Product, Range & Distrobution / Chocolate / Production

OUGD505 / DESIGN PRODUCTION 2

THE PRODUCTION

I actually know nothing about the making process involved in making this product. i know that there is sugar and cocoa beans involved but the actually production is something I have know clue on.

THE CACAO TREE

The cacao tree is very delicate and sensitive. It needs protection from wind and requires a fair amount of shade under most conditions. This is true especially in its first two to four years of growth. A newly planted cacao seedling is often sheltered by a taller growing tree for shade. Trees such as banana, plantain, coconut, rubber or just tall forest trees are very popular choices. Once established however, cacao trees can grow in the complete absence of shade but they must have well distributed rainfalls and rich, well drained soil. Cacao trees usually are started in nursery beds where seeds from high yielding trees are planted in fiber baskets or plastic bags. The seedlings grow so fast that in a few months they are ready for transplanting, container and all. When a cacao tree is full grown it usually measures 15 to 25 feet high, though it has been known to reach as high as 60 feet or more. How old the cacao tree can get is not known although there are individual cacao trees known to be over 200 years old. 

In three to five years the cacao tree will start to produce flower clusters, then flowers; the cacao tree is very colorful with these pink and white five-petaled blossoms. Thousands of these flowers form, which must be pollinated to produce what is called a pod. Unfortunately, though, only 1 in 500 flowers goes on to produce a pod. The pod is known as the fruit of the cacao bean tree. Green, maybe maroon, these pods contain the seeds that will become the cocoa beans. 

COCOA TREE WITH COCOA PODS / GOOGLE IMAGES

HARVESTING THE POD

Before chocolate is made, the pods need to be picked. The job of picking ripe cacao pods is not an easy one. The trees are so frail and its roots so shallow that to climb the tree is too dangerous. Long handled steel knives are used to reach the highest pods and snip them off without wounding the soft bark of the tree. Training and experience is needed to recognize which fruit is ripe and ready to cut. Ripe pods are found on trees at all times since the growing season in the tropics is continuous. 

Once the pods are cut they are gathered in baskets and transported to the edge of the field where the pod breaking operation begins. One or two lengthwise blows from a machete usually split open the woody shell. A good ‘breaker’ will open 500 pods per hour. (Bet they’re ready for a chocolate bar after that!) 

HARVESTED COCOA PODS / GOOGLE IMAGES

A great deal of patience is required to complete the harvesting. Anywhere from 20 to 50 cream-colored beans are scooped from a typical pod and the husk and inner membrane are discarded. Dried beans from an average pod weigh less than two ounces and approximately 400 beans are needed to make one pound of chocolate. 

COCOA BEANS IN THE FIRST STAGES BEING REMOVED FROM THE POD

The cocoa beans (also known as seeds) which are removed from the pods are put into boxes or thrown on heaps and covered. This next process, known as fermentation, is the beginning of the making of chocolate, although the beans are still many steps away from becoming chocolate. 

PREPARING THE COCOA BEANS

Left out in the heat of the day, the fermentation lasts from three to nine days. It is a simple “yeasting” process in which the sugars contained in the beans are converted to acid, primarily lactic acid and acetic acid. Visually, a layer of pulp starts to form around the beans; it almost looks like bubbling. Here the beans become darker, less bitter and begin to develop the chocolate flavor. During the high temperature of the fermentation process, the germ of the bean is killed and enzymes are activated to form the compounds which produce the chocolate flavour.

FERMENTED COCOA BEANS / GOOGLE IMAGES

The beans are then dried to prevent mold and mildew. In some countries, the beans are simply laid out on trays or bamboo mats in the hot sun. Otherwise, the beans can be dried indoors with hot air pipes. During the drying process, which takes several more days, the beans are turned frequently and continually examined for foreign matters or flat, broken beans. When completely dried, the beans are packed in sacks, inspected by buyers and shipped to factories for the making of chocolate. 

