PROJECT SUMMARY

chocolate is a raw or processed food produced from the seed of the tropical Theobroma cacao tree.
Cacao has been cultivated for at least three millennia in Mexico, Central and South America, with its
earliest documented use around 1100 BC. The majority of the Mesoamerican people made chocolate
beverages, including the Aztecs, who made it into a beverage known as  a Nahuatl word meaning "bitter
water". The seeds of the cacao tree have an intense bitter taste, and must be fermented to develop the
flavor.

After fermentation, the beans are dried, then cleaned, and then roasted, and the shell is removed to
produce cacao nibs. The nibs are then ground to cocoa mass, pure chocolate in rough form. Because this
cocoa mass usually is liquefied then molded with or without other ingredients, it is called chocolate liquor.
The liquor also may be processed into two components: cocoa solids and cocoa butter.
Unsweetened baking chocolate (bitter chocolate) contains primarily cocoa solids and cocoa butter in
varying proportions. Much of the chocolate consumed today is in the form of sweet chocolate, combining
cocoa solids, cocoa butter or other fat, and sugar. Milk chocolate is sweet chocolate that additionally
contains milk powder or condensed milk. White chocolate contains cocoa butter, sugar, and milk but no
cocoa solids.

Cocoa solids contain alkaloids such as theobromine and phenethylamine, which have physiological

effects on the body. It has been linked toserotonin levels in the brain. Some research found that
chocolate, eaten in moderation, can lower blood pressure.[1] The presence oftheobromine renders
chocolate toxic to some animals,[2] especially dogs and cats.

Chocolate has become one of the most popular food types and flavors in the world. Gifts of chocolate
molded into different shapes have become traditional on certain holidays: chocolate bunnies and eggs are
popular on Easter, chocolate coins on Hanukkah, Santa Claus and other holiday symbols on Christmas,
and chocolate hearts or chocolate in heart-shaped boxes on Valentine's Day. Chocolate is also used in
cold and hot beverages, to produce chocolate milk and hot chocolate. Around three quarters of the
world's cacao bean production takes place in West Africa.

INTRODUCTION
heobroma cacao, native to Mexico, Central and South America, has been cultivated for at least three
millennia in that region. Cocoa mass was used originally in Mesoamerica both as a beverage and as an
ingredient in foods.
Chocolate has been used as a drink for nearly all of its history. The earliest record of using chocolate
dates back before the Olmec. In November 2007, archaeologists reported finding evidence of the oldest
known cultivation and use of cacao at a site in Puerto Escondido,Honduras, dating from about 1100 to
1400 BC.[7] The residues found and the kind of vessel they were found in indicate that the initial use of
cacao was not simply as a beverage, but the white pulp around the cacao beans was likely used as a
source of fermentable sugars for an alcoholic drink.[7] The Maya civilization grew cacao trees in their
backyard,[8] and used the cacao seeds it produced to make a frothy, bitter drink.[9] Documents in Maya
hieroglyphs stated that chocolate was used for ceremonial purposes, in addition to everyday life.[10] The
chocolate residue found in an early ancient Maya pot in Río Azul, Guatemala, suggests that Maya were
drinking chocolate around 400 AD. In the New World, chocolate was consumed in a bitter, spicy drink
called xocoatl, and was often flavored with vanilla, chili pepper, and achiote (known today asannatto).
[11]
 Xocoatl was believed to fight fatigue, a belief that is probably attributable to the theobromine content.
Chocolate was also an important luxury good throughout pre-Columbian Mesoamerica, and cacao beans
were often used as currency.[12] For example, the Aztecs used a system in which one turkey cost one
hundred cacao beans and one fresh avocado was worth three beans.[13] South American and European
cultures have used cocoa to treat diarrhea for hundreds of years.[14] All of the areas that were conquered
by the Aztecs that grew cacao beans were ordered to pay them as a tax, or as the Aztecs called it, a
"tribute".[15]

Until the 16th century, no European had ever heard of the popular drink from the Central and South
American peoples.[16] It was not until the Spanish conquest of the Aztecs that chocolate could be imported
to Europe. In Spain it quickly became a court favorite. In a century it had spread and become popular
throughout the European continent.[16] To keep up with the high demand for this new drink, Spanish
armies began enslaving Mesoamericans to produce cacao.[17] Even with cacao harvesting becoming a
regular business, only royalty and the well-connected could afford to drink this expensive import.[18] Before
long, the Spanish began growing cacao beans on plantations, and using an African workforce to help
manage them.[19] The situation was different in England. Put simply, anyone with money could buy it.
[20]
 The first chocolate house opened in London in 1657.[20] In 1689, noted physician and collector Hans
Sloane developed a milk chocolate drink inJamaica which was initially used by apothecaries, but later
sold to the Cadbury brothers in 1897.[21]

Chocolate in its solid form was invented in 1847. Joseph Fry & Son discovered a way to mix some of the
cocoa butter back into the dutchedchocolate, and added sugar, creating a paste that could be moulded.
The result was the first modern chocolate bar.

For hundreds of years, the chocolate making process remained unchanged. When the people saw
the Industrial Revolution arrive, many changes occurred that brought about the food today in its modern
form. A Dutch family's (van Houten) inventions made mass production of shiny, tasty chocolate bars and
 related products possible. In the 18th century, mechanical mills were created that squeezed out cocoa
butter, which in turn helped to create hard, durable chocolate.[22] But, it was not until the arrival of the
Industrial Revolution that these mills were put to bigger use. Not long after the revolution cooled down,
companies began advertising this new invention to sell many of the chocolate treats we see today.
[23]
 When new machines were produced, people began experiencing and consuming chocolate worldwide.

