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Archive | process

Chocolate 302: The Story of Cafe Ingredients (in Hawaii)

March 27, 2014 by Cynthia Jonasson

Last April, a bunch of us Dandelions visited Steelgrass farms in Hawaii. It wasn’t what I was expecting from a farm. Steelgrass was lush and somewhat hilly, and nothing close to the monoculture farms I had always driven past on roadtrips as a child. Mostly it was beautiful, serene, full of interesting tropical plants, and warm hosts who quickly became friends.

The big house in which we stayed had an open living room/kitchen which was the perfect place for all of us to converge for communal dinners and conversation. Even now, a nostalgic feeling of enchantment sinks in when I think of the outdoor shower surrounded by brightly flowering bushes for privacy.

Fun in Hawaii

Enjoying Hawaii: Relaxing morning at Steelgrass Farms, Hiking, Snorkeling, Beach Time, Tasting new tropical fruits, Feeding the chickens at Steelgrass,

Exploring the cacao farm felt like an Easter egg hunt searching for ripe cacao pods.  While I knew a lot about the theory of harvest and fermentation, it’s the little details you can only learn from actually doing it yourself.  Like the sour smell of fermentation, the feel of an overripe pod, and the delicately sweet taste of fresh cacao pulp.

Exploring Cacao at Steelgrass Farms

Exploring Cacao Processing at Steelgrass Farms

We had such a great time visiting Steelgrass Farms, that we decided to invite all of you to join us and include some of the other ingredients we use in our cafe. So, we’re excited to announce Chocolate 302: The Story of Cafe Ingredients at Steelgrass Farms, Hawaii.

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Participants will get their hands dirty harvesting cacao pods, fermenting beans, and preparing them for drying. You’ll also have informational tours and hands on experiences to learn about other foods used in our cafe: sugar, honey, vanilla and coffee. You’ll make you’re own vanilla extract to take home, try your hand at beekeeping (if you’re willing) and even plant a cacao tree. It will all be interspersed with down time to hit up the beach, hike nearby trails or head off on your own.

Chocolate 302: The Story of Cafe Ingredients Itinerary
Note: Agenda is tentative & subject to change

3 Harvest 3

June 29th – July 6th

Steelgrass Farms, Kauai, Hawaii (near Kapaa)

  • Introduction: Arrival July 29th
  • Chapter 1: CHOCOLATE PART I – Tour Steelgrass Farms, chocolate tasting, harvest cacao pods, start cacao fermentation
  • Chapter 2: VANILLA – Vanilla processing demo & tasting, Make own vanilla extract
  • Chapter 3: NON-CAFE FOODS /ACTIVITY DAY – Macadamia Nuts, Coconuts, Snorkeling, Beach Time, Hiking
  • Chapter 4: COFFEE – Farm & roasting tour, Sunset at Waiamea Canyon
  • Chapter 5: SWEETENERS – Sugar cane demo, Honey & Beekeeping, Mead making demo, Luau
  • Chapter 6: CHOCOLATE PART II – Finish cacao fermentation/start drying, Beach Bonfire Dinner
  • Conclusion: Departure July 6th

 

Prices Start at: $1770 (including lodging, meals, ground transportation, activities; excluding airfare)

For more information or to reserve your spot, contact us at Trips@dandelionchocolate.com. Or attend our Info Session on April 15th in our Cafe.

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Beans Beans Beans!

February 5, 2014 by Maverick Watson
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Truck! Truck! Truck!!!

At Dandelion, we all wear multiple hats.  My name is Maverick Watson and most days you’ll find me in the cafe, serving up hot chocolates or coffee, but every Tuesday I am Dandelion Chocolate’s go to truck driver.  I pick up our cacao beans from warehouses in Hayward and Bayview and deliver them right to our factory on Valencia Street.

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And sometimes I make Greg deliver me to the bean room!

Today I delivered beans from Mantuano and Guaniamo, Venezuela, and Camino Verde beans from Ecuador!  It’s a really great experience to be able to see how the vast stacks of cacao in a warehouse in Hayward are gradually turned into the chocolate bars that we have on our shelves.  So until next week, I’ll be serving the chocolate, not trucking it.

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Safety First!

November 6, 2013 by Erica

One of the most important things to keep in mind when working at a chocolate factory, or in any other industry that involves dangerous equipment, is safety. At Dandelion Chocolate, we pride ourselves on being extra cautious when it comes to the safety of both our patrons and our employees. I, myself, am very involved in all things concerning safety at the factory, so when the opportunity arose to become certified in First Aid and CPR, I was happier than a slinky on an escalator! My co-worker Maverick was chosen to be my partner in crime, and needless to say we went to class eager to learn how to save lives “Dandelion Style”. For those of you unfamiliar with us wacky chocolate makers, we have an unspoken philosophy that all things Dandelion-related should be fun and lighthearted.

