Prepared by Sue Ann Hoang AT THE CHOCOLATE FACTORY… Waiting in line… – Chocolate History – Chocolate Records – Chocolate Facts – West Coast Chocolate Festival – Trivia games CHOCOLATE WORKS Chocolate Works is owned by Anmore resident, Jay Sheere. He started the company in 1995. There are two main areas of business: chocolate products gelato and gelato ingredients CHOCOLATE FACTORY TOUR WAREHOUSE – SHIPPING The warehouse area is where incoming bulk chocolate is stored. The bulk chocolate has been made by a cocoa bean processor. There is almost no processing done in North America – most of it is done in Europe. Cocoa bean processors create many forms of the bulk chocolate – depending on the end user. Chocolate Works purchases its chocolate from Belcolade, a Belgian chocolate manufacturer, and it arrives in slabs, or in small discs or calets. (pronounced cal – ays) CHOCOLATE FACTORY TOUR WAREHOUSE – SHIPPING (facts) Theobroma trees (which literally means, in Mayan, ‘food of the gods’,) grow near the equator – and produce cocoa pods which are harvested by hand, the pods split open and the beans laid out to ferment, then to dry. Dried cocoa beans are then shipped for processing. Their husks are removed by machine, and the cocoa beans are ground or conched, to separate the cocoa liquor from the cocoa mass. For many centuries, chocolate was actually only a drink. Originally the Olmecs and then the Mayans, ground the dried cocoa beans with cornmeal, water and hot pepper to make a medicinal drink. CHOCOLATE FACTORY TOUR WAREHOUSE – SHIPPING (facts) When the Spanish took the beans to Europe, they added sugar to the ground cocoa beans and drank it as hot chocolate. For many years pretty much only European royalty – most notably the French court – drank hot chocolate. The industrial revolution produced machinery that could separate the cocoa liquor from the cocoa mass, and that’s when more shaping and forming allowed hardened chocolate, or bars, to start being produced. CHOCOLATE FACTORY TOUR WAREHOUSE – SHIPPING (continued) About two years ago Chocolate Works began manufacturing gelato – they sell tubs of it to retail stores, restaurants, and sell the ingredients for it to about 45 Gelaterias in the lower mainland. Ingredients come from Italy. Most of Chocolate Works’ product is made to order and ‘private labeled’ for places like Costco, (‘Glerie au Cocolat’ line). Or for large Canadian retailers like A&P in eastern Canada. In their factory store, their products are marketed under the name “Rubens”. The large table just outside the packaging room, is where final packaging is done and checked before shipping out those large doors to the right. Now as we move towards the heart of the factory, the kitchen! The gelato freezer: product, once made, is kept here a minus 30 degrees! CHOCOLATE FACTORY TOUR THE KITCHEN METAL DETECTOR? It’s the last one the finished product passes through before being packaged. Why? Once the chocolates are made and laid out on trays, they must pass through this machine to ensure there are no minute bits of metal – such as bits of wrapping or tiny shards of metal from the scrapers used here. Once cleared they can move to the packaging area. CHOCOLATE FACTORY TOUR THE KITCHEN (continued) Mini-enrobing machine. It is hard to cover some items with melted chocolate – so a small machine like this makes the job go much faster. In this case, pretzels are placed on the small belt, and that feeds through the machine where the melted chocolate drips over them, and voila! ‘enrobed chocolate pretzels’. In larger factories these enrobing machines can be huge, stretching for many rooms, with the cooling taking place right along the conveyer belt. CHOCOLATE FACTORY TOUR THE KITCHEN (continued) MELTING/TEMPERING MACHINES There are three here: dark, milk and white chocolate. Milk is still the most popular, although as people learn more about how good dark chocolate can be for us – it’s becoming more and more popular. First thing in the morning, the staff heat up these melting/tempering machines. Then they pour in the bulk calets and melt and heat the chocolate to precisely 45 degrees. Then the chocolate must be cooled – by adding more solid calets – to exactly 32 degrees. This heating-up and cooling-down of the chocolate is called tempering. It’s the critical step in handling the chocolate. CHOCOLATE FACTORY TOUR THE KITCHEN (continued) If the chocolate is not properly heated and cooled, it doesn’t set up as well and can