How Chocolate Is Made

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Watch to the end to see the world's largest chocolate bar  Subscribe to help us become the #1 food channel :)  ╔═╦╗╔╦╗╔═╦═╦╦╦╦╗╔═╗ ║╚╣║║║╚╣╚╣╔╣╔╣║╚╣═╣ ╠╗║╚╝║║╠╗║╚╣║║║║║═╣ ╚═╩══╩═╩═╩═╩╝╚╩═╩═╝  Thank you to Blue Stripes + Hershey's for giving us the full chocolate experience that you saw in this video.  Follow for more: https://www.youtube.com/@NicksKitchen https://www.youtube.com/@chef https://www.instagram.com/nick.digiovanni https://www.facebook.com/nick.digiovanni https://www.nickdigiovanni.com  Credit to the following channels for the clips: • CraftChocolateTV - A Beginner's Guide to Bean-to-Bar Chocolate • CraftChocolateTV - Sourcing Cacao in Thailand | Ep 90 • How It's Made - How It's Made: Chocolate • CraftChocolateTV - Fermenting Cacao In Hawaii with Colin Hart | Ep.112 • Science Channel - Cocoa Beans and Bulk Chocolate • Factora - How Chocolate Is Made • CraftChocolateTV - How We Make Cacao Nibs | Ep.50 • Science Channel - Milk Chocolate, From Scratch | How It's Made • TODAY Food - See How Hershey’s Kisses Are Made In The Sweetest Place On Earth • Food Network - How Hershey's Kisses Are Made (from Unwrapped) | Unwrapped • Chocolade atelier Van Noppen - Largest chocolate bar by area

Transcript

00:00Chocolate is one of the most popular foods on the planet

00:02But did you know it all comes from this weird-looking fruit shaped like a dinosaur egg in this video?

00:06I'll take you from farm to factory to show you how chocolate is made and at the end

00:09We'll use all the chocolate you'll see in this video to attempt the guinness world record for the world's largest

00:14Chocolate bar and it all starts with the cacao tree this right here is where it all begins this little flower here will eventually grow

00:20Into a pod which will eventually grow into something slightly bigger and bigger then even bigger and then finally into something like this

00:26So yes, technically chocolate does grow on trees

00:29So now that you have some context on where cacao comes from

00:32I'm gonna introduce you to a really close friend of mine who I call the modern-day Willy Wonka

00:36He's a little crazy, but he knows more about chocolate than anyone on this planet. Hey, what's up?

00:40Oh dad, you come to see some cacao. I'm ready for chocolate, baby. Let's go sit

00:44So these guys have already picked a bunch of pods for us to look at. Oh my gosh

00:49Cacao really kind of does look like a big ice cream cone

00:51The seeds can come right off of the cacao pod like that

00:54This is all gonna be opened up now so they can take the seeds out

00:57There's no machine all the chocolate that we eat is harvested by hand for the world record that we're gonna attempt later in this

01:04Video we need

01:06250,000 cacao pods. So this is just the start so you can eat this right now

01:10And you suck off all the white pulp on the outside of each seed when you don't dry the cacao beans

01:15They're purple inside. It tastes a little bit like lychee pineapple citrusy. I know almost like a bit of a sour banana

01:21Sometimes it's phenomenal. There are two main things you can do with this cacao fruit

01:25You can drink the juice of the cacao fruit think of cacao water like coconut water, but ten times better

01:31And then what's the other thing obviously chocolate you take the beans ferment them grind them turn them into chocolate

01:37Let's go see how it's made. That's it before we go to the actual chocolate factory

01:41We're at the place where they make the cacao water

01:43We separate the pulp from the beans beans goes to make chocolate pulp goes to make cacao water

01:48We put it into the cold press machine getting all the cacao water out and that's gonna be the freshest cacao water

01:54You'll ever taste ever. It looks a little like coconut water

01:58It gives you a little bit of a kick that you get from biting a lemon slice and it just tastes kind of tropical

02:02Chocolate is bitter sometimes sour earthy. This is sweet fresh citrusy

02:07But never in a million years would you think that this kind of flavor is associated with chocolate?

