chocolate

1.0 Introduction

Chocolate is a key ingredient in many foods such as milk shakes, candy bars,

cookies and cereals. It is ranked as one of the most favorite flavor in North America and

Europe (Swift, 1998). Despite its popularity, most people do not know the unique origins

of this popular treat. Chocolate is a product that requires complex procedures to

produce. The process involves harvesting coca, refining coca to cocoa beans, and

shipping the cocoa beans to the manufacturing factory for cleaning, coaching and

grinding. These cocoa beans will then be imported or exported to other countries and

be transformed into different type of chocolate products (Allen, 1994).

On 16 March 2011, we had guided by Dr. Lau Wei Hong to have a visit to the

Beryl’s chocolate factory which is located in Serdang. In the field visit, we had learnt

about the knowledge and the information about the manufacturing process of

chocolate. We had known that Beryl’s it’s all about delivering the best chocolates in

Malaysia. Beryl’s Chocolate today offers more than 100 varieties of chocolate to suit

every customer mood and desire.

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2.0 List of Beryl’s Chocolate Products

i. Panned Chocolate

Almond Milk Chocolate Almond bittersweet chocolate

Aggio almond mlk chocolate

Assorted Milk Chocolate Almond white chocolate Assorted Milk Chocolate

Yoghurt raisin white chocolate Chocolate 4 in 1 Almond Milk Chocolate

ii. Bar Chocolate

Coconut delight bar chocolate

Hazelnut bar chocolate Fruit & Nuts bar chocolate

Almond bar chocolate Assorted bar chocolate4 in 1

Fruit & Nuts bar chocolate

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iii. Camior Bar Chocolate

Milk Prailines chocolate Almond milk chocolate Hazelnut milk chocolate

Bittersweet chocolate Assorted chocolate 3 in 1 Mini Carrior assorted chocolate

Light no sugar added Bittersweet chocolate

Light no sugar added hazelnut chocolate

Light no sugar added almond milk chocolate

iv. Mini Chocolate

Black bitter chocolate Strawberry white chocolate

Assortito Chocolate

Mint & Bitter Chocolate Black & White Chocolate Dark Chocolate 80% Cacao

Dark Chocolate With Wafer Strawberry White Chocolate With Wafer

Blueberry White Chocolate With Wafer

Mini Chocolate 4 in 1 Treasure Coin Milk Chocolate Coin Dark Chocolate 54%

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Cacao

v. Ghana Chocolate

Strawberry White Chocolate

Ghana Hazelnut Milk Chocolate

Borneo Almond Milk Chocolate

85g Bar Chocolate 3 in 1

- White

Ecuador Mass Dark Chocolate 72% Cacao

vi. Fruit Fiesta

Fruits Fiesta Chocolate- Blueberry

Fruits Fiesta Chocolate- Green Apple

Fruits Fiesta Chocolate- Mango

Fruits Fiesta Chocolate- Rockmelon

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vii. Tiramisu

Tiramisu Almond White Chocolate

Tiramisu Almond Chocolate Tiramisu Almond Milk Chocolate

Tiramisu Milk Chocolate

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3.0 Percentage of Energy in Milk and Milk-free Chocolate

The Percentage of Energy from Protein, Fat and Carbohydrate in

Milk and Milk-Free Chocolate

% Energy Contribution

Protein Fat Carbohydrate

Plain Chocolate 4% 57% 39%

Milk Chocolate 7% 52% 41%

White Chocolate 5% 51% 43%

Sources:

Multiple sources were used in developing this including

www.sallys-place.com, www.ilovechocolate.com.au, and other

online resources. All credits remain with their respective owners

although the information has been modified.

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4.0 Chocolate Manufacturing Process

1) Ingredient of chocolate

Cocoa mass, cocoa butter, sugar and milk powder are the main ingredient of the

chocolate.

2) Mixing

Cocoa mass, 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. 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.

3) Refining

The goal of refining is to make the thick chocolate crumb into a silky chocolate. It travels

through a series of five heavy steel refining rollers set at different intervals and different

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speeds. The gaps between the final rollers are so small that the chocolate components

are ground into a thick fluid mass which is then run off. This step reduces the particle

size to of the cocoa mass to 25 to 30 microns, both in the chocolate liquor and the

sugar. In some cases, extra cocoa butter is added to the chocolate liquor for a smoother,

more voluptuous mouthfeel. The smoother the chocolate desired, the more rolling.

4) 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.

5) Moulding

There are different methods for producing chocolates: enrobing, hollow figure, layer-

and-cutting and molding. Molding is the simples: solid shapes like bars and hearts are

poured into molds, as shown at the right. The enrobing process (photo below) is the

oldest method for producing chocolates: pre-shaped chocolates centers (caramel,

creme, croquant, marzipan, nougat, nuts et al) can be hand-dipped by artisan

chocolatiers and further ornamented with fruit pieces, nuts, candied violets, cocoa

butter transfer designs or other flourishes on top. In larger operations, the centers are

placed on a moving wire mesh belt which takes them to a coating machine. A shower of

chocolate falls down to cover the centers in chocolate.

6) Packaging

The chocolate is then send for packaging which can maintain the storage period and

easily send to customer. There are different types of chocolate package that the

manufacturer provided for customer choices.

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