Showing posts with label Cacao. Show all posts
Showing posts with label Cacao. Show all posts
How Do Large Companies Make Chocolate
How do large companies make chocolate? For one, they need capital to be able to buy the equipment they need and also the ingredients.
Given that there are not that many places in the US to harvest cocoa beans, these companies go to South America, the Ivory Coast and as far away as Ghana because deep in their jungles likes the cacao tree.
These trees grow a melon like fruit that is harvested by hand and inside, there are 20 to 40 seeds which are the cocoa beans.
Once the cocoa beans are removed, they are placed in large heaps or piles in a process known as fermentation. This usually takes a week giving the shells time to harden, the beans darken and the cocoa flavor develop. Afterwards, these are then transported to the chocolate factory.
Since companies that import cocoa beans order these in vast quantities, it is more practical to transport these back to the US by ship than by air. Once they reach the dock, it is then transferred to rail road cars on the way to the factory so they can be cleaned and stored.
Chocolates as we know taste different and this is depends on the country of origin of the beans. The first step in converting these into chocolate is to roast these in large revolving roasters at high temperatures.
Next, a special hulling machine dries it so the shell of the bean is removed and its content known as the “nib” is the one that is actually used in making chocolate.
The next step is to turn the “nibs” into its liquid form. This process is known as milling and to give you that added taste, other ingredients are added and these include chocolate liquor, cocoa butter, sugar and milk.
Chocolate liquor is a combination of milk and sugar. The end product of this coarse brown powder called a chocolate crumb. As for milk, this is taken from the farm where it is tested, pasteurized and mixed with sugar until it turns into a thick, taffy like material.
You then throw in cocoa butter to bring out the rich taste and creamy texture of the chocolate. Another machine known as steel rollers grind and refine the mixture to make it smoother.
After all that, the mixture becomes a thick liquid often referred to as chocolate paste. Since there still may be some gritty particles, it is placed inside another machine called the conche for 24 to 72 hours.
When the paste has been smoothened, this is the time that the liquid chocolate is poured into the mold. The process is very fast inside a factory as some produce about a thousand of these a minute that is something that can never be done manually. If the chocolate comes in many varies, this is also the time that almonds and peanuts are added.
In the machine, air bubbles are removed so the chocolate is able to settle evenly. They then make their way through a cooling tunnel so the liquid chocolate is turned into a solid candy bar.
The last step is obviously to wrap this up, put these in boxes and then deliver it to stores. Customers then buy these off the shelf and then enjoy its yummy taste without ever thinking for one moment how do large companies make chocolate.
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The Long Journey Of Chocolate From Cacao Beans To Fine Chocolate
All chocolates use cacao beans, from the mass produced stuff inside M&M's to the highest quality product that comes from Belgium. Cacao beans are also the most important ingredient, because even if all the other ingredients that go into the mix are top notch, if the cacao is not high quality the chocolate made from it won't be either. In a process that requires precision from its start at the very beginning when seeds are sown right up to its completion when the chocolate is done, even a slight mishap can spell the difference between chocolates that's good, sure, and chocolate that will knock your socks off.
In a process much like the cultivation of coffee, cacao beans are harvested, fermented and roasted. While this is essential the manufacture of chocolates, it is more or less mechanical and rule bound, so less interesting. Once the roasting is done, however, things start to get more interesting.
When the beans have been roasted, they are ground. This means that the cacao beans are shelled, and for most recipes, ground. When the beans are ground they secrete a thick liquid known as cacao liquor, which is used by chocolate manufactures. The liquor can be transformed into three different things, cacao butter, cacao powder, and chocolate. The first two are less dependent on the quality of the beans, and so usually only less remarkable beans are used to make them. The liquor from higher quality beans is most often made into chocolate.
Just because you have high quality cacao liquor doesn't mean that you have high quality chocolate. To get from the liquor to the finished bars or boxes given on Valentine's Day, fine chocolate makers must first add some extra ingredients. At this stage, most makers will add sugar and then regrind the mixture to avoid sandy textures and flavors. After this grinding, the chocolate is heated and mixed together a little bit under boiling temperature, at 180 degrees Fahrenheit. This heated mixing is known in the industry as conching. During conching, chocolate starts to take on the smooth, refined taste for which its finest examples are known. Depending on the desired end product, a chocolate may be conched for an hour, or even a whole day or more.
Conching itself is where much of a chocolate's flavor will come from. One mast chocolate makers secret process of cooking the chocolate can be very different from another's, and will impart a very different end result. Understandably, some chocolate makers can be highly guarded about their exact technique.
After conching, the pure chocolate is then turned into whatever the chocolate maker has in mind, milk chocolate, dark chocolate, cooking chocolate, or whatever else. Every step along the way, though, has to be just as carefully undertaken as those that preceded it.
