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CHOCOLATE: From Cocoa Pods To Chocolate Bar
Chocolate ranks as the favorite flavor of most people - adults as well as children. And yet, few of us know how this popular treat is made. Chocolate making is an art as well as science. Read on and find out how this unique blend is achieved.

Born in the Jungle

Chocolates are made from cacao beans which grow inside pods on trees called Cacao tress. Cacao frees are found in tropical jungles in Brazil, Indonesia, Ivory Coast and Ghana. Each pod contains about 20 - 40 cocoa beans.

After the beans are removed from the pods, they are fermented in large heaps or piles. The fermentation process takes about a week to complete. After fermentation, the beans are dried. During this time, the shells harden, the beans darken, and the rich cocoa flavor develops. After drying, the beans are ready for transport to the chocolate factory.

At the chocolate factory, these beans are cleaned and stored. They are then roasted in large, revolving roasters at very high temperatures. A special hulling machine then takes the dry, roasted cacao beans and separates the shell from the bean - called the "nib." This part of the bean is actually used to make chocolate.

The nibs now are ready for milling. Milling is a grinding process which turns the nibs into a liquid called chocolate liquor/ cocoa mass - a smooth, dark stream of pure chocolate flavor without any alcohol content. Sometimes instead of using Cocoa liquor/ cocoa mass directly, cocoa powder and cocoa butter are separated from it. Now the cocoa liquor is ready for the rest of the ingredients.


Mixing it Up

The main ingredients in chocolate are the cocoa powder, cocoa butter, sugar and milk. The whole milk-sugar mixture is slowly dried until it turns into a thick material.

At the heart of the chocolate factory goes the central blending operation where the cocoa powder is combined with the milk and sugar. This new mixture is dried into a coarse, brown powder called chocolate crumb.


Crumbing the Chocolate Liquor

The raw mixture of milk, liquor, sugar, and cocoa butter is churned until it becomes a coarse, brown powder called "crumb."


Perfecting the Product

The chocolate crumb powder is used to make milk chocolate. The crumb travels through special steel rollers which grind and refine the mixture, making it smoother.

The crumb becomes a thick liquid called chocolate paste. The paste is poured into huge metallic vats called conches. Once inside the conch, large granite rollers smooth out the gritty particles from the crumb. Now the chocolate paste has the smooth and creamy familiar look of milk chocolate and it's ready to be made into our favorite Mitchell's products. The paste is tempered, or cooled in a controlled manner to the right texture and consistency. Other ingredients like Hazelnuts/Almonds can be mixed into the paste during refining to boost up natural taste & flavour.


Tempering the Chocolate

The refined chocolate is warmed & cooled in a controlled condition before coating or filling in the moulds in a process called "tempering." This gives chocolate its glossy sheen, and ensures that it will melt properly.


Chocolate Bars

Most chocolate bars are made by pouring the warm liquid chocolate paste into moulds. The filled moulds then take a bumpy, vibrating ride to remove air bubbles and allow the chocolate to settle evenly. Finally, they wind their way through a long cooling tunnel where the liquid chocolate is gently chilled into a solid shiny chocolate bar.

One important point to remember is that chocolate needs to be stored at appropriate temperatures otherwise its fat content will separate resulting in the appearance of yellowish fat spots on the chocolate surface. This problem is called a fat-bloom.

The chocolate bars are now ready for wrapping…... fresh, delicious Mitchell's chocolate! A sophisticated distribution system makes sure that our chocolate arrives at retail outlets across the country.
Thanks for visiting our chocolate factory!


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