PROJECT CONCEPT AND PRODUCT

edits by:Bo, Krystle, Dave Crosby, Jonathan E. (see all)

Article

EditDiscussView History

Making chocolate from the bean isn't easy. Chocolate companies invest millions of dollars
into tools and machinery to turn bitter cacao beans into delicious chocolate bars. But with
many hours -- or possibly days -- of hard work and dedication to detail, along with some
equipment of your own, you can turn your kitchen into a miniature chocolate factory. By
following these instructions and techniques, you'll be able to make your very own brand of
chocolate.

editSteps

1. 1
 Roast the cocoa beans. The process is similar to roasting coffee beans, except with
gentler requirements: 5-35 minutes at temperatures between 120-160 degrees C(250-325
degrees F). You must generally expose the beans to an initial high temperature, lower the
temperature gradually, and stop roasting when the beans start to crack (but not burn). The
first image shows the cocoa beans before roasting, and the second image shows the after-
result. You can accomplish this in your oven or by using a store-bought roaster.
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o If roasting in your oven, you will need to do a bit of experimenting because

roasting times depend on the type of bean you're using. Lay the beans in a single layer
across a cookie sheet. Start off with an 18 minute roast in a preheated oven at 120 degrees
C (250 F). They'll be ready when they start to crack and when they actually taste like
chocolate (let them cool before tasting!).

For roasting larger quantities of cocoa beans, you may want to invest in a drum, which is
rotated over a gas grill.
o See the Tips and Warnings below about roasting.
 2. 2
Crack and winnow the beans. After roasting, the beans must be cracked into nibs and
winnowed, whereby the husks (chaff) are removed.

o You can crack the beans with a hammer and remove the husks (which should
be loose after proper roasting) by hand if you are working with a small batch.

For larger batches, you can use a very coarse, Corona type mill or purchase a specialized
mill [1](shown here, also see Citations below) to crack the beans into nibs. (In case you were
wondering, a meat grinder doesn't work.)

To winnow the nibs, stir them gently with your hands or a spoon as you blow on them with a
hair dryer or small shop vac until the husks are blown away.
3. 3
Grind the nibs into a cocoa liqueur. You will need equipment strong enough to liquefy the
nibs and separate the remaining husks. General food processors, Vita-Mix, coffee grinders
(burr and blade), meat grinders (manual and electric) mortar and pestles, and most juicers
will not work. You may need to experiment to find equipment that gets the job done. Many
home chocolatiers find success with a "Champion Juicer"[2] (see Citations below). Feed the
nibs into the juicer one handful at a time, being sure to push them in gently (not forcefully)
or else the motor may overheat. Cocoa liqueur will come through the screen and a mixture
 of husks and liqueur will find its way through the spout. Feed this mixture through the juicer
again until only the husk comes through the spout.

4. 4

Conch and refine the chocolate. By definition, conching affects the characteristic taste,

smell and texture of the chocolate, while refining reduces the size of the cocoa solids and
sugar crystals. Both processes can be applied at the same time with a powerful wet grinder
(success has been reported with a Spectra 10 melanger, also called the "Stone Chocolate
Melanger"[3]; see Citations below). How you conch and refine the chocolate will depend on
what equipment you use, but here are guidelines for the Spectra 10 melanger:

o Melt the chocolate and the cocoa butter in the oven to about 120 degrees F.
o Combine with non-fat dry milk powder, sugar, lecithin and a vanilla pod (split
and soaked in the cocoa butter 1 hour; this is an optional flavoring).
o Pour the chocolate mixture in the grinder, periodically pointing a hair dryer at
it for 2-3 minutes to keep the chocolate melted during the first hour (until the friction created
by grinding keeps the chocolate liquid without additional heat being needed).
o Continue refining for at least 10 hours and no more than 36 hours, until the
chocolate tastes smooth and balanced, but be sure not to over-refine (or it will get gummy).
o To take a break from refining (e.g. at night while you're sleeping, see
Warnings), turn off the grinder, put the covered bowl into an oven that's preheated to 150
degrees F but turned off, and leave it there overnight. It shouldn't solidify but if it does, take
the cover off and turn the oven on to about 150-175 degrees F until the chocolate melts (be
careful not to let the bowl itself melt, though).
 5. 5
Temper the chocolate. This is likely the most difficult part of the process, but it ensures
that the chocolate will be shiny and have a "snap" to it, rather than being matte and soft
enough to melt in your hands. However, the great thing about tempering is you can do it as
many times as you like and the chocolate won't be ruined. Alternatively, you can purchase a
tempering machine on the Internet for $300-400 (US). The most important thing is that you
do not let any moisture in the chocolate, or it will be ruined.

Melt your chocolate carefully. You can accomplish this in the oven if you are using larger
quantities of chocolate, or you can use a double broiler on the stove. It's your choice, just
make sure that the chocolate does not burn (keep stirring) and you melt more than 1.5
pounds of chocolate. Any less and tempering could prove difficult. When the chocolate is
melted to a temperature of around 110 or 120 degrees F, transfer it to a dry, cool bowl and
stir until the chocolate temperature drops to about 100 degrees F. Use a candy
thermometer to gauge the temperature. The chocolate in the bowl should remain at the
same temperature while you work with chocolate outside of the bowl.

