1.
Fermentation -During fermentation the cocoa pulp clinging to the beans matures and turns into a liquid, which drains away and the true chocolate flavour starts to develop. Fermentation methods vary considerably from country to country, but there are two basic methods - using heaps and "sweating" boxes. Heap: The heap method, traditionally used on farms in West Africa,
involves piling wet cocoa beans, surrounded by the pulp, on banana or plantation leaves spread out in a circle on the ground. The heap is covered with more leaves and left for 5-6 days, regularly turned to ensure even fermentation. Sweating: In large plantations in the West Indies, Latin America and Malaysia use strong wooden boxes with gaps in the slats of the base are used to allow air and liquid to pass through. This process takes 6-8 days during which time the beans are mixed twice.
2.
Drying and bagging -When fermentation is complete, the wet mass of beans is dried, either traditionally by being spread in the sun on mats or using special drying equipment. The cured beans are packed into sacks for transportation to Singapore, where we process the beans. After quality inspection they are shipped to our processing factory in Singapore, which produces the basic ingredients from which Cadbury chocolate products are made.On arrival at the factory, the cocoa beans are sorted and cleaned.
3.
Winnowing-The dried beans are cracked and a stream of air separates the shell from the nib, the
small pieces used to make chocolate.
4.
Roasting-The nibs are roasted in special ovens at temperatures between 105-120 degrees Celsius. The actual roasting time depends on whether the end use is for cocoa or chocolate. During roasting, the cocoa nibs darken to a rich, brown colour and acquire their characteristic chocolate flavour and aroma. This flavour however, actually starts to develop during fermentation.
5.
Grinding-The roasted nibs are ground in stone mills until the friction and heat of the milling reduces them to a thick chocolate-coloured liquid, known as 'mass.' It contains 53-58% cocoa butter and solidifies on cooling. This is the basis of all chocolate and cocoa products.
6.
Pressing - The cocoa liquor is fed into a press that divides the liquor into cocoa butter and cocoa cakes which can be ground into a fine powder known as cocoa powder. White chocolate contains
cocoa butter and no cocoa liquor. 7.
Chocolate making cocoa liquor is mixed with cocoa butter, sugar and in some cases, milk to make
chocolate. Producers can add fresh, sweetened condensed or powdered milk for milk chocolate depending on the desired taste. The mixture is placed into ‘conches’ which stir and smooth the mixture under heat. The longer it is conched, the smoother the chocolate will be. Conching can last for a few hours-three full days or even longer. The liquid chocolate is then either tempered and poured into molds for sale in blocks or shipped as it is in tanks. 8.
Consumer -People around the world enjoy thousands of different forms of chocolate with more than 3 million tons of cocoa beans consumed annually. Each country still has their own different preferences and distinctive blends. The cocoa, chocolate and confectionary industry is a key user
of other agricultural products including sugar, dairy products, nuts and fruits.