How is Chocolate Made? From Cacao Pod on the Tree to World’s Favorite Treat

History of Chocolate. How was Chocolate first made?

It’s mind-boggling to consider just how the process was discovered that takes the seeds of the cacao fruit through such a process as to create the beloved treat we all know and love, as chocolate. Some say it was all accidental and just “happened” to ferment, then toast and grind and add sweetener and boom! chocolate happened! More likely, fermentation of many different foods was common and well understood to the ancient Mayan people and they understood that it would help with the bitterness and from there, the food or drink “of the Gods” was first made. It was certainly a favorite discovery of early explorers as well as the royalty that enjoyed the chocolate brought back on those ships from the new world in the 1500s.

Since then, making chocolate has grown to be a huge business and enjoyed in nearly every corner of the earth. Ecuador is one of the top producers of cacao and living here among the orchards of cacao trees is a fun perk of our living here in Ecuador’s Amazon.

Step By Step Process to Making Chocolate

I realize the phrase is “bean to bar” when describing the process of how chocolate is made. But we’re going to back up to the pod on the tree. The process is neither quick nor easy and taking any shortcuts negatively affect the end product but the results continue to prove that it’s definitely worth it. Perhaps you’ll also better appreciate all that has to happen to make that little square of chocolate bar. Or cup of hot chocolate. Or cake, donut, frosting, or cookie. And it just might solidify it even more in your mind as the BEST treat out there. At least it does for me. I love the process and the beauty of each step. I love sitting down with my family around the table to shell the warm cacao. I love the excitement as each helps with this step or that and the part where we all sit down and enjoy a delicious treat. A favorite tradition we’ve had for years is to have chocolate fondue as a family treat at Valentine’s Day. I can’t wait to do that again now that we are in Ecuador and will plan to make our own chocolate dipping sauce from locally grown cacao. With bananas and pineapple from our backyard. Doesn’t that sound amazing? 

As a quick summary of steps to making chocolate, from the fruit on the tree to tasty treat ready to eat:

• Cacao pods picked from the tree and seeds separated from fruit.
• Cacao seeds are left to ferment for 3-5 days.
• Cacao seeds set out to dry for another 3-5 days.
• Cacao seeds toasted until begin to pop and blacken
• Cacao seeds shelled and beans/nibs gathered
• Cacaobeans/nibs ground into paste
• Additions stirred in- milk, sweetener, etc.

Cacao Pods and Cacao Fruit

It all begins with the cacao tree and the pods of fruit it grows. As we watch the fruits ripen in excited anticipation, we dream of all the things we might do with the chocolate in the end. But first, that fruit itself is also tasty! When you open the pod there is a tidy cluster of seeds, each wrapped up in sweet fruit. To enjoy, you just suck on the seed, being careful to not swallow the slippery bugger. 

Fermentation

Once you collect the seeds they must ferment for 3-5 days. This helps to remove the bitterness of the cacao. This is a step that is sometimes skipped by the big companies who will just add this chemical wash or that to cut the bitterness. But in really great chocolate? The time spent fermenting is important. 

Drying

Then the seeds are spread out in a thin layer for drying, which can take several more days. Small batches might use a dehydrator. It’s common to see a tarp spread out on the cement during a hot day with cacao drying in the sun. Big producers will have cement pads covered with tin roofs where the cacao is spread out to dry, come rain or shine. It’s important to watch for mold as even a single moldy seed can ruin the flavor and quality of the batch. 

Toast and Shell

After drying, the cacao is ready for toasting and shelling. As the seeds toast, they begin to smell like chocolate. The shell will begin to blacken and a few will “pop”. You can do this on the stove top or in the oven.  Once removed and still warm, we shell them, revealing the cacao and discarding the paper-like shells. At this point you have what we fondly refer to as “nibs”. Unsweetened and ready for many uses, these delicious little morsels don’t necessarily taste like chocolate yet- but they remind me of a nutty bitter chocolate. Cacao nibs are praised for their health benefits as it is full of antioxidants and flavenoids that help to reduce inflammation and increase blood flow. They can be added to any number of baked goods, yogurts, granolas etc. 

Make Chocolate

At this point the cacao nibs are usually transferred to the “chocolatiers” who grind the cacao into paste, separate out the portioned oils as cacao butter and add the sugar and milk to create whatever grand concoction they desire. 

At the Yachana, most visiting guest groups get to experience this part as we hand-grind the cacao and then make two favorite dishes- a yummy smooth hot chocolate and a thick dark dipping chocolate. There really is no comparison to the earthy yet heavenly taste of the chocolate you actually helped to make.

And just like that- chocolate is made. Check out the video of Douglas visiting a chocolate farm and watch for a new product from the Yachana, coming soon!

And if you get your hands on some cacao fruit pods or the nibs and want to make your own, check out these two recipes for that hot chocolate and dipping chocolate!