DRYING AND DECONTAMINATION OF COCOA BEANS / GOOGLE IMAGES

THE MAKING OF CHOCOLATE

When the picked, scooped, fermented, dried and inspected beans finally arrive to the chocolate making factories, the final art of making chocolate begins; a process comparable to the skill and finesse of the world’s greatest chefs. The manufacturing process requires much time and painstaking care. Just to make an individual sized chocolate bar, for example, takes from two to four more days.

Manufacturing methods will differ in detail from plant to plant, but there is a general processing pattern that prevails everywhere. It is this pattern that makes the chocolate industry distinctive from every other industry. For example, all manufacturers carefully catalogue each shipment according to its particular type and origin. This is very important, because it enables them later to maintain exact control over the flavor blending of beans for roasting. 

Basically, this is what happens to make chocolate.

  - After sorting and cleaning, the cocoa beans are roasted for up to two hours.

ROASTING OF FERMENTED COCOA BEANS / GOOGLE IMAGES

  - The cocoa beans are then shelled. What remains are chocolate nibs, which contain 54% cocoa butter. Cocoa butter is the natural fat of the bean.

SHELLED COCOA BEAN AFTER ROASTING / GOOGLE IMAGES

  - As the nibs are ground, cocoa butter is released, transforming the solid nibs into the free-flowing substance known as chocolate liquor. Chocolate liquor (not alcoholic, just liquid) is the essence of all real chocolate products.

GRINDING OF SHELLED COCOA BEANS

  - The chocolate liquor is passed through huge presses to remove a desired amount of the cocoa butter to be used later. Cocoa butter is an amazing vegetable fat that resists rancidity and oxidation and can be kept for years without spoiling. A small amount of cocoa butter is sold to the cosmetics industry.

RAW COCOA BUTTER EXTRACTED FROM GROUND COCOA BEANS / GOOGLE IMAGES

  - After the cocoa butter is removed, a pressed cake is left. This is the cocoa powder. The cocoa powder can still contain up to 10% of cocoa butter and will be sold bulk or as an ingredient for bakers, along with chocolatiers.

PURE CHOCOLATE READY TO BE DISTRIBUTED TO INDIVIDUAL CHOCOLATE MANUFACTURERS / GOOGLE IMAGES

  - Solid chocolate is made by adding back together the different parts -cocoa butter, cocoa power – and other ingredients - sugar, perhaps milk and vanilla - to achieve the individual manufacturer’s desired finished taste.

VARIOUS CHOCOLATE BARS FROM MULTIPLE COMMERCIAL MANUFACTURERS / GOOGLE IMAGES

WHITE CHOCOLATE

White chocolate is not chocolate in the strict sense as it does not contain cocoa solids, the primary nutritional constituent of chocolate liquor. During the manufacturing process, the dark-colored solids of the cocoa bean are separated from its fatty content (as with milk, semi-sweet, and dark chocolate) but, unlike conventional chocolates, the cocoa solids are not later recombined. As a result, white chocolate does not contain the antioxidant properties or many characterizing ingredients of chocolate, such as thiamine, riboflavin,theobromine, and phenylethylamine. Often, the cocoa butter is deodorized to remove its strong flavor.

Some preparations known as confectioner's coating or simmer coating may be confused with white chocolate, but are made from inexpensive solid or hydrogenated vegetable and animal fats, and are not at all derived from cocoa. These preparations may actually be white (in contrast to white chocolate's ivory shade) and will lack cocoa butter's flavour.

HISTORY

In the 1930s, a white chocolate bar was launched in Europe by Swiss company Nestlé.

In North America, Kuno Baedeker developed a white chocolate while working for the Merckens Chocolate Company in 1945.

Over all I think that the initial process in manufacturing chocolate seems quite simple and straight forward. I is interesting seeing the transformation from the pod growing on the cocoa tree. It has also put into the perspective the process that had taken place in the history of this product and understanding the way in which the origin was consumed.

By also seeing this product in its rawest form gives you a better understanding of the adaptations taken by so may other commercial manufacturers.

From my own understanding of the different types of chocolate, I know that milk and dark chocolate are created using this initial stage of production and then of on to be made into various brand creations. However I also know that white chocolate isn't really a chocolate and that this is a result of the addition of more sugar rather than what would be classed as  chocolate content.

