We make a variety of chocolates but the two main products are Cadbury Dairy Milk chocolate and Cadbury Old Gold dark chocolate.
The special taste and texture of Cadbury chocolate is based on long traditions of expertise in chocolate recipe and processing methods unique to Cadbury. Techniques are improving all the time and new technology enables the process to be highly tuned to consumer's evolving tastes and preferences.
Chocolate production is a highly sophisticated, computer controlled process, with much of the new specialist machinery being produced to our own design and specification.
The Chocolate Making Process
Production starts at the Singapore cocoa factory where the top quality cocoa beans are processed to produce the cocoa mass - which contains 53% cocoa and cocoa butter - the basis for all chocolate products.
When chocolate is made, the 'mass' goes straight to our factories in Victoria or Tasmania.
Fresh full cream milk is collected and condensed and transported to the factories. Sugar is added to the condensed milk with some of the cocoa mass, making a rich creamy chocolate liquid, which is then evaporated to make milk chocolate crumb.
As these ingredients are cooked together, the special rich creamy taste of Cadbury chocolate is produced. Each year, 22,000 tonnes of crumb is produced at Claremont to be made into chocolate.
On arrival at the chocolate factory, the crumb is passed through a pin mill and mixed with cocoa liquor and cocoa butter, as well as special chocolate flavouring. The amount of emulsifiers added depends on the consistency of the chocolate required. Thick chocolate is needed for moulded blocks, while a thinner consistency is used for assortments and covering bars.
Both milk and dark chocolate undergo the same final special production stages - refining, conching and tempering - which produce the famous smoothness, gloss and snap of Cadbury chocolate.
Conching involves mixing and beating the semi-liquid mixture to develop the flavour, removing unwanted volatile flavours and reducing the viscosity and particle size.
Tempering is the final crucial and complex stage which involves mixing and cooling the liquid chocolate under carefully controlled conditions to ensure that the fat in the chocolate crystallises in its most stable form. Highly sophisticated machinery has been developed for this process, which is one of the skills of the chocolatier.
Tempered chocolate is used in a number of ways to produce our famous brands.
Blocks of solid chocolate, including bars with added ingredients such as nuts and raisins, are known in the industry as 'moulded' products. Tempered chocolate is poured into bar-shaped moulds, shaken and cooled, then the moulded blocks continue to high speed wrapping plants. One of our most recently-commissioned plants will potentially produce 700 blocks per minute.
Other Chocolate Processes
In products such as Crunchie bar, Cherry Ripe bar, or TimeOut bar, the chocolate covers a centre filling. In a process called 'enrobing,' the centres pass on a continuous belt beneath a curtain of liquid chocolate.
Assortments such as the boxed selection Cadbury Milk Tray or the twist-wrapped Cadbury Roses are made either by the enrobing process or "shelling," where liquid chocolate is deposited into a mould to form a shell. The centre filling is deposited in the shell, which is then sealed.
Another process involves "panning," where pieces of biscuit, raisin or caramel are coated with chocolate in a revolving drum.
Shell Easter eggs are made by the shell moulding process while Cadbury has a unique process for products like Cadbury Creme Eggs.
Chocolate Tastes Around the World
Chocolate is made to a recipe, and is made with distinctive tastes and traditions in different countries of the world.
Dark chocolate is the most popular chocolate in Europe, where chocolate has a higher level of cocoa solids, giving it a much stronger flavour. Milk chocolate is the preferred choice in Australia, while Americans favour dark chocolate with the smoky flavours of South American beans.
Another important difference between the recipe traditions of European and UK chocolates is the kind of milk used. European manufacturers use dried milk powder, often mixed with whey powder. However we use fresh milk - we believe that the very best milk chocolate is made with fresh milk.