The roasting releases flavours.
- Cocoa beans are first sorted, then cleaned
- To assure the quality, we roast right here, in Broc!
- Roasted cocoa beans release more than 400 flavors.
- The roasting temperature varies between 100 and 140 degrees Celsius, depending on the origin of cocoa and its use.
Roasting permits cocoa beans to release its flavours fully. We have been roasting the beans ourselves here in Broc for generations and therefore we acquired unparalleled know-how. We proceed with soft roasting, which preserves all flavours of the chocolate.
The cocoa beans are fragmented.
- The cocoa beans lose their skin.
- Only the aromatic core of the beans enters in composition of chocolate.
- The niblets are fragments of peeled cocoa beans.
During crushing the cocoa beams are split in small-size fragments. These fragments are called niblets. The niblets are separated from the skin by aspiration. This way, only the precious aromatic cores of cocoa beans are used for production of chocolate.
The niblets are ground.
- The niblet size is reduced even further
- The cocoa butter contained in the beans liquefies.
- Smooth brown cocoa paste appears.
Under the pressure and friction of the mill the cocoa heats up and the cocoa butter contained in the grains - its natural fat - liquefies. This way we obain cocoa paste, also called "cocoa liquor", a creamy brown mass with very strong smell and taste.
PROCESSING OF MILK
The fresh milk is condensed slightly.
- The fresh milk is condensed slightly and mixed with the cocoa mass.
- Cailler is one of the few manufacturers worldwide to use slightly condensed milk instead of milk powder
- It is a special process of vaporizing the milk into the cocoa that gives Cailler chocolate its unrivalled taste and texture
- What is obtained is the "crumb", the dry mixture of cocoa and milk
Farmers in Broc and surrounding areas deliver fresh milk for Cailler. This milk is condensed slightly and enters the chocolate-making process. It is this milk that gives Cailler milk chocolate its characteristic caramelised milk taste.
Proper dosage of ingredients.
- The crumbs are mixed with other base ingredients of chocolate: cocoa butter and sugar
- Proper dosage of ingredients is crucial: it is one of the secrets of Cailler recipes.
- The result of mixing is the chocolate paste, which is smooth but coarse
The paste is mixed in a mixer until homogeneous and creamy consistency is obtained. It already smells like chocolate, but it still has sandy texture, rather bitter flavour and pungent taste.
- During the grinding the sandy chocolate paste acquires proper consistency.
- Cailler grinds the paste until the particles are between 15 and 18 micrometers in size.
- This fineness assures a pleasant feeling of melting in your mouth
- The grinders are 2.50 meter in size and process approximately 2,500 kg per hour.
The still coarse chocolate paste passes through grinders consisting of multiple cylinders until the particles reach a size between 15 and 18 micrometers. The grinding is an essential step imparting the finest qualities and developing the aromatic potential of the chocolate.
Long hours are devoted to improvement of fineness and development of aromas
- The chocolate paste becomes chocolate
- At Cailler, the shelling takes between 24 and 120 hours!
- Intense friction heats the mass to 80 degrees Celsius
- Heating and mixing bind various components.
- Pungency and unpleasant aromas evaporate
- Shelling is a complex thermal and physical process
The chocolate paste is heated by friction in containers called shells. It reaches the temperature of 80 degrees Celsius and liquefies. The shelling, which takes hours, makes pungent and bitter flavors evaporate, while the desired flavors and developed fully. The chocolate paste achieves a remarkable fineness so that it gently melts in the mouth.
The proper form of crystals
- The chocolate is reheated, then cooled down and then reheated again
- Thanks to these temperature variations, the crystals form correctly
- This step gives many essential properties to the chocolate: delicate melting, brilliant look, well-rounded taste, good cracking properties and long shelf life.
- Moreover, the chocolate obtains the consistency desired for the following step
The tempering is an important step giving delicate melting properties and a brilliant look to the chocolate. The temperature must be controlled precisely: The series of crystallizations and liquefactions are essential for the final consistency and appearance of the chocolate.
The chocolate bar assumes its shape
- The chocolate form has a remarkable influence on its taste.
- Depending on the final product, the chocolate is pressed, moulded into a given shape and coated
Thanks to various processes used - moulding, extruding, coating - it is possible to obtain an impressive diversity of forms: in addition to classical chocolate bars we produce blocks, branches, pralines, Easter eggs and many other varieties. The form of chocolate and the characteristics of its surface significantly affect the taste perception. For example, if the branches are presented in form of bars, they assume a completely different taste!
The new Cailler SUBLIM line of products is the best example of positive influence on the taste: The special form of chocolate squares with harmonious curves enhances the intense flavour of chocolate even more.
Protect the precious chocolate
- Chocolate does not like light, humidity or temperature differences
- The films containing a layer of aluminum are nowadays of very high quality and they meet the chocolate packaging needs.
- The products are packaged individually by robots.
Ideally, chocolate should be stores in a dry and well-ventilated place. The relative air humidity should be approximately 50% and should not exceed 70%. The storage place should also be protected from light and maintained at a temperature between 16 and 18 degrees Celsius.
Did you know?
The surface of chocolate sometimes becomes slightly whiting under the influence of differences of temperature. This is caused by sugar crystals forming on the surface. They are not toxic at all. The taste of chocolate is not altered significantly.
This is yet another reason to protect your chocolate and to eat it quickly!