Cocoa beans are carefully cleaned and sorted at the factory, and then roasted in special equipment at a temperature of 130−150 °Ñ. Waste moisture and acid compounds evaporate during the roasting process, and the beans become a uniform shade of deep-brown. Cocoa roasting is a very important stage of the whole manufacturing process, and the future quality of the chocolate, and its smell and taste depend on it just as much as they do on fermentation. Sometimes different grades of cocoa (or cocoa of one grade, but grown in different countries) are mixed for roasting. The majority of the major chocolate manufacturers keep their methods and conditions of roasting a secret. After roasting, the shells are removed and the cocoa beans are crushed into cocoa nibs.
Cocoa liquor
Roasted and cleaned cocoa-nibs are carefully ground. The finer the cocoa-nibs are ground at this stage, the fuller and finer the taste of the chocolate. The size of the cocoa particles passed through the grinding machinery, should not exceed 75 microns—such cocoa is called coca liquor.
Pressing
The cocoa liquor contains 54% cocoa butter, the very valuable substance essential for the production of real chocolate. Cocoa liquor is heated up to 95−105 °C and is then pressed. As a result, cocoa butter is separated from the solids, which are subsequently used for the production of cocoa powder.
Mixing and grinding
Cocoa liquor, sugar and part of the cocoa butter are mixed in specified proportions. After mixing the mass is ground. This stage is very important for the production of chocolate: the finer the crushing, the more delicate the taste. Please note that the overall content of natural cocoa-products in such a mix largely determines not only the quality, but also the cost of the chocolate. This especially concerns the contents of cocoa-butter, an extremely valuable and expensive product. But in various cheap substitutes cocoa-butter is almost invariably absent. It is the reason for the so-called “attractive” prices, which are used by not too scrupulous manufacturers to please not very experienced clients.
Conching
After mixing and grinding the chocolate mass is subjected to conching: intensive mixing at high temperature. Conching is a very long (up to 24 hours) process and, as a result, the superfluous moisture and the residual tannins are evaporated from the chocolate mass, and the cocoa solids are rounded off. The consistency of the chocolate becomes more homogeneous, and the taste—gentler, the well-known “melt in the mouth” effect. After processing the chocolate mass, the rest of the components are added according to the recipe: cocoa butter and lecithin—for mass attenuation and optimized moulding; natural flavoring agent (vanilla)—for a subtler and more delicate aroma.
Tempering
Tempering is a key part of chocolate production. It is a long and complex process, which requires great experience and skill. After conching, the hot chocolate mass should be cooled, but it requires several stages to do this, because of the cocoa-butter contents. The problem is that cocoa-butter is a polymorphic fat, which crystallizes and congeals while cooling, but can take on different consistencies according to cooling conditions. Tempering is necessary for the cocoa butter to obtain the most stable consistency. For this purpose, the hot chocolate is at first cooled down to 28 °Ñ, and then reheated to 32 °Ñ. If the process is upset at any one of the tempering stages, this will be reflected in the appearance and consistency of the chocolate. For example, a characteristic white bloom can appear on its surface. Such a “bloom” is the result of incorrect tempering. Moreover, the “bloom” does not appear at once, but some time later. Also, the chocolate can become hard-grained and crumbly due to incorrect cooling. In this case, its taste properties will be retained, but its appearance for marketing purposes will be hopelessly damaged.
Moulding
After tempering, the chocolate is poured into heated moulds. At this stage, if the recipe requires it, various additives (for example, nuts) are put into the chocolate. After that, the chocolate is put into coolers. The chocolate solidifies and a beautiful shine appears on its surface. Then the moulds with the solid chocolate are upturned and shaken on to the conveyor.
Packaging and labelling
The last stage in the manufacture of chocolate is its packaging and labeling. And if the chocolate is made by the VK company, it will have the precise packaging you, the customer, have ordered.
Conditions and length of storage
Chocolate should be transported and stored at 18±3 °Ñ, with a relative humidity of less than 75%. If these conditions are not observed, the chocolate can bloom and lose its marketable appearance.
The shelf life of VK chocolate is 12 months. That distinguishes our chocolate advantageously from similar products made by many other manufacturers. Please note that such a shelf life is only possible because we strictly adhere to a careful production process at all of its stages.
