The ripe pods are harvested and transported to the area where they will be broken. They are then cut in half to separate the inside (which has some mucilage and cocoa beans) and the shell.
bean to bar
HARVEST AND BREAKING OF PODS:
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 rules and 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 that are kept under the 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 by hand to remove all impurities.
A key step in production since roasting will help develop the precursor aromas of cocoa. We use a gas roaster that better respects cocoa beans than infra-red roasters.
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 for several hours until a silky smooth paste is obtained, the homogeneous structure, 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 shine.
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.
The next step before tasting is the packaging that is still done manually by us.