how its made - chocolate
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INSTITUT PENDIDIKAN GURU
KAMPUS DATO RAZALI ISMAIL
KUALA TERENGGANU
TERENGGANU
Prepared by :
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Fermentation
Fermenting and drying are the first crucial
steps in transforming cacao beans
into the flavor of chocolate as we know it.
After harvesting, the cacao pod
fruits are cut open and the beans(technically seeds) are scooped out.
Covered with a delicious, sweet whitish
pulp, the cacao beans are placed
in large, wooden boxes or, in the case of
Ghana (origin of our Chocolatey)
and much of West Africa, the wet cacao is
heaped in piles and covered with banana
leaves.
STEP 1 : FERMENTING
HOW ITS MADE
Chocolate
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Once the fermentation is complete, the
cacao beans have little or no pulp left on
them. The beans are transferred to
expansive cement patios or elevated
wooden or bamboo beds to be dried in
the sun. Constant turning by rake or byhand ensures even drying throughout. On
larger plantations, or at cooperatives,
during inclement weather beans can be
dried using artificial gas driers. In terms of
optimum flavor development, artificial
drying is never as good as slow sun drying
and great care must be taken.
STEP 2 : DYING
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Proper roasting is vital to crafting great
tasting chocolate. Different temperatures
and roast times bring out different flavors
and characteristics in the cacao. We have
to pay extraordinary attention to our
roasts. Unlike coffee, which roasts at
relatively high temperatures anywhere
from 400-460 F cacao beans need moregentle treatment. Cacao beans can be
roasted at 250 to 350 degrees for thirty
minutes to two hours depending on the
variety of cacao. Generally speaking, the
milder criollo beans are roasted at a lower
temperature than the stronger-tasting
forestero and trinitario cacao varieties.
STEP 3 : ROASTING
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After roasting, the beans are transferred to
a winnower that removes the shells of
the beans and leaves the nibsthe
essence of the cacao bean thats full of
cocoa solids and cocoa butter. The roasted
beans are first cracked open, then vibrated
in large vibrating machines and set over a
series of flat screens that haveprogressively smaller openings, so the
larger pieces of shell and debris are
removed, while the just nibs are collected
for the next step in the process.
After winnowing, the nibs are transferred
to the mlangeur or grinder, where they
are ground to a thick, rich paste called
chocolate liquor.
STEP 4 : WINNOWING
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After winnowing, the freshly roasted cacao
nibs are transformed into a liquid state
through a series of grinding steps utilizing
gentle heat and pressure. The resultingunsweetened liquid is commonly called
"cocoa mass" or "cocoa liquor" (although it
does not contain alcohol). The cocoa liquor
is then poured and cooled into block forms
for shipping, soon to become the core
ingredient of chocolate.
STEP 5 : GRINDING
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Here, the cocoa liquor (made from grinding
the nibs) is pumped in and mixed with
other all-natural ingredients : cane sugar,
cocoa butter, vanilla beans, and lecithin.
Depending on the raw materials, refining
can take 4-12 hours. Using the powerful
shear forces of the MacIntyres numerous
hardened steel blades, we refine these
ingredients until we reach a particle size of
about 16-18 microns. In addition to intense
pressure, heating and cooling cycles inside
the MacIntyre also help impact the finalproduct.
STEP 6 : REFINING
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Conching is a crucial step in making fine
quality chocolate. During this step, the
blended ingredients are agitated in a
folding or wave motion by a machine for
several hours or even days. This removes
excess moisture and astringency while
volatilizing certain undesirable organicacids that still remain from the
fermentation process. When done
properly, conching fully evolves the desired
flavors of the beans. The refined and
blended chocolate mass is kept in a liquid
state by frictional heat. During the
conching process, the fully refined particles
become evenly distributed, improving the
flow properties of the liquid chocolate.
STEP 7 : CONCHING
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There are three main components involved
with the tempering process: time,
temperature, and agitation. The best
quality chocolate begins by heating the
cacao to about 118 degrees Fahrenheit.
After the initial heat the chocolate is then
slightly cooled so that cacao crystals beginto form. While still being agitated the
temperature is increased a second time to
capture the most desirable crystal
formations that create the smooth surface
of the chocolate bar. The ideal crystals are
those that fit tightly together and disperse
flavors evenly. If the chocolate develops
the expected glossy finish and snap, its
properly tempered and ready for the next
stage.
STEP 8 : TEMPERING
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After the tempering process is completed,
the warm, molten chocolate is depositedinto molds to form signature square bars.
The molds run under the depositor in an
assembly line fashion. After depositing,
vibration in the assembly line helps work
out the air bubbles in the chocolate as the
chocolate settles into its future shape.Next, the mechanized conveyor belt brings
the molded chocolate through a cooling
tunnel, where the chocolate cools and
hardens. Depending on the size of the
chocolate bar being molded, the cooling
cycle takes between 20 minutes and two
hours. After cooling, the conveyor belt
moves the chocolate through a de-molding
mechanism that flips the bars out of their
molds. Now the bars are ready to be
wrapped.
STE 9 : L I
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After chocolate bars come off the molding
line and go through de-molding, the bars
are transferred to racks where theyre held
until being fed through the wrapping
machine. There are two wrapping
machines; one for 5g and 8g bars and theother is the 58g bar. Usually this machines
were imported from Europe. To wrap 58g
bars they are first machine-wrapped in
paper-backed foil then placed in a
paperboard carton. The 5g and 8g bars are
wrapped in die-fold process, whichcombines the foil with the paper wrapper
to complete wrapping simultaneously.
STEP 10 : WRAPPING
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HOW ITS MADE
Variety of Chocolate
Baby Chocolate
Variety of
Chocolate
F1 Chocolate
Hot Chocolate
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HOW ITS MADE
Variety of Chocolate
Keyboard
Chocolate
House
Chocolate
Chocolate
Fountain
Shoes
Chocolate
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