To fully appreciate a chocolate bar, it is undoubtedly useful to first know the different stages of chocolate making .
Below we report the main ones, without obviously explaining them in detail (a task for which an entire manual would be necessary), but limiting ourselves to illustrating their main steps.
If, after reading, you would like to discover first-hand how cocoa is processed, we await you at Enrico Rizzi's Chocolate Factory , located in the heart of Milan, in via Gian Giacomo Mora 18.
By purchasing your Chocolate Experience , you will be able to discover how chocolate is made, starting from the roasting of the bean (and even before, to tell the truth!), up to the packaging, and then directly taste some of the single-origin chocolates produced on site.
The Chocolate Experience is also an ideal gift for true gourmets : thanks to the coupons available below, the recipient of your gift will be able to choose the date and time of their visit later.
Chocolate making: the phases
Here is a summary of the stages of cocoa and chocolate processing.
Cocoa Cultivation
The production of chocolate starts, of course, with the cultivation of the cocoa tree , known by its scientific name of Theobroma cacao. This tree is native to the tropical regions of Central and South America, but today it is also cultivated in other parts of the world, particularly in West Africa, which represents about 70% of the world's cocoa production.
If you want to know more about the cocoa tree and its cultivation, we refer you to this article .
Harvesting and fermentation
Once the cocoa fruits, called pods, are ripe, they are harvested by hand. The harvesting process is a delicate operation, as the fruits must not be damaged during removal from the plant. Once harvested, the pods are opened to extract the cocoa beans and the pulp that surrounds them. At this point, the beans are not yet ready for processing: they must go through a crucial process called fermentation.
Fermentation is a fundamental step in chocolate making that contributes significantly to the flavor development of the final product. The beans and pulp are piled into containers or baskets and left to ferment for a period that typically varies from two to seven days . During this phase, the sugars in the pulp are transformed into alcohol and then into acetic acid, which helps reduce bitterness and develop the aromatic precursors that will give the chocolate its characteristic flavor.
Drying
After fermentation, the cocoa beans must be dried . This process can take up to two weeks and is usually done in the sun, although in some cases mechanical dryers may be used. Drying is important because it reduces the moisture content of the beans and prepares them for transportation and storage . Dried beans are more durable and less susceptible to mold or spoilage during storage.
During this phase, the beans also lose some of their weight, but acquire a more pronounced flavor and an internal structure suitable for subsequent processing. After drying, the beans are usually packaged in jute bags and shipped to the producers: in his Chocolate Factory, Enrico Rizzi awaits every day those he has personally selected, coming from the best plantations around the globe.
Read also: Chocolate, single origin or blend?
Roasting
Once the cocoa beans arrive at the production site, the first step is roasting. Roasting the cocoa beans is another crucial step in developing the final flavor of the chocolate. The temperature and duration of roasting varies depending on the type of cocoa and the type of chocolate you want to produce, but it is typically between 100°C and 130°C. Roasting not only improves the flavor of the cocoa, but also helps remove the outer skin of the beans, which is hard and inedible.
Usually the beans are roasted whole , but some producers prefer, for practical reasons, to crush the raw beans and then roast them at a later time.
Crushing and grinding
At this point in the chocolate making process, the cocoa beans are crushed and ground into a paste called cocoa mass or cocoa liquor, a combination of cocoa butter (the fat component) and cocoa solids. Grinding further breaks down the beans and releases the cocoa butter , resulting in a thick, runny mass.
The quality of cocoa liquor depends greatly on the type of cocoa used and the fineness of the grinding. Some manufacturers use advanced technologies to ensure that the consistency is perfectly smooth and creamy, a crucial step in producing high-quality chocolate.
Read also: Cocoa varieties, what are the main ones?
Cocoa pressing
The cocoa mass can now be used in two ways. It can be used as is to produce dark chocolate, as is done inside the Enrico Rizzi Chocolate Factory, or it can be subjected to a pressing process to further separate the cocoa butter from the solid mass.
Cocoa butter is the fatty component of cocoa, which is essential for giving chocolate its velvety texture. The remaining solids, however, are transformed into cocoa powder, which is used in products such as cocoa powder for drinks and chocolate powder.
The amount of cocoa butter in relation to the mass determines the percentage of cocoa in the final chocolate and influences its texture and taste.
Blending and refining
To produce the actual chocolate, the cocoa liquor is mixed with other ingredients such as sugar, milk powder (for milk chocolate) and in some cases additional cocoa butter. This step allows the chocolate's flavor and sweetness to be customized. Once the ingredients are mixed, the mixture is subjected to a further refining step.
During refining, the mixture is passed through rollers that further reduce the particles to a very fine consistency. This step is essential to ensure that the chocolate is smooth and free of lumps. A quality chocolate will typically have particles so small that the mouth will not be able to perceive them.
Read also: History and origins of gianduiotto
Conching
One of the most critical and distinctive steps in chocolate processing is conching. This process involves prolonged mixing of the chocolate in large heated containers, called "conches". Conching can last from a few hours to several days , depending on the type of chocolate you want to obtain.
During conching, the chocolate is continuously stirred and kept at a constant temperature, allowing the flavors to fully develop and giving the chocolate a smooth and creamy texture. This process also helps to eliminate any volatile acids, thus improving the final taste.
Tempering
After conching, the chocolate is subjected to a process called tempering. Tempering is a controlled heating and cooling step that allows the cocoa butter crystals to stabilize into a specific structure. This step is essential to ensure that the chocolate has a glossy texture, a clean break, and good resistance to melting.
If chocolate is not tempered properly, it will have a cloudy appearance and may form a white film on the surface, due to the separation of the cocoa butter. Tempering is usually done using special machines that carefully control the temperature and cooling rate.
Read also: What does From Bean to Bar mean?
Modelling and packaging
Here we are finally at the last step in the chocolate processing: once tempered, it is poured into molds to create the desired shapes , such as bars, pralines or chocolates. The molds are then cooled to solidify the chocolate. Cooling must be gradual and controlled to avoid the formation of unwanted crystals.
After cooling, the chocolate is ready to be packaged and distributed . This is when the finished product undergoes rigorous quality controls to ensure it meets the required standards.
Experience the chocolate making process first hand
Now that you know more about chocolate making, you can deepen your knowledge of this "sweet stuff" by coming to visit us in person at Enrico Rizzi's Chocolate Factory.
Come and discover Enrico Rizzi's selection of blends and vintage chocolates , or book your Chocolate Experience at via Gian Giacomo Mora 18 in Milan.
We are waiting for you!
