HOW WE MAKE OUR CHOCOLATE Double click me.

 

 

 

 

STEP 1:  SOURCING THE BEANS

 

Chocolate Maker Jeffray D. Gardner and his team select

cacao beans based on their purity as much as their

personality: sourced from unique locations in Central &

South America and other remote regions in the world,

resulting in as many identities and unique flavors.

Our chocolate can only be as good as the quality of the

cacao we source. We spend a lot of time searching for

these rare varieties of heritage cacao that produce the

finest of flavors. To secure these sources we work hard to

build relationships with our growers. Farmers dealing

with farmers – we strive to deal 100% direct. Depending on our source, sometimes we deal with partners who also have great relationships with various farmers in far away places.

 

STEP 2:  HARVESTING, FERMENTING AND DRYING

 

The cacao pods are harvested twice a year. Pod color is

only a rough guide to bean ripeness. Farmers rely on

experience to assess when the perfect ripeness has been

reached. A task not made easier by the fact that pods on

the same tree do not always ripen evenly. Once opened

with a machete, the beans are sorted and then left to

ferment for between 3 to 6 days to oxidize the mucilage

(the white, sweet pulp that surrounds the beans) that

endows the cocoa bean with its first organoleptic

properties. A diverse range of flavor is created through a

careful fermentation process. Fresh wet beans are placed

in wooden boxes, where natural yeasts combine with the

fruit sugars to kick-off the ferment and begin a complex

flavor development process. Balancing time and

temperature, the farmer purposely moves the beans

between the boxes to ensure full flavor development.

After the beans have completed fermentation they are

slowly sun dried. The drying process further develops

flavor complexity and bean quality. The way in which a

farmer skillfully dries the bean can be an art form

in itself.

 

STEP 3: SORTING, ROASTING

            AND GRINDING

Our small factory has specific chocolate making machines each

with a job all of its own. Each specifically chosen to perform a

traditional task in the intriguing craft of chocolate making.

The first step is to hand sort the beans to ensure only the finest

make it through. A key step in the manufacture of chocolate,

roasting increases and reveals its aromas. Roasting further develops

chocolate flavor and locks in bean personality. Roasting should be at

the exact temperature with perfect homogeneous rotation so the

bitterness, sweetness, toasted or smoked flavor of the bean is

revealed. The cacao beans are roasted at approximately 120°C and

lasts between 20 to 30 minutes depending on the variety, location

and moisture content of the bean. Once roasted, the beans are burst

open and coarsely crushed in the winnower. Pod and skin residues

are then removed by the use of our winnowing machine.

 

STEP 4: CRUSHING TO REFINING

 

The nibs obtained from the winnower are first crushed by our

massive granite wheels rotating inside our melanger.

Heated by friction, the cocoa butter melts and transforms into

cocoa paste. This granular, acidic paste is then mixed together

with sugar and milk powder (for milk chocolate). Through the

huge granite wheels, the cocoa paste is crushed until its particle size is reduced to 20 microns or less.

 

 

STEP 5: PRE-CRYSTALLIZE OR TEMPER

After aging, the chocolate is pre-crystallized or tempered which gives the chocolate a smooth texture, glossy shine and pleasant “snap” when bitten or broken. Finally the chocolate is carefully poured into molds and set to rest.

 

 

STEP 6: WRAPPING

Each bar is hand-wrapped in beautiful colorful prints inspired

from the Japanese art culture.

 


 

 

 

Torrance, CA - Los Angeles County | info@marsatta.com | 310.318.0489

© 2019 Marsatta Chocolate | Vegan - Organic - Handcrafted - Bean-to-bar