The ripe cocoa beans are harvested and transported to the area where they will be bursted. Then, the beans are cutted in half to separate the inside (containing mucilage and cocoa beans) and the shell.
bean to bar
HARVEST AND BURSTING OF BEANS:
FERMENTATION AND DRYING:
The mucilage is put into fermentation. The small quantity produced in Madagascar, allows producers to ensure a fermentation process of 5 to 6 days, all following the ancestral rulesand methods. Brewing every two days for a temperature ranging from 29 ° C / 30 ° C to 49 ° C / 50 ° C at the end of the process. It is the fermentation and the regular brewing that generate this heat.
The beans are then sun-dried on large wooden trays. Those are kept under sheds during the night and rainy periods to avoid moisture.
The majority of cocoa produced in Madagascar is for export. Less than 5% is processed on the island.
QUALITY CONTROL OF RAW MATERIAL:
On receipt, the beans are checked to verify their conformity. They are then sorted to avoid all the impurities.Roasting is a key step and makes the beans to develop all their aromas. We use a gas roaster which is more respectful for cocoa beans that infra-red roasters.
Crushing: One the roasting done and the beans completely cooled, they are crushed into particles’ fragments.
After roasting, once the beans are immediately cooled, the beans are crushed into fragments of particles. The result of this crushing is called cocoa nibs.
GRINDING AND REFINING:
The cocoa nib is then refined in roll mills in order to reduce the particle size (or fineness) of particles to an imperceptible size to the tongue and palate of the mouth – from about 20 to 30 μm – and thus improve the texture of chocolate.
After grinding, a thick, fragrant cocoa paste called “cocoa mass” is obtained.
The different ingredients (cocoa nibs, cocoa butter, sunflower lecithin, and possibly the other ingredients) are mixed in a conch that kneads, refines and heats the ingredients. After several hours, a silky smooth paste is obtained to give our chocolate.
Major step for the production of quality chocolate bar. Tempering consists of crystallizing through a set of temperatures that will make the chocolate brilliance.
Liquid chocolate is molded into tablets (75 or 25 grams)and pistoles of 4 grams for professionals. Then it goes through a refrigerated tunnel, which will harden the chocolate and keep it shiny.
Next step before tasting is the packaging that is still done manually by us.
We produce chocolates from Madagascar (beans Grand cru), a single origin for a premium quality chocolate.