Pour about one third of the contents of the bowl onto a hard, non-porous counter top or
other surface (granite or marble works best). Spread the chocolate out with the spatula, and
then bring it all back together.
 o

Continue doing this (for about 10-15 minutes) until the chocolate is about 85 degrees F. By
the time the chocolate cools down to that point, the chocolate should be a thick, gooey
mass.

Add some of the 100 degree F chocolate from the bowl to get the chocolate workable again.
Gently work the chocolate around.

Return the chocolate back into the bowl with the 100 degree chocolate. Stir it gently, and try
not to create bubbles.
o Check the chocolate's temperature. You want it around 90 degrees F,
but never over 92 degrees F. Anything higher than this and you may need to temper the
chocolate again.
6. 6
Mold the chocolatewhile it is still at about 90 degrees F. Pour the chocolate into the
molds, careful not to spill. Some people find it effective to use a large syringe to place
chocolate in the mold, but it is all about personal preference. When all of the chocolate has
been added to the molds, you may either freeze, refrigerate, or let them harden at room
temperature. Again, it's all about personal preference, and there is no rightway to do it.

7. 7
 Remove the chocolate from the molds when the chocolate is hardened. The molded
chocolate should have a glossy appearance and should snap cleanly in two. If you are
unsatisfied with your chocolate, you may re-temper the chocolate as long as the chocolate
remains dry and you haven't burned it.
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editTips
 There are many things you can do with your chocolate when you're done. You could
sell it, give it as gifts, or even enjoy it with friends and family. Homemade chocolate makes
a great gift -- experiment with it to make a variety of chocolate-based gifts. Give it for a
holiday or birthday and expect it to be enjoyed. Any way you choose, the process will be
rewarding and fun.
 Making chocolate is a learning process. Don't expect your very first batch to be
absolutely perfect. If you make chocolate several times, you'll find what works for you and
what doesn't. You might even consider adding ingredients of your own, or using your own
methods of roasting or tempering that work well for you. Do research about different
techniques and see what you can find, and experiment with your own.
 Don't skip the roasting. The beans need to be roasted in order to sterilize them and
reduce the risk of infection, as well as trigger the chemical reactions that make chocolate
taste like chocolate.
 It is possible to use a grinder or food processor to refine the chocolate, but this is
strongly discouraged as it doesn't work nearly as well as an actual refiner.
 It is likely that a mess will be made when you grind the cocoa.

 An example of a coacher/refiner

There are many different chocolate-making tools, it may just take some searching. Look
around in different stores and online. You might be surprised what you find!
 There is a way to make chocolate by hand, but it produces chocolate cruder than
that found here.
 There are also many more guides about making chocolate on the internet and also
try asking some of your friends who knows how to make chocolates.
 If you are using white colored chocolate and want to add coloring to it, never use
regular food color or food color paste since this too contains water. You should only use
powdered or gel varieties.
 If your melted chocolate is too thick to paint, add some parafinflakes until you get the
right mixture. If you don't have this, you can also use vegetable shortening or cocoa butter.
 Some people paint the chocolate after it has been taken out of the freezer. To do
this, you must hold the mold over you head so you can see it from the right side. If there are
any air bubbles, tap the area where they are using your fingers until it pops.
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editWarnings
 Always supervise your children when they make chocolate.
 Some of the machines you will be working with are dangerous, so always take safety
precautions and use your common sense.

editThings You'll Need

 Oven or store-bought cocoa bean roaster
 Cocoa mill/grinder
 Blow dryer
 Food processor or an electric cocoa grinder
 Concher/refiner (A food processor could be used as a substitute, but this is not
recommended. The concher/refiner is preferred over the food processor due to ease and
functionality.)
 Bowl
 Spoon
 Candy thermometer
 Cocoa beans
 Chocolate mold

Chocolate promoters
Top 10
1. Nestlé

Link:[Link]

Founded in 1860 by Henri Nestlé, a pharmacist, Nestlé is a multinational packaged food company
located in Vevey, Switzerland. Nestlé is globally renowned with its several product lines including milk,
chocolate, confectionery, bottled water, coffee, creamer, food seasoning and pet foods. Today, Nestlé
is considered one of the biggest chocolate companies with a wide range of chocolate products such as
Aero, 100 Grand Bar, Kit Kat, Nestlé Crunch and Rolo.

2. Cadbury Schweppes

Link: [Link]

One of the world’s largest confectionery company, Cadbury Schweppes was founded in 1905 and has
its headquarters in Berkeley Square, London, England. Apart from confectionery products, this British
confectionery company has also produced a great deal of beverage productions which has made the
company a strong regional presence in the beverage industry in the Americas and Australia. Cadbury
Schweppes has produced many types of chocolate brands such as Boost, Brunch Bar, Crispy Crunch,
Crunchie and many more.

3. Ferrero SpA

Link: [Link]

An Italian Chocolate manufacturer, Ferrero SpA, is a family business which produces chocolate and
other confectionery products. Ferrero SpA was founded in 1946 by a confectioner Pietro Ferrero and is
still owned by the Ferrero family. In each year, Ferrero SpA has produced many tons of chocolate
which are used in manufacturing chocolate products such as Ferrero Rocher, Mon Chéri, Confetteria
Raffaello and also produce the Kinder product series, including Kinder Surprise, Fiesta Ferrero, Kinder
Chocolate bars and Kinder Chocolate.

