How Chocolate is Made

Summary

In this video, Nate Hodge, the head chocolate maker and co-founder of Raqqa Chocolate, takes us behind the scenes at their Brooklyn chocolate factory. He explains the intricate process of transforming cacao beans into rich, flavorful chocolate, from cracking the beans and refining the nibs to tempering the chocolate for perfect texture. The factory uses unique equipment, including repurposed spice grinders and custom rollers, to create smooth, velvety chocolate. Nate also discusses adding flavors like steeped chanterelles in cocoa butter and the meticulous care involved in creating 1,600-2,000 chocolate bars daily.

Takeaways

• 😀 Nate Hodge is the head chocolate maker and co-founder of Raqqa Chocolate, based in Red Hook, Brooklyn.
• 🍫 The process of making chocolate begins with opening cacao pods and separating the seeds, which are then fermented.
• 🍃 A repurposed juicer is used for cracking cocoa beans and separating the shell from the nibs.
• 🔄 The nibs undergo a refining process to eventually become smooth, rich, and shiny chocolate.
• 🍯 Indian spice grinders, originally used for chai and curries, are repurposed for grinding cocoa, running overnight before sugar is added.
• 🌀 After going through a roller mill, the chocolate mixture thickens and sugar granules are incorporated into the mix.
• ⚙️ The chocolate particles are ground to become smaller and more rounded, giving the chocolate a smoother texture on the palate.
• 🔥 The chocolate undergoes a tempering process, aligning the polymorphic crystals in both the fats and solids for uniform hardening.
• 🌱 The cocoa bean is a 50% mix of cocoa powder and cocoa butter, which is used in creative ways to enhance flavor and texture.
• 🍄 Cocoa butter is flavored with steeped herbs like chanterelles, which don’t affect the texture but enhance the flavor profile.
• 📦 The finished chocolate bars are set in a humidity-controlled box to solidify, before being wrapped in a machine that processes up to 2,000 bars a day.

Q & A

What is the first step in chocolate production at Raqqa Chocolate?

The first step in chocolate production at Raqqa Chocolate is opening cacao pods and extracting the seeds, which are surrounded by a mixture of fruit. These seeds are then put into sacks and taken somewhere to be fermented.

What is the purpose of the repurposed juicer in the factory?

The repurposed juicer is used to crack cocoa beans and separate the shell from the nibs. This process helps in extracting the pure nibs that will later be refined into chocolate.

How does the factory refine the nibs into chocolate?

After the nibs are separated, they are run through a set of Indian spice grinders repurposed for cocoa. The nibs are then ground overnight before sugar is added, and the mixture is processed through a roller mill to gradually refine it into a smoother, thicker consistency.

What is the purpose of reshaping the cocoa particles into a pearl shape?

Reshaping the cocoa particles into a pearl shape is essential to ensure they roll off the palate smoothly rather than sticking to it. This results in a better texture and mouthfeel for the final chocolate.

What is the role of the tempering process in chocolate making?

Tempering is a crucial step where the chocolate is heated and cooled in specific ways to align the polymorphic crystals in the fats and solids. This ensures the chocolate hardens at the same temperature, resulting in a shiny finish and smooth texture.

What unique ingredient does Raqqa Chocolate experiment with in their chocolate production?

Raqqa Chocolate experiments with steeping chanterelles in cocoa butter, adding a unique flavor and silky texture to their chocolate. This method allows the cocoa butter to absorb the flavors of herbs or teas without affecting the texture.

How does humidity affect the chocolate-making process?

Humidity negatively impacts chocolate, so the chocolate bars are placed in a dry environment at 55 degrees to set properly. This helps the chocolate harden correctly and maintain its texture.

How many chocolate bars does Raqqa Chocolate produce daily?

Raqqa Chocolate produces between 1600 and 2000 bars of chocolate every day, demonstrating their high level of production efficiency.

What is the purpose of the humidity-controlled box used in the factory?

The humidity-controlled box is used to set the chocolate bars at a dry, controlled temperature of 55 degrees, ensuring they set perfectly without being affected by moisture.

How is the final product wrapped at Raqqa Chocolate?

After the chocolate bars are set, they are rolled out, stacked, and placed in white bins. These bars are then wrapped using a specialized wrapping machine, which efficiently wraps a large number of bars each day.