How Cadbury chocolate is made

The cocoa-bean -- the heart of the sweetest delicacy in the world -- is bitter! This is why, up to the 18th century some native tribes ate only the sweetish flesh of the cocoa fruit. They regarded the precious bean as waste or used it, as was the case among the Aztecs, as a form of currency.

The Varieties

There are two quite different basic classifications of cocoa, under which practically all varieties can be categorised: Criollo and Forastero cocoas. The pure variety of the Criollo tree is found mainly in its native Equador and Venezuela. The seeds are of finer quality than those of the Forastero variety. They have a particularly fine, mild aroma and are, therefore, used only in the production of high-quality chocolate and for blending. However, Criollo cocoa accounts for only 10% of the world crop. The remaining 90% is harvested from trees of the Forastero family, with its many hybrids and varieties. The main growing area is West Africa. The cocoa tree can flourish only in the hottest regions of the world. The Harvest Immediately after harvesting, the fruit is treated to prevent it from rotting. At fermentation sites either in the plantation or at, collecting points, the fruit is opened. Fermentation The fermentation process is decisive in the production of high quality raw cocoa. The technique varies depending on the growing region. Drying After fermentation, the raw cocoa still contains far too much water; in fact about 60%. Most of this has to be removed. What could be more natural than to spread the beans out to dry on the sun-soaked ground or on mats? After a week or so, all but a small percentage of the water has evaporated. Cleaning Before the real processing begins, the raw cocoa is thoroughly cleaned by passing through sieves, and by brushing. Finally, the last vestiges of wood, jute fibres, sand and even the finest dust are extracted by powerful vacuum equipment. Roasting The subsequent roasting process is primarily designed to develop the aroma. The entire roasting process, during which the air in the nearly 10 feet high furnaces reaches a temperature of 130 C, is carried out automatically. Crushing and shelling The roasted beans are now broken into medium sized pieces in the crushing machine. Blending Before grinding, the crushed beans are weighed and blended according to special recipes. The secret of every chocolate factory lies in the special mixing ratios which it has developed for different types of cocoa. Grinding The crushed cocoa beans, which are still fairly coarse are now pre-ground by special milling equipment and then fed on to rollers where they are ground into a fine paste. The heat generated by the resulting pressure and friction causes the cocoa butter (approximately 50% of the bean) contained in the beans to melt, producing a thick, liquid mixture. This is dark brown in colour with a characteristic, strong odour. During cooling it gradually sets: this is the cocoa paste.

At this point the production process divides into two paths, but which soon join again. A part of the cocoa paste is taken to large presses, which extract the cocoa butter. The other part passes through various blending and refining processes, during which some of the cocoa butter is added to it. The two paths have rejoined. Cocoa Butter The cocoa butter has important functions. It not only forms part of every recipe, but it also later gives the chocolate its fine structure, beautiful lustre and delicate, attractive glaze. Cocoa Powder After the cocoa butter has left the press, cocoa cakes are left which still contain a 10 to 20% proportion of fat depending on the intensity of compression. These cakes are crushed again, ground to powder and finely sifted in several stages and we obtain a dark, strongly aromatic powder which is excellent for the preparation of delicious drinks - cocoa. Cocoa paste, cocoa butter, sugar and milk are the four basic ingredients for making chocolate. By blending them in accordance with specific recipes the three types of chocolate are obtained which form the basis of ever product assortment, namely: Kneading In the case of milk chocolate for example, the cocoa paste, cocoa butter, powdered or condensed milk, sugar and flavouring - maybe vanilla - go into the mixer, where they are pulverized and kneaded Rolling Depending on the design of the rolling mills, three or five vertically mounted steel rollers rotate in opposite directions. Under heavy pressure they pulverise the tiny particles of cocoa and sugar down to a size of approx. 30 microns. (One micron is a thousandth part of a millimetre.) Conching But still the chocolate paste is not smooth enough to satisfy our palates. But within two or three days all that will have been put right. For during this period the chocolate paste will be refined to such an extent in the conches that it will flatter even the most discriminating palate. Conches (from the Spanish word "concha", meaning a shell) is the name given to the troughs in which 100 to 1000 kilograms of chocolate paste at a time can be heated up to 80 C and, while being constantly stirred, is given a velvet smoothness by the addition of certain amounts of cocoa butter. A kind of aeration of the liquid chocolate paste then takes place in the conches: its bitter taste gradually disappears and the flavour is fully developed. The chocolate no longer seems sandy, but dissolves meltingly on the tongue. It has attained the outstanding purity which gives it its reputation.

