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Bean to Bar Process: Start to Finish
Roasting
Through our experience while roasting the beans, we found that the roasting process allowed the hull to fall off smoothly, aiding us in the next stage. We found that roasting the beans allowed for further development within the flavor profile of our end product with our beans being from Peru, Vietnam, and the Dominican Republic.
Cracking
Following the roasting stage, we moved onto cracking the hulls, exposing the cocoa nibs which will later be refined. We executed the cracking stage by applying pressure to the beans with a small cake pan, allowing the hull to fall off of the nib with pressure.
Winnowing
With the use of air the lighter bits of hull are blown away leaving only the delicious nibs behind. We initially began winnowing through the use of a hair dryer, separating the husk from the nibs as they are tossed in a large bowl.
Grinding
At this point in the process, we added our cocoa nibs to the melanger, and allowed it to run until incorporated. We then continued by slowly adding cocoa butter and sugar in stages until they were both fully incorporated, and ran the melanger for 3 days. The stones in the machine work to create heat through friction while also reducing the particle size below 30 microns making it undetectable to the human palette.
Tempering
To control the crystalline structure of cocoa butter through temperature, manipulation, and agitation, we were able to create a product that is more shelf-stable ultimately by tempering our chocolate. Tempering the chocolate aids in a more pleasing mouthfeel, and produces a satisfying snap when eaten. We executed this step through tabling, which is the process of pouring melted chocolate onto a clean and dry marble slab, which is then spread back and forth with a metal spatula until it begins to thicken.
Molding
For molding, we went with a classic polycarbonate mold that allows the chocolate to take on unique shapes and reflect the creativity of our work leading up to this point in the project.
Wrapping
While preparing for packaging, we ensured our chocolate, packaging, label, and nutritional label were ready before beginning. Once the packaging material is ready, the chocolate products are then packed into desirable sizes. The package is then sealed, attempting to make it airtight. This process is vital to ensuring the product is protected from any contaminants.
Recipe
