If you take the Ashby exit in Berkeley off of interstate 580 west and then turn left onto 7th avenue, after about two blocks you will come to a small, unassuming brick building on the right, on Heinz street, that houses the Scharffen Berger chocolate factory. The building is solid brick and it’s construction was briefly interrupted by the 1906 earthquake.

Walking into the gift shop, you are assaulted by the scent of chocolate, to a degree that is very nearly unpleasant, but which is partially mitigated by the immediate cheerfulness and politeness of the shop staff.
Myself and two other people were there for the tour. After signing in, we were gathered up by Stephanie, our tour guide, to get started on the tour.
My cohorts and myself found ourselves in a small classroom, fully prepared to learn everything there is to know about making chocolate that can be learned in an hour. And Stephanie was fully prepared to teach us.
Cacao beans are grown in a very specific band around the equator. The trees can be grown anywhere that is reasonably warm, but they will only flower and fruit in these regions.
Chocolate begins it’s life as a tiny, orchid looking cacao flower roughly the size of your finger tip on the Theobroma Cacao tree. This eventually turns into a fruit roughly the size of a football. The inside of the cacao fruit is much like a pumpkin or cantaloupe, in that it has a thick, husk like skin, but inside that skin is a pulpy, edible fruit, said to taste much like lychee or passion fruit, and within that fruit are cacao beans.
The pulp and seeds are removed from the husk and placed into a bin, covered with banana leaves and allowed to ferment anywhere from 3-7 days. This process imparts a fruity quality to the cacao beans along with some of the natural astringency being leeched out. The beans are then dried in the sun so that they will not mold while being transported and so that they will not pick up any unwanted flavors from being dried using other types of heat. This is the form that the chocolate factory receives the cacao beans in, as a raw agricultural product.
The beans are then roasted in a large, old looking machine that was once a coffee roaster (the process for roasting coffee and the process for roasting chocolate are identical) for about an hour at 300 degrees, which gives them a mellow flavor.

The equipment used to produce the chocolate is vintage European equipment, sometimes cobbled together from more than one machine because the machines simply aren’t made anymore, artisinal chocolate having given way to mass produced chocolate.
The beans then go into a machine called a winnower, which cracks the beans and separates the husks of the beans from what are called the nibs, which are the seed bits that remain after the husks are blown away. This is the first time that the bean smells or tastes like chocolate, and it is the part of the bean that is used to make chocolate.

The cacao nibs are approximately half cocoa solids and half cocoa butter. In order to release the cocoa butter in the nibs, they are put into a machine called a melangeur (mixer) , which crushes the nibs between two 600 pound wheels, extracting the cocoa butter and mixing it with the solids and creating a substance called cocoa mass or chocolate liquor. This is also the point at which the product stops being considered cacao and starts being cocoa or chocolate.

At this point, the cocoa mass is still gritty and has not yet been refined to the point necessary to make what we think of as chocolate. It also is still unsweetened. Further refining and the addition of other ingredients, such as sugar, vanilla beans and soy lecithin (as an emulsifier), is done in a conche, a machine invented in Switzerland by Charles Lindt, which makes chocolate as we know it possible.
The conche grinds and aerates the cocoa mass, sugar and any other ingredients together until they are made into a smooth liquid, with all of the cocoa mass and sugar particles coated with cocoa butter.

After the chocolate is finished being conched, it is put into the tempering unit, where the temperature is repeatedly raised and lowered at very specific intervals until the chocolate has a crystalline chemical structure that allows it to be solid at room temperature.

The chocolate then goes to the molding line, where it is poured into specific molds for either commercial or consumer use, passed through a refrigerated tunnel to harden the chocolate and then packaged according to the market in which it will be sold.

Chocolate was brought to Europe from Central America by the Conquistadors. They learned of it from the Aztecs, who considered it sacred.
The Spanish were the first to add sugar to chocolate in order to make it sweet. Prior to that it was made into a beverage and drunk purely as a stimulant, much like coffee or tea. The British were the first to make candy out of it but it wasn’t until the industrial revolution that chocolate was created in the form that we know it today.