Historical background
Cocoa was well known to the classic Mayan
civilization which flourished and died in the Yucatan and Guatemala in the 1st
Millennium. Alongside deceased Maya dignitaries were buried implements like
jars and bowls which were used for making chocolate. They called it Ka-ka-w.
Linguistics believes that the Maya‘s probably learnt to use the product from
the earlier Olmec civilization which flourished between 1500BC to 400BC.
The beans became a commodity for trade, an object of
warfare and also a currency. The Mayans spread the chocolate far and wide to
the west of Yucatan where the Aztec established their power. In due course Cocoa
became a major source of wealth of the Aztec. To the Aztec chocolate was the
drink for the warriors and the elite. Chocolate lent itself to flavour mixtures
like maize flour and herbs. It was offered to the Gods and was used to anoint
new born children on the forehead, face, fingers and toes.
It was, only, under the invader Cortez, when the
Europeans, first learnt the full value of cocoa. Its new name ―chocolate‖
appears to be a Spanish inspired blend of Maya
and Spanish. The word was soon applied
to all products of cacao. As a commodity of trade cocoa beans began to reach
Spain in 1558. As an expensive exotic spice Chocolate was gradually introduced
to the rest of Europe. By the 17th century the Italians experimented
with new flavorings for chocolate including musk, jasmine, citron and lemon
peel. In 1659 A. D. David Chaliou was granted a monopoly for selling chocolate
throughout France. Chocolate was first sold in London in 1657
By the end of the 18th century there had
been a perceptible increase in the amount of chocolate being consumed in stabs,
in ices and sorbets, as an ingredient in desserts and main dishes and in pastas
and soups.
It was in 1828
that a Dutchman ―Van Houten patened the screw press
which removed 2/3rd of cacao butter. The
residue so obtained was known as Cocoa. This dispersed easily in water and was
considered to be more digestible.
Mr.Van Houten, also developed an Alkalizing process
by treating cocoa during processing with potassium carbonate which led to a
milder flavour and darker colour.
By adding the excess cacao butter to ground beans
created a smooth paste which could be moulded and remain solid when cool yet
melted easily in the mouth.By 1842 Cadbury Bros. was
selling block chocolates. By 1847 Fry were marketing chocolate déleciux à
Manger. Major contributions were made by Swiss for e.g. In 1880 Randolph Lindt
increased the amount of cocoa butter in his formula and developed CONCHING. In
1876 Daniel Peter produced the first milk chocolate.
SOURCES
The Cocoa tree provides with its seed the raw
material for making chocolate. The scientist ‗Linnacus‘ assigned the species to
a botanical genus, which he named ‗Theobroma‘ – food of the gods. Botanically
the leathery fruits are giant berries or pods.
In this genus 22 species are now recognized, all
native to central and South America, of these two are cultivated. Of greater
importance is ―Theobroma Cacao‖ from which nearly all the world‘s
chocolate is produced. Cacao is the term for the tree and for its seeds
corrupted to cocoa in English.
It is now cultivated all over the world within an area
of 20 degrees on both sides of the equator. This tree requires shade when young
and is susceptible to fungi and pests. There are many varieties however the
Forestero variety accounts for 80% of the world production.
Cacao flowers are pollinated by a species of Midge
and grow directly on the trunk of the tree. Only a few flowers develop into
fruit or pods and average yield annually being 30 per tree. Full grown fruits
are about 8 inches (20 cm) long and 4 inches (10 cm) across in an oblong shape.
The green pods when ripe are saffron, yellow or red in color and contain on an
average 30 to 40 seeds, occurring in rows and embedded in a white or pinkish
pulp.
West Africa is now the largest producer of Cocoa and
produces over 60% of the world‘s production.
MANUFACTURE & PROCESSING OF CHOCOLATE
Ripe pods are collected, split and the contents
scraped out. The seeds and the surrounding pulp are exposed to the sun allowing
the pulp to ferment. This fermentation process is completed in 5 to 7 days.
Fermentation is essential for the development of good flavor, for use in the
making of chocolate.
