Like always, things do not go as smooth here in Ecuador as I am used to. I was hoping to go to the chocolate factory with Judy in the morning, but when I called her the night before, she didn’t answer. This morning I called again and I got a whole story from her, which I didn’t totally hear, because I was walking down the busy Colón.
It turns out, there were some bus problems in Tena, forcing Judy to take the bus via Ambato, which is quite a detour. She arrived only at 11 in the centre of Quito. I met her at her house, the place that R. called his house before, when I first was there. Then we took three buses down North to the chocolate factory of Ecuatoriana de Chocolates. The factory that makes the Cacaoyere chocolate. I don’t know if it is known anywhere, but I hear they have contacts in Germany for selling the chocolate. All the way to the factory, Judy talks a lot. I think I’m quite up to date about the current things that are going on. I just need to get a hold of her to talk about the history of Kallari.
At the factory, we first sit down and Judy talks with the manager, and a chocolate maestro. Some things about the new batch of chocolate, which is quite good, though a bit acidic (which will go away within 3 months); and about packaging designs. Then they offer me a tour through the factory. I’m not allowed to make pictures, because they may be a bit careful: Kallari is going to build its own factory the coming year.
The cacao is first roasted for 45 to 48 minutes, after which it is rapidly cooled down and the skin gets removed. The beans are then ground into small bits. In the Kallari cacao we see some lighter pieces of cacao. These might be mutants or criollo varieties. The ‘contamination’ of the cacao with a small percentage of other varieties than Cacao Nacional is giving it a more nutty and floral taste, which is only a good thing.
The ground cacao beans are turned into a thing called cacao mass, going into cacao liquor. The exact process is not explained to me. In the next room they add the vanilla and the sugar, and they roll it into small pieces. Then it is mixed with cacao butter – which is at the moment bought from outside, a machine to make this is a million dollar – and ‘conched’. Meaning it is turned around and getting to the right taste. Some flavours will disappear while conching.
Now it is ready to pour it into bars. A machine turns the chocolate in different temperatures, preventing the fats to shift and thus preventing the formation of a white finish. It needs to be shiny and brown. It is poured into moulds and then goes through the cooling tunnel. At the end of the tunnel is light, but then it soon turns into darkness again, when the bars are packed into plastic and pushed into cramped boxes. Only at the consumer end will the chocolate ever see light again.
After the tour, I ask whether I could come back much later to do some interviews and that’s alright, they “love interviews”. After that it is time to take the bus back to the centre. Judy accompanies me for a while once more. When I get off, I pass by the café to say goodbye to Mari again; I pick up my stuff from the apartment, which I’m kind of using as a storage now, sorry; and I take a bus to Cumbaya. From there I pick the first bus to Tena, where I’m lucky to get a seat on the first row to watch… oh no… Jean Claude van Damme films. Luckily there’s a guy standing with his arms in front of my view.
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