HISTORY OF CHOCOLATE
The origins of chocolate can be traced back to the ancient Maya and Aztec civilisations in Central America, who first enjoyed 'chocolatl'; a much-prized spicy drink made from roasted cocoa beans. Throughout its history, whether as cocoa or drinking chocolate beverage or confectionery treat, chocolate has been a much sought after food. Because cocoa beans were valuable, they were given as gifts on occasions such as a child coming of age and at religious ceremonies. Merchants often traded cocoa beans for other commodities such as cloth, jade and ceremonial feathers.

The origins of chocolate can be traced back to the ancient Maya and Aztec civilisations in Central America, who first enjoyed 'chocolatl'; a much-prized spicy drink made from roasted cocoa beans. Throughout its history, whether as cocoa or drinking chocolate beverage or confectionery treat, chocolate has been a much sought after food. Because cocoa beans were valuable, they were given as gifts on occasions such as a child coming of age and at religious ceremonies. Merchants often traded cocoa beans for other commodities such as cloth, jade and ceremonial feathers.

''Chocolate' (in the form of a luxury drink) was consumed in large quantities by the Aztecs: the drink was described as 'finely ground, soft, foamy, reddish, bitter with chilli water, aromatic flowers, vanilla and wild bee honey'. The dry climate meant the Aztecs were unable to grow cocoa trees, and had to obtain supplies of cocoa beans from 'tribute' or trade.

The Spanish invaded Mexico in the 16th century, by this time the Aztecs had created a powerful empire, and the Spanish armies conquered Mexico. Don Cortes was made Captain General and Governor of Mexico. When he returned to Spain in 1528 he loaded his galleons with cocoa beans and equipment for making the chocolate drink. Soon 'chocolate' became a fashionable drink enjoyed by the rich in Spain..

An Italian traveller, Francesco Carletti , was the first to break the Spanish monopoly. He had visited Central America and seen how the Indians prepared the cocoa beans and how they made the drink, and by 1606 chocolate was well established in Italy.

The secret of chocolate was taken to France in 1615, when Anne, daughter of Philip II of Spain, married King Louis XIII of France. The French court enthusiastically adopted this new exotic drink, which was considered to have medicinal benefits as well as being a nourishing food. Gradually the custom of drinking chocolate spread across Europe, reaching England in the 1650s.

Up until this point all chocolate recipes were based on plain chocolate . It was an English doctor, Sir Hans Sloane, who - after travelling in South America - focused on cocoa and food values, bringing a milk chocolate recipe back to England. The original Cadbury Milk Chocolate was prepared to his recipe.

People around the world have grown up enjoying chocolate as a favourite treat for countless generations. But just how much does the average person really know about the potential benefits, beyond the great taste, that chocolate and its key ingredient - cocoa - provides? We all know that a bit of chocolate tends to make you feel good, but a wealth of research suggests that people can now have even more reasons to enjoy it. The last decade has seen a significant increase in our research and understanding of cocoa and chocolate. But understanding the properties of chocolate is not just a recent development. For centuries, civilizations from Mexico to Europe have recognised the benefits of cocoa and chocolate for medicinal and therapeutic uses as well as a food, beverage or treat. It has even been hailed as an aphrodisiac! Of course, we all need to ensure we don't over indulge and that we see chocolate as a treat but researchers are continuing to uncover more reasons to enjoy cocoa and cocoa products. "Chocology", the science behind chocolate, opens up that research and presents the facts in an easy to use report that we hope will be a useful resource when talking about the benefits that chocolate can offer. Join us in the exploration of "Chocology" - You may discover that there's more to chocolate than meets the eye. Reasons to believe Body of Evidence - Where can you feel the Benefits? Myths and Facts about Chocolate Did you know?

Cocoa Long before the current trend towards organic ingredients, cocoa was one of the best known natural foods. In its purest form cocoa is a natural food. The cocoa tree produces cocoa pods that grow from the trunk or branch of the tree. These pods contain the beans which characterise the finished chocolate. The cocoa beans are fermented under banana leaves to bring out the chocolate flavour and then dried under the tropical sun. They are then shelled and ground to produce chocolate liquor, an essential ingredient for making chocolate. The liquor can also be pressed to remove the fat and is cooled and ground to produce pure cocoa powder. Antioxidant Power Cocoa contains high levels of naturally occurring compounds called flavanols and a range of other polyphenols that have been shown to reduce blood pressure helping to improve heart health. Polyphenols have antioxidant properties and work by fighting the free radicals which attack cells causing disease and accelerated ageing. They are believed to impact on arteries and blood qualities, helping to reduce the risk factors for cardio-vascular disease, through lowering blood pressure and improved blood platelet function. Scientists have found that the polyphenols relax vessels by increasing the chemical nitric oxide. This has been shown in new studies at many universities around the World1. Dark chocolate contains especially high levels of flavanols and other polyphenols - this helped to boost sales of dark chocolate by over 15% in the UK last year2! It's not just bars of chocolate that have these high levels of antioxidants - a recent study revealed that hot chocolate beverages, high in cocoa content, can contain concentrations of antioxidants similar to those in red wine or tea3 Top Deliciously Nutritious Chocolate and cocoa containing products are often criticised as being low in nutritional value and "empty calories". On the contrary, milk chocolate for instance contains many vitamins including B1, B2, and E as well as minerals including potassium, sodium, magnesium, phosphorus, zinc, copper, manganese and by far the most important, calcium, providing over 15% of the recommended daily requirement in a 49g bar of Cadbury's Dairy Milk, all of which help to keep us healthy. In light of recent research which suggests taking supplements may be detrimental to your health, it's good to know that chocolate and cocoa contain so many nutrients! Boosting Brain Power A recent study in the United States at Wheeling Jesuit University, West Virginia (May 2006) has suggested that eating chocolate may improve the way our brains work. The theobromine and phenylethylamine, as well as the caffeine in chocolate appear to increase alertness and mental performance4. The team found that scores for verbal and visual memory were significantly higher for those people who had eaten milk chocolate, and the consumption of milk and dark chocolate was associated with improved impulse control and reaction time. Similar work at the University of Nottingham has shown that the