Fermentation develops ―flavor precursors‖ breaking
down sugar to glucose and fructose and turning some protein into free amino acids and
smaller peptides. After fermentation the beans are dried and exported to
manufactures. They lose 50% of their weight on drying and the yield of a single
tree is approx. 500 gms to 1 kg.
At the manufacturers a complex process of roasting
and grinding turns the seeds into chocolate mass i.e. cocoa and cocoa butter.
These two are mixed in varying proportion to form chocolate. Chocolate that
contains a very high percentage of cocoa butter and is known as CHOCOLATE
COUVERTURE.
Before preparing chocolate for dipping, moulding,
coating, sauces, etc. they must be stabilised or tempered.
TEMPERING
Before preparing chocolate for use they must be
stabilised or tempered. This process applies only to genuine chocolate
containing very high cocoa butter or chocolate couverture. Cocoa butter
consists of different fats, some melt at low temperatures others at higher
temperatures those with lower melting points are the first to solidify on being
cooled giving chocolate an undesirable grainy texture. It is the high melting
point fats that give high quality chocolate its shine and snap. The objective
of tempering is to distribute these fats evenly by creating very fine crystals
evenly throughout so that it becomes smooth, sets evenly and quickly.
Tempering consists of 3 stages:-
1. Melting: Chocolate couverture must be melted over a
Bain Marie to 49o- 50o C (120- 122oF)at this
temp all fats would have melted, it should be stirred constantly to evenly
distribute the fats.
2. Tempering: When the chocolate has melted it is removed
from the Bain Marie on to a marble top and stirred constantly to about 29oC
(84oF). The object of this process is to seed the mixture with cocoa
butter crystals of a uniform and stable type which will keep well during
storage. At this point nuts, fruits, etc. may be added.
3. RE-WARMING: After tempering and cooling, if the mass
is to thick for using it must be re warmed over Bain Marie till it reaches a
temp of 29oC(84oF). This step must be done carefully for if the temperature rises to 44oC or 111o
F the chocolate is no longer tempered, it SEIZES i.e. it goes hard and grainy.
Chocolate which has not been tempered will take
excessively long time to set and its texture will not be good. Also some of the
cocoa butter with float and then set making a whitish coating called the
‗BLOOM‘.
CHOCOLATE MAKING
Manual: Chocolates can be made by hand dipping, the
centres being lowered on a special dipping fork into molten chocolate, covered
and then deposited on paper to set. It is a skill which takes years to master
and is a method used mainly by craft confectioners, who wish to produce high
quality individual chocolate selections.
AUTOMATED:
There are two automated
methods:-
a)
Enrobing: It is a method in which the centres are
transported under a curtain of molten chocolate and then allowed to set.
b)
Shell moulding: Molten chocolate is deposited into
moulds to form a shell which is then filled. A lid of chocolate seals the
filling in before it is de moulded.
Hand Moulding: This is done
using moulds made of plastic, metal or rubber which must be kept clean and dry
as well as smooth. Molten chocolate is then deposited by hand into moulds to
form a shell which is then filled and covered by a layer of molten chocolate
and allowed to set. Chocolate shrinks when set thereby pulling it away from the
moulds so it can be easily De molded.
TYPES OF CHOCOLATE:
LIQUEUR CHOCOLATES can be made
by shell molding or by depositing the syrup into impressions made in trays of
starch & left undisturbed for some time, the syrup ―crusts‖ forming sugar
crystals and can be lifted out and en robed.
TRUFFLES: Are based on a ganache
flavored with sprites, essences and nuts.
WHITE CHOCOLATE is made by using only cocoa butter
Block Chocolates
Cocoa powder Cocoa powder is
made by dehydrating cocoa mass.
Drinking Chocolate: is made by dehydrating prepared Chocolate into
powdered form.
Chocolates contain Phenylethlamine a naturally occurring substance in the
brain which stimulates euphoric feelings. It also contains THEOBROMINE a
stimulant which acts on the muscles and Caffeine, but in much smaller quantities.
YIELD is 600
calories per 100 gms.
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