4. Callebaut

Link: [Link]

The second-largest chocolate producer in the world, Callebaut is a Belgian chocolate manufacturer
which produces a wide range of chocolate products for consumers and professional chocolatiers
around the world. Founded in Wieze, Belgium in 1850 by Eugenius Callebaut, this company was first
operated as a brewery. Later in 1996, Callebaut merged with rival chocolatier “Cacao Barry” to form a
new company which is now called “Barry Callebaut”. Its primary products are baking chocolate and
cocoa powder which is sold to consumers and professional bakers around the world.

5. Camille Bloch
Link: [Link]

One of the most prestigious chocolate manufacturers in Switzerland, Camille Bloch has been producing
high quality Swiss chocolate for over 75 years. Camille Bloch is renowned for their Ragusa Chocolate
which is filled with smooth praline cream and hazelnuts, available in a variety of sizes and package
types. Additionally, Camille Bloch also offers four different Chocolate Mousse Bars, each of which
features decadently smooth chocolate filled with one of four creamy mousse fillings. Camille Bloch’s
products were distributed to luxurious chocolate stores all over the world.

6. Divine Chocolate

[Link]

Established in the UK in 1998, Divine Chocolate Limited is a manufacturer of Fairtrade chocolate

products in the United Kingdom and the United States. The company is owned as a partnership
between the Kuapa Kokoo cocoa, Twin Trading and Oikocredit. Divine Chocolate’s first product, Divine
Milk Chocolate, was launched in October 1998 and followed by a long list of chocolate products such
as Divine White Chocolate, Flavored Milk Chocolate, Dark Chocolate and drinking chocolate.

7. The Favarger Company

Link: [Link]

Founded in 1826 by a pastry-cook, Jacques Foulquier. The Favarger Company is a Swiss chocolate
manufacturer which is located in Versoix, the Canton of Geneva, Switzerland. The company is not only
well-known for those who live in Geneva and the rest of Switzerland, but also available at many places
throughout the world where good quality chocolate is offered. Its soft chocolate and exceptional taste
are claimed to be made by the original recipe which has been passed down from generation to
generation. The Favarger Company has its famous chocolate products such as Les AVELINES de
Genève and Les NOUGALINES de Genève.

8. The Hershey Company

Link: [Link]

The largest chocolate company in America, The Hershey Company was founded in 1894 by Milton
Snavely Hershey. Globally, the company is commonly called Hershey’s and is also considered one of
the oldest chocolate companies in the United States. Milton Hershey began to plant cocoa trees in his
hometown, Derry Church, Pennsylvania, in 1903 and the manufacturing of chocolate proved
successful. Since then, the company has grown rapidly.

9. Royce’

Link: [Link]
One of the biggest chocolate manufacturers in Asia, Royce’ Confect Co., Ltd., is also known as E-
Royce’, has produced and distributed chocolate products to many countries in Asia and other
continents. Royce’ was first established in July 1983, with a total capital of ¥10.0 million and increased
its capital to ¥30.5 million in September of 1985. From1990, Royce’ became a significant player in the
Asian candy industry with many of its famous chocolate brands such as Dacquoise, Lurumaro Chocola,
Nutty Bar Chocolate, Royce’ Chocolate Bars, Royce’ Pure Chocolate and much more.

10. World’s Finest Chocolate

Link: [Link]

Established in USA in 1949, World’s Finest Chocolate is probably most recognized for its beneficent
activities which help to raise money for non-profit organizations. Its $1 Almond chocolate bar that is
used for fund raising can be labeled with a group’s name and fund raising purposes. This family-owned
business has its headquarters in Chicago, Illinois, and also has a sales office located in Campbellford,
Ontario, Canada. World’s Finest Chocolate is well known for being one of only 9 companies in the
United States that produces chocolate “from bean to bar”.

MANUFACTURING PROCESS & TECHNOLOGY

 

The cocoa-bean -- the heart of the sweetest

delicacy in the world -- is bitter! This is why, up to
the 18th century some native tribes ate only the
sweetish flesh of the cocoa fruit. They regarded
the precious bean as waste or used it, as was the
case among the Aztecs, as a form of currency.

The Varieties
There are two quite different basic classifications
of cocoa, under which practically all varieties can
be categorised: Criollo and Forastero cocoas.
The pure variety of the Criollo tree is found
mainly in its native Equador and Venezuela. The
seeds are of finer quality than those of the
Forastero variety.

They have a particularly fine, mild aroma and are, therefore, used
only in the production of high-quality chocolate and for blending.
However, Criollo cocoa accounts for only 10% of the world crop. The
remaining 90% is harvested from trees of the Forastero family, with
its many hybrids and varieties. The main growing area is West Africa.
The cocoa tree can flourish only in the hottest regions of the world.

The Harvest
Immediately after harvesting, the fruit is treated to
prevent it from rotting. At fermentation sites either
in the plantation or at, collecting points, the fruit is
opened.
Fermentation
The fermentation process is decisive in the production of high quality
raw cocoa. The technique varies depending on the growing region.

Drying
After fermentation, the raw cocoa still contains far too much water; in
fact about 60%. Most of this has to be removed.