02:12If you want to get creative you can also turn this fruit pulp into cacao fruit leather

02:15You guys know how much I love making fruit leather or even these chewy cacao fruit snacks

02:19Which look a lot like ground turkey while they're being made

02:22But now that we've seen how you can use that fruity outer part of the beans

02:25We'll go see how the inside of the bean is used to make chocolate

02:27We've made it to the chocolate factory and take a guess at what's in all these different bags around me if you guess cacao beans

02:33You'd be right

02:34But these beans can't go inside the factory until they've been fermented and dried

02:38Fermenting the beans is an important step that allows them to develop all of that chocolatey flavor in about a week

02:43They'll go from looking like this to something like this. You can smell there. They smell a little bit patient

02:48Yeah, like like a little bit like yeasty sourdough bread exactly

02:51What would a chocolate bar taste like if you didn't ferment?

02:54No, very bland flat probably just beater boring

02:58Nothing like interesting and then you take this to the drying process

03:01Once all the cacao is laid out to dry it just sits here in the hot

03:05Ecuadorian Sun and there's so much of it that I can literally make a chocolate snow angel all these seeds that are drying here

03:10They flip them over every 15 to 30 minutes to make sure that they're constantly being moved and that new ones are in the Sun

03:16To dry and we haven't made chocolate yet, but it's already starting to smell like chocolate

03:19So once the seeds are nice and dry

03:21They're all broken open like this and on the inside we get what looks a lot like a dinosaur egg

03:26But if you actually break all this apart in your hand and crumble it up a little bit

03:29Those are cacao nibs people put them on things like smoothie bowls all the time

03:32But if you grind these together into a paste sort of like if you grind peanuts into peanut butter

03:37It makes this sort of chocolate paste, which we're gonna go see now. Welcome to the Hershey's chocolate factory

03:42This is about as close as you're ever gonna get to real-life Willy Wonka

03:46You can see here that they have this huge hose with perfectly smooth chocolate paste

03:50But just moments ago that chocolate paste was in the form of these cacao nibs

03:54So this liquid chocolate paste can literally be turned into anything now, right?

03:59It's like eating a liquid chocolate. It is like, you know, we do not like it now that we're in the Hershey's chocolate factory

04:04I have two goals today first

04:05I want to see how Hershey's kisses are made because I've seen some cool videos online and it looks awesome and second we need to

04:11Make some chocolate bars. So now we're in the room where the Hershey's kisses are made in front of us is this giant crazy machine?

04:16That's pumping out Hershey's kisses 24 hours a day. There's some debate as to why historically they've been called kisses

04:23So Milton Hershey developed the kisses in the early 1900s story goes that because of the product kissing the belt

04:28And that's how the name was created

04:30I mean seeing this right now

04:31That would be my guess and you make 70 million of these every 70 million kisses a day after the depositors now

04:37We go through the cooling tunnel where we cool the kisses. So they're solid look how long this tunnel goes down

04:42I can hardly even see the end of it

04:43There's a continuous belt and the kisses ride on going through a cooling so that way the kisses harden

04:48You can see a small break right here in the tunnel. This is where our operators can do their quality checks

04:52They take kisses offline check to make sure that the shape is correct

04:55And they also weigh them off to make sure that they are the correct weight

04:58And so that's a laser that's checking every single Hershey's kiss to make sure that it's the perfect little shape

05:03I love how they're all kind of taking a little jump right there, too

05:05Now finally the exit here and now they're cool, right?

05:08They're ready for packaging now kisses come here onto the belt

05:10They go through a system of laning that gets them ready to go into the individual wrappers. Look at that. What a cool view

05:17I wonder how many Hershey's kisses I've eaten in my life like a good chunk of this assembly line. You see here

05:22We've got the further separation or chicaning of the kisses

05:25They can go into the in feeds of the wrappers and they're just coming out the line. They look so perfect

05:30That's the goal

05:31You see the shape of the kiss with it's had that little bit of a bevel on the bottom and it comes up to a

05:35Point at the top

05:36The nice thing is most of the time they end up looking like this when you get it in the package

05:40Sometimes you put in your pocket and melts you ruin your pants now that we've inspected all the Hershey's kisses

05:45They're good to keep moving from here

05:46They'll start to get diverted to either side to go to one of these wrapping machines

