Cocoa Beans to Chocolate Bar.

Process flow chart which explains how cocoa bean is converted to Chocolate bar

Cocoa beans or Cocoa comes from the cacao tree or Theobroma (a Greek word that means “food of the gods”) cacao.  Cocoa beans was the basic ingredient in the ancient times for the production of the chocolate.  During that period ,chocolates were made in liquid form and people used to drink it. Introduction to the chocolates bars happened in 19th Century and their sales grew more rapidly in the early 20th century.  Till date, cocoa beans are prominently used to manufacture the chocolates on a very large scale.


   Process of Cocoa beans to Chocolate bar

Now Lets see the Stage wise  process of how Chocolate Bar is formed from Cocoa Beans.


Stage 1 Growing of Cocoa Beans
  • The period of Cocoa trees is up to 25 to 30 years and it takes up to 5 years to produce the first Cocoa pods. The height of the tree is about 30 ft.
  • Every year these trees blossom thousands of flowers on their trunks and branches but hardly 1% of these flowers produce a cocoa.
  • The cocoa pods will begin to ripen 5-6 months after it blossoms.
  • They are found in dark brown to orange, red, yellow and green colors.
  • Each pod contains 30-50 beans (shaped like a flat almonds). These beans are finally transferred into cocoa powder.


Stage 2 Harvesting Cocoa beans
  • After the pods are ripen, they are cut down from the trees with the help of heavy knife and for the higher pods, long poles with a cutting edge are used.
  • Proper care is required while cutting the pods to prevent it from damage. Thus it won’t hamper the quality of the fruit produced throughout the year.
  • These pods are harvested in two harvest seasons: the main harvest and the Mid-harvest (falls after six months of main harvest).


Stage 3 Removing Cocoa
  • After cutting the pods, they are placed in piles.
  • With the help of the heavy knife, it is been cut in two halves.
  • The beans (roughly 30-50 in each pod) are removed.
  • These beans are piled on the top of large banana leaves.


Stage 4 Fermenting of cocoa beans
Cocoa beans are fermented for the following three purposes:
  • To remove the mucilage(an adhesive solution; gum or glue)
  • Stop the cocoa beans from germinating
  • To begin the flavor development
  • Fermentation is a requisite step for a high quality cacao bean development that will be transformed into gourmet chocolate.
  • Many farmers adopted the traditional approach of fermenting the beans in a large pile on the ground in between banana leaves or sacks.
  • Some groups ferment beans in wooden boxes for a period of six days.


Stage 5 Drying of cocoa beans
  • The drying stage is essential after fermentation, bringing the humidity of the beans below 10% for storage and export.
  • Cacao beans are often dried in the sun, which can happen on tarps or mats. They are continually raked so that they will dry more evenly.
  • It shouldn’t be dried too much as it becomes brittle.
  • Once dried, cocao beans can be stored for 4-5 years.


Stage 6 Roasting & Winnowing of cocoa beans
  • After the dried beans arrived at the processing plant, first they are cleaned to remove any debris.
  • These beans are roasted at different temperatures and in varied time duration depending upon the humidity, size of beans and the desired flavour to darken the color.
  • After roasting, beans are winnowed in which the shells of the beans are removed ,leaving behind the roasted cocoa core. It is the basic and vital ingredient to make the chocolate.


Stage 7 Grinding of cocoa beans
  • In this process, the cocoa nib or cocoa core is ground into a paste called chocolate liquor (having no alcoholic content).
  • Chocolate liquor can either be used directly in the production of chocolate bars or further processed to separate the fat, known as cocoa butter, from the cocoa solid, leaving cocoa press cake.
  • Cocoa butter is used in chocolate bars and beauty products. Cocoa press cake is milled into cocoa powder to be used for baking cocoa and hot cocoa.


Stage 8 Conching process
  • Conch comes from the Spanish word Concha, which means shell.
  • The name “conching” arouse because the original vessel used to hold the chocolate was shaped like a conch shell.
  • Conching is a modern process used in making chocolate. The characteristic taste, smell and texture of chocolate are developed at this stage.
  • To make chocolate bars, chocolate liquor and cocoa butter are blended with other ingredients such as sugar, vanilla, and milk (for milk chocolate).These ingredients are then refined.
  • This process thoroughly blends the ingredients, taking out some of the acidity of the cacao and further developing the flavors that will appear in the final bar.


