COCOA AND CHOCOLATE

Cocoa beans were first brought to Europe by Columbus in 1494. The cacao tree is
cultivated in the most tropical countries. It yields thick skinned pods containing seeds or
beans surrounded by a soft pulp. The beans and the pulp are allowed to ferment during
which the pulp is changed to CO2 and alcohol. The alcohol is oxidized to acetic acid and
packed for shipment.
At the chocolate factory the beans after sorting and cleaning are roasted. This renders the
skins easy to remove and at the same time improves the flavour. The roasted beans are
then broken into small pieces and blended with other broken beans in such a way that a
desired flavor color and eating quality is eventually attained. The blended pieces are then
milled to a fine particle size during which the temperature rises causing the cocoa butter to
melt so that the whole changes to a thick viscous mass known as crude chocolate. After
further milling it is run of into moulds and allowed to set. This is the unsweetened block
chocolate that is ideal for flavoring and coloring creams, fondant and cakes.
COCOA
There are two methods of producing cocoa The Dutch Process and the Natural process.
With the Dutch process the beans are treated with an alkali during roasting resulting in the
elimination of acetic acid giving the cocoa mass a better flavor and a richer color .The
mass is then pumped to hydraulic presses where some of the cocoa butter is removed.
When cool the pressed cake is reduced to powdered cocoa sieved and packed.
The natural process differs only in that the beans are not treated with an alkali, grinding
and pressing is the same as for the Dutch process.
CHOCOLATE: The blended and processed chocolate is mixed with cocoa butter, sugar
and in the case of milk chocolate with milk solids and refined until the particle size is
reduced to an extreme fineness. The viscosity is adjusted by the addition more cocoa
butter .The process is slow but necessary if fine chocolate is to be produced.
The chocolate now known a couverture is run into moulds and when set it is wrapped
ready for distribution or run into temp. Controlled tanks from where it can be pumped into
water tankers for bulk liquid delivery.
BAKERS CHOCOLATE: This is a chocolate made for coating cakes and fancies .It is
similar to couverture except that most of the cocoa butter is removed and replaced by a
hydrogenated fat together with a stabilizer such as lecithin.
Bakers chocolate cuts easily and unlike couverture it dose not splinter. It maybe bought
as either plain or milk. Because of the removal of cocoa butter which is a complex mix.
Of fats with different. Melting points and replacement by other fats, this product does not
have to be tempered.
The flavor is different from couverture. It is not suitable for chocolate dipping or for
moulding unless specially made for this purpose.
CHOCOLATES: Chocolates have the advantage for the confectioner that they can be
made all the year round since there is always a regular demand. Thus the confectioner is
always able to offer them freshly made to its customers. For first-class chocolates it is
necessary it use only first quality materials and to use great care in there preparation.
Chocolate centers are made from variety of basic mixture such asganache, gianduja,
marzipan, fondant, jelly and various nougats and praline .The centers are then coated with
a layer of couverture thick enough to protect the center from the chocolate while keeping

