Closer Look: How Chocolate is Made

Mark, Purchasing

Over the past several years, I’ve had the unique opportunity to travel with chocolate companies and experience the world of chocolate firsthand. In 2024, I traveled to Peru with TCHO, where I met cacao farmers and visited the cooperative that supports their work deep in the Amazon region. Then in 2026, I traveled to Madagascar with Beyond Good, where I once again met local farmers and workers to learn how cacao is grown, harvested, and transformed into chocolate. During that trip, I also toured a chocolate production facility to see how chocolate bars are made from start to finish. 

Chocolate’s journey from pod to bar begins on the cacao tree, Theobroma cacao, which thrives in warm, humid climates near the equator. The tree produces large oval pods that grow directly from its trunk and branches. Each pod contains 20 to 50 cacao beans embedded in a sweet, sticky pulp. Harvesting is done by hand, as the pods must be carefully cut to avoid damaging the tree. Once collected, the pods are split open to extract the beans and pulp. 

The next crucial step is fermentation. The beans, still coated in pulp, are placed in shallow containers containing 20 gallons or more, sometimes wrapped in banana leaves, and left to ferment for up to seven days. During this process, natural yeasts and bacteria break down the pulp, generating heat and triggering chemical changes inside the beans. Fermentation is essential for developing the complex flavors associated with chocolate. Without it, the beans would taste flat and bitter. 

After fermentation, the beans are spread out to dry, often under the sun. Drying reduces moisture content and helps preserve the beans for transport. Once dried, the beans are sorted, graded, and shipped to chocolate manufacturers around the world. 

At the factory, the beans are roasted at controlled temperatures to further develop flavor and aroma. Roasting times and temperatures vary depending on the desired taste profile. After roasting, the beans are cracked open and their outer shells are removed, leaving behind the inner nibs. These nibs are then ground into a thick paste known as chocolate liquor (despite the name, it contains no alcohol). This paste consists of cocoa solids and cocoa butter. 

From here, different types of chocolate are created by adjusting the proportions of ingredients. For dark chocolate, sugar and sometimes extra cocoa butter are added. Milk chocolate includes milk powder or condensed milk, giving it a creamier texture and sweeter taste. 

The mixture then undergoes refining, where it is passed through rollers to reduce particle size, resulting in a smoother texture. This is followed by conching, a process of continuous mixing and aeration that can last from hours to days. Conching enhances flavor and removes unwanted acidic notes. 

Finally, the chocolate is tempered—carefully heated and cooled to stabilize the cocoa butter crystals. This gives chocolate its glossy finish and satisfying snap. The tempered chocolate is poured into molds, cooled, and packaged, completing its transformation from a humble cacao pod to a polished chocolate bar. 

At Pilgrim's, we proudly offer a wide variety of exceptional chocolates from around the world. We value companies that not only produce high-quality chocolate but also invest in the communities where their cacao is grown. Both TCHO and Beyond Good go beyond traditional fair-trade practices by supporting local schools, healthcare centers, and community improvement projects, helping create a more sustainable future for the farmers and their families. The next time you stop by Pilgrim’s Market, explore Aisle 8 and discover a new chocolate to enjoy.