[ The Atlanta Journal-Constitution: 10/31/02 ]

How chocolate bars are made

By Deborah Geering
For the Journal-Constitution

1. It may seem like the all-American flavor, but chocolate originates in the tropics with fruit from the cacao tree.

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The trees, which grow in African, Asian and South American jungles, produce a melonlike fruitoff the trunk. The fruits each contain about 30 seeds, called cocoa beans. The beans are fermented and dried before being shipped to processing factories.

2. At factories, the beans are hulled and then milled, a process that grinds the beans into a liquid called chocolate liquor. At this point, manufacturers add ingredients such as sugar, milk and additional cocoa butter -- a fat derived from cocoa beans -- to create milk chocolate.

3. The mixture is dried and ground under huge rollers into a smooth, warm paste -- melted milk chocolate. It can be poured into molds to create solid candy bars or used to enrobe candy centers such as nougat or caramel.

In the enrobing process, the candy centers travel on a mesh conveyor belt through a drum that pours a continuous sheet of melted chocolate over the candies. Meanwhile, a chocolate-covered wheel beneath the mesh belt coats the bottom of the bars.

4. Whether the chocolate is poured into molds or used to enrobe centers, the candy is then carefully cooled to room temperature, in a step called tempering, to control the formation of crystals and give the chocolate a shiny, hard finish.

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