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them soft and thin enough for them to be dainty and appealing .The chocolate coating
should be bright and glossy and this can only be achieved if the couverture itself is
correctly tempered and the centers are the same temp. As the room where they are being
dipped.
According to the type of center the basic mixture may be rolled or poured out between
strips of wood and then cut out with cutters or a knife. For truffles the mixture is forced
out of a mixture bag fitted with a plain pipe into ropes which are then cut up with a special
caramel cutter and the pieces rolled into balls by hand.
The confectioner is able to produce a wide range of chocolates by skillful blending of
centers and flavours. The craftsman proud of his product will use parchment paper
carrying the negative imprint of his name on this he places the dipped chocolate. Thus
giving a personal touch to his products.
LIQUEUR CHOCOLATES: These chocolates are prepared by pouring liqueur syrup
into cavities made with moulds pressed into a bed of starch.
The starch should be very dry and sifted directly to shallow wooden boxes about one inch
deep .The starch is then beaten up with a metal whisk so as to make it light and then is
leveled off with a strip of wood and excess starch removed. Plaster moulds attached to a
strip of wood are then pressed into the starch to produce the cavities.
LIQUEUR CHOCOLATES MADE WITH STARCH: This are made by lining hinged
metal moulds with couverture and then filling them three quarters full with the liqueur
syrup at 28°C.Coat the lids of the moulds with couverture and close them .When they are
cold the chocolate s are removed from there moulds and wrapped individually like other
liqueur chocolates.
FONDANT CHOCOLATES: This are prepared in the same way as liqueur chocolates
but flavoured and coloured fondant is poured while warm the cavities in place of the
liqueur syrup. When the fondant is quite set remove the centers from the starch, brush
them and dip in vanilla couverture.In the same way novelties are obtained such as bells,
mice etc.
CHOCOLATE: Chocolate is a mixture of cocoa solids in fine fractions, cocoa butter and
flavors. It may contain sugar and milk solids. Whether it is plain milk it is known in the
British Isles as couverture, as distinct from bakers' chocolate, made especially for coating
and decorating cakes and fancies. It remains comparatively soft and unlike couverture
does not splinter when it was cut. Couveture needs correct tempering before it is used;
baker’s chocolate does not.
COUVERTURE:
The importance of tempering: Cocoa butter, which is an important constituent of
couverture, is a complex, mixture of fats, each having, a different melting and setting
point. It is the presence of these different fats fractions that make it so important that
couverture is correctly tempered.
To prepare couverture, it is first cut into small pieces and put into a dry bowl placed on a
saucepan containing warm water. It is of the greatest importance that no water, or water
in the form of condensed steam, comes in contact with any chocolate or it will thicken and
be useless for dipping and moulding therefore the bowl must be perfectly dry. It is of
equal importance that the chocolate does not come in contact with direct heat, or the fine
flavor will be lost; in addition, chocolate will quickly burn and will have to be thrown
away.

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Approximately temperatures for tempering are given below but there may be variations
due to the type of couverture used. Reputable chocolate manufacturers will provide
detailed instructions and these should be observed.
When the couverture, which should be stirred from time to time, has reached temperature
of 115-118° F (46-47°C) (milk couverture 110°F / 43°C) it is removed from the heat, and
after the bottom of the bowl has been dried with a cloth, it is poured on to a dry marble
slab and spread with a palette knife until it begins to set. It is then quickly returned to the
bowl and very carefully taken to temperature of 88°F (31°C) milk couverture at 84°F
(29°C). Great care must be taken at this stage for it will be found that the retained heat in
the metal bowl is almost sufficient to take the couverture up to these figures. If the
temperatures are exceeded, then the tempering must started all over again. Couverture
must be all times stirred gently; vigorous stirring will introduce air bubbles which will spoil
the smooth surface of the finished goods.
The reason for tempering is not easy to explain in simple terms; nevertheless an
understanding of it is necessary if it is to be done consistently well. When the couverture
is to be taken to a higher figure, all the fats in the cocoa butter are melted and well
distributes. The spreading assists in rapid cooling during which some of the fat fractions
set. When the couverture is reheated to lower figures these fractions remain crystallised
to act as nuclei on which compete crystallisation is effected when the couverture sets after
dipping and moulding.
If tempering is not done correctly, it will be found that the couverture will not set quickly
and moulded figures will not leave the moulds. When at last the couverture sets, it will be
found to have a flat bloom on the surface. This is due to the fat fractions not being mixed
so that they float to the surface, to be seen as a grey film completely spoiling the gloss that
is the beauty of correctly prepared couverture. Another form of bloom is the result of the
dampness when the sugar on the surface dissolves and re-crystallises in larger form on
drying. This is known as sugar bloom.
MOULDING: To produce chocolate figures, cups and Easter eggs, moulds are necessary,
which may be either metal or plastic. Metal moulds are more durable, but plastic moulds
being semi transparent give the chocolate craftsman the opportunity of seeing whether or
not the figure has come away from the mould.
The moulds are prepared by polishing them with a soft cloth or cotton wool, so that the
moulding surface is not only perfectly clean but highly polished. If any of the moulds
contains pieces of chocolate, they should be warmed and melted chocolate wiped out. On
no account should be chocolate removed from a sharp object or the moulds will be
scratched which will show on the finished goods. When the moulds are not in use they
should be cleaned and wrapped in soft paper before being stored in dry place. Mould for
chocolate are in one or two parts. Those in two parts are either totally enclosed or with
open ends in which the chocolate can be pored.
Single moulds are filled with the prepared couverture; tap well to bring any air bubbles
away from the moulded surface. The other half of the mould is placed over it and both
sections securely fastened with clips. The mould is then rotated evenly to distribute the
chocolate over both surfaces, tapping the mould from time to time to remove air bubbles
from inner surface. When set the clips are removed, the mould carefully opened and the
figure taken out.
With open ended moulds, the two sections are first clipped together. Prepared couverture
is poured in until they are well almost full, after which they are tapped well to remove the
air bubbles. After a short time they are taken one at a time and up ended and tapped with a

