The Cacao Tree
The cacao tree, native to the tropical regions of Central and South America, is primarily cultivated in West Africa for cocoa production.
Cocoa beans are found inside the fruit of the cacao tree, which are the primary source for cocoa and chocolate.
- Cacao trees thrive in the forest’s lower canopy, growing to a height of 6 to 12 meters (20 to 40 feet).
- Cacao tree flowers can be white, rosy, pink, yellow, or bright red
- A mature cacao tree takes four years to produce its first fruit
- Each cocoa pod contains 20 – 60 seeds
- Cacao trees thrive in temperatures of between 20 °C (68 °F) or 28 °C (82 °F) in average.
- Due to the humid environments in which they grow, cacao trees are highly vulnerable to pests and disease, and as such are difficult to grow on very large plantations.
- Most cacao varieties can be grouped into : Forastero (Outsider), Criollo (Creole), and Trinitario (Trinitarian).
1. Harvesting
Harvesting cocoa beans can occur throughout the year, but the main collection happens during two peak periods: October to February and May to August. Ripe pods are cut from the cacao trees and split open with machetes.
The extracted beans, still encased in their surrounding pulp, are then piled in leaf-covered heaps, placed in leaf-lined pits, or stored in large, shallow boxes with perforated bottoms to allow for drainage.
2. Fermentation & Drying
The fermentation process varies based on the cocoa bean variety: some beans typically ferment for 5 to 7 days, while Criollo beans, known for their distinct flavor, ferment for 1 to 3 days.
Regular turning of the beans during fermentation helps to dissipate heat and ensure uniform fermentation. During this time, the pulp’s liquid is drained away, the heat kills the seed germ, and the flavor begins to develop.
Fermentation causes the beans to swell, become moist, and turn a reddish-brown color with a sharp, heavy aroma.
Once fermentation is complete, our Agrobio beans are sun-dried or kiln-dried to reduce moisture to 6-7%, then bagged for shipment.
3. Cleaning, Roasting, and Grinding
Cocoa beans undergo a cleaning process to eliminate contaminants like twigs, stones, and dust. Roasting follows, which enhances flavor, reduces acidity, decreases moisture content, deepens color, and makes shell removal easier.
After roasting, the beans are cracked, and the shells are separated from the heavier nibs using blowers.
The nibs are then ground, breaking their cell walls and releasing cocoa butter, creating a paste known as chocolate liquor or cocoa mass. For alkalized (Dutched) chocolate liquor, raw cocoa beans may be winnowed, then alkalized, and roasted before grinding.
4. Conching
Conching is a crucial process for flavor development, aeration, and emulsification, carried out by conche machines over a period ranging from 4 to 72 hours, depending on the desired outcome and the type of machine used.
During conching, temperatures are controlled between 55 and 88 °C (130 to 190 °F) to achieve the optimal flavor and consistency.
5. Molding
In the molding process, liquid chocolate is poured into molds to form small consumer-sized bars for use by our confectioners.
These molds are then cooled using cold air to solidify the chocolate into its final shape.
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