How Production Works In A Chocolate Factory

As we all know by now, chocolate is basically made from cocoa beans, which are generally grown in tropical climates such as Africa, South America, and parts of Asia. Additionally, the beans must be harvested twice a year to provide the highest-quality chocolate ingredients. In this way, Cristal Chocolatier selects cocoa beans according to Swiss and Belgian methodologies and offers high-quality products. What does the chocolate factory do after purchasing the raw product?
Make chocolate paste. 

After receiving cocoa-based raw products such as butter, mass, powder, etc., we mix them with powdered milk and sugar. This process is carried out in special machines with a capacity of 500 kg to 2 tons, which automatically mix these ingredients. After 12 hours, a paste will form.

In fact, different types of chocolate paste are made using the same process. What differs is the proportion of each ingredient. For example, white chocolate contains the least amount of cocoa mass and more powdered milk and sugar, making it the sweetest of all types. Dark has the most flavor due to its higher cocoa mass content. It has less sugar content than others and does not contain powdered milk. Finally, milk chocolate ensures a balanced ratio of all ingredients.

Once the paste is complete, leave it for 24 hours.

Fill with chocolate and shape

Before filling with chocolate, first prepare the filling. Some, such as hazelnut, pistachio, and coconut gianduias, are made by machine over a period of 6 to 10 hours. Caramel, chocolate, and strawberry mousse are also handmade. However, we source fillings for waffles, cookies, smarties, etc. from our suppliers.
Once the filling is ready and the paste has rested, shape and fill with chocolate. These two processes are carried out simultaneously for 15–20 minutes at a temperature of 28 °C. When the shape of the final product is not determined, such as with dipping, it is shaped by hand. On the other hand, products with specific shapes (round, square, etc.) are loaded using specialized machines.

Once all this is done, the product is packed in aluminum foil and stored at room temperature up to 20°C. Add chocolate decorations. 

Edible decorations may be added after molding or during the process. To elaborate, I recently introduced a new method of decoration. With this approach, you create shapes (bears, cars, etc.) out of chocolate and then add edible ingredients (marzipan, smarties) to complete the design. This process takes place during molding, where the materials need to stick together, like Smarties. On the other hand, ingredients such as marzipan are made into edible decorations after being shaped.

At the end of the manufacturing process, the chocolate is stored at room temperature between 17°C and 22°C to deliver the highest quality chocolate. And as a chocolate wholesaler, we are ready to deliver our products to any store or retailer.

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