D Todo - Fábrica de chocolates (19/10/2016)

Introduction to Chocolate Production

Overview of the Chocolate Factory Tour

• Alexia introduces the chocolate factory tour, highlighting the transformation from cacao fruit to chocolate.

• Concepción, a chemical engineer, joins the tour to explain the processes involved in chocolate production.

Initial Steps in Chocolate Making

• The cacao arrives in bags as raw beans primarily sourced from Tabasco and Chiapas, Mexico.

• The factory has been producing chocolate since 1896 and emphasizes sanitation with specific rules for visitors.

Processing Cacao Beans

Fermentation and Roasting

• Cacao beans undergo fermentation to develop color, flavor, and aroma; roasting further enhances these qualities.

• The roasting process is crucial for removing moisture and achieving desired flavor profiles.

Shell Removal and Grinding

• After roasting, the outer shell of the cacao bean is removed to obtain the nib or granilla used for further processing.

• The grinding process produces cocoa mass or liquor, which is essential for making chocolate.

Extracting Cocoa Butter

Pressing Cacao Liquor

• The cacao liquor is pressed to separate solid cocoa cake from cocoa butter; both are vital ingredients in chocolate production.

• Regulations dictate specific ratios of cocoa butter and liquor required to label a product as "chocolate."

Creating Different Types of Chocolate

Mixing Ingredients

• To create various types of chocolate (dark, milk, white), different proportions of sugar, milk powder, and cocoa butter are mixed.

• Refining improves texture by ensuring that all components blend smoothly without graininess.

Conching Process

• Conching involves mixing chocolate at controlled temperatures for 24–48 hours to enhance creaminess and reduce moisture content.

Finalizing Chocolate Products

Tempering and Molding

• Tempering stabilizes cocoa butter crystals ensuring that finished chocolates have a glossy finish and snap when broken.

• Automated machines control dosages during molding while maintaining proper temperature settings throughout the process.

Filling Chocolates

• Once molded into shells (coquillas), chocolates can be filled with various fillings like liqueurs or creams before sealing them with additional layers of chocolate.

Packaging and Artisan Techniques

Individual Wrapping Process

• Finished chocolates are wrapped individually using automated machines designed for efficiency while maintaining quality standards.

Traditional Methods

• Artisanal techniques are still employed in some products like hojuelas where workers manually temper chocolate before shaping it.

Conclusion on Chocolate Varieties

Diverse Applications of Chocolate

• Various forms of chocolates can be created including covered nuts or fruits showcasing versatility in flavors.