The chocolate production process
Over 3,000 formulations, a wide range of selected raw materials – and nearly 100 years of experience. We make all of this available to our customers to turn their ideas, visions and wishes into reality. What's more, we are equipped to a high technical standard to also be able to complete all of the processes and steps involved.
The selected and weighed ingredients are kneaded in a mixer until a homogeneous paste-like mixture forms. The mixture is grainy and sand-like; the flavour will also not have reached its full potential.
This paste-like mixture is then ground in rolling mills using pressure and shearing forces. On completion of this step, the particles will be smaller than a 20th thousandth of a millimetre (< 20 µm).
After grinding, the cocoa liquor will however still be in its original state. As far as flavour is concerned, the individual constituents in the chocolate still not have been fully bound to one another. In the conches, the chocolate liquor will be stirred and kneaded until the unwanted acids have evaporated and a delicate, velvety smooth chocolate mixture has arisen.
The desired crystalline forms arise during the chocolate pre-crystallisation step. To achieve this, the chocolate is cooled from 50 °C to 28 °C to allow all the fats to form crystals. Next, precise re-heating to 30-32 °C is employed to melt the undesired low-melting-point crystals, until only the desired high-melting-point crystals remain in the liquid chocolate. During the following solidification process, the desired cocoa butter crystals arrange themselves in a manner that allows the solidified chocolate to be removed easily from the respective form; this chocolate portion also exhibits the sought-after smooth texture and silky sheen.
There are practically no restrictions on the imagination when it comes to the last step in making speciality chocolates. Different weights of chocolate bars, solid, filled or with additions like nuts or sultanas are just some of the many possibilities. There are also small formats such as 'neapolitans' and 'lunches', snack bars, 'branches' (chocolate twigs) and chocolate pralines with many different fillings. Seasonal items like Easter bunnies and Christmas tree decorations also make up our product range. Similarly, couverture chocolate and semi-finished products remain in demand for artisanal chocolateries, confectioneries and industrial firms.
The finished chocolate products are packaged in various materials on automated packaging machines.