The process, so far, is that employed for all kinds of cocoa and chocolate, the nuts, as before stated, being the basis of all: the variety depends on subsequent admixture, the best kinds being, of course, the purest and most delicately flavoured. Up to this point, we have the cocoa in its native condition, merely altered in form; but now it has come to the stage of sophistication.
A given portion of the cocoa liquid is poured into a pan, and weighed with other ingredients, which consist, in the main, of arrow-root, sago, and refined sugar—the latter reduced to an impalpable powder—besides the flavouring substances. The quality depends entirely on the proportions of these ingredients, and on their unexceptionable character. The unpractised eye may not detect any difference between a cake of genuine chocolate, and another two-thirds composed of red earth and roasted beans. We have seen documentary evidence laid before the Board of Excise, shewing that a certain manufacturer of cocoa used every week a ton of a species of umber for purposes of adulteration; and recent investigations have shewn, that such practices are only too frequent. No wonder that muddy and insoluble grounds are found at the bottom of breakfast-cups! No one pretends that manufactured chocolate or cocoa is unmixed; but it is a satisfaction to know, that the admixture is not only of good quality, but nutritious.
The necessary quantities having been weighed and duly stirred together with a large wooden spoon, are poured into a mould nearly three feet in length, about nine inches wide, and from three to four inches deep; and in from four to five hours the mass is sufficiently solid to bear removal, when it is turned out as a large cake or block, which might very well pass for a huge sun-baked brick from Nineveh. In this way any number of cakes may be produced, those made on one day being finally worked up on the next, by which time they have become somewhat more hardened.
In this final process, the cakes are laid one at a time in what resembles a chaff-cutting machine, except, instead of the ordinary broad knife wielded by grooms, that a wheel, armed with four sharp blades, whirls round at the open end. The block of cocoa, held by machinery, advances with a slow continuous motion, until it touches the blades on the wheel, when immediately a cloud of most delicate slices or shavings is thrown off, as rapidly as sparks from a knife-grinder's wheel. Cake after cake is thus comminuted, at the rate of a ton per day from a single machine. The shavings are collected as fast as they fall, and passed through a sieve, which reduces them to that coarse powdery form so well known to all consumers of soluble chocolate. It is then put into barrels, and despatched without delay to the packing-room by means of a railway.
That there is something in a name, is as true of cocoa and chocolate as of other things, and the difference of name implies, in most instances, a difference of manufacture. Hence there is a variety of processes going on within the building, the results of which are shewn in 'Cocoa Paste,' 'Rock Cocoa,' 'Eating Vanilla Chocolate,' 'Penny Chocolate,' 'French Bonbons,' 'Flaked Cocoa,' 'Homœopathic,' &c. So numerous are the sorts, that a purchaser is as much puzzled in his choice as an untravelled Cockney with a Parisian bill of fare. The making of the flaked cocoa is peculiarly interesting, and is, we were informed, peculiar to this establishment. To see how the amorphous mass comes from the mill in long curling ribbons, uniform in thickness and texture, is a sight that provokes astonishment, as much by the rapidity of the operation as by the ease with which it appears to be accomplished, but which has only been arrived at by a persevering circumvention of vexatious difficulties.
But however interesting the results, one grows tired at length of the noise and clatter of machinery; and it was with a feeling of relief that we mounted to the packing-room, where all was so light, cheerful, and orderly, as to prove that the good management everywhere perceptible had here put on its pleasantest expression. The most perfect cleanliness prevails. The half-score or more of girls, who work under the superintendence of a forewoman, are all dressed in clean Holland pinafores—an industrial uniform. All were packing as busily as hands could work: one weighed the cocoa; a second placed the paper in the mould, and turned the cocoa into it; a third compressed the contents by means of a machine-moved plunger; while a fourth released the packet, pasted down the loose ends, and laid it aside. This party, by their combined operations, weigh and pack a hundredweight per hour. Some were wrapping the 'homœopathic' in bright envelopes of tinfoil; others boxing the 'bonbons;' others coating the 'roll' with its distinctive paper; while others helped the forewoman to count and sort the orders—all performing their duties with that celerity which can only be attained by long practice. Finally, the respective orders are packed away in boxes of various sizes, from fourteen pounds to a hundredweight; and to give full effect to the system of cleanliness, none but new boxes are used, so that not the slightest ground is afforded for even a suspicion of uncleanliness.
In these professedly enlightened days, commercial progress cannot well be considered apart from moral progress; we want to know not only how work is done, but who and what they are who do it. Are they benefited by the 'mighty developments of commercial enterprise?' We may therefore very properly say a few words respecting the employés in the cocoa-factory. No girl is employed who is not of known good moral character. Some at first are found to be good rather passively than actively, but they have example daily before their eyes, and a spirit of emulation gradually develops their better qualities. Their hours of work are from nine A.M. to seven P.M., with an hour off for dinner—tea is supplied to them on the premises. Their earnings range from 5s. to 9s. per week. Once a week, during the summer season, they have a half-holiday for a little excursion to the country, and twice a week they leave work for evening school an hour before the usual time. With few exceptions, these elevating influences are found to tell favourably on their conduct; and besides the direct benefit to themselves, we may be permitted to take into the account, the benefit to the homes and families to which the girls belong. Accustomed to order and cleanliness through the day, they can hardly fail to carry these virtues with them to their dwellings. The men employed exhibit the good effects of proper management not less than the girls. Some have acquired a steady habit of saving, and with nearly all, from the mere force of example, teetotalism is the rule. Instances of misconduct are rare, and when reproof is called for, it is administered by an appeal to the better feelings in preference to angry demonstration. Factories conducted on such a system must be at once schools of morality and industry.
There is one more point which we feel bound to notice in closing our article. While going about the premises, we were asked to look to the top of the tall engine-chimney, where, to our surprise, none but the faintest whiff of vapour was visible. 'There is no need,' said our conductor, 'that any chimney in Birmingham should smoke more than that. I have told the people so over and over again, but to little use, for they will persist in wasting fuel, and blackening the atmosphere. This is Beddington's patent, and you shall see the effect of it.' The fireman was then told to shut off the apparatus from the flue; immediately a dense black smoke poured from the chimney-top, and when at the murkiest, the order was given: 'Now turn on again.' In five seconds, the smoke had vanished, and the almost imperceptible vapour alone remained. Thus, of the coal consumed daily, not a particle is wasted, and a considerable portion of the atmosphere is saved from deterioration. So perfect an example of what can be done towards the abatement of a nuisance, made us wish to be autocrat for a week—our reign should be signalised by the extinction of smoke!