Harvesting and Fermentation

Harvesting cacao beans is a delicate process. First, the pods containing cacao beans, are harvested by cutting the pods from the tree using a machete, or by knocking them off the tree using a stick. The beans with their surrounding pulp are removed from the pod and placed in piles or bins to ferment. The fermentation process is what gives the beans their familiar chocolate taste. It is important to harvest the pods when they are fully ripe because if the pod is unripe, the beans will have a low cocoa butter content, or there will be insufficient sugars in the white pulp for fermentation resulting in a weak flavor. After fermentation, the beans must be quickly dried to prevent mold growth. Climate and weather permitting, this is done by spreading the beans out in the sun from 5 to 7 days.[38]

Chocolate liquor

The dried beans are transported from the plantation where they were grown to a chocolate manufacturing facility. The beans are then cleaned (removing twigs, stones, and other debris), roasted, and graded. Next the shells are removed to extract the nib. Finally, the nibs are ground which releases and melts the cocoa butter producing chocolate liquor

Conching

The penultimate process is called conching. A conche is a container filled with metal beads, which act as grinders. The refined and blended chocolate mass is kept in a liquid state by frictional heat. Chocolate prior to conching has an uneven and gritty texture.
The conching process produces cocoa and sugar particles smaller than the tongue can detect, hence the smooth feel in the mouth. The length of the conching process determines the final smoothness and quality of the chocolate. High-quality chocolate is conched for about 72 hours, lesser grades about four to six hours. After the process is complete, the chocolate mass is stored in tanks heated to approximately 45–50 °C (113–122 °F) until final processing.

Tempering and Molding

The final process is called tempering. Uncontrolled crystallization of cocoa butter typically results in crystals of varying size, some or all large enough to be clearly seen with the naked eye.
This causes the surface of the chocolate to appear mottled and matte, and causes the chocolate to crumble rather than snap when broken. The uniform sheen and crisp bite of properly processed chocolate are the result of consistently small cocoa butter crystals produced by the tempering process.
The fats in cocoa butter can crystallize in six different forms (polymorphous crystallization). The primary purpose of tempering is to assure that only the best form is present.
After tempering is done, is time to mold the chocolate in whatever form you prefer and the magic is done, the Bean-to-Bar process is finished.