What could be more natural than to spread the beans out to dry on
the sun-soaked ground or on mats? After a week or so, all but a small
percentage of the water has evaporated.

Cleaning
Before the real processing begins, the raw cocoa
is thoroughly cleaned by passing through sieves,
and by brushing. Finally, the last vestiges of
wood, jute fibres, sand and even the finest dust
are extracted by powerful vacuum equipment. 

Roasting
The subsequent roasting process is primarily
designed to develop the aroma. The entire roasting process, during
which the air in the nearly 10 feet high furnaces reaches a
temperature of 130 °C, is carried out automatically. 

Crushing and shelling

The roasted beans are now broken into medium sized pieces in the
crushing machine. 

Blending
Before grinding, the crushed beans are weighed and blended
according to special recipes. The secret of every chocolate factory
lies in the special mixing ratios which it has developed for different
types of cocoa. 

Grinding
The crushed cocoa beans, which are still fairly coarse are now pre-
ground by special milling equipment and then fed on to rollers where
they are ground into a fine paste. The heat generated by the resulting
pressure and friction causes the cocoa butter (approximately 50% of
the bean) contained in the beans to melt, producing a thick, liquid
mixture.

This is dark brown in colour with a characteristic, strong odour.

During cooling it gradually sets: this is the cocoa paste. 

At this point the production process divides into two paths, but which
soon join again. A part of the cocoa paste is taken to large presses,
which extract the cocoa butter. The other part passes through various
blending and refining processes, during which some of the cocoa
butter is added to it. The two paths have rejoined. 

Cocoa Butter
The cocoa butter has important functions. It not
only forms part of every recipe, but it also later
gives the chocolate its fine structure, beautiful
lustre and delicate, attractive glaze. 

Cocoa Powder
After the cocoa butter has left the press, cocoa cakes are left which
still contain a 10 to 20% proportion of fat depending on the intensity
of compression.

These cakes are crushed again, ground to

powder and finely sifted in several stages and we
obtain a dark, strongly aromatic powder which is
excellent for the preparation of delicious drinks -
cocoa. Cocoa paste, cocoa butter, sugar and milk
are the four basic ingredients for making
chocolate. By blending them in accordance with
specific recipes the three types of chocolate are
obtained which form the basis of ever product assortment, namely:

Kneading
In the case of milk chocolate for example, the cocoa paste, cocoa
butter, powdered or condensed milk, sugar and flavouring - maybe
vanilla - go into the mixer, where they are pulverized and kneaded.

Rolling
Depending on the design of the rolling mills, three
or five vertically mounted steel rollers rotate in
opposite directions. Under heavy pressure they
pulverise the tiny particles of cocoa and sugar
down to a size of approx. 30 microns. (One
micron is a thousandth part of a millimetre.)

Conching
But still the chocolate paste is not smooth enough
to satisfy our palates. But within two or three days
all that will have been put right. For during this
period the chocolate paste will be refined to such
an extent in the conches that it will flatter even
the most discriminating palate.

Conches (from the Spanish word "concha",

meaning a shell) is the name given to the troughs in which 100 to
1000 kilograms of chocolate paste at a time can be heated up to 80
°C and, while being constantly stirred, is given a velvet smoothness
by the addition of certain amounts of cocoa butter. A kind of aeration
of the liquid chocolate paste then takes place in the conches: its bitter
taste gradually disappears and the flavour is fully developed. The
chocolate no longer seems sandy, but dissolves meltingly on the
tongue. It has attained the outstanding purity which gives it its
reputation.

CHCOCOLGY
People around the world have grown up enjoying chocolate as a
favourite treat for countless generations. But just how much does the
average person really know about the potential benefits, beyond the
great taste, that chocolate and its key ingredient - cocoa - provides?
We all know that a bit of chocolate tends to make you feel good, but a
wealth of research suggests that people can now have even more
reasons to enjoy it. The last decade has seen a significant increase in
our research and understanding of cocoa and chocolate. But
understanding the properties of chocolate is not just a recent
development. For centuries, civilizations from Mexico to Europe have
recognised the benefits of cocoa and chocolate for medicinal and
therapeutic uses as well as a food, beverage or treat. It has even
been hailed as an aphrodisiac!

Of course, we all need to ensure we don't over indulge and that we

see chocolate as a treat but researchers are continuing to uncover
more reasons to enjoy cocoa and cocoa products. "Chocology", the
science behind chocolate, opens up that research and presents the
facts in an easy to use report that we hope will be a useful resource
when talking about the benefits that chocolate can offer. 

Join us in the exploration of "Chocology" - You may discover that

there's more to chocolate than meets the eye.
 
•  Reasons to believe
•  Body of Evidence - Where can you feel the Benefits?
•  Myths and Facts about Chocolate 
•  Did you know?

Cocoa 
Long before the current trend towards organic ingredients, cocoa was
one of the best known natural foods. In its purest form cocoa is a
natural food. The cocoa tree produces cocoa pods that grow from the
trunk or branch of the tree. These pods contain the beans which
characterise the finished chocolate. The cocoa beans are fermented
under banana leaves to bring out the chocolate flavour and then dried
under the tropical sun. They are then shelled and ground to produce
chocolate liquor, an essential ingredient for making chocolate. The
liquor can also be pressed to remove the fat and is cooled and
ground to produce pure cocoa powder.