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Portrait with “Bob” and the Ambubaby

I have to admit, it was humorously difficult for us to get past the creepy dolls without faces (which were actually stored in equally creepy plastic bags!), but during instruction time we payed super close attention and worked hard to make sure we understood the procedures. As a matter of fact, Maverick was the lucky guy chosen to be the choking victim!

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Maverick is Choking and Unconscious!

During the class, we learned all of the ways to identify “breathing emergencies” and how to tell the differences between them. We were shown how to handle the situations based on the victim’s age and body type. We learned how to use an AED machine, give CPR, and about the proper protocols in contacting Emergency Medical Services. We are now skilled in burn treatments, cuts and lacerations, and some really awesome tricks for bandaging wounds!

Preparing "Bob" for CPR

Preparing “Bob” for CPR

All joking aside, it was awesome to learn how to respond in emergency situations. I am proud to be certified by the Red Cross and I know Maverick is too. We had a great time learning the material and I can’t tell you how good it feels to know that there are people in the factory that are ready and willing to help if the need ever arises. Hopefully, our visitors will feel safer knowing that we are prepared as well!

Me and the Ambubaby

Me and the Ambubaby

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Venezuela 3 of 4: Cumboto, A Charmed Cacao Farm

June 27, 2013 by Caitlin

This is part 3 of 4 documenting Greg and Caitlin’s trip to Venezuela. Here’s part one and here’s part two.

Cumboto, Venezuela

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We got out of the car, dusty and car sick from the road that never did seem to straighten out and a bad encounter with some spiced caiman at the previous day’s lunch.

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On second thought, maybe it was the salsa…(yes, that’s fire ant salsa)

The day was already alive with bugs and the sounds of birds welcoming us. To get to the farm itself we had to cross a small stream which everyone in boots could wade through. I kicked my shoes off and felt the sandy soil slip under my feet sliding down into the river. We splashed across, following Lugo like a bunch of ducklings. I didn’t want to leave the perfectly refreshing water, but there was no time to dawdle.

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Up the next bank and into the forest we hopped along the path avoiding the spiny plants, low tree limbs, and ants that bite. Small cacao farms don’t feel much like farms at all. Covered in a canopy of shade trees and the ground carpeted with plants, you simply feel like you are in the forest. Patrick, our fearless Venezuelan host, relived how the last time he was at this clearing, he had been barefoot. He had accidentally stepped into a fire ant nest and while he was trying to brush them off, he felt a mosquito biting his neck. He reached up to slap at the mosquito and suddenly there were ants on his neck.  He hurriedly brushed them off and then while attempting to get the last of them off his neck he leaned up against the nearest tree, only to find out the hard way that it was covered in half inch thorns.

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We picked our way carefully along the small foot-worn path until we came to a clearing. Jose Lugo proudly announced that the giant cacao tree standing before us was his favorite tree. It was around 150 years old, which made a stark comparison to the 20 year old trees we had seenat the Piaroan farms. It was hung with light pink pods and taller than any cacao tree I had seen. Lugo stood, holding onto the trunk like a proud father, while he told us all about the tree. Older cacao trees are less practical because they grow more of their fruit in their canopy which makes it difficult to harvest. It was so quiet and cool among the trees and the smile on Lugo’s face showed us how proud he was of his farm.

SONY DSCWe stopped at another farmer’s grove further down the road so Lugo could show us some grafted trees. Grafting is a process where you can splice the varietal you want to grow onto already established root stock (commonly used in apple orchards). It is helpful with cacao because farmers can grow cacao with more desirable genetics and the trees produce cacao pods faster (because the roots are already established so they can provide more nutrients and water).

Lugo knows so much about cacao farming and it was such an honor to get to travel around with him and see all the knowledge he shares with others along the way.

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Venezuela 2 of 4: Guaniamo, A Piaroan Experience

May 8, 2013 by Caitlin

Guaniamo, A Piaroan Experience.

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Photo credit: Diego Mata Martinez

Everyone sprung to action, looking for a tree limb or log big enough to leverage the 4×4 up.  Patrick, our host, and Jose Lugo, a farmer from the Ocumare region, moved quickly — donning rubber boots and looking in the river for a log big enough.  They found one and hoisted it up.  After trying a few leverage points and only falling in the river once, they managed to pry the truck up just enough so the driver could throw it into reverse and skid backwards up the river bank.  The second attempt was much more successful and we were soon all back in the 4×4 and bumping along, the sides of our vehicle brushing vegetation on both sides.  Suddenly, something loomed in our headlights.  It was a man!  With a rifle!  In the middle of the night. With no light.  In the jungle.  Was this the part where we were getting kidnapped?  But then I heard someone in the back seat whisper, “cazador” (hunter in Spanish) and I breathed a sigh of relief.  But as we passed him, he waved and I thought, “you my friend have got cojones.”

