Growing

Cocoa Beans

A ll chocolate begins with cocoa beans,

the fruit of the cacao tree (also called
a cocoa tree). Scientists know that the cacao tree
originated somewhere in South or Central America.
Some say the first trees grew in the Amazon basin
of Brazil, while others place its origin in the Orinoco
Valley of Venezuela. Wherever its first home, we know
the cacao tree is strictly a tropical plant thriving only in
hot, rainy climates. Cocoa can only be cultivated within
20 degrees north or south of the equator.

Growing Region
Growing Cocoa Beans

The Need for Shelter

The cacao tree is quite delicate. It needs protection from direct
sun and wind, requiring a canopy of shade to thrive. Cacao
seedlings often are planted in the shelter of taller mother trees
such as banana, plantain, coconut and rubber which provide the
necessary shade while also producing other important crops.
Once the cacao trees are established, they can tolerate much
more sunlight, but they grow best on small plots of land in partial
shade, tended regularly.

As a general rule, cacao trees get their start in a nursery bed

where seeds from high yielding trees are planted in fiber baskets
or plastic bags. The seedlings grow so fast that in a few months
they are ready for transplanting.
Growing Cocoa Beans

The World Cocoa Foundation, sponsored by the chocolate and

related industries, supports sustainable cocoa growing in its
mission to improve the standard of living of cocoa farmers
around the world. The Foundation provides programs that teach
cocoa farmers efficient methods to produce quality cocoa in a
sustainable, environmentally friendly manner.

A Closer Look at the Cacao Tree

Everything about the cacao tree is just as colorful as its history.
An evergreen, the cacao tree has large glossy leaves that are red
when young and green when mature. At maturity, the cultivated
cacao tree stands 15-to-25 feet tall, though the tree in its wild
state may reach 50 feet or more. Cacao trees have been known
to live 200 years in their natural environment, but they are most
productive for about 25 years.

Moss clings to the cacao tree’s trunk, sometimes alongside colorful

lichens. In some areas, small orchids grow on its branches.
Throughout the year, the tree trunk and major branches sprout
clusters of tiny, waxy pink or white five-petaled blossoms. Of the
thousands of flowers that grow on a single tree, only 3-to-10
percent are pollinated by tiny flies and other insects. The pollinated
flowers develop into mature fruit about six months later — the
pods that contain cocoa beans.

The cocoa pods are a rather unusual site, growing directly from
the trees trunk and major branches. The pods are oval, or
football-shaped, ranging from 7-to-14 inches long. At first, the
pods are green or maroon in color. The green pods generally
ripen to a bright yellow-gold and the maroon pods become
orange or yellow-orange.

Varieties of Cacao
There are two main species of cocoa: Criollo and Forastero. Criollo
is sometimes called the prince of cacaos because it is a very high
quality grade of cocoa with exceptional flavor and aroma. Less
than 15 percent of the world's cocoa is Criollo, grown mainly in
Central America and the Caribbean. Forastero is a much more
plentiful variety of high quality cocoa, representing most of the
cocoa grown in the world. Grown mainly in Brazil and Africa, it is
hardier, more productive (higher yielding) and easier to cultivate
than Criollo and is used in just about every blend of chocolate
that is made.

A third type of cocoa also deserves mention. Trinitario, a hybrid or

cross between strains of the other two types, originated in Trinidad
nearly 300 years ago. It possesses a good, aromatic flavor and the
trees are particularly suitable for cultivation.

Within these main types, there are several varieties of cocoa, each
with distinct qualities. Chocolate makers purchase different varieties
of beans and blend them to create their chocolate products. C
 The Cocoa
Bean harvest

C ocoa pods are harvested by hand, one by one. Each pod

is carefully cut from the tree with a machete or sharp
knife. Pods that grow on the tallest branches are harvested with
knives attached to long poles. On small family-owned farms, the
entire family may participate in the harvest of cocoa pods as well
as other crops.

It requires training and experience to know by appearance which

cocoa pods are ripe and ready to be picked. Ripe pods are found
on trees at all times of the year since the growing season in the
tropics is continuous. For most cocoa-growing regions, there is
a main harvest and a secondary harvest about six months later.
Climatic differences cause wide variations in harvest times with
frequent fluctuations from year to year even within the same region.
What Happens After Picking
The pods cut from the trees are collected in piles in an
open area not far from the cacao trees. Here the woody pods are
opened with one or two lengthwise taps from a well-wielded
machete. A good breaker can open 500 pods an hour. Inside the
pod, 20-to-50 cocoa beans are hidden in a moist, cream-colored
pulp. The beans are scooped from the pod and the outer shell
and inner membrane are discarded. If you tasted a bean at this
point you would notice a sweet, lemon-like flavor from the pulp.
The bean itself would be too bitter and hard to eat.