Antioxidant Power 
Cocoa contains high levels of naturally occurring compounds called
flavanols and a range of other polyphenols that have been shown to
reduce blood pressure helping to improve heart health. Polyphenols
have antioxidant properties and work by fighting the free radicals
which attack cells causing disease and accelerated ageing. They are
believed to impact on arteries and blood qualities, helping to reduce
the risk factors for cardio-vascular disease, through lowering blood
pressure and improved blood platelet function. Scientists have found
that the polyphenols relax vessels by increasing the chemical nitric
oxide. This has been shown in new studies at many universities
around the World1.

Dark chocolate contains especially high levels of flavanols and other

polyphenols - this helped to boost sales of dark chocolate by over
15% in the UK last year2! 
It's not just bars of chocolate that have these high levels of
antioxidants - a recent study revealed that hot chocolate beverages,
high in cocoa content, can contain concentrations of antioxidants
similar to those in red wine or tea3
Top
Deliciously Nutritious 
Chocolate and cocoa containing products are often criticised as being
low in nutritional value and "empty calories". On the contrary, milk
chocolate for instance contains many vitamins including B1, B2, and
E as well as minerals including potassium, sodium, magnesium,
phosphorus, zinc, copper, manganese and by far the most important,
calcium, providing over 15% of the recommended daily requirement
in a 49g bar of Cadbury's Dairy Milk, all of which help to keep us
healthy. In light of recent research which suggests taking
supplements may be detrimental to your health, it's good to know that
chocolate and cocoa contain so many nutrients! 

Boosting Brain Power 

A recent study in the United States at
Wheeling Jesuit University, West Virginia
(May 2006) has suggested that eating
chocolate may improve the way our brains
work. The theobromine and
phenylethylamine, as well as the caffeine
in chocolate appear to increase alertness
and mental performance4. The team
found that scores for verbal and visual
memory were significantly higher for those
people who had eaten milk chocolate, and
the consumption of milk and dark
chocolate was associated with improved impulse control and reaction
time. 
Similar work at the University of Nottingham has shown that the
consumption of dark chocolate can increase blood flow to the brain
leading to improved cognitive function.
Top
In the Mood
Chocolate is said to contain at least 300 natural chemical
compounds, resulting in a complex range of tastes and odours that
connect with the human brain as it runs over the taste buds of the
tongue. The slowly released energy and feelings of fullness and
satisfaction induced by its sugar and fat content, refuel the body's
energy levels and create feelings of wellbeing. Eating chocolate
triggers the release of endorphins, mood enhancing chemicals
produced by the brain. These produce feelings of pleasure. 

Chocolate has such a luscious texture and aroma that all the body's
taste and olefactory sensors are fully exploited, heightening the
pleasure of the experience. So much so that a recent survey by
Cadbury has found that 52% of women prefer eating chocolate to
having sex! Over the years, psychiatrists and researchers have
pointed out substances in chocolate that they think may make us like
it so much - however, they're in such small amounts they can't really
be the reason we crave chocolate. 

The simple pleasure of chocolate melting in the mouth adds to the

pleasure of eating it - chocolate has the property of melting at body
temperature, cooling the mouth slightly as it does so. Most
interestingly, one expert has pointed out that "chocolate's a blend of
flavours and aromas so complex that food chemists have never been
able to duplicate it in the lab 5 ." We may never understand why
chocolate makes us feel good, adding to its mystery. A standard 45g
bar of dark chocolate contains 12% of the Recommended Dietary
Allowance (RDA) of iron. Iron is essential in transporting oxygen in
the blood to all parts of the body, and an iron deficiency can cause
anaemia. 

When cocoa is combined with ingredients such as milk, sugar, fruit

and nuts significant quantities of nutrients are provided- giving
nutrition and energy as well as great taste. But as the products are
often high in fats and sugars it is important that consumption is in
moderation and that such products are consumed infrequently as
"treats" - but are certainly not "empty calories".
Top

 
Teeth 
While you should always brush teeth, naturally occurring substances
in cocoa, such as tannins, may play a role in inhibiting plaque
formation by coating the teeth to protect them6. 

Brain 
Eating chocolate releases endorphins, hormone-like natural
substances, which produce a feeling of pleasure and reduce
sensitivity to pain. Chocolate contains many substances that act as
stimulants, such as theobromine, phenylethylamine, and caffeine.
Research has found that consuming chocolate can lead to increased
mental performance. 

Throat 
A study carried out by Imperial College, London in 2004 claimed that
high doses of theobromine contained in chocolate are a third more
effective at stopping persistent coughs than codeine. 

Heart 
Research by Professor Carl Keen at the University of California in
2000 has shown that a bar of milk chocolate (45g) contains the same
quantity of antioxidants as a 150ml glass of red wine. Dark
chocolates with higher levels of cocoa contain even more, as
presented in February 2006 at the American Association for the
Advancement of Science's (AAAS) annual meeting in Boston. 

Circulation 
A number of studies, including one at the University of Cologne
revealed that dark chocolate helps lower blood pressure10. The study
focused on adults with untreated mild hypertension, some of whom
had white chocolate, some dark. Blood pressure remained fairly
unchanged in the group that ate white chocolate, which does not
contain flavanols. But after two weeks, blood pressure readings had
dropped significantly in the group who consumed dark chocolate. 

