Chocolate made in Switzerland

A visit to the Swiss chocolate factory

The day Rapunzel launched the world's first organic chocolate in 1987, it was almost like a revolution. Simultaneously, though, it was a challenge, because whole cane sugar is processed differently from conventional white sugar. With the chocolate manufacturer, Maestrani, Rapunzel has found a reliable and experienced partner by its side who is also open to new ideas.

Chocolate makes you happy

Step by step, to the finished slab of chocolate

Let's go!

First, Stefan Köhler pushes the cocoa butter and cocoa mass into melting ovens in blocks, where they are melted slowly and gently. Only once this is done, can they be processed further.

From coarse to fine: many steps

In the next step, the liquid cocoa butter and cocoa mass are placed in a mixer with other ingredients such as sugar, ground nuts or milk powder. The respective recipe determines which ingredients come together here and in which quantities. All ingredients are thoroughly mixed and stirred until the mixture is homogeneous. The result is a viscous mass. Which is, however, still far from the beloved chocolate: In this state, it is very rough, both in taste and mouthfeel. And it has a slight vinegary smell. This comes from the acetic acid that is naturally present in the cocoa bean, Stefan explains.

Pre-refining

The sugar crystals are crushed in the pre-refining stage. The mass is then sent to the fine refining stage. Rollers and mills ensure that the mass becomes finer and finer, until only a powder remains. Yet, how does this powder become fine melting chocolate?

The secret is in the conche

Now the conches come into play, in which the powder is liquefied again by heat. Conching is the most important process in producing fine chocolate bars. During this process, which can take many hours, the numerous cocoa flavours develop, and the delicate melting of the chocolate starts. In the conches, the powder is simultaneously mixed and heated, aerated and stirred. In the process, the overall taste becomes rounder and softer, and the flavours come to the fore.

Finding the right temperature

Tempering is the final step before the chocolate mass is poured into a slab form. This involves heating the mass and then cooling it down to 28 °C in two further steps. Thanks to this careful temperature control, the chocolate gets a longer shelf life, a silky sheen and a crunchy break. Depending on the variety, other ingredients are now added to the chocolate - for example, everything that is chunky: from fine pieces of ginger to slivered almonds or whole nuts.

At the end of the many steps

Once the right temperature has been reached, the chocolate is pumped into a dosing machine, before being poured into the chocolate slab moulds. A vibrator removes all air bubbles from the chocolate slab mould and ensures that the mass is evenly distributed. The liquid chocolate solidifies in the cooling tunnel. Now it is released from the mould and packaged. The compostable organic film protects the chocolate slabs from external influences such as odour or moisture. To ensure that the chocolate arrives in one piece, it is then packed in a cardboard box.

The person counts

Even though many work steps here are taken over by machines, people are and remain the most important factor. Without Stefan Köhler, Niklas Sutter and the other employees, nothing would work here. Because their experience is worth its weight in gold.

Delicious range of Maestrani chocolate

Bittersweet chocolate 85% HAND IN HAND

Nirwana vegan chocolate HAND IN HAND

Bittersweet chocolate 70% (Rapadura) HAND IN HAND

Semisweet chocolate with espresso splits 51% HAND IN HAND

Semisweet chocolate with coconut cream HAND IN HAND

Milk chocolate with creamy caramel filling HAND IN HAND