05:50So as the belt empties out here this arm comes out to pull more kisses into the in feed just tons of Hershey's kisses

05:57And they're all doing the same thing. Everything is mesmerizing

06:00I appreciate Hershey's kisses so much more right now from here from this in feed belt

06:04The kisses that are single filed through this chicaning system here so that way they can go

06:09Individually into the wrapper to have the flag and foil applied and then wrapped

06:13So as the kisses come out of the conveyor they go down this chute and onto then a conveyor belt

06:18We have that spiral in there. So that way we're handling the kisses as delicately as possible

06:22So they look as pristine to the consumer as they do when they come off the line

06:25So they all get sorted by that big machine and then they come here to get individually weighed and measured out

06:31Yes, they're coming through

06:32We got a vibratory conveyor to feed them in and then each of these

06:35Individual bucket has way hopper scales to know how much kisses are in it the computer system inside the baggers and drops the right

06:43Combination of scales to make the target weight for wherever bag size

06:46We're running after all the kisses are sorted out

06:48Now we have to package them into bags and this roll right here is where it all starts

06:52So the kisses have been weighed out to the perfect amount and then they drop through here and go straight into these bags

06:58We're saying go on to this conveyor belt right here

07:00That conveyor belt will take them to our case packer

07:02The bags come down the conveyor the robotic arm then is placed in the end of the case into the right

07:07Configuration based the item that we're running after the cases are filled they come through they go through a vibrator

07:12To shake out the bags inside the case to make sure they fill in properly robotic head now is gonna go over

07:17It's gonna pick up cases. It's gonna put them on in the right orientation that needs from the load

07:21That's building and this is a finished bag. I can open it. You can open it here. Yep

07:25Oh, it even smells fresh you smell the chocolate and they look good. It passes the inspection for me again

07:30This is the start of the chocolate bar process

07:32We're running extra large bars today on this line

07:34And obviously we need extra large chocolate bars to try to break the world record later

07:38So this makes a lot of sense the molds come through here

07:40They're tempered to the right temperature before they go into the depositor

07:44Then the depositor is dropping the right amount of chocolate into each of those cavities of the mold after the chocolate put it in the mold

07:50We've got to get the chocolate into the whole full cavity of the mold

07:53So through this cabinet the molds go side to side and through vibration the molds get shaken and the chocolate distributes throughout the whole mold

08:00So we're trying to get air bubbles out and fill up the whole cavity

08:03So the candy comes out of the shaker cabinet and then it goes into our cooler. This is me for scale

08:07It's a big fridge and you can totally see now that they're already cooled off

08:10You know when you've been at home when you have an ice tray that you're trying to get the ice out of and you kind

08:14Of bend the ice tray on either side to push the ice out. That's what's happening right here with all these chocolate bars

08:20This machine is basically doing exactly that

08:22so after the mold twisters the candy goes through the demolding cabinet where the molds are turned upside down and the chocolate is separated from

08:29The mold and onto the demolding belt and this belt is timing the rows

08:33So that way instead of mold groups, we have them lined out in rows

08:36So how many bars do you make every day? So across all the lines here at West Hershey

08:40We make about 9 million bars a day. That's more than enough to make a world record

08:43We got a quality check these two. Take that one

08:46Oh, each one of those little blocks is a pip

08:48So we're taking a look at it making sure that they're all there and they all say Hershey

08:51This looks even more perfect than the hisses. It's shimmering in the light here. I'm looking up close on this thing

08:57I don't think I see anything wrong at all. It passed the shiny test

09:00But let's see if it passes the crack test. You ready? Three, two, one. Oh

09:05Yeah, I think these are winners all marks in the good temper and a good bar

09:08We saw the bars downstairs and then they get lifted up here by this conveyor belt system

09:12And then they're going down this line right here into the infeed

09:15So these lasers are hard at work because every time they see an empty gap between the bars

09:19They speed up the other conveyor belt to catch them up to the bars ahead of them. That's right. That's amazing

09:24So after the lasers get them all together

09:26We then have the turning belt the turning belts are turning the bars

09:29So that way they're end-to-end as opposed to side-to-side to feed into the wrapper more lasers. They're controlling speed

