Mature cacao pods are harvested, cut open, and the wet beans are scooped out and placed into the first wooden fermentation box. They are covered with banana leaves and tightly sealed to begin fermentation.
1. HARVESTING
2. FIRST TURN
After two days, the beans are turned by transferring them to the next box. They remain there for another two days. On the second day, the cover is opened and the beans are mixed vigorously to stimulate enzymes and microorganisms. The goal is to reach 48–50°C.
After two more days, the beans are moved to the third box for continued fermentation. After one day, the farmer cuts the beans to check if the desired fermentation level has been reached (brownish color with visible structure inside).
3. SECOND TURN AND FERMENTATION CHECK
4. DRYING
Fermented beans are spread on raised platforms under a covered drying facility. Slow, intermittent drying using solar and air methods takes about eight days, depending on temperature.
Once the beans reach ideal moisture, they are sorted to remove defective beans, bagged, and stored in a cool, dry place ready for shipping.
5. SORTING AND BAGGING
6. SHIPPING TO CHOCOLATE FACILITY
Dried beans are shipped from our farm to our production facility in Norridge, Illinois, where they begin their transformation into fine chocolate.
Cacao beans are roasted to develop complex chocolate flavors and reduce acidity. Once roasted, they pass through a winnower that gently separates the edible nibs from their brittle shells, leaving behind the pure essence of chocolate ready for the next stage of crafting.
7. ROASTING AND WINNOWING
8. GRINDING AND CONCHING
Nibs are ground into a fine paste in melangers until particles are below 20 microns. The mixture undergoes conching to smooth texture and enhance flavor.
The chocolate liquor is tempered for stability and shine, then molded into bars, pralines, and bonbons, completing the Tree-to-Bar journey.
9. TEMPERING AND MOLDING