Unveiling the Ancient Art: How Traditional Chocolate is Made | Kaicao chocolate factory

Unveiling the Ancient Art: How Traditional Chocolate is Made

Ido is the founder and CEO of Kaicao.
By Ido Talmor
Kelly Hendrickse
Edited by Kelly Hendrickse

Published September 18, 2023.

Chocolate has a rich history of evolution.

Both chocolate and cocoa originate from the cacao bean, the fruit of the cacao tree, but their paths diverge in production and flavor. Cocoa is the powdered essence of roasted cacao beans, often used in baking or hot beverages. In contrast, chocolate is made from cacao beans utilizing a meticulous process of fermentation, drying, roasting, and grinding, with ingredients like sugar or milk added for specific varieties.

The flavor of both is deeply influenced by the cacao bean's origin and the specific harvest, akin to the unique profiles of wine vintages. The bean-to-bar movement emphasizes this, spotlighting the distinct taste notes each origin offers, such as El Salvador's tobacco tamarind or the Dominican Republic's coconut nut essence. Chocolate makers, with their unique processes, further accentuate these flavors, making each batch distinct. In this rich tapestry of cacao, it's not just about the type of chocolate but the origin, farm, and unique taste notes.

Dive into the world of bean-to-bar and discover a universe of flavors where, once you've tasted the craft, there's no going back. Learn about this movement from Kaicao's founder, Ido Talmor, who eagerly explores the world of this special chocolate.

Exploring the History of Chocolate

Chocolate has a fascinating journey that spans continents and cultures with its evolution in taste and form.

How Did Chocolate Come to America?

Chocolate's roots in America can be traced back to the ancient civilizations of Central and South America, where it was primarily consumed as a drink. The Mayans and Aztecs, believed to have made chocolate first, revered cacao, the primary ingredient in chocolate. And the first chocolate ever made was in beverage form, which the Mayans and Aztecs often consumed in ceremonial contexts.

Chocolate was first brought to Florida on a Spanish ship in 1641. The first American chocolate house is believed to have opened in Boston in 1682. By the late 1770s, cacao beans were a major import into American colonies and were consumed by all classes.

Madrid: The European Chocolate Hub

Madrid holds a special place in the history of chocolate. As the first European city to be introduced to cacao, it has a longstanding tradition of consuming chocolate primarily as a drink. "Madrid is usually a place where people drink chocolate a lot more than consuming it as chocolate bars until today", explains Talmor. With Kaicao's drinks and powders, this preference may be a nod to its historical connection with cacao.

Bean to Bar vs Industrial Chocolate

Bean to Bar

This type of chocolate can be easily explained as the purest form of chocolate-making by using a type of fruit. Talmor explains, “In Kaicao, we try to keep the ingredients as minimalist as possible. We maintain the purity of the cacao by using dates instead of sugar.” While many associate cacao with a bitter taste, its flavor profile is far more intricate. In fact, its taste can vary based on its origin. For instance, our Tanzanian beans from the Kokoa Kamili farm boast notes of raspberries and tropical fruits, while our beans from Ecuador exude a distinct mineral and earthy essence.

How long does it take to make chocolate? The process of bean to bar can take "anywhere between 35 to 40 days from the moment the cacao beans are sourced until they transform into chocolate bars," says Talmor.

Ethical Sourcing and the Importance of Farms

Kaicao is part of the bean-to-bar movement that's revolutionizing the chocolate industry. They emphasize using ethically traded fine-aroma cocoa beans from single-origin farms. This means they maintain a close relationship with the farmers, ensuring the beans are of the highest quality. Most of these beans come from small farmers and cooperatives, ensuring ethical trade and organic practices.

Industrial Chocolate

On the other side of the spectrum, we have industrial chocolate. While some brands still try to keep their ingredient list short and sweet, others might include additives like soy lecithin. And then there are those that go a step further, adding preservatives and other additives that can alter the natural taste and properties of the chocolate.

The Art of Crafting Chocolate at Kaicao

At Kaicao, the chocolate journey is deeply rooted in tradition, quality, and a commitment to the environment and the farmers. Let's dive into the intricate steps to make chocolate from scratch:

  • Harvesting the Cacao Fruit: The process begins with the cacao fruit, which grows directly on the trees. When the fruit is ripe and its sugar levels are just right, it's manually cut from the trees using a machete. The fruit is then opened, to reveal the inner pulp that covers the beans. Wondering how to know if cacao is ripe? Shaking it is a good trick as, when unripe, the fruit usually sticks to the inside of its husk.
  • Fermentation: The beans, along with the pulp, are placed in wooden boxes for fermentation. "The fermentation that comes from the alcohol in the sugar heats up the cacao beans," explains Talmor. Beans are fermented for anywhere between 3 and 7 days, depending on the farm. The process is crucial as it determines the flavor profile of the cacao.
  • Sun Drying: Post-fermentation, the beans are laid out on wooden beds under the sun to dry. This step helps reduce the beans' humidity and any remnants of the fruit. The drying process can vary, lasting from 7 days to a couple of weeks, depending on factors like humidity and sunlight.
  • Hand Sorting: Once dried, some farms hand-sort the beans, removing any that are too small, flat, or molded. This process ensures only the highest quality beans make their way to the chocolate makers.
  • Roasting: At Kaicao, ovens are used with ample air circulation, creating a unique roasting profile for beans from different origins. The aim is to develop the flavor without burning the beans. Interestingly, the roasting process at Kaicao is more akin to baking, with temperatures not exceeding 120 degrees Celsius.
  • Cracking and Winnowing: After roasting, the beans have a husk that needs to be removed. Machines crush the beans, separating the nibs from the shell. The nibs are the primary ingredient for making chocolate.
  • Stone Grinding: The nibs undergo stone grinding for 3 to 5 days. This process not only refines the texture but also develops the chocolate's flavor. The grinding releases cacao butter from the beans, giving the chocolate its creamy consistency. This is the juncture where chocolate makers can playfully decide on the flavor profiles they want to introduce.
  • Maturing: Once the chocolate is ready, it's poured into molds to solidify. These chocolate blocks are then aged for at least a month, allowing the flavors to mature and meld together.
  • Tempering: The solid chocolate blocks are remelted and tempered. This process involves carefully manipulating the chocolate's temperature to ensure it's shiny, snaps crisply, and melts smoothly in the mouth.
  • Molding and Packaging: The tempered chocolate is poured into molds to create the final chocolate bars. After setting, they're carefully packaged, ready to be enjoyed by chocolate lovers everywhere.

Roasting Process and Types of Beans

When we roast the beans, we actually create a roasting profile for each cacao bean we have. We use beans from El Salvador, Dominican Republic, Peru, Ecuador, Tanzania, and Uganda.

From Bean to Bar: Wrapping Up the Flavors and Facts

The story of chocolate is a tale of evolution, from the sacred cacao drinks of ancient civilizations to the indulgent chocolate bars of today. Kaicao is more than just a chocolate company; it's a bridge between the ancient traditions of cacao and the modern world of chocolate-making. By understanding and appreciating this history, you can savor this chocolate with a deeper sense of gratitude and wonder.

Buying bean-to-bar chocolate also helps the environment and the farmers and ensures ethical practices in the industry. So, the next time you bite into a piece of Kaicao chocolate, remember the millennia-old journey it took to reach you.