The Chocolate Making Process Production starts at the Singapore cocoa factory where the top quality cocoa beans are processed to produce the cocoa mass - which contains 53% cocoa and cocoa butter - the basis for all chocolate products. When chocolate is made, the mass goes straight to our factories in Victoria or Tasmania. Fresh full cream milk is collected and condensed and transported to the factories. Sugar is added to the condensed milk with some of the cocoa mass, making a rich creamy chocolate liquid, which is then evaporated to make milk chocolate crumb. As these ingredients are cooked together, the special rich creamy taste of Cadbury chocolate is produced. Each year, 22,000 tonnes of crumb is produced at Claremont to be made into chocolate. On arrival at the chocolate factory, the crumb is passed through a pin mill and mixed with cocoa liquor and cocoa butter, as well as special chocolate flavouring. The amount of emulsifiers added depends on the consistency of the chocolate required. Thick chocolate is needed for moulded blocks, while a thinner consistency is used for assortments and covering bars. Both milk and dark chocolate undergo the same final special production stages - refining, conching and tempering - which produce the famous smoothness, gloss and snap of Cadbury chocolate. Conching involves mixing and beating the semi-liquid mixture to develop the flavour, removing unwanted volatile flavours and reducing the viscosity and particle size. Tempering is the final crucial and complex stage which involves mixing and cooling the liquid chocolate under carefully controlled conditions to ensure that the fat in the chocolate crystallises in its most stable form. Highly sophisticated machinery has been developed for this process, which is one of the skills of the chocolatier. Tempered chocolate is used in a number of ways to produce our famous brands. Blocks of solid chocolate, including bars with added ingredients such as nuts and raisins, are known in the industry as moulded products. Tempered chocolate is poured into bar-shaped moulds, shaken and cooled, then the moulded blocks continue to high speed wrapping plants. One of our most recently-commissioned plants will potentially produce 700 blocks per minute.
Posted on: Tue, 13 Jan 2015 06:35:33 +0000
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