09:35We have other ones that are looking for gaps in the bars also for broken bars

09:38There's any broken bars that's gonna reject those down here so that way they don't get wrapped

09:41So one of the bars somehow breaks the laser sees it and then that little thing right there blows it with air and discards it

09:47How are they wrapped? You've got the film here, which again similar to like we saw in kisses

09:51We have the roll stocks that goes through fed through the line and that's wrapped around the bar all in high speed

09:57You can see them down in here. See the bars feeding in the wrap goes around the bar and it's sealed

10:02This whole wrapping system is crazy to watch because there's so many different ways and twists and turns

10:07There's a lot going on when the machine stopped for a second

10:10You can see how the packaging kind of feeds over the top of the bar

10:13But if the machine started moving again, so I couldn't finish my sentence the bars come out of the wrapper

10:18They go through the wheel trooper heads pick them up and put them onto the trays. It moves

10:23Incredibly fast at the end each time

10:25That's just using suction just air to pick them all up and then stack them up perfectly so they can then go into boxes

10:31Once they've seen all that chocolate get boxed up

10:33It goes around these crazy conveyor belts that go all over this entire building

10:37These are one of the things that makes it feel in here like Willy Wonka's chocolate factory now that we've made more chocolate than you

10:42Could ever imagine let's take all that chocolate and try to make the world's largest chocolate bar over the next 24 hours

10:48This warehouse in Ecuador will be completely transformed from this to this

10:53We can't build this chocolate bar outside because it's about 95 degrees in Ecuador

10:57So we're bringing all this chocolate from the farm to a giant warehouse, which is gonna be air-conditioned

11:02And that's where we're gonna build the bar. This is pretty fun

11:04Oh, let's go break the record currently the Guinness World Record world's largest chocolate bar is

11:09383 square meters in size and behind me is the layout for a 400 square meter chocolate bar

11:14if we pull this off this bar will be the same size as a full-size basketball court way the same as

11:20183,000 regular chocolate bars

11:21And if you melted it you'd have enough to fill 80 bathtubs with all of that chocolate that we're bringing inside

11:27This is gonna be happening all day long behind the scenes

11:29The whole team here is just gonna be unpacking boxes and boxes and boxes of chocolate as we know Guinness World Records is very strict

11:36We have to clean ourselves off really well then hair nets on then we have to put these funny-looking things on our shoes

11:41And we can step on it's showtime

11:43We're gonna start by placing the bars down in the middle of this whole mat

11:47But it has to be one full chocolate bar to count as a record

11:50So what we have here is just a bag of melted chocolate

11:52Basically like a chocolate hot glue gun and we're gonna very carefully go in between all the chocolate bars so that everything starts to stick

12:00together oh

12:02So cool well now we just got 9,000 more to go now that we've started working on the bar

12:06I know I've already given you guys some comparisons

12:08But just so you understand it's gonna take 11 tons of chocolate to fill this whole white mat here

12:13That's about the same weight as two fully grown

12:15Elephants and if you ate a square of this every single day take you 30 years to finish it look how long this chocolate bar

12:21Is already becoming it's crazy look at Odette here comes Willy

12:24How's it feel to be trying to make the biggest chocolate bar in the world when you are a Willy Wonka you make the biggest?

12:28Chocolate bar every day, but this time. It's gonna be the biggest. I've made it in my life by the way guys

12:33I haven't talked about this yet, but this room smells really good

12:37Oh

12:39Chocolate we are having a lot of people come and help throughout the day because it's so much chocolate

12:43It's already what an hour. I hope we're gonna make it on time the name of the game here is speed

12:48I always get so nervous in the corners because it's like did we mess it up, or will it fit?

12:53The moment of truth is it gonna fit?

12:57Like good

12:59What do we do if it didn't fire the Oompa Loompa?

13:02What's the name of this big kid in the movie of Charlie and the chocolate cut the camera one Augustus gloop?