As you can see, there is a great deal that goes into a simple bar of chocolate. The entire process takes great care, and the slightest mistake can spell disaster, or at least mean that this or that bar will be slightly less heavenly.
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A Brief Look at the Past of Making Chocolate
The Theobroma Cacao or the food from the Gods is what you all know as the cocoa tree. Its origin can be traced on America's rainforests, specifically in Central America. But historians are still debating about certain facts about this tree.
Xocolat, Anyone?
There are arguments that the Mayans first grew such tree in 300 AD. And the Aztecs had their turn in cultivating such in 1100 AD. The chocolate that you all know now used to be called Xocolat. This was a special beverage that was made out of chilies, anise seed, vanilla, cornmeal and some more spices. Only royalties get to be treated with such delight at the time. It was served using golden cups that were to be used only once.
Save the Chocolates
The cocoa tree is sensitive to its surroundings. It will most likely grow in the shades of the canopy of the rainforest. For this reason, chocolate lovers must unite in the goal of saving the environment, especially in saving the rainforests where the cacaos will most likely survive.
This tree is unique in the sense that its fruits grow on its branches and trunk. The reason for this is because of midges. These are the tiny insects that cause the pollination process during nighttime.
Did you know that the cacao tree can have approximately 10,000 blossoms but only about 10 to 50 of those will mature into fruits or the pod? This is because like an intelligent human being, the tree of cacao can regulate its blossoms to the amount that it can handle and grow.
The cacao tree self regulates in this process to be able to sustain its good health. It knows what it can contain and handle. It knows just how many is enough and too much. The tree does this to preserve its internal systems and to prevent its branches from breaking or falling apart.
The cocoa beans come from the fruit or the pod from the intelligent tree. Harvesters wait for the pod to ripen. They will handpick the trees and crack up the pods until they see white pulpy elements that surround the seeds. The pulps are then trashed while the seeds are kept because those are your cocoa beans, the source of your chocolate treats.
These seeds are actually bitter during such time. For this reason, these will go through the fermentation process for about three to seven days. This method will cause the seeds to go through some chemical as well as physical changes. The result of this will then be used for the royalties' treat, the Xocolat.
The beans need to go through several procedures after which before it can be used for the traditional making chocolate purposes. Now that you know where it came from, you'll never look at your favorite chocolate the same way ever again. Or probably not. Whatever it has been through, chocolates will remain a favorite among children and child at heart.
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Making Chocolate
The first thing that needs to be done is to harvest the cacao beans. Large companies buy these from farmers or buy the farm and harvest these themselves. They then put these in an oven at a temperature between 120 to 163 degrees Celsius that is about 250 to 325 degrees Fahrenheit for 5 to 35 minutes.
Naturally, you will gradually lower the temperature and stop roasting them when the beans start to crack.
There are two reasons why cacao beans stay in an oven at varying times.
First is to prevent them from burning. Naturally, you will gradually lower the temperature and stop roasting them when the beans start to crack. Naturally, you will gradually lower the temperature and stop roasting them when the beans start to crack.
Second, the cooking time of cacao beans varies depending on the type of bean that is being used.
Since companies produce chocolates in vast quantities, the cacao beans are stored in drums and then rotated over a gas grill. After they are roasted, the beans must be cracked into small bits better known as nibs while those that can’t are removed.
The next step is to grind the nibs into a cacao liqueur. For that, you will need a machine to liquefy this and at the same time separate the remaining husks that were not removed after roasting.
You then conch and refine the chocolate so you are able to give the chocolate its distinct taste. This is what makes Hershey’s chocolates different than for example M&M which can be achieved by using a powerful wet grinder.
You first have to melt the chocolate and the cocoa butter in the over at about 120 degrees Fahrenheit. You should then mix non fat dry milk powder, sugar, lecithin and a vanilla pod for about an hour. This mixture is then poured into a grinder together with some heat to keep the chocolate in liquid form. This should be refined for at least 10 hours but not more than 36 hours.
When it is ready, you then temper the chocolate so it looks shiny and soft enough to easily melt in your hand.
The second to the last part in making chocolate is to mold this into whatever shape or form that you would like. To produce these in vast quantities, chocolate companies but custom made molds. The chocolate is then poured there and after this is cooled, this is then packaged and ready for delivery to stores.
Some companies even sell these in the form of blocks so people can buy them, melt it and mold this to whatever shape they desire.
Making chocolate is easy as long as you have the equipment and all the ingredients needed. It doesn’t matter if this is produced in large volumes or in small quantities because the principle behind it is the same. If you want to learn more about making chocolate, sign up for some classes.