consumption of dark chocolate can increase blood flow to the brain leading to improved cognitive function. Top In the Mood Chocolate is said to contain at least 300 natural chemical compounds, resulting in a complex range of tastes and odours that connect with the human brain as it runs over the taste buds of the tongue. The slowly released energy and feelings of fullness and satisfaction induced by its sugar and fat content, refuel the body's energy levels and create feelings of wellbeing. Eating chocolate triggers the release of endorphins, mood enhancing chemicals produced by the brain. These produce feelings of pleasure. Chocolate has such a luscious texture and aroma that all the body's taste and olefactory sensors are fully exploited, heightening the pleasure of the experience. So much so that a recent survey by Cadbury has found that 52% of women prefer eating chocolate to having sex! Over the years, psychiatrists and researchers have pointed out substances in chocolate that they think may make us like it so much - however, they're in such small amounts they can't really be the reason we crave chocolate. The simple pleasure of chocolate melting in the mouth adds to the pleasure of eating it - chocolate has the property of melting at body temperature, cooling the mouth slightly as it does so. Most interestingly, one expert has pointed out that "chocolate's a blend of flavours and aromas so complex that food chemists have never been able to duplicate it in the lab 5 ." We may never understand why chocolate makes us feel good, adding to its mystery. A standard 45g bar of dark chocolate contains 12% of the Recommended Dietary Allowance (RDA) of iron. Iron is essential in transporting oxygen in the blood to all parts of the body, and an iron deficiency can cause anaemia. When cocoa is combined with ingredients such as milk, sugar, fruit and nuts significant quantities of nutrients are provided- giving nutrition and energy as well as great taste. But as the products are often high in fats and sugars it is important that consumption is in moderation and that such products are consumed infrequently as "treats" - but are certainly not "empty calories". Top

Teeth While you should always brush teeth, naturally occurring substances in cocoa, such as tannins, may play a role in inhibiting plaque formation by coating the teeth to protect them6. Brain Eating chocolate releases endorphins, hormone-like natural substances, which produce a feeling of pleasure and reduce sensitivity to pain. Chocolate contains many substances that act as stimulants, such as theobromine, phenylethylamine, and caffeine. Research has found that consuming chocolate can lead to increased mental performance. Throat A study carried out by Imperial College, London in 2004 claimed that high doses of theobromine contained in chocolate are a third more effective at stopping persistent coughs than codeine. Heart Research by Professor Carl Keen at the University of California in 2000 has shown that a bar of milk chocolate (45g) contains the same

quantity of antioxidants as a 150ml glass of red wine. Dark chocolates with higher levels of cocoa contain even more, as presented in February 2006 at the American Association for the Advancement of Science's (AAAS) annual meeting in Boston. Circulation A number of studies, including one at the University of Cologne revealed that dark chocolate helps lower blood pressure10. The study focused on adults with untreated mild hypertension, some of whom had white chocolate, some dark. Blood pressure remained fairly unchanged in the group that ate white chocolate, which does not contain flavanols. But after two weeks, blood pressure readings had dropped significantly in the group who consumed dark chocolate. Bones Milk and milk products have been part of our diet for thousands of years and the milk in chocolate - particularly milk chocolate - provides useful quantities of a wide range of nutrients including calcium. A 49g bar of milk chocolate provides over 15% of the adult Reference Nutrient Intake (RNI) of calcium. Drinking chocolate made with milk contains even more calcium. Top

Eating Chocolate Is Inconsistent With A Healthy Diet With so much going for it, it's unfortunate that chocolate is often surrounded by myths and misconceptions that result in its unjustified reputation as an 'unhealthy' food. Scientists are beginning to dispel common myths about the concerns of eating chocolate, demonstrating the ways in which chocolate can make us feel good when enjoyed in moderation. One example of this would be the high levels of cardiovascular friendly antioxidants contained in chocolate in fact, dark chocolate in particular contains more antioxidants by volume than red

