1. STEM Research Project The Engineering of Chocolate Scoil Mhuire na nGrást-The Newton Rangers Presenters: Clara, Emma, Eloise & Mia

2. Why we Chose Chocolate?
We wanted to show that engineering is more than building blocks in the literal sense
Engineering helps to tingle the taste buds too.
We looked at what was manufactured using machines in Munster
Engineering machines have had a long history in the evolution of the chocolate bar

3. The History of Chocolate
Chocolate was discovered by the Aztecs and the Maya in South America. It dates back to 500BC. They drank hot chocolate for special occasions like marriages, births and funerals. It was bitter without sugar. (source: Brain pop)
In fact, the Maya traded in cocoa beans it was so important and a luxury. 1 Turkey cost 100 cocoa beans (Source: Small World History)
The word cocoa comes from the Spanish because they discovered South America. Columbus saw it on his 4th mission.

4. The Old Ways-Slow and Manual
The love of chocolate was brought back to Europe.
In South America cocoa plantations were developed using workers from South America and Africa.
It was slow, hard, tiring and manual work.
Chocolate was a luxury until the industrial revolution in the 1700’s and the invention of steam powered machines which speeded up the process. The first steam-driven chocolate mill was created by a French inventor named Debuisson. (source: Wikipedia)
In 1815, a Dutch chemist, Van Houten, discovered adding salts to chocolate, reduced its bitterness.

5. The Engineering of Chocolate How Modern Manufacturing Speeds up the Process
Chocolate comes from the cocoa bean from the cacao tree.
The fruit of the cacao tree is a yellow or red pod.
Cocoa beans are now grown in South and Central America, Africa, Indonesia, India and South East Asia.
Chocolate is made from the 40 white seeds inside.

6. How Engineering Helps in the Manufacture of Chocolate
When the cocoa bean goes to the factory it is sifted to remove anything other than the cocoa beans.
The beans are fermented for 1 week
Dried in the sun
Roasted to give flavour
Roasted beans are winnowed (de-shelled)
Then, mashed into chocolate liquor

7. How Engineering Helps in the Manufacture of Chocolate
It is bitter and sugar is added.
Poured into moulds and becomes solid
This is unsweetened baking chocolate
More sugar and flavourings are added to make it taste even better. E.g. Dairy milk

8. Interesting Research Facts
Some is put into a Press to separate cocoa butter and cocoa solids.
Cocoa butter is used in skin and hair products. E.g. Palmers body butter.
White chocolate is made from cocoa butter e.g. Milky bar.
Conching means mixing chocolate and Tempering means heating it.
It takes 400 cocoa beans to make 1 pound of chocolate.
Chocolate is decreasing because of a drought in Africa affecting the supply where 70% of cocoa beans are produced.

9. Tally Sheet Results of favourite bar of Chocolate in 5th class:
Boys
Girls
Total %
Cadbury 6 12
60%
Lindt 2 4
20%
Kinder 1
10%
Nestle 5%
Other 20

10. We sent a survey to Cadbury’s Employees and checked out their website for the Secret Ingredient!

11. Quiz What is the native continent chocolate comes from?
How many beans approximately in a cacao pod?
What colour are the pods?
What colour are the beans inside the pods?
On which mission did Columbus see chocolate?
Was chocolate first made manually or mechanically?
Name the Dutch chemist who added salt?
Name the French inventor who made the first steam chocolate mill?

12. Acrostic Team Poetry C-cocoa powder H-hot chocolate O-oh so yummy
C-Cadbury’s voted number 1
O-overwhelming the taste buds
L-luxurious, lavish liquor
A-a nice treat
T-thrilling taste
E-enjoy!

13. Interview with Cadbury Employee
What is the hardest part of the chocolate production? The production plants that produce the chocolate crumb which is not the finished product have to be in perfect running order at all times. We have to meet the parameters that are required e.g. planning maintenance.
How long does it take to make a bar of chocolate John? hours approximately to make a cadbury’s flake bar.
What country do the cocoa beans used in Cadbury’s Kerry come from mostly? Ivory Coast

14. Interview with Cadbury Employee
How many cocoa beans do you need to make a Cadbury’s bar? We import our cocoa bean in liquid form so cannot specify the exact number of cocoa beans
What is the easiest part of the chocolate production? When all of the ingredients are mixed and cooked correctly. Secondly, seeing the final product which in my section is the chocolate crumb.
How many machines does it take approximately to make a bar? For the manufacture of the chocolate crumb it goes through six machines