Bones 
Milk and milk products have been part of our diet for thousands of
years and the milk in chocolate - particularly milk chocolate - provides
useful quantities of a wide range of nutrients including calcium. A 49g
bar of milk chocolate provides over 15% of the adult Reference
Nutrient Intake (RNI) of calcium. Drinking chocolate made with milk
contains even more calcium.
Top

 
Eating Chocolate Is Inconsistent With A Healthy Diet 
With so much going for it, it's unfortunate that chocolate is often
surrounded by myths and misconceptions that result in its unjustified
reputation as an 'unhealthy' food. Scientists are beginning to dispel
common myths about the concerns of eating chocolate,
demonstrating the ways in which chocolate can make us feel good
when enjoyed in moderation. One example of this would be the high
levels of cardiovascular friendly antioxidants contained in chocolate -
in fact, dark chocolate in particular contains more antioxidants by
volume than red wine11 12. There is no need to exclude chocolate
from a healthy diet as long as it is consumed responsibly and in the
context of the dietary needs of the individual and their energy
balance. 

Chocolate causes Tooth Decay

Chocolate has sometimes been blamed for tooth decay but there is
research showing that chocolate isn't as bad for your teeth as people
think. Research has indicated that naturally occurring substances in
cocoa, such as tannins, may play a role in inhibiting plaque
formation. 

Eating Chocolate gives you spots 

Despite the persistence of this myth, research by the Pennsylvania
School of Medicine and also by the U.S. Naval academy13 found no
link between acne and chocolate consumption. 

Chocolate has no nutritional value 

Few people know that chocolate actually contains a number of
important nutrients. Milk chocolate is a source of potassium, calcium
and magnesium, while being low in sodium. It also provides us with
vitamins - including B1, B2 and E. 

Chocolate is Aphrodisiac
Though not definitively proven, recent research has indicated that this
might not be a myth after all! A study conducted by San Raffaele
hospital, Milan14 has found greater levels of sexual desire in the
group that reported daily chocolate intake as opposed to those who
did not eat chocolate. 

LOCATION AND INFRASTRUCTURE

Top

Key Data
Order year
2005
Construction started
2006–2007
Project type
Chocolate production and development
Production
Chocolate crumb
Location
Dunedin, South Island, New Zealand
Estimated investment
NZ$20m (€10.3m)
Completion
October 2007
Full specifications
In December 2006 Cadbury Schweppes, the well-known confectionery
manufacturer, announced the expansion of its operation in New Zealand
on the South Island in the city of Dunedin. The Dunedin facility
employs over 700 personnel and produces in excess of 5,000t of
chocolate crumb every year as well as finished products.

Chocolate crumb is one of the basic ingredients of manufactured

chocolate products. The demand for chocolate crumb in China, India
and the Asia Pacific region is increasing and Cadbury Schweppes is
responding by increasing the production capacity of the Dunedin plant.
Dunedin is a major centre for Cadbury Schweppes in the region, with
the site playing host to 'Cadbury World' and being a major production  Expand Image
and distribution centre. Dunedin is on the South Island
of New Zealand and has an
excellent climate for dairy
farming.

 Expand Image
The factory produces chocolate
crumb and also finished
products for the Asia Pacific
The factory is the largest chocolate manufacturing plant in New market.
Zealand. It supplies finished products for the domestic markets in New
Zealand and Australia and, in addition, exports chocolate crumb to
Cadbury finishing plants in Australia, Pakistan and China.

As an example of the potential in emerging markets, Cadbury

Schweppes' market share for chocolate in the Indian market has
increased from 18% in 2002 to over 75% in 2006. Although these  Expand Image
markets represent only a small part of the whole group sales (around The expansion of the Dunedin
20%) they have been identified as having the greatest potential. facility is a result of increased
demand for chocolate crumb
production.
Dunedin in New Zealand was chosen by Cadbury because of its
excellent infrastructure and a plentiful supply of rich milk for chocolate
production. Chocolate crumb is a commodity that is in demand globally
as the consumption of chocolate per capita worldwide increases to
record levels.
Financial  Expand Image
The Dunedin site also plays
host to 'Cadbury World',
The expansion project required a total investment of NZ$69m (€39m). alongside being a major
In August 2008, an additional investment was announced taking the production and distribution
total amount of investment in the project to NZ$69m. Part of the centre.

investment was contributed through the Investment New Zealand

Strategic Investment Fund. This amount was around NZ$2m and was
granted ostensibly for Cadbury to establish an international chocolate
crumb research and product development centre at the Dunedin site.

Cadbury contributed a further NZ$17.5m for new buildings, plant and

environmental work. The company provided a further NZ$500,000 for
the R&D centre.

"The Dunedin facility currently employs over 600

personnel and produces in excess of 5,000t of
chocolate crumb every year as well as finished
products."  Expand Image
Ross Campbell of Invest New Zealand commented: "The 'state-of-the- Cacao has to be imported and
art' Dunedin chocolate crumb factory will future-proof the factory's is then combined with local
milk.
viability and significantly strengthen its ability to bid for further
expansion projects. It sends a clear signal to international investors that
New Zealand is a desirable location for globally competitive firms."

Mark Smith, the managing director of Cadbury Schweppes Australia &

New Zealand, commented: "This investment is further evidence of
Cadbury's commitment to the future of the Dunedin manufacturing site.
As part of our investment here, Cadbury will establish a global crumb
research and development centre at Dunedin.

