Cocoa production
Besides the nutritional characteristics of cocoa, the processing of the beans is of the utmost importance in order to guarantee quality chocolate. This process can be subdivided into the following phases:
HARVEST
The cocoa pods, which grow on the trunk and the larger branches of the plant, are broken off in order to remove the beans enclosed in their mucilaginous pulp. The beans are piled up on banana leaves to facilitate the fermentation process.
FERMENTATION
During the fermentation process - which lasts from 4 to 6 days – the bitterness and astringency of the beans is curbed and the basis for the aromas is developed. The cocoa bean is subjected to an increase in temperature of up to 50° C, which melts the mucilaginous pulp and facilitates the development of chemical reactions inside the bean itself.
DRYING
At the end of the fermentation process, the cocoa beans, now free of the mucilaginous pulp, are dried on the ground if the season is favourable. In case of rain, they are placed in well-aerated places. The drying process reduced the humidity to 7%.
ROASTING
The roasting of the cocoa is the most delicate operation and the identification of the ideal roasting point requires great experience. Bad roasting may have negative effects on the quality of the cocoa, which may have a burnt taste.
When the cocoa beans exit the cleaning machines they enter the roaster whole and are then heated to a temperature between 120 -140° C. They are then cooled and thrown into the winnowing machine that separates the shell from the meat, or nib, inside.
GRINDING
During this phase the cocoa bean is ground and turned into a liquid paste called cocoa liquor or paste, Made of cocoa butter and the dry part of the bean. This paste is mixed with sugar (or with milk in the case of milk chocolate) and refined. The chocolate is born.
CONCHING
The chocolate is put into vats and mixed at a constant temperature for up to 72 hours (but sometimes as long as 120 hours). This eliminates any humidity, unpleasant aromas, excess bitterness or acidity, and perfectly emulsifies all the ingredients.
TEMPERING
With the procedure the process of crystallization and solidification of the chocolate begins. This operation determines the chocolate’s ductility, gloss, and consistency.
Photo: The conching process (courtesy of the Touring Club Italiano and La Madia Travel)
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