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What Does It Take To Make Chocolate
First, chocolate is produced from cocoa beans that from the Theobroma cacao tree. In English, this term means “food for the Gods” because of its heavenly taste that the Aztec and Mayan civilizations have enjoyed for years.
These degrees are harvested mainly from the Ghana and the Ivory Coast with some getting their supplies from other countries in South Africa and South America.
The reason why chocolate is abundant is because the pods from these trees are produced all year long. There are three types that each have their own distinctive flavor namely Forastero, Criollo and Trinitario.
Of the three, the most abundant among them is Forastero. Criollo on the other hand is very rare while Trinitario is a hybrid of the two.
Harvesting the pods is usually done by hand with machetes. The farmers have to split open the pods to get to the cocoa beans. Afterwards, they scrape the pulp and beans from inside the pods and left to ferment in baskets from 2 to 8 days.
Fermentation is important because without it, the beans inside would be too bitter to enjoy. After this process, the contents are spread in a single layer to dry usually under direct sunlight before this is packed and shipped to the buyer.
Now you understand what farmers do, it is time to explain what the manufacturers do. Once the beans reach the factory, this is roasted and then transferred to a winnower. This machine removes the shell of the bean and leaves the “nibs” which is what is used to making chocolate. This is then grounded and turned into a rich thick paste now called chocolate liquor.
The liquor then undergoes one more process to remove the cocoa butter which has an end product known as “cocoa presscake” or cocoa powder and here, manufacturers decide what kind of chocolate to make.
If the presscake is of low quality, this will have to be mixed with other ingredients like vegetable fats, sugar and artificial flavoring. If what they have is of good quality, then this will added again to chocolate liquor and other ingredients like milk, sugar and vanilla before this is transferred to a conching machine.
The conching is considered to be the last step in screening the chocolate in order to get its ultimate flavor and texture. The speed, temperature and length of this process has a lot to do with the taste of the chocolate. Also, this helps remove any acidic tones.
This is then tempered into a large machine which pours the chocolate into the mold. Once it is frozen, the bars are then packed and ready to be shipped off to the consumer.
Now that you know what it takes to make chocolate, you can begin to appreciate what you buy whenever you go to the grocery store and buy a few of these as a snack. Some of these are cheap while others are expensive and it all boils down to what kind of cocoa tree was used to make the finished product.
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Only The Sweet Stuff: Guide for Making Chocolate
Essentially, making chocolate begins with the conversion of cacao beans into the bars of chocolate we see in the supermarket shelves. Some other people enjoy eating the cacao beans in its raw form, since it has the basic component that we crave for in the processed chocolates.
A chocolate maker must have persistent attention to detail and dedication to constant practicing. This guide will not ensure to make a chocolate factory out of your kitchen, but it will surely give you the basic idea-- just enough for you to enjoy a bar or two of chocolate at any time you wish without hurting your budget. Moreover, since you are directly involved in making your chocolate, you get to know the materials and amount of calories you are placing in every bar.
It begins with Cocoa Beans
If you are familiar with brewing coffee, it is similar to the beginning of the chocolate-making process. You need to roast the beans. But then, do not roast it too much. Initially, place it in a high temperature, then slowly diminishing the temperature afterwards. Turn the heat off right before the moment the beans hit their cracking or breaking point. You can do this either on your oven.
Or if you are planning to feed many people with your chocolate, have a larger container to accommodate the huge number of beans. From time to time, test the taste of your chocolate. The moment you start tasting chocolate from the cocoa, it is also an indicator to turn off the heat.
After roasting, the beans must be cracked open, removing the hard husks. You can do this by hand or with use of a small hammer. Depending on the size of your beans, you can use other tools for cracking, since the husks are not that useful for eating. Once the husks are removed, you can now grind the remaining portions until it liquefies. You must thoroughly liquefy the said concoction in order to help you become a home chocolatier.
Coco gets refined over time.
The process of conching involves the refinement of chocolate. It may require you to have certain equipment such as the Sancha refiner, which is a common favorite among home chocolatiers. This is where you start adding sugar and milk as part of the delicious chocolate mixture.
You will need to refine and conch for a long time, approximately 10 to 30 hours in length, until you achieve the balance of the ingredients. Excessive refining will turn your chocolate into gum, so be very careful. At this point, even when you let the mixture rest, it must not solidify yet.
Packaging Chocolates: Tempered after refinement.
When you are finished refining your chocolate, you need to make sure that it is under the right temperature before you place it in the mold. Not doing this meticulous tempering process will make your chocolate lumpy and unbalanced.
The rich, creamy quality of most chocolate bars in the market come from effective tempering of the chocolate after refinement.
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