Production of chocolate

Production of cocoa

The main component of chocolate, cocoa, cocoa beans, is extracted from the seed of the cacao tree. Cocoa beans are in jute bags of approximately 70 kg imported from tropical regions. The cocoa beans were already fermented and dried (see cocoa tree). Upon arrival, the beans of various origin, mixed to a smooth taste. Then the beans are cleaned: twigs, rope, pebbles and similar items are removed. Then the beans are roasted in revolving drums at a temperature up to 140 ° c. The temperature and duration determine to a large extent the final taste of cocoa. The roasted beans then go by a breaker. The CAP breaks open and is blown away so that only the core (nib) remains. The cores are in the cocoa Mills finely ground to form a thick paste fixed. This is called the cocoa mass. From this product can be withdrawn from the fat. This is called the cocoa butter. The thick, hard lump that remains, is ground into skinny cocoa, or cocoa powder.

Below is the production in greater detail.

-Fermentation

The first step in the production process is the fermentation. This can happen in different ways.
On a smaller scale in the beans and hope this covered with leaves of the banana tree. This hope can contain 25 kg to 2500 kg beans. Sometimes also the beans in baskets. Most growers mixes their beans on the second or third day of fermentation, on the one hand, to obtain more homogeneity, on the other hand, to involve more oxygen in the process, in order to avoid lactate formation.

In plantations or gisterijen be the beans and pulp collected in large wooden bins, which contain 1 to 2 tonnes of beans. Usually the baking is not too high to have a large contact surface with air oxygen. Sometimes the beans ferment after a while, in another FRY also for reasons of oxygen supply. On a large scale the beans usually ferment longer than on a small scale.

Depending on the species, the mass two to eight days rest. In a first phase, there are micro-organisms, mainly yeasts, in the pulp. Presumably are insects like fruit flies responsible for these introductions. The temperature can reach up to 50 degrees. The yeast is responsible for that on the first day the sugar in the flesh is converted into alcohol and carbon dioxide. Also lactate formation can occur, but that is detrimental to the taste and should therefore be avoided, by enough oxygen. Pectolytic enzymes and other glycosidasen are responsible for the degradation of the polysaccharide structuurgevende. The pulp is liquid and washes away. The extra oxygen available which leads to further oxidation of the alcohol to acetic acid, mainly from the second through fourth day.

The decrease of pH of about 6.5 to 4.5 ensures that the cell membranes of the beans are more permeable. The cocoa beans lose their germination potential and oxidation process begins also now within the beans themselves. Of the fifth to the seventh gistingsdag are especially the phenolic components which oxidised and condensed. These are responsible for the typical color (reddish brown) of the fermented cocoa beans. The decrease in quantity improves the original strong, bitter taste dissolved phenols. The fermentation process is very important for the final aroma of cocoa, and must therefore be done with care. Of course, also the growth of harmful micro-organisms must be avoided. The fermentation of the cocoa usually finds place in the country of production.

-Drying

The fermentation process is stopped by drying the seeds until they have a moisture content of less than eight percent. This physical process must happen slowly. If it happens too quickly, some chemical reactions from the fermentation process but half ' finished ' what fatal for the final taste. There are two dry methods: dry in the Sun and artificial drying. For drying in the Sun, the beans are spread over a dry, clean surface. The beans are rotated to ensure a uniform drying. Drying in the Sun is little done on an industrial scale. Artificial drying is done mainly with warm air.

-Burn

The fermented and dried cocoa is transported to the consumer countries and further processed. The beans are collected and purified according to size. It is important that the cocoa beans is roughly equal to be burned. Burning contributes to the further oxidation of phenols (important for taste) and further reducing the moisture content, up to three percent. Also the eggs and larvae of pests are destroyed in this way. The flavor of the beans is the better, deeper color. The seed is hard and brittle. The pel is looser as a result of enzymologische and thermal responses.

Maturity, moisture content, size, and previous processing steps determine the degree of roasting. In general rises the temperature when roasting not above 150 ° c. Toasting itself lasts for 10 to 35 minutes. The heat transport happens directly via heated surfaces or via warmeluchtstroom, without incurring the peel of the burned beans. The beans are cooled immediately after roasting: in this way is the toasting process completely stopped.

-Seven

The roasted beans are sifted after burning to the peel and remove the germ to carrots. After the seven achieves about 80% beans, 10% pel, a small amount of germs and approximately 4% fine cocoa particles at the ' waste '. The beans themselves still contain 1.5 to 2% Peel and germs. Although the cocoa Peel waste is considered to be of little value, it can be used for different purposes such as winning theobromine, as a tea or, after the extraction of fat, if fertilizer or fuel. What is widely regarded as good, pure cocoa contains up to 1.8% Peel residues.

-Times

The cocoa beans are ground now. A homogeneous, viscous cocoa mass. This mass is partly directly used in chocolate production, otherwise, cocoa powder and cocoa butter.

Presses: cocoa butter and cocoa powder

This mass is now subject to an alkali satie process. The intention is to improve the taste by partial neutralization of the free acids, but also to the color, homogeneity and suspension to improve capacity. In the alkali satie process, introduced in 1828 by Coenraad Johannes van Houten, the cocoa mass treated with an aqueous 2-2.5% alkaline solution at a temperature of 75 to 100 ° c. Then the whole, if necessary, neutralized with acid. The whole is dried to a moisture content of 2% using a vacuum dryer or by further kneading of the mass above 100 ° c. This treatment causes a swelling starch with due to a spongy and porous structure of the cocoa mass. The alkaline cocoa mass contains about 55% fat. This cocoa butter is removed with hydraulic presses from the mass. This happens at a pressure of 400 to 500 bar and a temperature of a small 100 ° c. There remains a harsh, dry chocolate cake, which still contains 10 to 24% fat. This is then ground into cocoa powder. The largest part of the cocoa butter is used in the production of chocolate. Cocoa powder with a low fat is processed in Sandwich siege and bakery products. Cocoa powder with a high fat content is, among other things used in the manufacture of chocolate milk and ice cream.

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