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1. CHOCOLATE BAR : PRODUCTION PROCESS
- NATURAL RESOURCES
- Tropical Evergreen Cacao Trees
- Produce cocoa pods (main ingredient in chocolate)
- Also used to produce cocoa butter
- Also used to produce cocoa butter
- Produce cocoa pods (main ingredient in chocolate)
- RAW MATERIALS
- COCOA BEANS
- Evaluated for bean size, mold, infestation, filth and degree of fermentation
- Collected from regions within 20 degrees north or south of the equator
- Cut from the trees with machetes or knives mounted on poles
- Beans are manually removed and are left to be heated in the sun for several days
- Graded and bagged in sacks weighing from 130 to 200 pounds
- Graded and bagged in sacks weighing from 130 to 200 pounds
- Beans are manually removed and are left to be heated in the sun for several days
- Cut from the trees with machetes or knives mounted on poles
- Collected from regions within 20 degrees north or south of the equator
- Evaluated for bean size, mold, infestation, filth and degree of fermentation
- SUGAR
- Used in the manufacturing of milk and dark chocolate
- Used to add flavour
- Used to add flavour
- Used in the manufacturing of milk and dark chocolate
- MILK PRODUCTS
- Vary among suppliers - some include whole milk, nonfat dry milk, anhydrous milk fat, and milk
crumb
- blended with cocoa mass to form chocolate liquor, which is then evaporated to make chocolate crumb
- blended with cocoa mass to form chocolate liquor, which is then evaporated to make chocolate crumb
- Vary among suppliers - some include whole milk, nonfat dry milk, anhydrous milk fat, and milk
crumb
- WRAPPING/PACKAGING MATERIALS
- e.g. paper, foil and card
- e.g. paper, foil and card
- LABOUR
- CAPITAL
- conveyor belt, sweltering tunnel, winnowing machine, nib-grinding machine, rectangular molds,
mixing machines, conchers, conveyor belt moods, cold tunnels
- Machines/Equipment used during manufacturing-
- Machines/Equipment used during manufacturing-
- INFORMATION
- Competition
- How to distinguish the company from competitors
- Participate in community outreach activities?
- Environmentally sustainable?
- Other incentives to buy their chocolate vs. competitors chocolate
- Participate in community outreach activities?
- How to distinguish the company from competitors
- Information on Target Audience
- Which type of chocolate they prefer
- How to package in order to catch customer's attention
- Which type of chocolate they prefer
- New Technology
- Whether to use renewable sources or minimize parts of their production process
- How to maximize productivity
- Whether to use renewable sources or minimize parts of their production process
- MANAGEMENT
- Quality Control
- Ensure product meets the 1944 Federal Food, Drug,
and Cosmetic Law, and more recent laws/regulations S
- Raw ingredients are tested for freshness and flavour.
- Chocolates with imperfections are removed
- Ensure product meets the 1944 Federal Food, Drug,
and Cosmetic Law, and more recent laws/regulations S
- Allocation of financial resources
- Purchase raw and additive ingredients
- Transportation costs
- Packaging costs
- Pay factory workers
- Insurance Costs
- Marketing and Research
- Purchase raw and additive ingredients
- Allocation of Human Resources
- Hire factory workers Arrange and organize factory workers (includes appointing managers, supervisors
and managing quality control)
- Hire factory workers Arrange and organize factory workers (includes appointing managers, supervisors
and managing quality control)
- Quality Control
- Competition
- Space required - farms, factories, offices,trucks etc.
- Packaging and packaging machines
- - used to wrap chocolate in paper wrappers.
- - used to wrap chocolate in paper wrappers.
- conveyor belt, sweltering tunnel, winnowing machine, nib-grinding machine, rectangular molds,
mixing machines, conchers, conveyor belt moods, cold tunnels
- HARVESTING COCOA BEANS
- 1. Plucking pods - When pods turn orange and are about the size of a football, harvesters use
machetes to gently detach the pods from the trees.
- 2. Opening pods - After pods are collected, they are carried to a processing house. Pods are opened
and cocoa beans are extracted from pod shells. Each pod contains 50-60 cocoa beans.
- 3. Fermenting and drying seeds - The beans are placed in large shallow trays and are covered with
banana leaves. The beans are then placed in the sun for five to eight days or until they turn brown.
- 3. Fermenting and drying seeds - The beans are placed in large shallow trays and are covered with
banana leaves. The beans are then placed in the sun for five to eight days or until they turn brown.
- 2. Opening pods - After pods are collected, they are carried to a processing house. Pods are opened
and cocoa beans are extracted from pod shells. Each pod contains 50-60 cocoa beans.
- 1. Plucking pods - When pods turn orange and are about the size of a football, harvesters use
machetes to gently detach the pods from the trees.
- MANUFACTURING CHOCOLATE
- 1. Roasting -Beans are roasted on screens and heated revolving cylinders where the moisture in the
beans goes from 7% to 1%. When they are roasted, they begin to develop a richer flavour.
- 2. Winnowing - Outer shell of cocoa bean is removed and inner cocoa bean is broken into small pieces
called “cocoa nibs”. The cocoa beans are placed through sieves and filters that separate pieces of the
cocoa bean shell from the the nibs, and strain and sort the cocoa nibs by size.
- 3. Grinding - Cocoa nibs are ground and heated into cocoa liquor (unsweetened chocolate) by revolving
granite blocks. In this process cocoa butter, sugar and sometimes milk are added to the liquor.
- 4. Refining - The liquor is further ground between metal drums. This process ensures that the cocoa
liquor is smoother and flows easier.
- 5. Cooling - After additional ingredients (varies - company/flavour) are added to the cocoa liquor,
mixture can be placed in olds and is cooled at a gradual rate to ensure that the cocoa butter doesn’t
separate from the mixture.
- 5. Cooling - After additional ingredients (varies - company/flavour) are added to the cocoa liquor,
mixture can be placed in olds and is cooled at a gradual rate to ensure that the cocoa butter doesn’t
separate from the mixture.
- 4. Refining - The liquor is further ground between metal drums. This process ensures that the cocoa
liquor is smoother and flows easier.
- 3. Grinding - Cocoa nibs are ground and heated into cocoa liquor (unsweetened chocolate) by revolving
granite blocks. In this process cocoa butter, sugar and sometimes milk are added to the liquor.
- 2. Winnowing - Outer shell of cocoa bean is removed and inner cocoa bean is broken into small pieces
called “cocoa nibs”. The cocoa beans are placed through sieves and filters that separate pieces of the
cocoa bean shell from the the nibs, and strain and sort the cocoa nibs by size.
- 1. Roasting -Beans are roasted on screens and heated revolving cylinders where the moisture in the
beans goes from 7% to 1%. When they are roasted, they begin to develop a richer flavour.
- CAPITAL
- COCOA BEANS
- Sun
- Source of energy used throughout production
- Might be used during the fermentation process, instead of heated trays.
- Typically used in the drying process, where beans are laid out to dry.
- Typically used in the drying process, where beans are laid out to dry.
- Might be used during the fermentation process, instead of heated trays.
- Source of energy used throughout production
- Sugarcane
- Used to produce sugar (an added ingredient in chocolate)
- Used to produce sugar (an added ingredient in chocolate)
- Bauxite, iron ore, oil/petrochemicals, silica
- Used to produce aluminum foil (used in packaging)
- Used to produce aluminum foil (used in packaging)
- Trees
- Used to produce paper (used in packaging)
- Used to produce paper (used in packaging)
- Cows
- Produce milk
- Produce milk
- Tropical Evergreen Cacao Trees
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