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stick so that the balance of the melted chocolate is returned to the bowl, leaving as shell of
couverture in the mould. The moulds are then stood up on greaseproof paper, so that any
melted chocolate will run down, sealing the open end to form a pedestal so that the
chocolate figure can be stood up.
When completely set, the moulds are unclipped and if the couverture has been properly
tempered, the figures should leave the moulds, with a fine gloss.
EASTER EGGS
Easter eggs are made in two ways:
1. Prepared couverture is poured into the polished moulds which are then tapped to
remove bubbles, when about six are filled, the first are inverted on the bowl and shaken
with a rotary motion of the hand to remove the surplus chocolate. This will leave a shell of
even thickness in the mould. That each is dealt with; it is inverted onto paper so that some
of the melted chocolate runs down to form a flange round the inner rim.
2. The couverture is brushed into the prepared moulds with a soft dry brush`; when it is
set another coat is applied. A third may be done if necessary. When the last coating has
been applied the moulds are inverted on to paper as described above.
If the couverture has been correctly tempered it will leave the mould on setting; this is
because the chocolate will contract more than the metal or plastic of the mould. Before
removal from the mould, however, the edge should be trimmed with a stout piece of
plastic care being taken not to remove the flange.
To assemble eggs, a little melted chocolate is piped on to the flange; two sections can be
fixed together. Easter eggs can be decorated in many ways, with the piping chocolate, cut
out or modeled flowers crystallised violets or raised petals. Nylon ribbon will also give an
excellent finish. Care should always be exercised with the finished chocolate products;
careless handling will leave fingerprints and smears and fine gloss will be spoiled.
When the confectioner is working with chocolate, he needs a special room for the dipping
and moulding if good results are to be obtains, ideally, the room should be kept at a
temperature of 68° F (20°C). Praline centers to be coated with couverture must be dry
and of same temperature as the room where the work is to be done. If they are colder, the
couverture will set too rapidly and will have a dull appearance; on the other hand, if the
centers are too warm, the couverture will turn grey on account of separation of the cocoa
butter from the chocolate. Even when the chocolates have cooled down, they must not be
subjected to variations in temperature as they could become discoloured and lose their
gloss. They should be stored at a temperature of 55-60°F (12-15° C) away from sunlight
and dampness.