Cadbury India Ltd. is a part of the Kraft Foods Group. Cadbury India operates in five categories - Chocolate confectionery, Beverages, Biscuits, Gum and Candy. In the Chocolate Confectionery business, Cadbury has maintained its undisputed leadership over the years. Some of the key brands are Cadbury Dairy Milk, Bournvita, 5 Star, Perk, Bournville, Celebrations, Gems, Halls, clairs, Bubbaloo, Tang andOreo. Our core purpose "make today delicious" captures the spirit of what we are trying to achieve as a business.

In India, Cadbury began its operations in 1948 by importing chocolates. After 60 years of existence, it today has five company-owned manufacturing facilities at Thane, Induri (Pune) and Malanpur (Gwalior), Bangalore and Baddi (Himachal Pradesh) and 4 sales offices (New Delhi, Mumbai, Kolkota and Chennai). The corporate office is in Mumbai. Cadbury enjoys a value market share of over 70% - the highest Cadbury brand share in the world! Our billion-dollar brand Cadbury Dairy Milk is considered the "gold standard" for chocolates in India. The pure taste of CDM defines the chocolate taste for the Indian consumer. In the Milk Food drinks segment our main product is Bournvita - the leading Malted Food Drink (MFD) in the country. Similarly in the medicated candy category Halls is the undisputed leader. We recently entered the biscuits category with the launch of the Worlds no 1 biscuit brand Oreo. Since 1965 Cadbury has also pioneered the development of cocoa cultivation in India. For over two decades, we have worked with the Kerala Agriculture University to undertake cocoa research and released clones, hybrids that improve the cocoa yield. Our Cocoa team visits farmers and advise them on the cultivation aspects from planting to harvesting. We also conduct farmers meetings & seminars to educate them on Cocoa cultivation aspects. Our efforts have increased cocoa productivity and touched the lives of thousands of farmers. Hardly surprising then that the Cocoa tree is called the Cadbury tree!

Northfield, Ill.-based Kraft Foods Inc. (NYSE: KFT) is a global snacks powerhouse with an unrivaled portfolio of brands people love. Proudly marketing delicious biscuits, confectionery, beverages, cheese, grocery products and convenient meals in approximately 170 countries, Kraft Foods had 2010 revenue of $49.2 billion, more than half of which was earned outside North America. Twelve of the companys iconic brands - including Cadbury, Jacobs, Kraft, LU, Maxwell House, Milka, Nabisco, Oreo, Oscar Mayer, Philadelphia, Trident and Tang - generate revenue of more than $1 billion annually, and 40 have been loved for more than a century. A leader in innovation, marketing, health & wellness and sustainability, Kraft

Foods is a member of the Dow Jones Industrial Average, Standard & Poor's 500, Dow Jones Sustainability Index and Ethibel Sustainability Index. For more information, visitwww.kraftfoodscompany.com and www.facebook.com/kraftfoodscorporate. Heritage: We have come a long way since J.L Kraft started selling cheese from a horse drawn wagon in 1903. Hard work, imagination and commitment to bring the world its favorite foods has helped us grow into a company that touches more than a billion people in 160 countries. Everyday. One at a time. Some fast facts on the combined company: Our Global Reach y Annual revenues of $ 49.2 billion y More than 25% of Global revenue from emerging markets y #1 in global confectionery y #1 in global biscuits y More than 50% of global revenue from snacks and confectionery Our Brand Portfolio y 11 brands with more than $1 billion in revenue y 70+ brands with more than $100 million in revenue y 40+ brands over 100 years old y 80% revenue from #1 share positions

Consumers inspire us. To make today delicious, we begin with our consumers. We listen, we watch and we learn. We understand their joys and their challenges because were consumers too. What we do. We make delicious foods you can feel good about. Whether watching your weight or preparing to celebrate, grabbing a quick bite or sitting down to family night, we pour our hearts into creating foods that are wholesome and delicious. Our reach. We believe we can make a delicious difference, everywhere. Were constantly looking for fresh ideas to improve our workplace, our partnerships, our communities and our world. How we behave Our Values We understand that actions speak louder than words, so at Kraft Foods: y y y y y y y We inspire trust. We act like owners. We keep it simple. We are open and inclusive. We tell it like it is. We lead from the head and the heart. We discuss. We decide. We deliver.

How we grow.

We focus on creating sustainable, profitable growth. And our strategies guide our efforts: y y y y Build a high performing organization Reframe our categories Exploit our sales capabilities Drive down costs without compromising quality

About our people. It takes great people to make great brands. Our approximately 127,000 diverse employees around the world are the reason we succeed.