Once all of the beans are scooped

from the pods, they are placed in
sacks and carried to the area where
they will be fermented and then dried
as the next steps in their many days
of processing.

Fermenting and Drying

Fermenting is a simple “yeasting”
process in which the sugars contained
in the beans are converted to acid,
primarily lactic and acetic acids. The
fermentation process takes from two-to-eight days, depending
upon the cacao variety (Criollo beans ferment more quickly than
Forestero). The beans are placed in large shallow wooden boxes
or, on smaller farms, are left in piles and covered with banana leaves.

The fermentation process generates temperatures as high as 125

degrees Fahrenheit, activating enzymes in the beans that break
down bitter substances and begin to develop the more familiar
flavor and aroma of chocolate. When fermentation is completed,
the result is a fully developed cocoa bean with a rich brown color,
a sign that it is now ready for drying.
The Cocoa Bean harvest

Like any moisture-filled fruit, the beans must be dried if they are
to be preserved. In some countries, drying is accomplished simply
by laying the beans on trays or bamboo matting and leaving them
to bask in the sun. When moist climate conditions interfere with
sun-drying, the beans can be dried inside a covered structure.
Blowers circulating hot air may also be used.

The drying process takes several days.

Farmers or workers turn the beans
frequently and use this opportunity to
pick through them, removing foreign
matter and flat, broken or germinated
beans. During drying, beans lose nearly
all their moisture and more than half
their weight. When the beans are dried,
they are ready to be shipped to chocolate
factories around the world.

Farmers take the fermented and dried

beans to collection sites where they are
mixed with beans from surrounding
farms. The beans will be loaded into 130-to-200 pound sacks and
transported to shipping centers.

Marketing For Export

Cocoa buyers sample the quality of the crop by cutting open
a number of beans to see that they are properly fermented. The
beans should have a brown center and be aromatic. If the crop
is found satisfactory, the grower is paid at the current market price.
The market price depends not only on the abundance of the
worldwide crop and the quality of the beans, but also on a
number of economic conditions throughout the world. There are
Cocoa Exchanges, similar to stock exchanges, in major cities such
as New York, London, Hamburg and Amsterdam. C
 From Bean
To Chocolate

W e now come to the remarkable art of chocolate-making.

The manufacturing process requires much time and
painstaking care. Making an individual-size chocolate bar, for
instance, takes at least two-to-four days.
from bean to chocolate

The pressed cocoa cake that remains after the cocoa butter is
removed can be cooled, pulverized and sifted into cocoa powder.
The powder is packaged for sale in grocery stores and in large
quantities for commercial use as a flavor ingredient by dairies,
bakeries and confectionery manufacturers. Some companies use
what is called the Dutch process to further process their cocoa
powder. This involves treating the cocoa with an alkali, which
develops a slightly lighter flavor and darker color and makes the
cocoa powder easier to mix with water.

How To Make Eating Chocolate

While cocoa butter is removed to make cocoa powder, it must be
added to make chocolate. This holds true of all eating chocolate,
whether it is dark, bittersweet or milk chocolate. Besides enhancing
flavor, the added cocoa butter makes the chocolate more fluid.

One example of eating chocolate is sweet chocolate, a combination

of unsweetened chocolate, sugar, cocoa butter and perhaps a little
vanilla. Making it entails melting and combining the ingredients in
a large mixing machine until the mass has the consistency of dough.
Milk chocolate, the most common form of eating chocolate, goes
through essentially the same mixing process except that it involves
using less unsweetened chocolate and adding milk.
Whatever ingredients are used, the mixture then travels through
a series of heavy rollers set one atop the other. These rollers press
against the ingredients until the mixture is refined to a smooth
paste ready for “conching.”

What Is Conching?
Conching is a flavor development process which puts the chocolate
through a “kneading” action. It takes its name from the conch
shell-like shape of the containers originally used for this process.
The “conches,” as the machines are known, are equipped with
heavy rollers that plow back and forth through the chocolate mass
anywhere from a few hours to up to seven days. At this stage,
flavorings are added if called for in the recipe. Conching develops
the complex flavors and makes the chocolate velvety smooth.