Stage 9 Tempering & Molding of Chocolate
  • After the conching is complete, the chocolate is then “tempered” through a slow, stepped decrease in temperature. During this process, the chocolate is cooled and then warmed, then cooled further and warmed once again, and so on until it reaches the correct temperature, creating an even crystallization of the ingredients throughout the chocolate.
  • After the chocolate is properly tempered, it is ready for additional ingredient inclusions such as almonds, coffee beans, or sea salt.
  • The chocolate is then poured into molds, which form the shape of the bar. The chocolate cools until it becomes solid and is then removed from the molds as chocolate bars.


Stage 10 Quality Analysis of Chocolate

The quality department needs to perform the following functions:

  • To check the quality of every chocolate and Cocoa product leaving from their warehouse,
  • Members from this department undergo requisite trainings and they need to explore their talents to improve the standard of the chocolate bars.
  • The department compares a new shipment of chocolate to a previous shipment, to ensure consistency
  • They need to fill a feedback form about the product’s aromas, flavours and taste.

I hope  you are enlightened with the entire process. If you have any querries,please do not hesitate to ask us .

Interpack17: An Important information

Interpack 2017 some important information before you start you journey for trade-fair and take most out of it

We are in last week of April 2017 and this reminds me that from next week Interpack17 will start. As you know that this provide a solution for packaging industries, chocolate, confectionery, pharma and other related process technologies under one roof, which is  organized after every three years. By end of this week everything at Düsseldorf will be tightly packed. Quickly lets go through some of the important information which will help you to manage your trip in better way.

Finding exhibitors, planning your visit Interpack 2017:

You will find all exhibitors and products in database at their official website of traid fair organizer

With “MyOrganizer“, you can put a list together of all exhibitors (incl. their locations) that you would like to visit. With the site plan, you have a perfect overview of the trade fair.


How to use MyOrganiser

Perfect completion: components at #interpack17

One ticket. Two trade fairs. One way. The supplier trade fair components is an integral part of interpack 2017 this year.

Realistic networking

Discussing, getting advice and exchanging ideas.


Not booked ticket yet?

Buy your ticket or redeem voucher now at ticketshop

To ticketshop

Many other important information is complied one interpack’s website, clickhere to know more.

Note: Image is taken from Interpack’s Facebook page.

Want to go to asme Interpack 2017?

It is always better to prebook your seat to most popular shows. For Interpack 2017 you must buy ticket now to avoid last minute rush.

It is always better to be an early bird or pre book very well known live concert, popular books, gadget or technology before it gets stockout. Same goes with Interpack 2017 as it organised after every three years and it is very important exhibition for Food, chocolate, confectionery and packing solutions. You have made up you mind and planning to go to ASME Interpack 2017 then its a perfect time for book you tickets in advance to avoid last minute rush.

Buy your eticket swftly and trouble free now at

Why to buy Interpack 2017 tickets in advance?

There are many reasons of buying Interpack 2017 tickets right now some of thwm are as follows.

  • You can save some money compared to buying it on site.
  • No need to stand in long queue at site. Time saved cacn be spend in exhibition to learn about new developments.
  • Also we can use it as a travel tickets to the exhibition center on all public transport marked VRR.

Hope to see you all at Interpack 2017

Intepack 2017: “Packed with Innovation ” by Gea

Lets have a look at the exhibitors who will be taking part in Interpack 2017- Gea

Interpack 2017 is two and half week away and I hope everyone is ready to visit this show. This is very popular exhibition where you find each and every solution in Food , Chocolate, confectionery and many other industries.

I just thought to share the details of exhibitors which can be beneficial to everyone.

“Packed with Innovation” Gea’s tag line this year for Interpack 2017

In this post we will be talking about Gea world class in food proxesing industry.

Almost everyone develops new technology in their segment and try to be updated in this competitive world. Gea is also coming with new technology in this Interpack 2017.

For more details about Gea’s new developmemt  click here.

Have you booked your Interpack 2017 pass yet?

Interpack 2017 dates are already announced.

Interpak 2017 dates to plan your travel to get most benefits

After Gulf food exhibition, we came to share another world class exhibition details to save you time. It’s Interpack 2017.

There are many exhibitions are held during every year across the globe and many equipment manufacturers display their work in these exhibitions. In this fast moving world, everyone wants to utilise their time.

In this digital era, it’s our prime responsibility that we must identify the Exhibition where world class technology is displayed.

Interpack is the mother of all show

What is Interpack 2017?

Interpack is the essential event for the food, beverage, confectionery, bakery and other sectors. No other trade fair in the world presents the entire supply chain. click here to read in details.

Where Interpack 2017 will be held?

It is big and held in Dusseldorf, Germany.

What is the schedule of this show?

Interpack 2017

We will share more details in coming time.

In case you required any other details use the comment box.

Till then wishing you,

Mery Christmas and Happy New Year 2017