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Cacao Tree
Freshly harvested cacao pods
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The long way of the cocoa - from the pod to the chocolate- starts
in the consistently warm and wet tropical zones, in areas lying within
1000 km to the south and north of the equator. These are the Earth's
biotopes with the greatest diversity of species that have offered
us the base form of the cacao tree, together with pineapple, vanilla
and many other delicious useful plants.
Here, ccacao finds all conditions necessary for its growth: a consistent
high temperature, plentiful rainfall, and many large trees, known
as mother trees that shade the young cacao trees. The gnarled cacao
tree reaches a height of up to
15 m, but is mostly cut back to 6 m. The cacao harvest takes place
3-4 times a year and amounts to approx. 2 kg seeds - the cacao beans.
The pods which are approx. 25 cm long and cucumber-shaped are harvested
and sliced open manually using machetes. Now the whitish beans which
are surrounded by pulp can easily be removed.
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Coverage for fermentation
Cocoa beans drying in the sun
First of all, the cocoa beans are roasted
whereby the full cocoa flavour develops
The beans are broken and separated from
their shells resulting in an aromatic cocoa bean breakage.
As cocoa bean breakage, the mixture
is finely grinded producing a dark brown and liquid cocoa mass.
Dry, powdery mixture
Liquid Cocoa Mass
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NIn the country of origin, the almond-shaped cacao beans are fermented
and dried.
Fermention reduces the bitter taste, gives the brown colour to the
bean and breaks down the remaining pulp. Additionally, the typical
cocoa flavour develops.
In the countries of importation, the cocoa is sorted, cleaned and
mildly roasted whereby the full flavour of the beans develops.
The roasting is followed by winnowing where the cacao shells are removed.
Now the beans are ready to be grinded.
Hereby, the fat contained in the beans - the cocoa liqueur - becomes
liquid. From this viscous , oily raw cocoa mass, part of the fat is
squeezed out producing cocoa butter and cocoa cake - the raw materials
for the cocoa and chocolate production.
Cocoa butter belongs to one of the most valuable fats. It has a neutral
flavour and is easily digestable as it smelts at body temperature.
For the chocolate production, cocoa mass,
milk, sugar and additional cocoa butter or cream is mixed together
- depending on the kind of chocolate (milk or plain).
The adherence to a defined recipe and a careful mixture are decisive
for the special flavour of the finished products. Just one more production
step is necessary for achieving the full flavour: conching. During
the conching the cocoa mass is poured into a stirring and milling
machine. The permanent rolling, turning, airing and tempering takes
several days resulting in a smooth and fine chocolate.
Now the chocolate can be further processed to chocolate bars, chocolates,
truffles, etc.
When producing chocolate bars, the liquid mass is spread on bar moulds
by pouring heads. Theses pouring heads work exactly to the hundredth,
thus guaranteeing an exact weight.
Following the pouring, the moulds come onto a vibrating table ensuring
that the mass is evenly spread. Then they run through a cooling tunnel
where the chocolate mass slowly sets and slightly pulls together.
The chocolate is then de-moulded by turning over the moulds. Crumbs
are removed from the shiny brown bar surface, and faulty bars are
removed immediately from the belt.
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Coating machine
Production of Truffle Chocolates
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There are three different methods for producing chocolates: Enrobing,
Hollow Figure, and Layer- and Cutting procedure.
The enrobing process is the oldest method for producing chocolates,
which was improved and automated over the years. Automatically pre-shaped
chocolates centres (such as marzipan, nougat, croquant) are placed
on a moving wire mesh belt which takes them to a coating machine.
Here, a curtain of chocolate falls down onto the belt covering the
centres in chocolate.
Especially hiqh quality chocolates are decorated by hand - beautiful
ornaments from colourful chocolate or with fruit pieces, hazelnuts,
almonds, pistachio or half a walnut placed on top. The chocolate coating
solidifies in a cooling tunnel. Finally the chocolates can be packed.
The hollow figure process is also used for producing filled chocolate.
Liquid chocolate mass is filled in tempered moulds. The moulds are
then turned over, so that the excess chocolate can flow away. A thin
chocolate layer sticks to the mould and is solidified by cooling.
A filling is then dispensed and covered with another thin layer of
chocolate mass. This procedure is used for chocolates with liquid
fillings and semi-liquid fillings (such as egg flip).
The layer and cut procedure is used for chocolates consisting of various
layers (such as marzipan, nougat, croquant or fruits). The solid or
semi-solid masses are laid on top of another, and after cooling cut
into bite-sized pieces, that are often partially or entirely covered
with chocolate.
"Photos: Info-Centre Schokolade Leverkusen"
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Conveyor belts
Packaging line |
Conveyor belts transport the chocolates to the packing machines or
packing lines. Here, various high quality chocolates (chocolates assortment)
are placed into trays in a split second, and then packed into aroma-protected
chocolates boxes or tins. Carton die cuts for the final packaging
are automatically errected, filled and glued. All this happens without
a human hand touching the chocolates.
The chocolates are counted, assorted, piled and placed into boxes
or display cartons. The chocolates are then placed on palettes that
are protected against damage and are transported to the traders
and finally reach the consumer.
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High racks
Commissioning shelves |
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Before our high-quality chocolate comes into the shops, they are stored
in most modern high rack warehouses. Hereby, temperature and humidity
is of great importance. Temperature should not fall below 12°C
and should not exceed 18°C.; the relative humidity should be between
55% and 60%.
From the warehouses, the goods are commissioned and packed individually
for each trade partner. In trucks the palettes reach the trade and
thus the consumer. Now, the customer simply has to open the high-quality
chocolate product with pleasure and can enjoy it to the full.
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