The cacao beans are roasted, thus loosening their shells and developing flavor.
The shell is removed from the cacao bean, leaving the nib.
The cacao nibs are ground into cocoa liquor using authentic stone mills from Oaxaca, Mexico.
The cocoa liquor is moved to the mixing tank, where organic raw cane sugar is added, resulting in a chocolate mass.
Chocolate mass for the Chocolate Mexicano Discs go through stone mills for a final grind.
Chocolate mass for the chocolate bars passes through the roll refiners several times, becoming smoother.
In the holding tank, the refined chocolate is kept at 110 degrees in a liquid state. Each tank holds up to 3,000 pounds of chocolate.
The tempering machine heats and cools the chocolate so crystalizes in a way that gives it a glossy appearance.
The tempered chocolate is molded into discs and then sent to the cooling room to solidify.
The tempered chocolate is molded into bars and then sent to the cooling room to solidify.
In the packing room, the discs are wrapped at a rate of 48 per minute.
Currently the bars are hand-wrapped at a rate of one per minute. A new machine will soon wrap them at nearly one per second.