end up with a whitish ‘bloom’ on it. Some of you may have seen chocolates or a chocolate bar with this ‘bloom’. There’s actually nothing wrong with the chocolate - it just hasn’t been tempered properly. The chocolate could be re- melted – brought up to temperature and then back down again – and it would be fine. But it doesn’t look very appetizing. Once the chocolate is properly tempered, it’s time to start making chocolates! CHOCOLATE FACTORY TOUR THE KITCHEN (continued) Here at Chocolate Works, all the chocolates are made by hand. That is – the molds are filled by hand. This room can produce up to 60,000 filled chocolates a day. Chocolate makers take molds – then run them quickly under the chocolate spout to fill all the spaces – then set them briefly on a vibrating machine to get all the air bubbles out. Any chocolate with a tiny hole in it when de-molded is rejected as a ‘second’ – it’s perfectly yummy! Just not perfectly-formed. Once the air is all jiggled out, they quickly turn the mold upside down to let the excess chocolate run out. They’ve now formed the top part of the chocolate. Now the chocolates must all go to the walk-in cooler in the back corner – to set the chocolate. There’s a lot of activity here in this room – because after every step of the process, the chocolates must go and stand in the cooler for about 10 minutes before the next step. CHOCOLATE FACTORY TOUR THE KITCHEN (continued) Once the shell is set, the filling can be added. That used to be done by hand with big pastry piping bags – but now they use a pumping machine which fills two molds at once – very fast! All fillings are made by hand here in the cooking corner of the kitchen. Chocolate Works makes about 20-25 different flavours of filling. Some of the most popular ones are Amaretto, Grand Marnier. Nobody much cared for the banana ones, or the raspberry ones. Champagne and Sambuca are also very popular! And the pure chocolate-filled ones are also very popular. How long a shelf-life the chocolates have, depends on the type of filling. Anything with cream in it, for example, is only good for about three months. Other types of fillings can last longer. Sometimes the molds are completely filled with chocolate – like the ones being made here today – in maple leaf shape. In a few minutes, you’ll get to package your own molded maple leafs to take home. CHOCOLATE FACTORY TOUR THE KITCHEN (continued) Once the filled chocolates are cooled, they’re ready for the covering. This is actually the bottom of the chocolate. (So now you know how they get the gooey centers into the caramilk bar! It would be added to the shell in a harder form that would melt at normal room temperature, and then covered.) Once again – after the molds have passed under the pouring chocolate and the chocolate drained so the covering is the right thickness, the trays are sent back to the cooler for 10 minutes. Then the de-molding takes place. They tap the mold upside down on these large trays, and there are your chocolates! This is where those tiny holes could be seen, although they’ll be set aside in the packaging room. It takes about one hour from beginning to end, for a mold to be filled, cooled, filled, cooled, filled, and cooled. CHOCOLATE FACTORY TOUR THE KITCHEN (EXTRA) Chocolate Works also produces custom orders for seasonal molded chocolates like bunnies, snowmen, etc. These molds can be quite large – and come in two halves, with all the detail of the finished product molded right in. The first step is to paint with a contrasting chocolate, any parts of the shape they want to show up more – like a bunny’s paws or ears, or a snowman’s buttons. Then the mold- halves are cooled. Next the two halves of the mold are clipped together to form a whole shape, and naturally there’s a ‘hole’ for the chocolate to enter. The mold is filled with chocolate – then it’s turned upside down so the chocolate can drip out, leaving just a coating inside the mold. Next step? ……. Yes, that’s right. Cooling. Again the mold is filled and emptied and cooled, and again a third time. It takes at least three layers to create the strength and the good-looking finished product. Then it’s de-molded, and goes to the packaging room for its ribbon or other trims before packaging. CHOCOLATE FACTORY TOUR THE KITCHEN (continued) This is also where Chocolate Works makes its gelato. In the summertime, this machine never stops! There’s actually quite a big difference between gelato and ice cream, even though