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MORE INFORMATION

There are many other factors that are taken in to account such as the different types of cocoa bean that are available, were they are grown and the aroma these give of as well a their cost.

Around 2 thirds of the entire worlds cocoa is produced in West Africa. Cote d'lvoire holds 43% of cocoa sourced. Unfortunately child labour is a regular thing with in this plantation source

According to the World Cocoa Foundation, some 50 million people around the world depend on cocoa as a source of livelihood. In the UK, most chocolatiers purchase their chocolate from them, to melt, mold and package to their own design.

Production costs can be decreased by reducing cocoa solid content or by substituting cocoa butter with another fat. Cocoa growers object to allowing the resulting food to be called "chocolate", due to the risk of lower demand for their crops. The sequencing in 2010 of genome of the cacao tree may allow yields to be improved.

There are two main jobs associated with creating chocolate candy, chocolate makers and chocolatiers. Chocolate makers use harvested cacao beans and other ingredients to produce couverture chocolate (covering). Chocolatiers use the finished couverture to make chocolate candies (bars, truffles, etc.).

TYPES OF COCOA BEANS

CRIOLLO

This is the rarest form of cocoa bean and only makes up 5% of all cocoa beans grown in its native realms of Central America,  The Caribbean islands and the northern tier of South America.

They are rare due to their venerability to multiple environmental threats such as strong winds and heavy rain. They also produce only a small amount of fruit per tree in comparison to other varieties. They are said to be delicate in both taste and texture.

FORASTERO

This is the most common variant of cocoa bean and is a native of the Amazon basin. They are hardier and tougher to the natural elements.

TRINITARIO

This type of cocoa bean is a natural born hybrid of both the Criollo and Forastero and originates from Trinadad Most of the cocoa produced over the last five decades have been formed from either the Forastero or a lower grade of the Trinitario variety. 

CRIOLLO / FORASTERO / TRINITARI

BLENDING

The three main types of chocolate are Dark, Milk & White. These variants are based on the amount of chocolate liquor is present within the ingredients. The ratio of liquor and cocoa butter creates the variants. From the highest:

- Dark chocolate: sugar, cocoa butter, cocoa liquor, and (sometimes) vanilla;

- Milk chocolate: sugar, cocoa butter, cocoa liquor, milk or milk powder, and vanilla;

- White chocolate: sugar, cocoa butter, milk or milk powder, and vanilla.

The more expensive chocolate tends to be processed longer and thus have a smoother texture and mouthfeel, regardless of whether emulsifying agents are added.

Different manufacturers develop their own "signature" blends based on the above formulas, but varying proportions of the different constituents are used. The finest, plain dark chocolate couvertures contain at least 70% cocoa (both solids and butter), whereas milk chocolate usually contains up to 50%. High-quality white chocolate couvertures contain only about 35% cocoa.

There are a few stages to getting the chocolate to the correct consistency as well as ensuring the chocolates components are combined appropriately.

CONCHING

The penultimate process is called conching. A conche is a container filled with metal beads, which act as grinders. The refined and blended chocolate mass is kept in a liquid state by frictional heat. Chocolate prior to conching has an uneven and gritty texture. 

The conching process produces cocoa and sugar particles smaller than the tongue can detect, hence the smooth feel in the mouth. The length of the conching process determines the final smoothness and quality of the chocolate. High-quality chocolate is conched for about 72 hours, lesser grades about four to six hours. After the process is complete, the chocolate mass is stored in tanks heated to approximately 45–50 °C (113–122 °F) until final processing.

TEMPERING

The final process is called tempering. Uncontrolled crystallization of cocoa butter typically results in crystals of varying size, some or all large enough to be clearly seen with the naked eye. This causes the surface of the chocolate to appear mottled and matte, and causes the chocolate to crumble rather than snap when broken.^[65] The uniform sheen and crisp bite of properly processed chocolate are the result of consistently small cocoa butter crystals produced by the tempering process.

The fats in cocoa butter can crystallize in six different forms (polymorphous crystallization).^[65][66] The primary purpose of tempering is to assure that only the best form is present. The six different crystal forms have different properties.