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1.0 Introduction
Chocolate is a key ingredient in many foods such as milk shakes, candy bars,
cookies and cereals. It is ranked as one of the most favorite flavor in North America and
Europe (Swift, 1998). Despite its popularity, most people do not know the unique origins
of this popular treat. Chocolate is a product that requires complex procedures to
produce. The process involves harvesting coca, refining coca to cocoa beans, and
shipping the cocoa beans to the manufacturing factory for cleaning, coaching and
grinding. These cocoa beans will then be imported or exported to other countries and
be transformed into different type of chocolate products (Allen, 1994).
On 16 March 2011, we had guided by Dr. Lau Wei Hong to have a visit to the
Beryl’s chocolate factory which is located in Serdang. In the field visit, we had learnt
about the knowledge and the information about the manufacturing process of
chocolate. We had known that Beryl’s it’s all about delivering the best chocolates in
Malaysia. Beryl’s Chocolate today offers more than 100 varieties of chocolate to suit
every customer mood and desire.
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2.0 List of Beryl’s Chocolate Products
i. Panned Chocolate
Almond Milk Chocolate Almond bittersweet chocolate
Aggio almond mlk chocolate
Assorted Milk Chocolate Almond white chocolate Assorted Milk Chocolate
Yoghurt raisin white chocolate Chocolate 4 in 1 Almond Milk Chocolate
ii. Bar Chocolate
Coconut delight bar chocolate
Hazelnut bar chocolate Fruit & Nuts bar chocolate
Almond bar chocolate Assorted bar chocolate4 in 1
Fruit & Nuts bar chocolate
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iii. Camior Bar Chocolate
Milk Prailines chocolate Almond milk chocolate Hazelnut milk chocolate
Bittersweet chocolate Assorted chocolate 3 in 1 Mini Carrior assorted chocolate
Light no sugar added Bittersweet chocolate
Light no sugar added hazelnut chocolate
Light no sugar added almond milk chocolate
iv. Mini Chocolate
Black bitter chocolate Strawberry white chocolate
Assortito Chocolate
Mint & Bitter Chocolate Black & White Chocolate Dark Chocolate 80% Cacao
Dark Chocolate With Wafer Strawberry White Chocolate With Wafer
Blueberry White Chocolate With Wafer
Mini Chocolate 4 in 1 Treasure Coin Milk Chocolate Coin Dark Chocolate 54%
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Cacao
v. Ghana Chocolate
Strawberry White Chocolate
Ghana Hazelnut Milk Chocolate
Borneo Almond Milk Chocolate
85g Bar Chocolate 3 in 1
- White
Ecuador Mass Dark Chocolate 72% Cacao
vi. Fruit Fiesta
Fruits Fiesta Chocolate- Blueberry
Fruits Fiesta Chocolate- Green Apple
Fruits Fiesta Chocolate- Mango
Fruits Fiesta Chocolate- Rockmelon
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vii. Tiramisu
Tiramisu Almond White Chocolate
Tiramisu Almond Chocolate Tiramisu Almond Milk Chocolate
Tiramisu Milk Chocolate
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3.0 Percentage of Energy in Milk and Milk-free Chocolate
The Percentage of Energy from Protein, Fat and Carbohydrate in
Milk and Milk-Free Chocolate
% Energy Contribution
Protein Fat Carbohydrate
Plain Chocolate 4% 57% 39%
Milk Chocolate 7% 52% 41%
White Chocolate 5% 51% 43%
Sources:
Multiple sources were used in developing this including
www.sallys-place.com, www.ilovechocolate.com.au, and other
online resources. All credits remain with their respective owners
although the information has been modified.
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4.0 Chocolate Manufacturing Process
1) Ingredient of chocolate
Cocoa mass, cocoa butter, sugar and milk powder are the main ingredient of the
chocolate.
2) Mixing
Cocoa mass, sugar and part of the cocoa butter are mixed in specified proportions. After
mixing the mass is ground. This stage is very important for the production of chocolate:
the finer the crushing, the more delicate the taste. This especially concerns the contents
of cocoa-butter, an extremely valuable and expensive product. But in various cheap
substitutes cocoa-butter is almost invariably absent.
3) Refining
The goal of refining is to make the thick chocolate crumb into a silky chocolate. It travels
through a series of five heavy steel refining rollers set at different intervals and different
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speeds. The gaps between the final rollers are so small that the chocolate components
are ground into a thick fluid mass which is then run off. This step reduces the particle
size to of the cocoa mass to 25 to 30 microns, both in the chocolate liquor and the
sugar. In some cases, extra cocoa butter is added to the chocolate liquor for a smoother,
more voluptuous mouthfeel. The smoother the chocolate desired, the more rolling.
4) Conching
After mixing and grinding the chocolate mass is subjected to conching: intensive mixing
at high temperature. Conching is a very long (up to 24 hours) process and, as a result,
the superfluous moisture and the residual tannins are evaporated from the chocolate
mass, and the cocoa solids are rounded off. The consistency of the chocolate becomes
more homogeneous, and the taste—gentler, the well-known “melt in the mouth” effect.
After processing the chocolate mass, the rest of the components are added according
to the recipe: cocoa butter and lecithin—for mass attenuation and optimized moulding;
natural flavoring agent (vanilla)—for a subtler and more delicate aroma.
5) Moulding
There are different methods for producing chocolates: enrobing, hollow figure, layer-
and-cutting and molding. Molding is the simples: solid shapes like bars and hearts are
poured into molds, as shown at the right. The enrobing process (photo below) is the
oldest method for producing chocolates: pre-shaped chocolates centers (caramel,
creme, croquant, marzipan, nougat, nuts et al) can be hand-dipped by artisan
chocolatiers and further ornamented with fruit pieces, nuts, candied violets, cocoa
butter transfer designs or other flourishes on top. In larger operations, the centers are
placed on a moving wire mesh belt which takes them to a coating machine. A shower of
chocolate falls down to cover the centers in chocolate.
6) Packaging
The chocolate is then send for packaging which can maintain the storage period and
easily send to customer. There are different types of chocolate package that the
manufacturer provided for customer choices.
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