they’re both made with milk. FIRST: gelato is lower in fat than ice cream. A big plus! – ice cream is generally over 10% butterfat – usually about 14%. – gelato is usually 4-10% butterfat. In Vancouver, (because people’s tastes can vary from region to region in a country, or from country to country.) The average is 6 ½ to 7% butterfat content. CHOCOLATE FACTORY TOUR THE KITCHEN (continued) SECOND: gelato has much less air pumped into it. – this process is called the over-run. – ice cream has a lot higher over-run – 50-100%. – gelato has 25-30% over-run. THIRD: the flavours are more intense in gelato than ice cream. – this is partly because of the natural flavours imported from Italy – pastes and gels. And partly because of the lower over-run. This manufacturing process produces denser, richer products – despite the fact that it has less butterfat – which is what ice cream (and many other foods!) rely on for that full flavour. As a result of all this, gelato has a shorter shelf-life than ice cream. It’s a fresher product, more flavourful, that’s better for you than regular ice cream. CHOCOLATE FACTORY TOUR PACKAGING ROOM This is where all the finished chocolates and molded products are inspected, seconds are set aside for bagging and selling in the factory store. Normally, the staff stands around this very large table and hand-pack the chocolates into whatever boxes they’re preparing: different shapes of boxes and containers, privately-labeled for different retailers. Sometimes the boxes are just ribboned, sometimes no ribbon, and sometimes they’re actually wrapped in paper. All the packaging and the different ribbons are located on the shelves. THE HISTORY OF CHOCOLATE THE HISTORY OF CHOCOLATE 1000 B.C. 300 A.D. In tropical forests on the South of current Mexico, the Mayans named the cacao Gulf of Mexico, the plant ‘tree’. Only this plant received the honor of a Olmecs cultivated the name, and this because it was believed to be the cacao tree. nourishment of the gods. The Olmec died off. The tree’s pods became the symbol of fertility & life. They were used in sacred rituals, and carved into palace and temple walls. Cacao was made into porridge-like corn mixtures and spiced up, a favourite spice being hot chili. A bitter cacao brew was reserved for kings and noblemen. The ‘tree’ was a gift to humans. And the Mayans mysteriously disappeared within 600 years. THE HISTORY OF CHOCOLATE 900 A.D. 1502 The Toltecs settled in Mayan territory. Christopher Columbus arrived in Aztec The king, the god of air, believed his land and was given cacao beans, but he did mission was to bring cacao seeds from not realize their importance. Eden to man & teach crop cultivation. He missed that cacao beans were used as He fled political unrest, became ill, set currency – a slave could be purchased for sail on a tiny raft, and vowed to return in 100 cocoa beans, a prostitute for 10, and a another life to reclaim his kingdom. rabbit for 4. The people became known as the Aztecs, and predicted that in 1519, a white-faced king would return to release the Toltec people. THE HISTORY OF CHOCOLATE 1519 1522 When the Spanish explorer, Hernan Cortes Cortes destroyed the Aztec arrived, he was seen as the returning god and kingdom. showered with gifts, including a cocoa plantation, Spanish settlers speckled Mexico, by the Aztec king, Montezuma. Ecudor, Peru, Venezuela, Haiti, Montezuma soon questioned the reincarnation of and the Dominican Republic with the long-dead Toltec king. prosperous cocoa plantations. Sensing his fall from grace, Cortes organized the imprisonment of Montezuma. He had understood the importance of cocoa beans - that the Aztecs literally grew money on trees. Cortes recognized the potential of cocoa beans to cultivate gold currency. THE HISTORY OF CHOCOLATE 1580 1600 - 1699 A chocolate processing plant was Cocoa trees were planted throughout set up in Spain. Europe. The Dutch brought it to East India, and it spread to the Philippines, New Guinea, Indonesia, and Samoa. The French brought it to Brazil and Martinique. THE HISTORY OF CHOCOLATE 1800s 1900s The Portuguese carried the Malaysia and South-East Asia Brazilian cocoa tree to West started crops of cocoa trees. Africa. THE HISTORY OF CHOCOLATE As countries have colonized and successfully invaded various lands, they have familiarized the world with the cocoa tree, cultivating prosperous crops of the ancient symbol of life and fertility. Montezuma may have doubted the reincarnation