How Chocolate is Made: From the Cacao Tree to Chocolate

If you have ever wondered how chocolate is made, it all starts with the cacao tree in the shade of the rainforest canopy. These trees grow a melon-like fruit (or pod) that contains seeds, which are the cacao beans.

When the pods are ripe, they are harvested by hand. Inside the pod are 20 to 40 cacao beans. The pods are cracked open and the white pulpy elements that surround the seeds are discarded.

When the cacao beans are removed, they are placed in large heaps for fermentation. This process usually takes a week, during which time the shells harden, the beans darken, and the cocoa flavor develops.

Then the beans are transported to a chocolate factory.

The first step in converting cacao into chocolate is to roast it in large revolving roasters at high temperatures.

Next, a special hulling machine dries the cacao so the shell of the bean is removed. Its content, known as the "nib," is used in making chocolate.

The next step is milling, which turns the nibs into liquid. It's at this time that other ingredients are added (chocolate liquor, cocoa butter, sugar, and milk).

The mixture is now a thick liquid often referred to as chocolate paste. The paste is placed in another machine called the conche for 24 to 72 hours. Conching is an oxidation process used as part of the process of blending the cocoa butter, cocoa beans, and sugar to reduce the natural bitterness of cocoa beans.

Next, the liquid chocolate is poured into molds, air bubbles are removed, and the chocolate is cooled.

The last step is obviously to wrap the chocolate, put it in boxes, and deliver it to stores.

Watch a video tour of how chocolate is made at Hershey's.