Volume 18 2026 BEAN-TO-BAR CHOCOLATE PRODUCTION: PROCESSING, PACKAGING AND STORAGE Authors Izzreen, I.*, Johari, K. , Nur Farisya Izzani, S., Nur Athirah, M.K. & Nurul Ain, M.T. ABSTRACT Today, Malaysian artisan chocolate companies increasingly focus on handmade, high-quality chocolate made through bean-to-bar processing. This review outlines the small-batch process, from selecting premium cocoa beans from a specific location to producing finished chocolate. The process uses small-scale equipment such as ovens, melangers, marble slabs, and a digital micrometer. Cocoa bean roasting is a crucial step in developing flavour and reducing microorganisms. Then, achieving particle sizes of 20-30 μm and a final tempering temperature of 31-32°C is essential for dark chocolate production. Controlling particle size is im portant because it affects chocolate texture, with smaller particles creating a smoother mouthfeel and a more refined final product. Careful physical inspections during chocolate moulding help prevent under-filling and trapped air bubbles. Fat crystallisation is maintained by properly cooling the chocolate to 8-12°C, ensuring stable form V β1 polymorphs. This specific fat crystal structure is crucial to chocolate's glossy appearance, snap, and resistance to melting at room temperature. To preserve fine flavours and prevent chocolate bloom during storage, suitable packaging is used. High-barrier aluminum foil protects the chocolate against moisture absorption, light, and odours, while paperboard provides structural support and traceability information. Chocolate storage is carefully controlled, with temperatures kept between 18-22°C and a relative humidity of 50-60%, monitored by wireless thermo-hygrometers to prevent fat and sugar bloom. This approach maintains product quality, enhances consumer appeal, and extends the shelf life of the dark chocolate bar made with premium cocoa beans through bean-to-bar production. VIEW PDF DOWNLOAD