STORING
In concluding this section, mention should be made of the means of storing chocolate
products. Here are the advantages of wrapping them individually in cellophane.
1. The chocolate retains its flavour.
2. The mouldings are kept free from dust.
3. Finger prints and other marks are eliminated.
4. Storage is simplified, since some mouldings can be placed inside each other (the shells
of Easter eggs, for instance)
CHOCOLATE CUT-OUTS

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To make chocolate cut-outs for decorating gateaux and ices, prepared couverture is
spread onto thick paper. The paper is picked up and allowed to drop several times so that
then chocolate runs level. When it is set, it is cut with the point of a knife or with sharp
scissors to desired shapes. The pieces are easily removed by inverting the paper on to a
clean sheet and peeling it off. The shapes can then be collected and the debris returned for
the further use.
BAKERS CHOCOLATE
This chocolate can be purchased as either plain or milk. It is similar to couverture except
that almost all the cocoa butter has been removed and replaced by a hydrogenated fat,
together with a stabilizer as lecithin , to prevent the fat used and its increased stability, this
chocolate does not need tempering.
Baker’s chocolate is prepared initially in the same way as couverture and then taken to a
temperature of 130°F (54°C). The temperature is then allowed to drop until the desired
consistency is reached. the higher the temperature, the thinner the chocolate. The generally
accepted rule is that it should be warmer for larger articles such as gateaux and cooler,
105-110°F (40-43°C) for smaller fancies. These are optimum temperatures, although it is
possible to use bakers chocolate at a temperature range between 90-130°F (32-54°C) with
satisfactory results. As with couverture, no water or steam must come in contact with the
chocolate or it will thicken and be useless for either dipping or spreading.
PIPING CHOCOLATE
Piping chocolate can be purchased from the manufacturer and should be used accordingly
to instructions. It can be made by the craftsman, however, by very carefully adding a little
glycerine or stock syrup to melted couverture which can be either plain or milk. A very
small addition will thicken the couverture to a consistency so that it can be piped. Piping
chocolate is an excellent medium for piping, lettering outlines and chocolate motifs for
gateaux, torten, fancies and ices etc. It can be applied directly on to the product, or on to
a wax paper, when after it is set, it can be removed and placed on to the article to be
decorated.
Chocolate cigarette or rolls: The successful making of chocolate requires a great deal of
skill and this is acquired only from practice and patience. Pour a little tempered couverture
on to a marble slab and spread thinly with a palette knife and continue working it until the
surface is semi set and has a grey appearance. With the edge of a knife or with a scraper
on the surface of the chocolate, move it from left to right in an upward direction which
gives a cutting action. If the couverture will curl into rolls.
Chocolate shavings: Proceed exactly as for chocolate rolls but the couverture need not to
be tempered. Alternatively, the block of chocolate can be shaved with a sharp knife.
Chocolate leaves: A variety of chocolate leaves can be made by using a natural or plastic
leaf as a mould. The leaf is carefully cleaned and dried, then very thinly smeared with olive
oil, after which the chocolate is carefully spread on the surface. When set, the leaf will
easily peel off. Chocolate holly leaves make an excellent form of decoration for Christmas
gateaux, torten and fancies.
Chocolate Petals: These are made by placing dabs of tempered couverture on to a
greaseproof paper with a palette knife, so that as the knife is withdrawn from the paper,
petal shapes are formed that are thicker at the edges and thin in the centers.
GANACHE
Ganache is an easily made mixture of chocolate couverture and cream. A cheaper variety
can be made by using a mixture of cream and milk, or by using milk alone.

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The couverture used may be plain or milk. Because plain couverture imparts a pronounced
flavour of chocolate, additional flavour is not generally used. Ganache made from milk
couverture may be flavoured with rum, kirch or coffee. Here is the recipe for ganache.

Couverture 4.0 Kg
Cream 2.5 Kg
Ganache is made first by melting the couverture, then bringing the cream or milk to the
boil. The two are mixed thoroughly together and left in a cool place for 24 hours before
use.
The consistency of ganache may be adjusted by decreasing or increasing the proportion of
chocolate; an increase is advised in hot weather. A further increase will cause the ganache
to set quite firm when it can be cut for chocolate centers.
Ganache is normally used for spreading and piping. It is prepared by beating until it is light
and workable. If it should curdle or separate during beating, it should be warmed a little
warm chocolate may be run in. Properly prepared, ganache should be soft when used; it
will, however, set quickly making it suitable for dipping into fondant or chocolates.

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