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					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.

				
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