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When the cocoa pods ripen they are cut off from the trunks and branches of the trees, where they grow, and are then cut open. The pods are ripe when they are green in color, this signifies a good quality cocoa, some of them turn orange or brown which indicates a lower quality cocoa.
The pods contain a sweet pulp in which the almond-shaped seeds are embedded. They are either cut open immediately or this can be done in the fermentation area. The seeds are removed and then laid on racks, placed in bins, or in most cases left on the ground to ferment. They have to be constantly raked to move them around. When the beans begin to ferment, the pulp liquefies and runs off, leaving the beans to dry out. This is an important process and cannot be shortened or the cocoa beans will rot.
Fermentation reduces the bitter taste of the beans and helps to develop the aroma. Once this has been done the beans are cleaned, graded and packed ready for shipping. They are mostly shipped to United States and Europe. Netherlands is the biggest exporter of processed cocoa in the world.
Cocoa beans are selected roasted and then shelled. The inner parts of the seed, which are called nibs, will then be ground between huge heated rollers. This is done in high- speed mills. The product that is produced is called chocolate liquor and it contains about 50-55% cocoa butter and is too bitter to eat.
The cocoa butter is then pressed out of the cocoa and is sold to chocolate manufacturers. They prefer the cocoa butter to have a neutral taste otherwise it affects the flavor of the finished product. Cosmetic companies also make use of cocoa butter in many of their products. The cocoa butter can be processed to eliminate any odors for this use.
The cocoa that remains after the cocoa butter has been removed will be refined to form the cocoa powder, as we know it. This product can then be used for baking, confectionary and many other culinary uses. More and more uses are being found for cocoa, as people become more aware of the health benefits of cocoa.
Many chocolate manufacturers still prefer to grind their own cocoa beans, but still have to purchase additional cocoa butter in order to manufacture the chocolate.
All chocolate is made from chocolate liquor and manufacturers add the flavorings that they want to make their chocolates unique. The additives are usually sugar and milk, for milk chocolates and various spices.
There are three cultivars of cacao trees that are cultivated for processing cocoa for the world market. The most expensive and sought after one is the Criollo as it has the best flavor. This accounts for 10% of the world quantity. The Forastero group is much hardier and easier to grow and accounts for about 80% of world cocoa production. This cultivar is a cheaper product than Criollo. Then there is a hybrid of Criollo and Forastero, which also accounts for about 10% of world production.
