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10/1/2012 Elizabeth Smith

Making Hersheys Chocolate

Born in the Jungle All around the world, from Brazil to Indonesia to the Ivory Coast and Ghana, deep in the tropical jungle there grows the cacao tree. Cacao trees grow melon-like fruit, which is harvested by hand. Inside each pod are about 20-40 seeds, or cocoa beans. After the beans are removed from the pods, they are placed in large heaps or piles. This is called fermentation, and takes about a week. During this time, the shells harden, the beans darken, and the rich cocoa flavor develops. After drying, the beans are ready for transport to the chocolate factory. Liquid Chocolate Railroad cars carry the cocoa beans from the docks to the chocolate factory where they are cleaned and stored. Cocoa beans from different countries each have a distinct flavor. After arriving at the factory, the beans are stored by country of origin until they are blended precisely. Cocoa beans are roasted in large, revolving roasters at very high temperatures. A special hulling machine then takes the dry, roasted cocoa beans and separates the shell from the inside of the bean - called the nib. This is the part of the bean actually used to make chocolate. The nibs now are ready for milling. Milling is a grinding process which turns the nibs into a liquid called chocolate liquor - a smooth, dark stream of pure chocolate flavor which contains no alcohol. Now it is ready for the rest of the ingredients! Mixing it Up The main ingredients in chocolate are the chocolate liquor, cocoa butter, sugar and milk. Tanker trucks bring the fresh milk to the factory every day where it is tested, pasteurized, and then mixed with sugar. The whole milk-sugar mixture is slowly dried until it turns into a thick, taffy-like material. At the heart of the chocolate factory is the central blending operation where the chocolate liquor is combined with the milk and sugar. This new mixture is dried into a coarse, brown powder called chocolate crumb. Perfecting the Product The chocolate crumb powder is used to make milk chocolate. Hershey adds cocoa butter to the crumb which brings out the rich taste and creamy texture of the chocolate. The crumb travels through special steel rollers which grind and refine the mixture, making it smoother. The crumb becomes a thick liquid called chocolate paste. The paste is poured into huge vats called conches. Once inside the conche, large granite rollers smooth out the gritty particles from the crumb. This process can take anywhere from 24 to 72 hours to complete. Now the chocolate paste has the smooth, familiar look of milk chocolate and its ready to be made into favorite HERSHEYS products. The paste is tempered, or cooled in a controlled manner to the right texture and consistency. Other ingredients, like almonds or peanuts, can be mixed into the paste during tempering or added directly to the molds. Chocolate Bars and HERSHEYS KISSES Chocolates Most chocolate bars are made by pouring the liquid chocolate paste into molds. The molding machines can fill more than 1,000 molds per minute with delicious HERSHEYS chocolate. The filled molds then take a bumpy, vibrating ride to remove air bubbles and allow the chocolate to settle evenly. Finally, they wind their way through a long cooling tunnel where the liquid chocolate is chilled into a solid candy bar. Now its ready to wrap. While a lot of HERSHEYS chocolate products are poured into molds, HERSHEYS KISSES Chocolates are made a little differently. Special machines drop a precise amount of chocolate onto a moving steel belt and then quickly cool it to form the famous HERSHEYS KISS shape. Hershey makes more than 80 million Kiss-shaped products every day at its chocolate factories in Hershey and California.

The Ghirardelli Manufacturing Process

Bean Selection and Cleaning After the cocoa beans are carefully selected, they are cleaned when they pass through a bean cleaning machine that removes extraneous materials. Different bean varieties are then precisely blended to produce the desired flavor of chocolate. Developing the right formula of beans is integral to the art and science of chocolate making. Ghirardelli selects only the finest cocoa beans, rejecting around 40% of the beans we sample because they do not meet our rigorous flavor standards. Bean Roasting The beans are roasted to develop the characteristic chocolate flavor. They are roasted in large rotary cylinders. Depending on the varieties of the beans and the desired end result, the roasting lasts from 30 minutes to two hours at very high temperatures. During roasting, the bean color changes to a rich brown, and the aroma of chocolate comes through. After roasting, the bean shells are cracked and removed, leaving the essence of pure chocolate called the "nib". For Dutch roasts, an alkaline solution is added to produce nibs that are darker and less acidic in flavor. Nib Roasting at Ghirardelli Chocolate Different from many chocolate manufacturers, Ghirardelli Chocolate utilizes a nib roasting process that allows for deeper roasts in order to produce a more robust chocolate flavor. During the bean cleaning process, the shells of the beans are removed, leaving the nib (or the meat) of the bean. The unshelled nibs then undergo the roasting process. This gives us more control over the temperature and time, so we can get a more specific flavor. The result is a deeper roast that produces the legendary intense flavor of Ghirardelli chocolate. The roasted nibs are milled through a process that liquefies the cocoa butter in the nibs and forms "chocolate liquor." Chocolate liquor is non-alcoholic and simply refers to the chocolate liquid. The chocolate liquor can either be pressed for cocoa butter and cocoa powders, or molded and solidified to make unsweetened chocolate. Cocoa Pressing The cocoa press hydraulically squeezes a portion of the cocoa butter from the chocolate liquor, leaving "cocoa cakes." The cocoa butter is used in the manufacture of chocolates; the remaining cakes of cocoa solids are pulverized into cocoa powders. Ingredients

