From Bean to Bar – How We Manage Quality in the Chocolate Production Process
In today’s modern food industry, consumers expect not only exceptional taste and sensory experiences but also guarantees of quality, safety, and transparency of product origin. At Terravita, a company that has been delivering chocolate products to domestic and international markets for over four decades, these values form the foundation of our daily operations.
Chocolate production is much more than simply combining ingredients – it is a complex, multi-stage process where quality is managed with meticulous precision. We control quality at every stage of chocolate production – from the selection of cocoa raw materials to the finished chocolate bar. We implement standards and technological solutions to meet the highest market expectations.
1. Selection and Evaluation of Raw Materials – The Beginning of Quality Control
The process of creating high-quality chocolate begins long before the production line starts. The key raw material is the cocoa bean and the cocoa mass derived from it. Each batch of raw material undergoes detailed quality verification. Samples are evaluated for:
• moisture level, acidity, and fat content,
• presence of physical impurities,
• microbiological purity,
• sensory profile (aroma, appearance, taste).
We use modern laboratory equipment, which allows us to precisely determine the quality of each raw material. Only batches that meet all quality standards proceed to production.
2. Mixing – Recipe Precision and Batch Consistency
Depending on the recipe, cocoa mass is blended with sugar, milk powder (for milk chocolate), natural vanilla or flavorings, lecithin, and cocoa butter.
At this stage, the key factors are:
• accuracy of ingredient dosing,
• consistency of recipes across batches,
• monitoring of physicochemical parameters.
At Terravita, we use automated weighing systems that ensure the repeatability of mixtures. These systems are regularly calibrated, and dosing results are verified by trained staff.
Each batch of chocolate mass undergoes sensory evaluation in the laboratory – assessed for consistency, taste, and aroma to ensure compliance with the defined quality profile.
3. Refining and Conching – Developing Flavor and Texture
Refining and conching are stages that have a fundamental impact on the properties and quality of chocolate. During these processes, the chocolate mass is intensively ground, mixed, and heated, leading to the evaporation of excess moisture and volatile compounds, as well as the reduction of particle size to ensure a silky-smooth texture.
At Terravita, we use modern horizontal conches that allow for individual programming of parameters for each recipe – including duration, temperature, and mixing intensity.
The conching process can last up to 24 hours, depending on the type of chocolate. During this stage, the laboratory conducts:
• particle size measurements,
• rheological assessments,
• sensory tests.
The result of conching is a smooth, aromatic chocolate mass free from undesirable flavor notes and rough texture.
4. Tempering – The Key to Stability and Aesthetics
After conching, the chocolate mass is transferred to tempering units, where it undergoes controlled cooling and reheating. The goal of tempering is to form the proper type of cocoa butter crystals (beta-V), which are responsible for:
• the chocolate’s glossy finish,
• its stable structure,
• the characteristic “snap” when broken.
At Terravita, we use tempering machines with precise temperature control at every stage. We monitor not only temperature but also the temper index, which indicates the degree of crystallization of the chocolate mass. The finished product is then molded, cooled, and packaged under controlled conditions.
5. Multi-Level Quality and Safety Control
Terravita operates an extensive quality control system, which includes:
• Microbiological laboratory – confirming microbiological compliance,
• Physicochemical laboratory – analyzing moisture, fat content, pH, rheology (viscosity and yield stress), density, dry matter content, free fatty acids, additive percentage, and allergens,
• Sensory laboratory – organoleptic evaluations conducted by a trained sensory panel.
Samples are taken at every production stage – from raw materials through semi-finished products to finished goods. We also conduct environmental monitoring (surfaces, equipment, air), in compliance with:
• GHP (Good Hygiene Practice) – relating to sanitary and hygienic conditions in the workplace, including cleanliness of rooms, equipment, personnel, and controls,
• GMP (Good Manufacturing Practice) – concerning production methods that ensure the proper quality of raw materials, production processes, and controls. GMP focuses on guaranteeing that products are manufactured consistently and according to established standards.
An important aspect is also allergen monitoring – both in the final product and across production lines. We implement effective cleaning procedures and validate their efficiency.
6. Quality Systems and Certifications
Terravita’s production process complies with international food quality and safety standards. The company holds, among others:
• BRC – a food safety certificate recognized by most retail chains in Europe,
• HACCP – applied at all production stages,
• Rainforest Alliance and Fair Trade certificates – ensuring sustainable cocoa sourcing,
• RSPO certificate – guaranteeing sustainable palm oil sourcing.
As a producer working with numerous business partners, we are also regularly audited under client-specific standards, further strengthening our quality supervision system.
7. Quality Logistics and Traceability
At Terravita, we place great emphasis on full product traceability – from the batch of raw material to the finished chocolate bar on the store shelf. Each ingredient has its own batch number and is assigned to a specific production series.
The traceability system enables immediate tracking of the supply chain and swift action in case of product withdrawal or recall. All data are digitally stored and accessible at every stage of the product’s lifecycle.
8. Training and Food Safety Culture
Even the most advanced technology cannot replace the awareness and competence of people. That’s why we invest in continuous training for our employees – production, laboratory, and engineering staff alike.
Every new employee undergoes comprehensive training in GHP, GMP, HACCP, as well as food safety and allergen management. We also conduct workshops in sensory evaluation and detection of production defects.
Food safety culture is not a document – it is daily practice. At Terravita, every employee has a real impact on the final quality of products and knows how to respond in case of non-compliance.
9. Terravita – Quality That Tastes
Our quality philosophy does not end at the production line. It also applies to our relationships with business clients who expect reliable deliveries, product consistency, and compliance with their standards. Terravita supplies chocolates to several European countries, cooperating with retail chains both domestically and abroad.
Our quality starts with the beans but doesn’t end with the bar – it is a comprehensive system of responsibility toward our customers, the environment, and the market.
Terravita – quality that begins with the bean and ends with trust.
To the press compartment of Terravita Sp. z o.o.
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