13:07Yeah, that's the kid

13:10I have an idea you go to that end. I'll go here. We'll race to the middle Augustus ready fire

13:15This guy right now Nick ready. Yes, go it's got to be perfect still Pat

13:19Mine's gonna be more perfect than yours the key to winning this race is to stay cool calm and collected usually in life

13:24I like to stress and then it all works out

13:26I think I'm gonna go over to Pat's side before he even gets like a quarter of the way down

13:29I'm almost there Pat. I'm so far past the middle already and the thing is also about doing it nice

13:34I'm just pouring chocolate all over like a crazy man. You need to start it from the beginning look at that

13:40Yeah

13:42Everyone's yelling at me today

13:43So right now my Oompa and I are lining up all the chocolate so that we can have it ready for them to pipe

13:47In that warm chocolate and glue it all together. Oh

13:50Yeah, have you seen any violations today things are going very well right now

13:54What if anybody eat any of the chocolate you can't eat the chocolate right here?

13:57I'm taking another room. Have you eaten any chocolate? No

14:02You're lying. The risk factor for me is very low

14:06Who did you get that on camera Nick?

14:08What happened the lights went off one thing we're dealing with during this record is once in a while right now in Ecuador

14:13they're having an issue with the energy grid and so the lights just

14:16Shut off. Sometimes it should come back on with the generator

14:18The most important part though is the air-conditioning because it's 95 degrees outside and it could melt this chocolate

14:24This is bad. It's been five minutes now. They're using flashlights over there right now to keep working on the chocolate bar

14:29Oh, I think that's the generator. That sounds good. That sounds good. Oh, it just went off again

14:34This is really not good now been 18 minutes with no power starting to freak out guys

14:40It went from bad to worse. We need power be crazy if it went on like right now

14:47No, well at this point guys, it's been over 30 minutes with no power

14:50So we're gonna get back to work in the dark because otherwise this is never gonna get finished. I'll tell you what worries me

14:55Yeah, what's that? No power. No AC. Yeah, if this starts to melt it's over. It's not only over

15:01It's like what are we gonna do is all this mess here. It's gonna go all over the place

15:05It reminds me what happened in the movie, you know, you were there

15:08I already feel that the chocolate it's getting a little softer Willy Wonka. What do we do here?

15:13Honestly, there's no solutions not in my chocolate Bible

15:16So we just got a bad update from the health inspector

15:18The temperature is 75 right now if it gets up above 80 the chocolate's gonna start to melt and if we get to 80 degrees

15:24Videos done no record

15:26Dude, it's actually getting very hot in here

15:36I can feel the AC back on temperatures starting to come down as long as this holds out

15:41You're gonna be back on schedule with the lights finally back on and we can start building again

15:44But this chocolate bar is taking way longer than we expected

15:47So I'm just gonna show you guys a really cool time-lapse and now we're 50% of the way through on this chocolate bar

15:52As you can see we had to bring in a few extra helpers. We were never gonna finish this thing

15:55Otherwise, we've done about 80 rows out of the 106 that we need to do to complete the entire chocolate bar

16:00I think it's the biggest chocolate mirror. Look how shiny it is. Literally you need the Willy Wonka sunglasses

16:06The shine means that it's been perfectly tempered which means when we snap it later. It should have a perfect snap

16:11We've sort of been patrolling throughout the day and word on the street right now is the corner in the back there is working a

16:17Little bit slow. We're gonna step in and help them out. Look at all your chocolate all over you. Look at this

16:21This is a real Oompa Loompa. How did you get all this chocolate on you?

16:25You love chocolate. I think it looks cool and you smell delicious. We started today at 7 30 a.m. And now it is

16:32722 p.m. And in this last corner, we're now down to just 10 squares left nine

16:38eight

16:40Seven six five four three

16:49Two

16:51What are Nick here? It is you guys ready for the reveal of what we hope is about to be the world's largest chocolate bar

16:59We did it after

17:0122,000 pounds of chocolate and lots of teamwork

17:03This is unofficially the biggest chocolate bar ever made in the history of the world

17:08But now it's up to the Guinness World Records officials whether this is a new world record the current world record for the largest

17:15chocolate bar by Aria is

17:18383 square meters after all the measurements

17:28You have achieved a new Guinness World Records title

17:34None

17:36Of this chocolate will go to waste we're gonna break this whole chocolate bar up and give it to kids all across Ecuador

17:41Wait, I literally just realized we never tried it. Oh

17:46Cheers

17:47That is amazing the end

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