Cacao Production Process: From Bean to Bar

Cacao—the humble seed behind every chocolate bar—travels a meticulous path from tropical pods to polished nibs. In 2025, with global cacao production hitting 5.2 million tonnes (ICCFO Report) amid climate challenges and $12,000/tonne prices, understanding the process is key for enthusiasts, makers, and conscious consumers. 

This bean-to-bar breakdown covers harvesting, fermentation, drying, roasting, winnowing, grinding, conching, tempering, and beyond—rooted in tradition but boosted by 2025 innovations like AI fermentation monitors and solar dryers.

Whether you’re in West Africa (45% of supply), Latin America, or Asia, the core steps remain. Let’s trace the full production cycle.

1. Cultivation & Harvesting: The Tree-to-Pod Stage

Cacao trees (Theobroma cacao) thrive in the “Cacao Belt”—20° north/south of equator.

Key Facts:

• Varieties: Criollo (fine, rare), Forastero (bulk, robust), Trinitario (hybrid).

• Growth: 5–10m trees, pods (15–25cm) grow on trunk.

• Harvest: 2x/year (main + mid-crop).

Process:

1. Hand-Pick Pods: Ripe (yellow/orange) only—machete or clippers.

2. Split Open: Extract 20–50 beans + white pulp.

3. Yield: 1 tree = 20–30 pods = 1–2kg dry beans.

2025 Tech: Drones scan ripeness via color AI.

2. Fermentation: The Flavor Birthplace

Beans + pulp ferment in heaps, boxes, or baskets for 2–7 days.

Why It Matters:

• Kills Germ: Prevents sprouting.

• Develops Precursors: Acids break down bitter compounds → chocolate notes.

Steps:

1. Heap/Pile: Cover with banana leaves.

2. Turn: Every 24–48 hrs for even heat (45–50°C).

3. Duration:

• Criollo: 2–3 days

• Forastero: 5–7 days

Science:

• Yeast → alcohol

• Bacteria → acetic/lactic acid

• Enzymes → 300+ flavor compounds.

Innovation: Sensor pods track pH/temp in real-time.

3. Drying: Moisture Lock-Out

Reduce from 60% to 7% moisture to prevent mold.

Methods:

• Sun Drying: On mats/trays, 5–10 days. Turn daily.

• Mechanical: Forced air for rainy seasons.

Tips:

• Slow & Even: Preserves acidity.

• Global Shift: Solar dryers in Indonesia cut time 40%.

4. Sorting & Bagging: Quality Gate

• Hand/Mechanical Sort: Remove flat, moldy, or clustered beans.

• Bag: 60–65kg jute sacks.

• Ship: To roasters worldwide.

Traceability: Blockchain tags track farm-to-factory.

5. Roasting: Flavor Unlocked

Beans roasted at 120–150°C for 20–40 mins.

Goals:

• Sterilize

• Reduce Moisture (to 2%)

• Maillard Reaction: Nutty, caramel notes

Profiles:

• Light: 120°C, fruity

• Dark: 140°C+, bold

Trend: Infrared roasters for precision.

6. Winnowing: Shell vs. Nib

Crack roasted beans → separate nib (meat) from husk.

Process:

• Cracker: Breaks shells.

• Air Stream: Blows light husks away.

• Yield: 80–85% nibs.

7. Grinding: Nib to Liquor

Nibs ground into cacao liquor (paste).

Steps:

1. Stone Mills/Melangeurs: Heat + friction → liquid.

2. Particle Size: 15–30 microns for smoothness.

Composition: ~50% cocoa butter, 50% solids.

8. Pressing (Optional for Cocoa Powder)

• Hydraulic Press: Separate butter (fat) from cake.

• Cake → Powder: After alkalization (Dutch process).

9. Conching: Silk & Soul

Liquor refined in conche machines for 4–72 hrs.

Benefits:

• Evaporate Volatiles: Reduce acidity.

• Emulsify: Smooth texture.

• Flavor Meld: Rounds notes.

Luxury: 72-hr conche = velvety mouthfeel.

10. Tempering: Snap & Shine

Melt → cool → reheat chocolate to stable crystals.

Temp Curve (Dark):

1. Melt: 45–50°C

2. Cool: 27°C

3. Reheat: 31–32°C

Result: Glossy, snappy bar.

11. Molding & Packaging

• Pour tempered chocolate into molds.

• Cool, demold, wrap.

Full Process Timeline

Stage	Duration	Output
Harvest	Instant	Wet beans
Fermentation	2–7 days	Brown beans
Drying	5–10 days	Dry beans
Roast–Bar	1–3 days	Finished chocolate

Total: 3–4 weeks farm-to-bar.

Regional Variations

Region	Key Trait	Top Producer
West Africa	Bulk Forastero, heap ferment	Ivory Coast (40%)
Latin America	Fine Criollo, box ferment	Ecuador
Asia	Trinitario, solar drying	Indonesia

Innovations

• CRISPR Trees: Disease-resistant hybrids.

• Lab-Grown Cacao: Cell cultures cut land use.

• Carbon-Neutral: Agroforestry + renewables.

DIY Mini Bean-to-Bar (Home Scale)

1. Buy fermented beans online.

2. Roast 30 mins at 130°C.

3. Winnow (hairdryer hack).

4. Grind in food processor + sugar.

5. Temper in microwave.

Result: Rustic 70% bar.

Challenges & Sustainability

• Climate: +2°C = 50% yield drop by 2050.

• Fair Trade: Only 30% certified.

• Solution: Shade-grown, direct trade.

The Final Bean

Cacao production isn’t science—it’s alchemy.

One pod → complexity in every bite.

Your turn: Source beans, try a step.

Share your journey at tealocker.blogspot.com or #BeanToBar—we’ll feature the craft!

Sources: ICCFO, Cocoa Barometer 2025, Journal of Chocolate Science.

#CacaoProcess #BeanToBar #Chocolate #GlobalCraft