artisanal thinking

I’m happy to report a partial solution to my earlier troubles with tempered, cooling chocolate. The ceramic baking dish I grabbed for $2 from homeworks is reatining enough heat to successfully mold almost all of a 6lb batch. When there is only about 8 ounces of chocolate left in the dish, it cools quickly just because of its small volume, but prior to that, my chocolate remained workable for up to an hour, sufficient time to do my work. I think a melamine or thick plastic bowl would be even better, but ol’ blue is fine until I find something else on the cheap. Truly, my 7th batch, Panama again, tempered and molded well, and I celebrated by: in the morning—inviting people over to scrape the scrap chocolate in our grinder with bread and apples. In the evening—inviting more over to share wine and food (and chocolate!), followed by a wrapping party assembly line featuring me cutting foil and waxed paper, Phil wrapping bars in foil, Jay and Juan cutting and wrapping with colored paper, finally Leonardo, Minas and Keihly labeling the bars with designs of their own inspiration. Fondue and wrapping parties are really fun and since the process is returning to its groove, I will continue partying at the end of each batch.

My groove is shallow and imperfect, but it is what I am currently capable of. What can we do to further improve the process and our bars of chocolate? Some primary concerns right now are the physical molds I have, the way molded chocolate is cooled and what we do with bars after they come out of the molds. There are two grades of molds one can buy, ‘hobby’ and ‘professional’. Hobby molds are made from PETG, a copolymerization of PET plastic, the stuff soda bottles are made of. The main issue with these molds is that they are thin, they flex—when I fill a tray of molds with chocolate, the middle mold will sag a bit. The bars I’ve been producing, then, are not rectangular boxes in 3d, they are the bases of extremely shallow parabolae. I’ve also read that the final chocolate hobby molds produce is not as glossy-shiny as molds from more rigid, higher grade plastic. You may recall that well-tempered chocolate contracts slightly as it cools, and as a result, most of the area of every bar pulls away from the mold. Then when turned over, they just fall out. In my case, there are usually a couple of concentric rings where perhaps because of sagging and thus increased pressure in a region of the mold, the chocolate does not contract and cool away from the mold, but is flush and has a ’stuck on’ look in contact with the mold. When I demold, these rings stay slightly more matte than the rest of the bar, a flaw.

For the serious and respectable chocolatier, molds come in only one variety, ‘professional.’ These thicker molds are made from polycarbonate, a durable substance which can be used to make bullet-proof glass, cds or the case of the previous generation of apple laptops. When using polycarbonate, there would not be any parabolic geometry, there should not be my matte-finish rings, and possibly there would be an even higher sheen overall, perfect for creating chocolate … mirrors. The advantage price-wise, as in all things, goes to the hobbies. A tray of molds holds close to three-quarters of a pound, making my collection of 9 molds enough for 6 pounds of chocolate, about my current batch size. I spent about $50 buying hobby molds from the home chocolate-maker supply store—I could have gotten away even cheaper if I had ordered from the mold manufacturers. Unfortunately, to upgrade all these to professional versions would be in the hundreds of dollars.

I was recently chastised for not coming up with enough areas for improvement in the technique of chocolate making, referring instead to polycarbonate molds, holding tanks, grinders… the never ending supply of upgradeable toys that can consume any hobby. I feel slightly as a photographer with chipped lens, that a new Leica would be an objective improvement and justifiable upgrade, but what we’ll actually do is try to give my equipment some more love. A simple solution to my saggy-molds would just be a stack of paper used as a shim to support the underside of the mold—I intend to put my molds on a pedestal, elevating them and the quality of the bars.

Subtleties in Handling Any Equipment, Hobby or Otherwise

There are more minutial concerns with how we’re cooling the molded chocolate. One must keep in mind that when it enters the fridge (or for commercial makers, ‘the cooling tunnel’), the 85F chocolate is a flowing liquid. That means that if they trays are not placed on a level surface, for instance if when trying to maximize space usage, one side of the tray rests atop a notch where the fridge rack attaches to the side…if they are not level, chocolate will flow just a bit to the lower side of the mold. Then we have not just parabolically shaped ‘bars,’ but truncated pyramid-parabolic bars, where one side is thicker, one side thinner. All of this unique geometry leads to interesting situations wrapping the bars where the paper band will only fit around the foil-wrapped bar under a specific orientation. Some gracious folks have commented that this spontaneity is what you would expect and possibly desire from an experimental craft chocolate maker, but I would at least like to refine my process, improve my technique and intimate knowledge of my tools to the point where I can choose whether to be pyramidal or rectangular.

Because we work extremely hard making well-tempered, smoothly molded, unsaggy and rectangular bars, we must be extremely careful in handling them after taking them out of the fridge and eventually demolding them. Originally I would take a couple of large plastic bags, collect my bars from the molds and then put them in little stacks 3 or 4 high filling the area of the bag. Inevitably this leads to collisions among the bars causing scratches and powder to collect on them, deglossing and mattefying the surface which through tempering and careful molding I had worked hard to achieve! For the last wrapping party, which was held six hours after I finished cooling the bars, I took the molds out of the fridge, wrapped each tray in a bag, and put those in my chocolate cellar in the basement. This way we demolded the bars just as we were about to wrap them, and we could ensure they would look snazzy. We’ll eventually start using gloves as well when we are wrapping the bars so that we don’t scuff the surface with fingerprints. When I unwrap a bar, I want it to pop, not have a powdery handprint on it!

Final Update for Now

On the business side of things, and I’ve certainly been busy…after batch #7, I took my flock to Siebel for cold storage and stacked up 26 two-ouncers, 15 one-ouncers, three licorice bars, one each of almond, nib and plain dark bars, plus some older Peruvian dark bars. Last night I witnessed a sequence of rapid-fire 20 slide, 20 seconds per slide presentations from the ‘local creative class’: Pecha Kucha. I saw some cool quilts, theoretical illustrations, thoughts on the ’stuff’ of art, stories from the knitting circle, and thoughts on hocking old stuff. My moment in the sun came during the intermissions and at the after party while I was mingling, trying to get people to try samples of my chocolate and asking for their support in the form of a mutually beneficial transaction. I made a repeat experiment in direct sales this morning at the Urbana Farmer’s Market. Sometimes, when extending my hand, shouting, “HI! I’m Dan! … Do you like chocolate?”, and reaching into my backpack for the samples bag—I give someone a good freak out…but the rest of the time, it is really fabulous fun.

This entry was posted on Saturday, September 12th, 2009 at 5:45 pm and is filed under Business, Chocolate Making, Events. You can follow any responses to this entry through the RSS 2.0 feed. You can leave a response, or trackback from your own site.