it affects the flavour in different ways.

First of all, we pour the mixture into our conching machines. These basically consist of heavy metal rollers that roll over and over through the chocolate mixture, and this process can take anywhere from a couple of hours to a few days depending on the type of chocolate we’re making. The longer it is conched for, the smoother the chocolate will be!

Depending on the speed and the temperature of the conching, the process aerates the chocolate; by exposing the mixture to more oxygen it forces the beans to expel volatile acids. This can help reduce any remaining bitterness in the chocolate.

At this stage, we add more cocoa butter and an emulsifier, like lecithin. This helps the fat of the cocoa butter and the other solid ingredients to blend together in a stable way. Without an emulsifier, the chocolate is much more volatile and prone to chocolate bloom, which is where cocoa butter melts separately to the chocolate mixture, leaving white streaks on the chocolate.

The constant blending causes cocoa butter to encase each of the tiny particles (of sugar, cocoa, milk powder and any other ingredients). Our chocolate has such a smooth melt as each solid particle is wrapped in a cocoa butter casing, too small to see but a delight to taste.

11. Tempering the chocolate

Now we’ve got our melted chocolate! But, if we just poured it into moulds or used it in our chocolates now, it would be a disappointment. The chocolate would be matte and crumbly, and wouldn’t melt as smoothly as you’re used to from our products.

Tempering chocolate is what gives it its satisfying snap and shine. We do it by slowly lowering and raising the temperature of the warm chocolate mix. This makes sure the cocoa butter crystals are exactly the right shape for a firm, shiny chocolate. Once it has been cooled to a stable temperature and is perfectly tempered, we start pouring our chocolate into moulds and start using it to create our chocolates.

After this, we transport our chocolates to our stores nationwide or ship them directly to your door.

12. The sky’s the limit

We use our chocolate in many different ways, from our classic chocolate bars to our truffles and pralines. Each new chocolate we create goes through a thorough four-step taste test with our chocolatiers and tasters to ensure that our flavours are perfectly balanced.

The creativity of our chocolate makers are such that not only do we take pride in making classic, smooth chocolate slabs, but we also love branching out into flavours you won’t find anywhere else. Our Mojito Selector or our Salted Espresso Martini Selectors are just a couple of our favourites, but we also developed a full patisserie selection of bite-sized desserts, like our award-winning Carrot Cake chocolate.

We also love to hear what you do with our chocolate! Whether you hide it from your family in a special cupboard, give it to a loved one, or melt it down and use it in baking, we want our chocolate to bring a smile to your face. Tag us on Instagram @hotelchocolat to show us where our chocolate takes you.

We hope this blog has given you a better understanding of how we make our chocolates. If you want to find out more about how to make chocolate, and even try your hand at making it yourself, have a look at our chocolate experiences, where you become the chocolatier!

How is chocolate made?

The delicious treat starts life as bitter cacao beans covered in a sweet, white pulp.

Chocolate is made from the beans of Theobroma cacao, a small evergreen tree native to the rainforests of Central and South America. Translating as ‘food of the Gods’ in Greek, its elongated pods grow up to 35cm and vary in colour from bright yellow to deep purple.

Today, cacao is grown commercially grown in the tropical zones around the equator where climate conditions are well suited for their finicky nature; high temperatures, plenty of rainfall and moist air, while the rainforest canopy provides shade and protection from the wind.

1. Growing

The Theobroma cacao tree bears flowers in small groups along the trunk and lower main branches. Once pollinated, these flowers develop into berries, called ‘pods’. The pods take around five or six months to mature and ripen, turning a yellowy-orange colour as they do so.

2. Splitting

The elongated pods are harvested by hand and split open to reveal between 20 to 60 oval beans arranged along the long axis in a sweet, white, mucilaginous pulp. This usually happens on the same day as they are harvested, or at least within a few days.

If you want to, you can eat the cacao beans raw. The beans themselves have an intense, bitter, somewhat earthy flavour, and are a purple-brown colour on the inside.

The white pulp that surrounds the beans has a very complex flavour: it’s much sweeter and fruitier, with a hint of citrus.

3. Fermenting

The pulp and the beans are scooped out of the pods, and the beans are separated from the placenta. Careful fermentation develops the flavour by microbial succession.

First, the yeasts react, then the lactic acid bacteria, and finally the acetic bacteria. The fermentation process essentially modifies the beans and eliminates the mucilage, changing the colour, taste and smell of the beans.

4. Drying

The beans are dried to remove the moisture content. Traditionally, this is done naturally by the Sun, and the drying process continues to develop the flavour. Drying the beans quickly will result in a more bitter taste, but careful moderation will allow volatile acetic acid to evaporate during the drying process, resulting in a less acidic (and more pleasant) taste.

5. Roasting

Roasting develops the flavour further, and also sterilises the beans, killing microorganisms (like bacteria) on the outer shell. Successful fermentation is an important microbial process, and will naturally create conditions ideal for bacteria, fungi and mould, so roasting is essential to remove these potentially dangerous pathogens.