We arrived at the village around 11:30 at night and set up our hammocks in a thatched mud building while some bleary eyed Piaroans looked on curiously at all the hubbub of guests.  The next day dawned early and I got to breakfast on a guanabana.  Little did I know, this would be the last food I would be getting for awhile.  Due to some mix ups or things lost in translation, the plan to cook up the supplies and eat together with the villagers was not happening.  Thank goodness for protein bars!

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The whole village gathered and we trekked into the forest to see the cacao trees.  Jose Lugo and Patrick led a workshop on pruning.  Like many fruit trees, cacao trees do better when the branches that grow downward or don’t produce much fruit are trimmed off.  It also allows more air to circulate, which keeps pests down.

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Photo credit: Diego Mata Martinez

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Photo credit: Diego Mata Martinez

The farmers seemed very receptive and tried their hand at pruning some limbs.  If they can implement what they learned in the workshop, it will increase their yields and health of the pods.

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We trekked back to the village, our bellies grumbling thinking we were heading back to lunch, but we were sadly mistaken.  It was time for the presentation part of the workshop.

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After lunch, we learned that there were not one, but two communities from the same indigenous group who grew cacao.  They used to be all one community and had split due to religious differences several years ago.  We came to understand that they were expecting us to visit as well and that they were “just down the road.”  I broke the number one rule of traveling: sensible shoes and slipped on some sandals since we were going “just down the road.”

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Over an hour later, we were told to get out of the 4×4 and get into a wooden dugout canoe that really didn’t seem to have a back.  At the moment we arrived it was piloted by two eight-year-olds, who were soon rescued by their dad who was waiting on our side of the river.  We made it across without anyone getting too soaked and then got on the back of a motorbike with a Piaroan teenager to be driven down a bumpy dirt single-track lined path with rather abundant and sharp bushes/low hanging branches.  I was about a head taller than my Piaroan driver and he didn’t really take this into account in his driving route, but thankfully, I made it through unscathed.

The second community was overjoyed that we were there and we quickly fell in love with them as they brought forth woven baskets filled with bananas, pineapple, and sugar cane.  It was the best banana I have ever eaten.

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We were shown to the school building where Patrick and Lugo would lead the fermentation and drying workshop.  It was fenced in, like many schools, but there, the school is fenced to be able to lock the children in rather than keep strangers out.  Apparently, many of the children would rather run and play in the forest than attend classes (and who can really blame them, they live in tropical paradise!).   The workshop went smoothly and again the whole village turned out.  Their fermentation rates were much better than the previous village, but they were very interested in how to improve more.  We also got to talk to them about how we make chocolate and how we want to make the best chocolate possible from the best beans possible, which is why they, as farmers, are so important.

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Jose Lugo looking at the quality of the beans

After the lecture some of us took a swim.  I was busy taking photos and when I gestured to the elderly Piaroan man to ask if he was going swimming where the others were, he looked at me horrified.  I shrugged it off, but didn’t rush to join my comrades in the beautiful stream.  We later learned this “swimming hole” was where the whole town did their dishes.

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The sun was getting low, but there was one last surprise.  DINNER.  Rice, guinea fowl, mortadella, and fried plantains were served up and I was beside myself, I was so happy.

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Then, it was back to the first village for one more abbreviated night in the hammocks as we left before dawn to head back to Caracas.

Driving back out over the crazy trail-road made me appreciate these villages’ cacao that much more because they export 40 metric tons per year and to transport it, they take it out one metric ton at a time.  That’s 40 trips of about twelve hours each.  And all those trips have to happen in the season when it is not flooding, which is only about four months out of the year.  It’s pretty amazing that these beans make it to market at all.  Juana, a farmer in Sucre who was with us on the trip, told us the first time they tried to sell their beans, she told them to come meet her so they could talk about it and they showed up at her house in Sucre (which is the complete opposite end of the country) with their whole harvest of 40 metric tons.

Thanks to Patrick, he was able to help Juana find a market for these beans, which brought them to us and ultimately, to you.  And I appreciate them so much more knowing just how far they came and the wonderful farmers they came from.

Also, a big thank you to Diego, who is a professional photographer, for letting us use his photos!