of the Toltec god of air, but Cortes did arrive in 1519 as predicted, and he carried out the king’s mission by starting the introduction of the world to the cocoa bean. CHOCOLATE RECORDS CHOCOLATE RECORDS LARGEST BOX OF LARGEST CHOCOLATE BAR CHOCOLATES LARGEST Elah-Dufour United CHOCOLATE The largest box of chocolates Food Companies Ltd. Made (individual) ever made is a Frango mint a scaled-up version of a Novi chocolates box weighing The largest chocolate chocolate bar, weighing 1,463 kg (3,226 lb) created by weighed 6.816 tonnes 2,280 kg (5,026 lb), at the Marshall Field's, Chicago, (15,026 lb) and was Eurochocolate 2000 exhibition made by match.com TALLEST Illinois, USA in Turin, Italy, in conjunction with CHOCOLATE on November 14, 2002. on March 16-19, 2000. MODEL Marco de The scaled-up version of the original Comunicacion (Spain) The Gremi Provincial chocolate box measured 203 cm (80 in) and exhibited at the de Patisseria, Confiteria wide, 439 cm (173 in) long, 48 cm Hard Rock café, i Bolleria School in (19 in) deep and contained a calorie- Madrid, Spain from Barcelona, Spain, went induced 90,090 individual chocolates, February 13-19, 2004. completely choco and which alone weighed 1,065 kg made the world's tallest (2,347 lb). chocolate model. After LARGEST S'MORE LARGEST COOKIE eating their massive 27 The largest cookie ever made was a ft 10.5 in (8.5 m) tall, 42 "Please sir, may I have s'more?" That's what a bunch of happy holiday campers at the Beals Point giant chocolate chip snack with a ft 8 in (13 m) long and 8 diameter of 24.9 m. (81 ft 8 in), ft 2½ in (2.5 m) wide campground in California, USA, yelled when it was time to eat the largest s'more ever made. This and an area of 487.15 sq m chocolate sailing ship, (5,243.6 sq ft), made they would have been in gigantic campfire feast – short for "some more" – was made on May 23, 2003, from 20,000 toasty hot by Cookie Time, chocolate lovers' heaven Christchurch, (and hospital)! marshmallows, 7,000 Hershey's chocolate bars, and 24,000 graham crackers... and weighed a incredible New Zealand, February 1991 725.7 kg (1,600 lb)! on April 2, 1996 CHOCOLATE FACTS 1. Chocolate tops the list of foods most often craved by North Americans. 2. Eating chocolate does not give you acne. 3. Eating chocolate does not raise your blood cholesterol levels. Cocoa butter (the fat in chocolate) contains high levels of stearic acid, a fatty acid that behaves differently from other saturated fats. Eating a small amount of chocolate should not raise your cholesterol. 4. One ounce of milk chocolate has 3 milligrams of caffeine – about the same amount as in an 8-ounce mug of decaf. coffee. 5. Chocolate, as well as other foods such as red wine, aged cheese and peanuts, are suspected of triggering migraines in some people. 6. More than a billion people in the world eat something chocolatey every day. CHOCOLATE FACTS 7. Contrary to popular belief, ounce for ounce, carob actually has MORE calories and fat than milk chocolate. 8. Cocoa butter melts at body temperature. That’s why chocolate, which is made of cocoa butter, divinely melts right in your mouth. 9. Cocoa beans are purple (they turn brown during the fermenting and drying process), and white chocolate isn’t chocolate at all! It’s made of cocoa butter, milk, sugar and flavouring. 10. Chocolate is a $13 billion in industry in the US. 11. Chocolate lovers live on average, one year longer than non-chocolate lovers CHOCOLATE WEBSITES CHOCOLATE WEBSITES www. chocolocate.com www.completechocolate.com Provides consumers with access to www.chocomusee.com Candy industry site that includes all the finest chocolate that the information for chocolate internet has to offer. Everything Erico’s finest chocolates. Virtual tours, history, order online. ‘hobbyists’. from truffles to diet chocolate, based in Boston. www.chocophile.com Chocolate.com Excellent resource on ‘chocolate Provides links to more appreciation’ – book reviews, than 1,125 chocolate sites. etc. Very focused on higher end Also chocolate makers. quality. www.zchocolat.com www.baking.about.com/od/chocolate Provides consumers with the ability to Offers recipes and articles. purchase and personalize their very own French chocolates. Each piece is hand made www.trendychocolate.com and one of a kind. These chocolates aren’t available anywhere else except the artisans Offers an online catalogue, own store, in France. personalized chocolate bars. Chocolate history, and tips and trends.