"This site will become a centre of excellence for innovation and

development of crumb. We have chosen to invest in Dunedin because
the plant is already highly efficient, and we have access to quality
ingredients, such as fresh milk."

Project

The expansion project saw an increase in the chocolate crumb

production capacity of the plant by three times to over 15,000t. This
quantity of chocolate crumb production is worth around NZ$30m per
year.

The restructuring project involves product changes. This means that

Cadbury will move products to different factories across different
locations. According to the company, the move will streamline
operations, keeping product costs low and providing jobs for locals.

Contractors working for Cadbury Schweppes included Production

Logistics NZ for control system integration and software development
for the manufacturing control systems. Streat Automation supplied
process control and information systems for the project and was also
involved in the upgrade of the existing crumb plant and addition of a
second reactor (crumb plant automation).

Streat Automation has also worked on the Pack100 Wrapper

Automation upgrade that involved the redesign and upgrade of the PLC
and servo controls and mechanics for the high-speed wrapping machine,
MANPOWER
186,336 (2008)

Health Benefits of Chocolate 

Since ages, chocolate is loved by all people due to its special taste. Many experts have noted that chocolates are unhealthy
and continuous eating often results in tooth decay. Some medical experts have stated that chocolates contain sugar
substances and thus add calories to the body and increase the sugar levels in the blood. But, it has been recently found that
chocolates are good for our health as they have a lot of advantages. Chocolates contain antioxidants. Therefore they kill the
free radicals and obstruct the oxidization of lipids into our body. The antioxidants are a concentrated form of flavonoids. 
The antioxidants help in the anti-ageing process. According to the study if you consume chocolates you are reducing your
chance of heart problems. Chocolate is an anti-inflammatory agent too. Chocolate contains cocoa butter to some extent and
this helps in regaining the lost elasticity in the body. 
Besides these properties, chocolate acts as an interesting medication for depression. The French suggest that you munch a
chocolate whenever you feel like eating it. You can really pass your time in a very interesting way and forget all the problems
of life when you taste delicious chocolate. So, what are you waiting for, go get your chocolate bar now! 
Although healers in ancient Latin American societies used chocolate extensively in medicinal practice, modern societies took
a dim view of chocolate as having benefits. Chocolate has been reputed to cause acne, cavities, and a host of other health
problems. Recent scientific evidence however, has been debunking what they call "chocolate myths." And, to the
chocoholics delight, concluding that not only is chocolate not detrimental to your health, it can actually be beneficial. 

35
Agro food
products
private ltd”
is a
manufacturi
ng company
andgoing to
start
production
of jaggery
from
sugarcane(n
ot
traditionalm
ethod). I am
Mr. Somnath
Tapare the
owner of
company.
Sugar
industry in
India is a
well-
developed
industry and
one of the
largest after
textiles. It
provides
rural
employment
opportunitie
s and plays
an important
role in
Indian
[Link]
ggery is
also
manufacture
d from
sugarcane
juice and
is verywidel
y used not
only in
individual
households
but also in
manyeaterie
s,
restaurants,
clubs and
hostels and
it
has certaini
ndustrial
applications
as well.
Compared
to this,
production
of jiggery is
very simple
and the
capital cost
is also very
[Link]
to its wide
applications,
theMarket
for jaggery
is
continuously
[Link]
are
investing Rs
12 laces in
this project.
In which, as
aproprietor
of company
I
(Mr. Somnat
h Tapare)
would
investingRs
4 laces. i. e.
33% of total
capital and
remaining
67% willtake
from bank i.
e. 7.5 laces.
 

We are
making
more than
10 different
products.
Thoseprodu
cts we are
selling
in urban,
rural areas.
Basically
fewproducts
like
chocolate
are going to
sale in
urban
[Link]
has good
market for
chocolate
and it is
growing day
byday. What
chocolate
we are
making? It
will not
create
aproblem
for teeth. 
2.
Organization
al
background:
Number of
employees:S
.No.D e s i g
nation 
No of p
erson1 
CEO 12  
A t   f a
c t o r y  
1 2 3 On 
field i.e. f
or cane c
u t t i n g   1 0 4 
D r i v
e r s  
2 Annual
sales
figures:Com
pany’s
crushing
capacity
would be 20
tons/day.
Company
will
havebeen
operated
180 days in
a year.
From 1 ton
of cane,
90 to 100
kgjaggery
will make. In
one season
is 325 to 350
tons.
Company’s
target of
sales of
jaggery
is 350 tons
per
annumKey
product
lines:
Jaggery is a
typical
Indian
product with
several
uses in
dailyfood
preparations
and it is also
used to
make many
sweet
foodprepara
tions. This is
a product
with scatter
ed
[Link]
pany’s
concern is
not only
produce
jaggery, but
also chikkia
nd so many
other,
jiggery
related prod
[Link]
days people
don’t bother
about
prepare
food, so
companyals
o will make
powder of
it.R & D has
going on for,
how
to make
chocolate,
hot
chocolate,dr
inking
chocolate
and I am
successes
in it.2.1 R &
D: on
products
•

 Chocolate
Jaggery
•
Dry fruit
Jaggery
•

Jaggery
Candy
•

Jaggery
Cubes
•
Jaggery Lad
doo
•

Jaggery
Powder
•

Jaggery
Sugar
•
Jaggery
Syrup
•

Kolhapuri
Jaggery
(chemical
less jaggery
)
•

Natural
Jaggery
Location of
facilities: