Day 4 - Completion of process from Bean to Bar!

Another day spent with the smart and wonderful associates at the Mars Centre for Cocoa Science (MCCS)!

In the morning we split in 4 groups – representing the main 4 research buckets the centre deals with – Microbiology, Genetics, Breeding  and Chemistry. In each group we spent some time understanding and practicing the subject matter to then present back to the rest of the group.

My group and I were chosen to learn more about Microbiology. Stefan (who heads up microbiology at the MCCS) was fantastic at taking us through his findings on fermentation. He helped us understand the importance fermentation has on the taste of the final cocoa liquor and eventually chocolate and therefore the importance of his experiments. In so doing he introduced us to the main 7 flavour profiles of chocolate – cocoa, floral, fruity, bitter, astringent, acidity and other – which it was fascinating to learn about. It felt like being back in science class for the day!

Understanding fermentation with Stefan - collecting samples

Analysing fermentation samples in the lab

We re-grouped with team who took us through all of their findings with their own subject matter experts. All in all we got to really understand what happens at the MCCS  - the fantastic research & experiments that are taking place as well as having the opportunity to ask the subject matter experts any questions we might have.

Cocoa genetics 101 

Rani learning about breeding 

Groups sharing back the science they have learnt

In the afternoon we completed the chocolate bean to bar cycle:

1) We collected the dried beans, weighed them and packaged them into large 60KG bags. This is a standard measure of weight that cocoa beans are bought in – which is the same of other types of agricultural crops like cereal, corn etc.

Collecting the beans and weighing them into 60Kg bags 

2) We then took the beans to roast. This is done at very high temperatures (exceeding 200 degrees Celsius) using hot air in oven type machinery for a short periods of time (around 15mins).

Beans are opened and checked they are fine before roasting

To roast!

3) Once the beans were roasted and de-shelled the cocoa nibs (which are in fact the inside of cocoa seeds which have been fermented, dried and roasted) are put to grind at high temperatures which in turn creates the cocoa liquor. Cocoa liquor contains everything in the cocoa nibs, but is often split between cocoa butter (the fat content) and cocoa powder. This is so that at the time of making the final chocolate one can vary the measures of each  product to adjust the chocolate according to taste, texture etc. We also had a taste of cocoa liquor (which is in fact what professional cocoa tasters taste to differentiate between different cocoa varities) which was quite different to chocolate. Much more intense flavour, more bitter and mostly more astringent.

4) To turn the cocoa liquor into chocolate we need to add milk (powdered milk), sugar, pectin (or similar) and usually vanilla extract or other flavours.

5) Once all of these ingredients are mixed in we are left with a liquid substance which we would now recognise as chocolate. However, before moulding we need to temper the chocolate. This process involves heating the liquid up and then making it cool to approx. 28 degree by moving it around a cold surface. This process helps the chocolate achieve a lower melting temperature when formed and also gives the finished chocolate the shiny finish we have learnt to expect from it.

Chocolate is poured on a clean cold surface for tempering

Chocolate tempered by moving it around the cold surface with two spatulas

Chocolate is cooled to approximately 28 degrees Celsius

6) Finished tempering the chocolate is then molded according the different shapes and sizes one wants create.

Chocolate placed into molds for cooling

7) This is left to cool in fridges after which it is tapped out of the mold and ready to be eaten!!

And there you have it! On Day 4 we had completed our chocolate journey learning and experiencing hands-on the process of making chocolate from bean to bar!

From bean to bar

Of course after this process were all keen to try a bit of our very own chocolate we had made…and it tasted delicious! We also put it on trays and distributed it amongst the MCCS associates who were at this point leaving to go home. Judging by the smiles they were really happy to receive this treat at the end of the work day :-)

Handing out our freshly made chocolate to MCCS associates