About
The Mission
The Cocoa Forge is an artisan, micro-batch chocolate factory crafting rare heirloom and fine-flavor cacao varietals into stoneground, bean-to-bar chocolate with online shopping. My modus operandi, pure and simple:
- Seek out the world's most extraordinary, rare, exquisite, and responsibly grown cacao, direct-sourced from smallholder farms around the equator.
- Reverently craft this Food of the Gods into the purest form of chocolate possible; honoring slow and deliberate traditional chocolate making techniques.
- Respectfully present it to you with candid frankness and clarity.
Speaking of (chocolate) flowing, let's flow right onboard. Our transportation, the good ship Eleanora, awaits! We will wend our way towards our chocolate destinations, gracefully dodging around the perils, pitfalls and storms of this journey. Because it's not all sunshine and joy, although that is the goal and we will get there.
Off of the misty port side there will be shark infested waters (that would be the chocolate imposters thrashing about trying to get our attention). And what's that eerie music off the starboard rail. Oooh yes, the Sea Sirens (media, social or otherwise), those mythical sea creatures with beautiful voices that lure unprepared cacao sailors onto the rocks. There will be Shrieking Eels (slick marketers) appearing out of the starry darkness from the unknown somewhere. You know, the ones "that always grow louder when they are about to feed on human flesh". And. There will be doldrums. Economical, environmental, political; it's hard to predict. Do not be alarmed. The Eleanora will fall for none of this bruhaha. With those freakishly piercing blue eyes, she can see/sense these obstacles a mile away. She is always alert, always suspicious and always amused. So all we have to do is hold on to our hats and enjoy the chocolate voyage towards delight, discovery and enchantment.
Which, all that brings us 'round to a little chocolate philosophy. Like wine, like life really, real chocolate (this chocolate) doesn't stay exactly the same. Because even if I wanted to shoot for sameness and consistency, the beans hanging out in the exact same barrel from the exact same harvest go through some sort of personal growth and development behind my back. So sometimes, even if I love a batch, I can't duplicate it EXACTLY. Because, like people, they don't stay the same. And it's not just differences in harvests or fermentation or roasting - aging happens, they mature and evolve. They don't lose life force and vitality, they just develop. Often into richer and more intense versions of their younger selves. And when it comes time for a new batch they present themselves to me with new inspiration! They always surprise me! So if this sort of chocolate journey is your cup of tea (cocoa), you are in the right place.
And this is where I say something corny like "weigh anchor!". But I won't do that to you. Oh wait. Yes I will because I'm a cornball. Hoist those sails!! Haha!
The Why
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The What
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The How
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For Whom
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The When & Where
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The Promise
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Start the slideshow!
From the bean...
...To the Bar.
The chocolate bar, that is.
Ready to journey cacao voyagers?
LET'S ROLL!
Perhaps the most important step. Find the small-holder farmers. The ones that are attached to their land.
The farmers with cacao running through their DNA. Those that honor their ancestors and want to keep their cacao legacys alive. Sometimes that means bringing back long abandoned groves and traditions.
Because they are the Guardians. Knowledge of tending the trees passed down from countless generations. They are why we now have such a spectacular array of cultivars with astonishing flavor notes.
This curious tropical tree with an ancient heritage is extremely particular about where and how it grows. An understory tree, it needs to be in the deep dark forest with a madre de cacao overhead and a deep forest mulch on its feet. They need to be within 20 degrees of the equator and preferring lowland valleys out of the wind and with minimal moisture fluctuations. Picky, right? You bet.
Tiny orchid-like flowers, very few of which will develop into fruits, emerge on the trunk and lower, inner branches (cauliflory). It’s main pollinator; a tiny midge with it’s own peculiar/particular requirements.
Colorful pods of red, yellow, orange and light green hang like lanterns in the deep under-story, purposefully beckoning to squirrels, monkeys and humans - who are its only means of dispersal.
Flowers, baby pods and mature pods can be seen on the tree at the same time although a bigger flower flush happens after a harvest. Healthy pods will mature in about 6 months. Harvest is by hand only, care taken not to damage the cushion where more flowers will emerge.
Usually with a machete, the pods are opened and the fruit pulp and seeds (baba) are scooped out.
Then quickly to the fermentation pile (within 3 days). Proper fermentation is essential; without it the seeds (cacao beans) will never achieve their full flavor potential. This step takes 3 to 8 days, depending on the varietal and conditions.
Proper sun drying, usually on mats or trays (down to 7% moisture) is absolutely necessary (not too fast, not too slow, not too rainy), usually 2 weeks depending on conditions.
Into their sacks they go, awaiting transport to the gleefully anticipatory chocolate makers.
Just look at these beauties! They are sorted at this point if needed. But with this quality of bean they are often already pristine.
Meet Cooper the Copper Roaster. So named because I traded my adorable chocolate colored mini cooper for this glorious beautiful beast.
Roasting day! Another essential and careful three stage process to fully bring out the potential flavors of the cacao. See the fancy control panel? It's had a complete frontal lobotomy. I don't use it because each roast is unique to the bean and must be individualized.
Cool Beans! The beans must cool completely within 4 to 6 minutes. The epitome of beauty and function, this Turkish chiller does it in 4 minutes flat.
Once cooled, it’s time to crack and winnow the roasted cacao beans - separating the shells from the seed (now called nibs). The shells then detour to the soil-building or compost pile and the nibs continue on their chocolate journey.
And now, more magic happens. The Next three steps; stonegrinding the nibs, refining and conching (anywhere from 1 to 5 days). Slow but worth the wait. ...I wish you were here to smell the intoxicating aromas!
Next comes tempering. We want it to have that beautiful shine and snap.
Quickly, while the chocolate is still in a liquid state, it is molded into Grand Adventure Bars and also Tasting Tiles for shorter cruises.
Once the chocolate has fully crystallized (24 hours), the bars are ready for wrapping.
Now dressed in their Sunday best, the bars are ready. 40lb glassine plus a protective layer for the inner wrap, then into the 40lb glassine outer envelope; biodegradable, compostable, recycleable, Beautiful.
