Everyone loves chocolate. This deliciously sweet piece of heaven is often referred to as the “food of the gods”. The substance itself comes from cocoa, also called cocoa beans. But how exactly does the bean turn into those brown candies that you love so much? The answer is in the chocolate factory.Here are some of the processes you can see when you visit the factory:
What Is Cocoa Bean Processing?
Cocoa beans are unlikely to be harvested since most factories source the beans from different parts of the world. However, you will see how the beans are processed. First, see how beans are cleaned and sifted to remove unwanted substances like pulp and dried pods.
After cleaning, you’ll see how beans are classified by country of origin. What is the purpose of it Did you know that the taste of chocolate produced by a cocoa bean is affected by its growing conditions? This means that beans from different countries produce different types of chocolate. After sorting, the grains are mixed according to the wishes of the company. Each company has its chocolate mix.
When the mixture is made, the beans are roasted, giving them the rich brown color that people love. This is where the aroma of chocolate is released.
What Is Milling and Pressing?
Roasted beans are put into a process of breaking and separating the bean shell from its top or part in the middle. The tip is the actual part from which chocolate is made. When the tips separate, they are placed in the grinder where they are ground to extract the liquid known as chocolate liquor.
The chocolate liquor is placed in another machine that uses hydraulic pressure to extract the oil known as cocoa butter. What remains are dark brown cakes that turn into cocoa powder after drying and grinding. Later, cocoa butter is added to precise amounts of powder to make different chocolate liqueur blends for different products.
Milk and sugar are other important ingredients for the production of chocolate. A chocolate factory often uses gallons on gallons of milk to make chocolate. First, milk and sugar are mixed in exact quantities. Then the chocolate lye is added, which turns the mixture brown. Continuous mixing and application of heat make the combination a powder. Then more cocoa butter is added to this powder.
The mixture of ingredients can be called chocolate, but the chocolate factory isn’t over yet. The liquid is continuously rolled and agitated to get a smoother texture. The longer the processing, the better the texture. After that, different product lines can be made from chocolate.
Make Chocolate Paste
After receiving raw cocoa-based products like butter, dough and powder, the chocolate factories have to combine them with a milk powder and also sugar. This process takes place in certain machines with a capacity of 500 kg to 2 tons that automatically mix these ingredients. Chocolate paste forms 12 hours later.
Below you can see how chocolate turns into these delicious snacks that make people so happy. In a chocolate factory, you may be able to see how the liquid flows into the molds and becomes bars. You may even see nuts and other little things in the molds to make chocolate-covered products.
When the chocolate has hardened and hardened, see how it is packaged. Each bar or piece of chocolate is individually packed with machines. Even Hershey’s kisses are packaged individually. Is not that great?
When you visit a factory, you are more likely to end up in a shop where the products are sold. Without a doubt, his entire journey and observations have led him to develop a great craving for chocolate. Why not buy some? You will find the different results of the same wonderful bean called cocoa.
Modern Chocolate Factory
When people think of a chocolate factory, they are likely to instantly conjure up the quaint place. And although the reality is far less charming, the truth is that the modern chocolate factory creates its form of magic to bring the gift of chocolate to the masses.
Statistics say everything; Chocolate consumption is estimated at more than £ 3.3 billion a year in the United States alone. To keep up with this constant demand, today’s chocolate factory uses a complex system to deliver a variety of chocolate products to consumers in record time.
The chocolate manufacturing process in today’s chocolate factory has largely remained the same when mechanical chocolate production made its debut during the industrial revolution. Start with cocoa beans that have been carefully classified to rule out blemishes. As a rule, this is a hand-made process, one of the few hand-made processes that is still carried out in the chocolate factory and culminates in the separation of each seed in the type and country from which it comes. From there, the seeds are thoroughly cleaned and weighed.
Then the cocoa beans are roasted in the chocolate factory until all of the moisture is completely removed and the beans have a rich, dark brown color. After roasting, the seeds go through a machine in which the bowls are opened to reach the seed pieces or seed pieces inside. The tips are classified by size in a chocolate factory process known as winning. The tips contain the taste of chocolate and are crushed in heavy chocolate liqueur, to which milk and sugar are added to preserve the chocolate that we know and love.
Hygiene is a very important aspect in a chocolate factory in the Middle East. The reason goes beyond certification and building a good reputation. It’s about protecting people’s health through a clean and hygienic environment. Here are some ways to maintain good hygiene in your chocolate factory:
How to keep food equipment and infrastructure in constant maintenance
All devices used for chocolate production must be checked regularly and any signs of deterioration repaired immediately. If the defective part can be repaired without being removed from the production area, delicate work and the placement of an insulating screen are required. It is very important not to create a mess that affects the entire machine or, worse, the product itself. On the other hand, the devices and machines that have to be removed from the production room for repair must be handled with care. Everything that comes from the food sector must be clean and sterilized.
Regarding the infrastructure part, regular checks have to be carried out to keep your work environment safe and clean. Anomalies in the building must be corrected immediately before major problems such as floor and dust arise. Buildings and building repairs should be carried out outside the production periods. However, if this is not possible, a partition should be erected to isolate the production room.
Organize a safe work environment without contamination.
The reputation of the factory (and brand) is damaged if a small thing develops in an undesirable way. Therefore, all tools that can come into contact with an ingredient must be disinfected. Cleaning and disinfection must be part of the daily work in your factory. Unwanted materials such as dirt and foreign bodies should be removed from all devices to keep them clean and hygienic.
To protect your products, however, 2 storage rooms must be separated from each other. The first room is used for disinfection products to keep them away from the production area. The other is used to protect your edible materials from contamination and should be cleaned and disinfected with intensive care.
Keep pests away by constantly using pesticides.
Food factories, particularly chocolate factories, attract insects by smells. These places are considered a good habitat for insects to have water, food and shelter. For this reason, inspectors must constantly visit your factory to identify and eliminate the danger. To rule out future risks, inspectors should review past results. However, if pest control technicians are absent, employees should warn of potential dangers as they are always present at the factory.
Put a hygiene policy on all of your employees and visitors.
Chocolate production areas must be free of contaminants. For this reason, clear rules must be laid down for everyone ready to enter this area. Personnel working near chocolate must take more serious precautions. Every step you take must be safe. If you work directly with chocolate, you have to wash your hands regularly. This does not prevent them from wearing gloves, masks, hairnets and clean and disinfected clothes. Any violation of the hygiene standards must be severely punished.
As a symbol of sensuality, every male applicant is wise to offer a chocolate gift to every future woman. A delicious box of dark foods, all wrapped in decorative gold foil, will make every chocolate-loving woman’s face smile. Cocoa has always been associated with fertility and love for indigenous cultures.
In conclusion , a good hygiene structure requires the efforts of everyone involved to maintain the reputation of the brand and the product, and above all the health of the consumer. Starting with top-level administration for all employees, chocolate factory employees must take precautions to maintain a healthy environment and maintain a high level of chocolate production.