such as chocolate liquor, sugar, cocoa butter, and milk powder, in quantities that make up the different types of chocolate, are blended in mixers to a paste with the consistency of dough. Chocolate refiners, a set of rollers, crush the paste into flakes that are significantly reduced in size. This step is critical in determining how smooth chocolate is when eaten. At Ghirardelli, we refine many of our chocolates to 19 microns, giving them an extremely smooth texture with no "graininess," unlike other mass market chocolates that are only refined to 40 microns. Conching Conching is a flavor development process during which the chocolate is put under constant agitation. The conching machines, called "conches," have large paddles that sweep back and forth through the refined chocolate mass anywhere from a few hours to several days. Conching reduces moisture, drives off any lingering acidic flavors, and coats each particle of chocolate with a layer of cocoa butter. The resulting chocolate has a smoother, mellower flavor.

Tempering and Molding

The chocolate then undergoes a tempering heating and cooling process that creates small, stable cocoa butter crystals in the fluid chocolate mass. It is deposited into molds of different forms: chips, chunks, wafers, SQUARES, and bars. Proper tempering cr eates a finished product that has a glossy, smooth appearance.

Cooling and Packaging

The molded chocolate enters controlled cooling tunnels to solidify the pieces. Depending on the size of the chocolate pieces, the cooling cycle takes between 20 minutes to two hours. From the cooling tunnels, the chocolate is packaged for delivery.

How Godiva Makes Chocolate.

It All Starts With Beans
Chocolate making starts with the most precious ingredient the cocoa bean, which grows on trees in large cocoa pods. Cocoa beans grow best in the tropics along the equator, most notably in Africa, Central & South America, and parts of Asia. Once harvested, cocoa beans are fermented and dried before being carefully examined for quality. The beans are shelled to reveal cocoa nibs, which are roasted to bring out their extraordinary aromas. The next step is creating the cocoa liquor, the most important ingredient in chocolate. Cocoa liquor is created by grinding the nibs into a very fine liquid comprised of cocoa butter and cocoa solids. Godiva takes care to grind the nibs into extremely fine particle.

Add More Good Stuff

Grade A dairy butter and heavy cream are used in large quantity in the formulation of our fillings. U.S. Grade #1 nutmeats earn our nut confections high distinction. Notably, many of our chocolates contain hazelnut praline, a favorite European nut filling that is in keeping with our Belgian heritage. Real cherries that contain no food coloring are used to make our famous Cherry Cordials. For other fruit-filled confections, we use fruits that undergo a special drying process to capture the freshness that is lost during conventional freezing. Pure, additive-free cherry and raspberry juices give flavor to Cherry and Raspberry Buttercreams.

Belgian Recipes
. Godiva Dark Chocolate is made from cocoa liquor, cocoa butter, and sugar that together deliver a rich flavor and texture. Cacao percentages refer to the amount of the recipe that is made from the cocoa bean. In chocolate that has a very high percentage of cacao, the strong and deep characteristics of the cocoa bean become more prominent. There is less sugar, so the chocolate is less sweet. Godiva Milk Chocolate also includes cocoa liquor, cocoa butter, and sugar. The addition of milk brings a new characteristic of sweetness and creaminess. Milk chocolates tend to have a lower percentage of cacao, and therefore tend to be sweeter than dark chocolate. Godiva White Chocolate is made of cocoa butter, sugar, and milk, but does not contain any cocoa solids. It is the sweetest of the three types of chocolate.

Signature Shapes and Styles

. Enrobing involves coating a formed center, like rich caramel, with smooth, melted chocolate. This method is used in the creation of our Dark Chocolate Truffle, French Vanilla Truffle, and Milk Caramel Embrace, among others. Shell-molding is the method used to produce most Godiva chocolates. Practiced extensively in Europe, the process begins with a mold composed of intricately designed "impressions." Each cavity is filled with melted, tempered chocolate. The mold is inverted and most of the chocolate runs out. It is then cooled, which solidifies the remaining chocolate, forming a "shell." Next, the shell is filled with a

center, allowing enough space for a thin layer of melted chocolate to be layered over the filling. After cooling, the chocolates are released from the mold. This method is used in the creation of our Milk Chocolate Bliss, Midnight Swirl, and Dark Lion of Belgium, among others. Godiva produces some symmetrical shell-molded confections by "book-molding" two identical filled molds together. The Heart, Walnut, Chestnut, and Scallop, are among our book-molded creations. The shell-molding process has enabled Godiva to design unique molds. Milk and Dark Almond Bark

Historical image of Ghirardelli Chocolate Refiner Mixing and Refining

Historical image of Ghirardelli Chocolate Mixer

Historical image of Ghirardelli Chocolate Mill