What is the Bean to Bar Chocolate and How Does It Differ from Industrial Chocolate?
Bean to bar chocolate is produced in a complete process from the cocoa beans to chocolate bar, by the same company or artisan, without resorting to intermediaries. This involves special attention paid to each step of the production process, starting from selecting high-quality cocoa beans, roasting, grinding, blending and refining the chocolate, to molding and packaging.
Let’s examine the journey of cocoa beans from the farm to the final chocolate bar.
Step 1: Harvesting and Fermenting the Cocoa Beans
The journey of the cocoa beans begins with the harvest. Cocoa trees grow in tropical climates and are harvested twice a year by hand. Workers use knives or machetes to cut the cocoa pods from the tree, making sure not to damage the beans inside. Once harvested, they are split open and the beans are removed.
The cocoa pods are then fermented. This process is crucial in developing the flavour of chocolate. The pods are placed in a container, which is usually a wooden box or wicker basket, and it is covered with banana leaves. The fermentation process takes between two and seven days and is controlled by the cocoa producer. During fermentation, the pods produce heat and their flavour develops.
Step 2: Drying the Cocoa Pods
After fermentation, the pods are spread out to dry. They are usually laid out on bamboo slats or concrete platforms in the sun. This process can take between one and two weeks, depending on the weather. It is crucial to dry the pods thoroughly to prevent mold growth.
Step 3: Roasting the Cocoa Beans
Once the beans are dry, they are ready to be roasted. Roasting helps develop the flavour of the chocolate by caramelizing the sugars inside the beans. The chocolatier will roast the beans to their desired flavour profile. Some chocolatiers prefer a light roast to preserve the chocolate’s fruity and floral notes, while others prefer a darker roast to bring out the chocolate’s nutty and chocolatey flavours.
Step 4: Grinding the Cocoa Beans
Next step, after roasting, the cocoa beans are prepared for grinding by separating them from the shell. The beans are placed in a grinder, which crushes them into small pieces called cocoa nibs. The artisan will choose a grinder based on the desired texture and the amount of chocolate they want to produce.
Step 5: Making the Chocolate
The cocoa nibs are then placed in a machine: a stone or steel ball mill, which grinds the nibs into a fine paste
called chocolate paste.
The manufacturer will then add sugar and other ingredients, such as milk powder, freeze-dried fruit, spices, and cocoa butter to the chocolate paste. The mixture is ground for several hours until it becomes a smooth, velvety texture.
Step 6: Tempering the Chocolate
The final step in making chocolate is tempering. Tempering is a process that involves heating and cooling chocolate to specific temperatures to create a stable crystalline structure. This process gives chocolate its characteristic shine and brittleness. The chocolate is poured into molds and allowed to harden.
Step 7: Packaging and Shipping
Finally, once the chocolate has hardened, it is ready for packaging and shipping. The artisan wraps the chocolate bars in foil and paper and package them for shipping. The chocolate will then be carefully transported to a distributor or retailer, where it will be sold to customers.
Conclusion
Bean-to-bar chocolate production is a labor-intensive process that requires attention to detail at every step. From the farm to the final chocolate bar, the artisan has control over the flavor, texture, and quality of the chocolate. By starting with high-quality cocoa beans and carefully controlling each step of the process, bean-to-bar chocolate makers are able to produce some of the finest chocolate in the world.
Craft Chocolate vs. Industrial Chocolate
Bean-to-bar chocolate makers are usually interested in obtaining chocolate with a unique flavor, and the process of manufacturing directly from cocoa beans allows them to experiment with different varieties of cocoa and create chocolates that are unique in taste and texture. Depending on the manufacturer’s specific recipe, other ingredients may be added, such as milk, vanilla, freeze-dried fruits, spices or nuts.
Bean-to-bar chocolate is generally natural and less processed than industrial chocolate, with an authentic cocoa taste and a greater variety of flavors and taste notes.
By contrast, industrial chocolate is produced in a mass-production process, where cocoa beans are purchased from various sources, chemically treated by alkalization, roasted at high temperatures, and ground into a standardized blend, and then the chocolate is produced in large quantities using automated machinery and processes. Industrial chocolate generally has a more uniform and less complex taste than bean-to-bar chocolate, and may contain additives, preservatives, and other ingredients to extend shelf life and improve consistency and texture.
Livstory production – bean to bar chocolate – roasting and refining
Livstory production – bean to bar chocolate – grinding
Livstory – bean to bar chocolate production – tempering
Livstory – bean to bar chocolate production – tempering