From bean to bar: the chocolate making process

The chocolate making process is far more complex than it appears. More than just a chocolate bar, it is the result of weeks of careful, precise work. From harvesting cacao pods to moulding the chocolate, every deliberate gesture, step by step, shapes the CAOYA chocolate you enjoy.

The steps of chocolate making

The chocolate making process is a craft that demands precision and attention at every step, to offer you a unique taste and aromas that tell the story of the bean’s origin.

1. Harvesting the cacao pods

The cacao pod is the fruit of the cacao tree. It grows directly on the trunk and is harvested by hand, one by one, at a precise moment of ripeness. A pod picked too early or too late alters the aromatic profile of the bean.

The pod is then opened to reveal the cacao beans, which are extracted and moved on to the next step.

2. Fermentation

The extracted beans are placed in wooden crates and left to ferment for 3 to 8 days. This is the most decisive step in the chocolate making process. It is here that the aromas develop, the ones that will, later, give your chocolate its fruity, floral, woody or spiced notes.

Without careful fermentation, aromas develop poorly or not at all. In industrial supply chains, this step is often cut short, which diminishes the aromatic depth of the cacao.

3. Drying

After fermentation, the beans dry slowly in the sun for one to two weeks. This step reduces their moisture and stabilises the aromas developed earlier. Drying too quickly or artificially can create imbalances in the bean and degrade its flavours.

Once dry, the cacao beans are bagged and exported to chocolate makers. This is where the farm’s work ends, and chocolate production begins.

In some tree-to-bar supply chains, the beans stay on site: the chocolate is produced directly on the farm, from the cacao tree to the bar.

4. Roasting

Roasting comes next, whether it takes place at the chocolate maker’s workshop or directly on the farm in a tree-to-bar supply chain.

Heat transforms the bean. The beans are heated to a precise temperature, for a controlled length of time. This is where the character of the cacao reveals itself: sweet, bitter, roasted or herbaceous notes.

For exceptional cacao, roasting is adjusted to each origin, and sometimes to each individual harvest. In industrial supply chains, this step is standardised to guarantee a consistent taste, which smooths out the natural differences that come from the terroir.

5. Grinding and conching

Once roasted, the beans are cracked to remove the shell, then ground until a smooth, dense cacao paste forms. This is the stage where other ingredients are added, such as sugar.

For our milk chocolates, we use only oat flour to replace dairy. Coconut milk and almond milk powder can also be used by other chocolate makers.

The paste then goes into a machine called a conche: in continuous motion, at gentle heat, the paste is refined for hours until perfectly smooth. Flavours develop while unwanted acidity is released. The longer the conching, the rounder and more balanced the chocolate is on the palate.

6. Tempering and moulding the chocolate

Before moulding, the chocolate must be melted and then tempered to achieve a glossy, smooth and snappy finish. By cooling and reheating the chocolate to precise temperatures, the cocoa butter crystallises to give the desired texture. This is what we call tempering.

The chocolate is then poured into moulds, cooled and unmoulded. The bar is finally ready.

The benefits of cacao-rich chocolate

Cacao has real benefits for your health. It contains antioxidants and magnesium, particularly in dark chocolate, which has a higher cacao content.

But these benefits depend on the chocolate making process. The more a chocolate is processed, sweetened or enriched with fats, the less it retains what the bean had to offer.

Our bars are crafted to take care of both you and nature: a short ingredient list, carefully selected cacao, well fermented and slowly conched, to preserve all its natural richness.

A chocolate bar: the result of a long journey

Chocolate may look like a simple treat. Yet behind each of our bars lies a craft, producers, small farms, local communities, passionate people, and lands worth preserving.

Understanding the chocolate making process changes the way you savour it, with more meaning, and the awareness that every bite has an impact on nature.

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