In some manufacturing setups, there is an emulsifying operation

that either takes the place of conching or else supplements it.
In this operation, a machine that works like an eggbeater breaks
up sugar crystals and other particles in the chocolate mixture,
creating a fine-grained, extremely smooth chocolate.

21
from bean to chocolate

After conching, the mixture is “tempered” — a process of carefully

cooling the mixture while continually stirring it. Finally, the liquid
chocolate is ready to be poured into molds shaped like the final
product. The molds may be in any shape and size ranging from
your favorite chocolate bar to a chocolate bunny to a ten-pound
block of solid chocolate destined for use by others in the
confectionery industry.

The liquid chocolate also is used to enrobe (coat on all sides)

certain chocolate bars such as those with whipped nougat centers
and boxed chocolates which contain a variety of centers made
from cream, fruit, nuts, and other ingredients. The liquid chocolate
is pumped into an enrobing machine where it is stirred and kept
warm. The already-formed centers travel through the enrobing
machine on a conveyor belt where they are coated with chocolate
and then cooled.

Ready For Shipment

The molded or enrobed chocolate products are carefully cooled
in a cooling chamber and then are ready to be wrapped or
packaged. If the product is a chocolate bar, for example, it will
travel through an automated wrapping machine that precisely
wraps it and then sends it down the production line to be placed
in cases for shipment to distributors and retail stores throughout
the country.

For convenience, chocolate is frequently shipped in a liquid

state when intended for use by other food manufacturers.
Whether solid or liquid, chocolate provides candy, cookie and
ice cream manufacturers with the most popular flavor for their
products. Additionally, chocolate is used for coatings, powders
and flavorings that add delicious flavor to many foods in a
thousand different ways. C
 Inside A
Chocolate Factory

T he chocolate factory is an amazing environment where

science, technology and art combine to create many
delightful products. Every step in the making of chocolate in the
modern chocolate factory is carefully controlled from the moment
the sacks of cocoa beans arrive until the finished products are
carefully wrapped, boxed and shipped to retailers nationwide.

Computers control the entire manufacturing process in many

factories. They regulate temperatures, stabilize the moisture
content of the air and control the carefully timed intervals of each
manufacturing operation. This exacting control helps the company
achieve precise, quality results with every batch of chocolate made.
Inside a chocolate Factory

Creating Safe and

Wholesome Products
Only the purest, high-quality ingredients
are used to make chocolate. Raw
materials such as milk, nuts, and
flavorings are carefully tested for safety
and purity before they are accepted as
ingredients. Throughout the chocolate
production process, samples are taken
and tested to ensure the products meet or exceed safety and
quality standards.

Cleanliness also is stressed in the chocolate factory. Stringent daily

sanitation programs include thoroughly cleaning the equipment
and manufacturing environment.

All chocolate manufacturers also must meet standards set by the

U.S. Food and Drug Administration. These regulations govern
manufacturing formulas. For example, the FDA specifies the
minimum content of ingredients such as milk and chocolate
liquor in chocolate products. The FDA also imposes strict rules
regarding the flavorings and other ingredients that may be used
in chocolate products.

As part of their laboratories, many chocolate factories have

pilot plants — a small plant within the main facility that contains
miniature equipment that duplicates what is found in the main
plant. Here, new processes are tested and new products
developed to further tantalize the taste buds of chocolate
C
lovers.
Chocolate MANUFACTURE
COCOA BEAN PROCESSING CHOCOLATE-MAKING

DRYING AND
FERMENTING
COCOA
BUTTER
+ CHOCOLATE
LIQUOR
BEANS
+
SUGAR MILK
SHIPPING TO
CHOCOLATE
FACTORIES

BLENDING OF BLEND & MIX

COCOA BEANS

CLEANING AND
CRACKING CREATES NIBS
(WINNOWING)
REFINE

ROASTING

CREATES CONCHING
GRINDING CHOCOLATE
LIQUOR

PRESSING CREATES
(OPTIONAL) COCOA
BUTTER
TEMPERING

PRESS
CAKE

GRINDING, CREATES CHOCOLATE CHOCOLATE LIQUID BULK

COOLING AND COCOA BARS, CHIPS, BLOCKS CHOCOLATE
TEMPERING POWDER ETC.