Crafting

Artisanal Chocolate

From the moment a pod is selected for harvest to the final tempering of each bar, our process is shaped by intention, cleanliness, and an unwavering respect for the cacao itself. Our approach honors both the art of chocolate-making, the science that protects its purity and the culture rich land it grows on.

Last Resort 100% Kauai Grown and 100% Handcrafted i Kauai Seal

The Chocolate Laboratory

Blueprint drawing of the interior of the Last Resort Chocolate workroom where the chocolate is made.

Our Process

The idea among Chocolatiers of “Bean to Bar” chocolate has been around a while. Take cacao “beans” (it’s really a seed) and process them into chocolate. Then there was “Tree to Bar,” expanding upon the “Bean to Bar” concept and incorporating the farming side. Then there are those who live the dream. While researching equipment manufacturers, discovered one who shared that same mantra as we do: “Dream to Bar.”

Years of research brought the farm to one concept. Space was limited to one building on the farm at roughly 350 sqft and the farm is relatively small. The agriculture side vs. the production side is far more demanding so efficiency is a must.

As the farm matures and yields increase, the concept was to harvest in a day and ferment for one week. Dry for a week or two depending on weather. During this three week period and longer if needed, work would be ongoing on the farm. One week would be set aside for the production of chocolate. Equipment selection would be paramount.

A drum roaster would begin the process. Efficient and delivering a uniform and repeatable roast with minimal damage to the dry seed and powered by the already existent propane source rather than expensive electrical. Research and reaching out to various manufacturers revealed a used machine with only 200 hours on it. Manufactured by Diedrich Roasters™ in Idaho, the IR-12 was an automated, cacao-specific roaster ready to be shipped. The only drawback was that it required a fuel source conversion from natural gas to propane. Coated in a familiar fire engine red powder coat, this IR-12 was a perfect fit.

Moving on down the line of production, refining the nibs is the next step. Research reveals there are a few different paths to take and each with their own drawbacks and benefits. Quality, space, efficiency and production time became significant factors. Enter Packint™. Hailing from a region just south of Milan, Italy, this equipment manufacturer has an impressive line of equipment and an equally impressive reputation among chocolate makers. Expectations were met and engineering began.

The Crafting Process

Click each tab to learn more about each step.

Fermentation

A graph showing temperature levels over a week of time on the Last Resort chocolate farm in Kauai.

Once harvested, the cacao begins its transformation.

Before entering the ferment boxes:
• Excess pulp drains naturally by gravity
• Pods remain separated based on harvest conditions until all draining is completed.
• The sweet pulp collected in preparation for fermentation is one of nature’s treasures—a favorite farm treat, and occasionally the base for a very memorable margarita or mimosa.

Fermentation
• Our very calculated 'spontaneous ferments' do not use any external innoculant or imported yeast sources making it possible for a true to terroir chocolate.
• The first 48 hrs of the ferment are anaerobic.
• At the conclusion of the first 48 hrs, the ferment is aerated by scooping the ferment from one box to another allowing the seed to fall through the air. This 'turn' is completed every 24 hrs until the termination of the ferment.
• The ferments are monitored by our Davis Instruments™ Weatherlink Live ensamble. Metrics are gathered from 3 positions within the ferment and one from the enclosure for comparison.

View Live Weather

Post Ferment

Drying

We work with the island, not against it. Kaua‘i’s environment is powerful, unpredictable and alive. Full sun drying on our elevated drying racks allows a slow reduction of moisture from the fermented seed. Our normally abundant and often intense sunshine and gentle trades promote an even drying for our cacao seed.

Aging

Most dried seed heads directly to the Chocolate Laboratory to be processed into chocolate. However we are experimenting with aging our cacao nibs in a Buffalo Trace™ Single Barrel Select Bourbon barrel. This is sure to be a favorite.

Try The Bourbon Bar

Roasting

Diedrich Roasters™ of Ponderay, Idaho, makes specialty roasters and they showcase a full line of Cacao Roasters. Our cacao specific IR-12 has a slower drum speed and a programmable roasting profile offering the ability to dial into perfection. During roasting, you can smell a hint of brownies walking through the orchards as the trades swirl through the valley. As the roast profile is terminated, roasted seed exits the roasting chamber and into a perforated cooling tray and cool air is drawn over the seed as they are gently turned and cooled.

A Diedrich Roasters IR-12 cacao roaster machine.

Cracking

Once the roasted cacao seed is cooled, the exterior husk needs to be removed to reveal the cacao nibs within. Enter Packint™. From the Pavia province of Italy, this company makes beautiful stainless steel chocolate machines among other equipment lines. The Packint™ Pre-refiner consists of two adjustable Italian precision granite rollers. Roasted seed is passed between the rollers and crack each seed open dropping the nib and chaff onto a conveyor belt. The collected mass is then brought across the room for winnowing.

Winnowing

Winnowing is the separation of the chaff from the nib of the roasted cacao seed. The lighter chaff can be separated using enough airflow. The process can generate dust so we went to work designing a makeshift winnower using a shop vac, dust collection system hidden in an exterior closet for sound and dust mitigation, a hopper and an auger from a pellet fired smoker, all connected via piping with adjustable vents. This 'Frankenstein' winnower allows us to refine the airflow and eliminate the chaff from the nibs and capture both for consumption. The nibs move onward into chocolate and the chaff is separated into a chocolate drinking powder and the larger chaff is packaged for more of a tea or brewing consumption.

A homemade winnower machine used in the chocolate making process.

Conche

Conching is the final development of flavors. Packint™ manufactures the perfect size Conche for our Chocolate Laboratory. The Packint™ 50 kg Vertical Conche serves as a holding tank during the milling process. Upon the completion, each 10 kg mill batch is transferred, held and stirred at ideal temp in the temperature controlled bowl of the Conche. Once the last of the mill batches have been transferred over, customized programming begins. Precise heating and cooling, slow speed stirring and circulating facilitates the release of volatiles. By increasing the surface area of the chocolate over the heated sidewalls, in combination with air circulation within the chamber and over the chocolate surface, volatiles are released and flavors develop. The sheer stress device helps the chocolate liquor by releasing available cocoa butter from the surface of chocolate particles. In addition any zest flavors can be introduced through the aromatizer and quickly picked up by the cocoa butter.

Tempering

Tempering is the final mechanized process in our Chocolate Laboratory. Another Italian manufacturer steps up to the plate. Aloha to Gami. Gami provides us this 25kg Constant Tempering and Dispensing Machine.

Tempering involves creating a crystalline structure or polymorph of cocoa butter molecules. With six crystal structures, each varying in characteristics and forming in precise temperature windows, we strive for crystal 'V'. This best serves the chocolate for the bar moulding process and your consumption. Crystal 'V' provides for a good shiny surface finish to the bar, a crisp snap, a good mouth feel and an easy to package bar.