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Scrapeasaurus Rex

February 21, 2013 by Tod Chubrich

There’s no shortage of Wonka-esque molten chocolate flows in the factory: between the four melangers, two temperers, and dozens of pans that ferry the chocolate between them, we have innumerable surfaces with luscious chocolate coatings that we need to scrape clean. My quest for the ideal implement (a treasure trove of innuendo if there ever was one) began when I emptied a melanger for the first time back in July–it’s a messy business at best–and thought, there’s got to be a better way!

there's got to be a better way!

We experimented with various spatulas, metal, plastic, and silicone, but a satisfying scrape eluded us until light dawned and I considered the squeegee.

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Our silicone savior arrived just in the nick of time for our new molds and the transition to the fill-and-scrape method of tempering, which was one small scrape for a man, but one giant leap for our company. We’re still searching for the perfect squeegee–just an inch longer and a tad sturdier, please!–but for now, these silicone squeegees from OXO are pretty awesome, so we ordered fifteen more. And…if you put them all together in a hotel pan after doing the dishes…you get a Scrapeasaurus Rex…rawr…which is rad!

Scrapeasaurus Rex

Because we’re actually dinosaurs.

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Valentine’s Day Recap

February 18, 2013 by Cynthia Jonasson

Valentines Day at the factory saw sparks flying (literally). As cute couples held hands over cups of hot chocolate and made clever cards, our oldest melanger decided it needed some love too. Caitlin was emptying a batch of Dominican Republic chocolate when the base of the melanger came loose, pulling wires with it which then sent sparks her way!  Thankfully, no one was hurt and the melanger should be up and running on Monday.

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Apparently our Big Selmi was jealous so it decided to get in on the action. In the middle of our morning tempering round, the temperer refused to  work until it received more love (and a new part that won’t arrive until Monday). Luckily, Greg and Cam came to the rescue. Above, Greg takes a break from fixing Selmi.

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Bar-to-Bean

January 16, 2013 by Todd

By now you’ve heard of bean-to-bar chocolate, but have you heard of bar-to-bean? Our friend Ryan at Cat Trick Films made us an awesome and quirky video for our opening. Check out how chocolate bars are (un-)made:

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Temperer Distemper Redux

January 11, 2013 by Cam

We thought we were done with our temperer problems when we fixed the compressor thermal overload protector near the end of December. Boy were we wrong. The tempering machine, a Selmi Top, worked for all of two and half days before it stopped pumping chocolate out of its top nozzle. At first, we thought maybe there was just a chocolate blockage in some of its internal pipes, so we tried disassembling the machine a bit and cleaning everything out. Unfortunately, that didn’t resolve the problem and we had to start using our smaller, back up tempering machine which really hurt our production.

After verifying a few simple things (no blockage, motor spinning the right direction), we disassembled the machine a bit more and looked more close at the different parts. Here’s the auger (thank you, Archimedes!) that drives the chocolate up the column and, ultimately, out of the nozzle:

auger

We couldn’t see anything obviously wrong with the auger and we were starting to get pretty confused. That’s when we noticed some suspicious marks near the bottom but we weren’t sure what they meant:

broken weld

Fortunately, we’d been talking with Sean at Tomric (the US representative for Selmi) and he was hugely helpful. He forwarded our pictures on to Italy where one of Selmi’s engineer recognized those marks as a broken weld. Apparently, the screw is held to the center shaft by a single weld and that weld had broken, allowing the shaft to spin without turning the screw. We quickly found our way to Kevin at Standard Metal Products and he got the auger repaired quickly. After a thorough cleaning and popping it back into the machine, the chocolate was flowing again:

fixed!

Since we had to use our less efficient machine for a week or two, we’ve fallen behind so now we just need to play a little catch up and make a lot of chocolate!

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December Distemper

December 18, 2012 by Cam

December and tempering problems always seem to go together and this year is no different. Things had been going really well until last week when our Selmi Top tempering machine started cooling a lot less effectively. It still worked just enough to temper the chocolate but it made everything so much less efficient, just what we needed for the holiday rush. After demonstrating that the compressor would come on but not stay on and that the machine had plenty of liquid coolant, we narrowed the problem down to low refrigerant, a broken compressor, or some control problem (a circuit not supplying power to the compressor when it should). While we wear many hats as chocolate makers, a refrigeration specialist isn’t one of them. After most refrigeration people told us they only worked on specific brands of appliances, we got in touch with Ceasar at KC Refrigeration. He was able to come out the next day and he quickly got to work diagnosing the problem. After about 45 minutes, he found the culprit: a failed compressor thermal overload protector:

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Not only was the part cheap ($3!), but he had a spare with him! After swapping the bad one for a new one, the compressor was able to stay on and the machine was fixed! We feel pretty lucky that it wasn’t the compressor (expensive and time consuming to replace) or something wrong with the machine’s circuit board (even more expensive and time consuming to replace). Now we can get back to making more chocolate!

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