The production of premium bean-to-bar chocolate bars can be divided into the following steps:
1. Selection and Fermentation of Cocoa Beans
The process begins with the careful selection of fine cocoa varieties, often sourced from small plantations in countries like Peru, Ecuador, or Ghana. After harvesting, the beans are fermented and dried—steps that are crucial for developing complex flavors. The length of the fermentation has a significant impact on the final taste of the chocolate.
2. Roasting and Grinding
The dried beans are gently roasted to bring out the desired aromas. They are then broken, and the shells are removed, leaving behind what are known as cocoa nibs. These nibs are ground into a fine cocoa mass.
3. Conching
The cocoa mass is mixed with other ingredients such as sugar and cocoa butter in a conche, where it is intensively stirred and aerated for several hours. This step gives the chocolate its smooth, melt-in-the-mouth texture and refines its flavor.
4. Tempering and Molding
After conching, the chocolate mass is tempered—cooled and reheated in a controlled manner to achieve the correct crystal structure. It is then poured into molds and solidifies into bars or pralines.