How is Chocolate Made from Cacao? Production Stages
The journey from cacao bean to chocolate bar. All stages of chocolate production: harvesting, fermentation, roasting, grinding and tempering.
When you eat a chocolate bar, you’re actually tasting the result of a complex production process that has gone through dozens of stages. This journey from cacao bean to chocolate is both science and art.
1. Cacao Harvesting
Everything begins with the cacao tree growing in tropical climates:
- Cacao trees bear fruit twice a year
- Each cacao fruit (pod) contains 30-50 seeds
- Harvesting is still done by hand - machines damage the fruit
- Ripe fruits turn yellow-orange in color
70% of the world’s cacao production comes from West Africa, especially Ivory Coast and Ghana.
2. Fermentation
Harvested seeds are not processed immediately - they must first be fermented:
- Seeds are placed in banana leaves or wooden boxes
- Natural fermentation occurs for 5-7 days
- Temperature rises up to 50°C
- At this stage, chocolate’s flavor profile is formed
Without fermentation, chocolate would have a bitter and unpleasant taste.
3. Drying
Fermented seeds are dried:
- Drying in the sun for 1-2 weeks
- Moisture content is reduced below 7%
- Seeds are turned regularly
- At this stage they acquire their brown color
4. Roasting
Dried seeds are roasted:
- Temperature: 120-150°C
- Duration: 30 minutes - 2 hours
- Chocolate’s aroma develops at this stage
- Each producer uses different roasting profiles
Roasting is one of the most critical stages determining the final taste of chocolate.
5. Cracking and Winnowing
Roasted seeds are cracked:
- Outer shell (cacao husk) is separated
- Inner part is called “cacao nibs”
- Nibs are pure cacao - contain 50-55% cacao butter
6. Grinding
Cacao nibs are ground:
- The grinding process produces heat
- Cacao butter melts and creates “cacao liquor”
- This mass is not yet chocolate but is the base material
7. Pressing or Mixing
At this stage there are two paths:
Cocoa Powder Production:
- Cacao liquor is pressed
- Fat (cacao butter) is separated
- Remaining mass is ground to become cocoa powder
Chocolate Production:
- Sugar is added to cacao liquor
- Milk powder is added for milk chocolate
- Only cacao butter is used for white chocolate
8. Conching
Chocolate is kneaded for hours:
- 24-72 hour mechanical process
- Acids and unwanted flavors evaporate
- Chocolate becomes smooth
- Flavor fully develops
The word “conching” comes from the first machines being shaped like seashells (conch).
9. Tempering
Critical stage for chocolate’s final appearance:
- Chocolate is heated and cooled at specific temperatures
- Dark: 31-32°C, Milk: 29-30°C, White: 27-28°C
- Cacao butter crystals form properly
- Result: Shiny appearance and snap sound
Untempered chocolate appears dull and feels grainy in the mouth.
10. Molding
Final stage:
- Tempered chocolate is poured into molds
- Air bubbles are removed with vibration
- Solidified in cooling tunnel
- Removed from mold and packaged
The Difference of Handmade Chocolate
Unlike industrial production, in handmade chocolate:
- Every stage is carefully controlled
- Production is done in small batches
- Personalized recipes are used
- Fresh ingredients are preferred
We invite you to taste our handmade chocolates prepared with professional chef experience at ChefMade.
For ChefMade handmade chocolates: Visit our menu page. To see the chocolate making process up close check out our workshop page. Read our story.