The Process of Transforming Cocoa Beans into Chocolate

1. The cocoa beans are cleaned to remove all extraneous material.
2. The beans are roasted to bring out the chocolate flavor and color . The temperature, time and degree of moisture involved in roasting depend on the type of beans used and the sort of chocolate or product required from the process.
3. A winnowing machine is used to remove the shells from the beans, leaving the cocoa nibs.
4. The cocoa nibs undergo alkalization with potassium carbonate, to develop the flavor and color.
5. The nibs are then milled to create cocoa liquor. The temperature and degree of milling varies according to the type of nib used and the product required.
6. The different beans have to be blended together to the required formula, since manufacturers generally use more than one type of bean in their products and therefore use blending to effect flavor.
7. The cocoa liquor is pressed to extract cocoa butter leaving a solid mass called presscake. The amount of cocoa butter extracted from the liquor is controlled to produce presscake with varied proportions of fat.
8. The processing now takes two different directions. The cocoa butter is used in the manufacture of chocolate. The cocoa presscake is broken into small pieces to form kibbled presscake, which is then pulverized to make cocoa powders with differing cocoabutter content.
9. Cocoa liquor is used to make chocolate through the addition of additional cocoa butter. Other ingredients such as sugar, condensed milk or cream, emulsifying agents, flavors and cocoa butter equivalents are also added and mixed using a machine. The proportions of these ingredients depend on the type of chocolate.
10. The mixture then undergoes a refining process by travelling through a series of rollers until a smooth paste is formed. Refining improves the texture of the chocolate.
11. The next process, conching, further develops flavor and texture. Conching is a kneading or smoothing process. The speed, duration and temperature of the kneading affect the texture and flavor of the finished chocolate. An alternative to conching is an emulsifying process using a machine that works like an eggbeater.
12. The mixture is then tempered, passing through a heating, cooling and reheating process. This prevents discoloration and fat bloom in the product by preventing certain crystalline formations of cocoa butter developing.
13. The mixture is poured into moulds or used for enrobing fillings and cooled in a cooling chamber.
14. The chocolate is then packaged for distribution to wholesale or retail outlets.

References:
The story of chocolate. The Chocolate Manufacturers Association of the USA
Dand, R. The International Cocoa Trade. Woodhead Publishing, 1993
Minifie, B.W. Chocolate, cocoa and confectionery science. 3rd edition. Van Nostrand Reinhold, 1989