Roasting also helps to get rid of some of the lingering acidic flavours, and makes the next stage much easier.

6. Cracking

The roasted beans are cracked by applying pressure with a cacao crusher, separating the husks from the beans.

7. Winnowing

Winnowing removes the lighter husks and dust particles, leaving the heavier beans or ‘nibs’.

Originally, winnowing was done by hand in a winnowing basket. The beans would be tossed into the air before being caught again in the basket, causing the brittle shells to break apart and separate from the beans. If done outside on a windy day, the lighter shells would blow away and the heavier nibs would fall back into the basket. Clever!

Today, it’s mostly done by a winnower machine. Vibrating shelves shake the beans, causing them to fall through a series of screens before a vacuum removes the lighter shells, leaving the precious nibs ready for the next stage.

8. Grinding

The now shell-less beans are ground up, and sugar is added. Cacao nibs are naturally quite bitter with a strong flavour, so adding sugar makes them sweeter.

Adding sugar was a later development in the production of chocolate, having come about in the 16th Century, after the beans arrived in Spain.

9. Tempering

Slowly heating and cooling the chocolate allows the fats to crystallise uniformly and the chocolate to break with a satisfying snap. It also helps give chocolate that smooth and glossy finish.

10. Moulding

The mixture is poured into a mould where it cools, before being packaged and shipped off to distribution centres ready for eating.

Read more:

To submit your questions email us at questions@sciencefocus.com (don’t forget to include your name and location)

Authors

Holly is the staff writer at BBC Science Focus. Before joining the team she was a geoenvironmental consultant and holds an MSc in Geoscience from UCL.

How is chocolate made?

Chocolate production begins at the cocoa tree, where cocoa pods containing cocoa beans in a cotton wool-like pulp are harvested between October and December. The beans are placed between layers of banana leaves for six days to drain the pulp away, a method known as ‘heap’, before being dried in the sun, packaged and sent to a factory for chocolate making.

Inside a chocolate factory, the beans are heated inside a continuous roaster as they travel along a conveyor belt. The time of this process varies depending on the flavour required. Once suitably roasted, they are broken down into small pieces and their brittle shells are removed, leaving only the meaty centres of the beans, the ‘nibs’, which contain the essential cocoa butter for chocolate production. A mill grinds these nibs into a thick brown liquid known as ‘cocoa liquor’, the basis of all chocolate products, which is then mixed with varying amounts of sugar and milk depending on the required type of chocolate. Typically, dark chocolate consists of 70% cocoa liquor, while milk and white chocolate have 30%.

Vacuum ovens then dry this mixture into what is known as a chocolate ‘crumb’, before giant rollers squash the liquid together. It is then grinded between rollers to improve the silky texture, before being smoothed even further in a process known as ‘conching’. This involves kneading the mixture in giant tanks at about 46°C, with the very best chocolate being conched for more than a week. The final process is tempering, where the liquid is continuously cooled and heated in a cycle until it is a stable chocolaty consistency.

After this stage of the chocolate-making process, the liquid can be poured into moulds, cooled and wrapped at high speeds to make products like bars of chocolate. To make chocolate with a particular filling, such as caramel, the insides of the bars pass along a conveyor belt and are ‘enrobed’ by the liquid chocolate before being cooled and wrapped.

How chocolate is made

The origins of chocolate

Chocolate is derived from the theobroma (‘food of the gods’) cacao tree and was consumed by the Mayans as a drink. Chocolate became a sacred elixir to both the Mayans and Aztecs; it was used during state executions and religious ceremonies. Archaeologists have discovered residues of chocolate in ancient jars that were found in Honduras and dated to 1100 BCE.

Cocoa trees grew in abundance throughout the Mayan territories, and by 600 CE their pods (pictured) were processed in order to produce a frothy, bitter drink. The Mayans blended their chocolate with spices like chilli pepper and vanilla; once consumed they were believed to ward off tiredness. Evidence suggests that cocoa beans were also ground to a powder. During this process, other ingredients could be added – in this instance, the resulting powder was mixed with cold water to create porridge.

A theobroma cacao tree

Record-breaking chocolate

Largest bar of chocolate

In September 2010, Armenian-Canadian JV ‘Grand Candy’ Co Ltd made the world’s largest chocolate bar, a mammoth 4,410kg hunk of chocolate.

Largest chocolate bar collection

American Bob Brown holds the record for the largest chocolate bar collection, racking up an impressive 770 different variants of the sweet brown stuff.

Longest bar of chocolate

Italian A Giordano Laboratorio Di Cioccolato produced a record-breaking bar of chocolate, measuring 11.57 metres long and 1.1 metres wide, in 2010.

Most valuable chocolate bar

An uneaten 100-year old Cadbury’s chocolate bar became the most valuable bar in the world when it sold for £470 in 2001 to an anonymous bidder.

Most strawberries dipped in chocolate in one minute

Here’s a bizarre one that sounds breakable: American Collin Gouldin set the record for the most strawberries dipped in chocolate in one minute in 2008. He managed 53.

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