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From cocoa bean to bar

Bean to Bar Machinery

Discover the complex process of chocolate manufacturing: from bean to bar

Chocolate is a well-known treat across the globe, and the chocolate sector has seen a continuous increase in demand over time. The process of producing chocolate, which encompasses a range of chocolate products, is complicated and spans various parts of the world. At the forefront of chocolate manufacturing lies Royal Duyvis Wiener, we are a worldwide producer of cocoa and chocolate processing machinery. In this blog post, we will explore the different phases of chocolate production, starting from the cacao bean, concluding with the end product, and the quality.
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What are the phases of chocolate production?

From chocolate bars to truffles, chocolate comes in many different forms and flavors. But have you ever wondered about the process that goes into making this delicious treat? The production of chocolate involves a complex and multi-stage process, starting with the harvesting of the cacao bean and ending with the finished product that we all know and love. We take a closer look at the different phases of chocolate production:

The harvesting of cacao beans: Cacao trees grow in equatorial regions of the world, predominantly in South and Central America, and parts of Africa. Cacao farmers typically harvest the ripe cocoa pods using a sharp blade, revealing the cacao beans inside. The beans are then placed in jute bags and transported to the cocoa processing house.

Fermentation of cocoa beans: Upon arrival at the cocoa processing house, the cacao beans undergo a fermentation process. This process is crucial in developing the chocolate flavor as the fermentation stage allows the cacao beans to develop complex flavor profiles. The beans are laid out on bamboo mats or banana leaves and left to ferment for several days. During this process, micro-organisms like lactic acid bacteria and acetic acid bacteria help break down the pulp around the beans, releasing heat and carbon dioxide.

Drying and roasting of cocoa beans: After the fermentation stage, the beans are dried on large trays or racks, where they are exposed to air and sunlight. This process helps to reduce the moisture content and improve the cocoa flavor. Once the beans are dry, they are roasted at high temperatures, which helps to develop the chocolate flavor and color. The roasting process also helps to remove any foreign matter and reduce the bitterness in the beans.

Grinding of cocoa nibs: After roasting, the cocoa beans are cracked into small pieces known as cocoa nibs. These nibs are then ground into a paste using heavy rollers. The grinding process releases cocoa particles, which combine with the cocoa butter to form a smooth liquid chocolate called chocolate liquor.

Separating the cocoa solids from cocoa butter: The chocolate liquor is then separated into cocoa solids and cocoa butter. This separation process involves a hydraulic press, which separates the cocoa butter from the cocoa solids. Cocoa butter is an essential component of chocolate, and additional cocoa butter may be added to the mixture to achieve the desired cocoa butter content.

Conching process: The conching process involves mixing the chocolate liquid with sugar and flavor ingredients in a special machine known as a conch machine. The mixture is agitated for several hours, and the heat generated during this process helps to remove any remaining moisture in the chocolate. This stage also helps to develop the smooth and creamy texture of the finished chocolate product.

Tempering process: The tempering process involves heating and cooling the chocolate mixture to create a stable and glossy texture. This process involves heating the chocolate mixture to a specific temperature, and then rapidly cooling it, stirring it continuously. The tempered chocolate is then poured into molds and left to cool and harden, resulting in the finished chocolate product.

In some cases, additional ingredients may be added to the chocolate mixture to create unique flavor profiles. Milk powder and milk fat can be added to create milk chocolate, while white chocolate is made using cocoa butter, sugar, and milk powder. Dark chocolate has a higher percentage of cocoa solids and is often made without any additional milk products. Of course, this depends on your wishes as a producer of chocolate.

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Chocolate quality and taste

The quality and taste of chocolate does not only depend on the process. It also depends on various factors, including the quality of the cocoa beans and the addition of any additional ingredients. Chocolate makers often aim to create a unique flavor profile for their unique chocolate products by using specific cocoa bean varieties and processing methods. The bean flavor profile is a crucial aspect of chocolate production, as it determines the overall taste and aroma of the finished product.

This flavor profile of the cacao bean must be created with a lot of care. The components of cocoa beans, including hydrophobic amino acids and volatile acids, contribute to the bean’s flavor profile. The predominant side-chain sugar also affects the bean’s taste, determining whether it has a fruity or nutty flavor. Criollo beans are known for their complex and delicate flavor profile, while Forastero beans have a stronger and more robust taste. Trinitario beans, a hybrid of Criollo and Forastero beans, have a unique flavor profile that combines the best of both worlds.

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“The smart design of this machine allows universal roll management. Do you have main brand rolls and gears in your warehouse? Not to worry, all main brand rolls and gears can be fitted into this machine with the service you’re used to from Royal Duyvis Wiener technical support engineers”

Chocolate manufacturing machine systems

Last but not least, chocolate manufacturing machine systems also play a big role in the chocolate-making process. These machines help to automate the various stages of chocolate production, ensuring consistency in quality and taste. From the roasting and grinding of cocoa nibs to the conching and tempering of chocolate, specialized machines are used to ensure that each stage of the process is carried out efficiently. If you are curious about the different machines and their features, get in touch with Royal Duyvis Wiener. We have more than 100 years of experience within the global cocoa, chocolate and nuts & seeds processing industry, and can provide you with the complete production process from bean to bar, helping your company to reduce production costs, save energy and minimize downtime for maximum efficiency.


In conclusion, the chocolate production process involves various stages, each of which contributes to the flavor, texture, and appearance of the finished product. From the harvesting of cocoa pods to the conching and tempering of chocolate, each stage requires precision and attention to detail. The quality of the cocoa beans, the addition of extra ingredients, and the use of specialized machinery also affect the chocolate’s taste and quality. As the demand for chocolate products continues to grow worldwide, chocolate factories and manufacturing facilities play an important role in providing consumers with exceptional quality chocolate treats.

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