La Fascinante Producción de Nutella: Un Viaje desde la Avellana hasta el Frasco

Each year, over 13 tons of hazelnuts, 700 tons of cocoa, and approximately 500 tons of powdered milk are utilized to produce Nutella, a popular chocolate cream. The production process involves massive presses that compress cocoa paste into discs weighing up to 7 kg. The Nutella factory reveals the intricate process behind this beloved food item.

Nutella was originally created in the 1940s as an alternative to chocolate due to cocoa shortages during World War II. An Italian pastry chef, inspired by the local abundance of hazelnuts in the Piedmont region of northern Italy, developed a mixture of roasted hazelnuts and cocoa. This innovative creation was first presented in bar form in 1946 and quickly gained worldwide popularity, with over 360,000 tons sold annually today.

A significant portion of the hazelnuts used in Nutella comes from Turkey, particularly from the Black Sea regions known for high-quality hazelnut production. Specialized harvesters are employed to collect the hazelnuts when they reach maturity, utilizing a vacuum system to ensure thorough collection and preserve the integrity of the nuts.

After harvesting, the hazelnuts are transported to a container attached to the harvester and sorted by color, weight, and size. They undergo a cleaning process to remove their shells and impurities, followed by a manual selection to ensure only the highest quality nuts are sent to the factory. A quality control inspector uses a special guillotine to cut a sample in half, ensuring the nuts meet quality standards before processing.

In the Nutella factory, around 1,300 tons of hazelnuts are processed annually. The hazelnuts are first peeled to separate the shells from the kernels, then roasted in a forced convection oven at a constant temperature of 105 degrees Celsius. This controlled roasting process ensures uniformity and quality in the final product.

The hazelnuts used in Nutella are roasted to perfection, achieving a distinctive aroma reminiscent of exquisite dried fruits. Following roasting, they undergo industrial milling, transforming them into a fine powder that forms a creamy paste, essential for the product's characteristic texture. Notably, Nutella factories utilize approximately 25% of the global hazelnut production, with each jar containing an average of 50 hazelnuts, contributing to its unique flavor.

Cocoa, another fundamental ingredient in Nutella, is sourced from Côte d'Ivoire, where workers labor under extreme temperatures to harvest the cocoa pods. This manual process is meticulous, ensuring the mature fruit is not damaged. The cocoa beans are carefully extracted, spread out to dry under the tropical sun for about 10 days, and then packaged in sacks for shipment to the Nutella factory.

Upon arrival at the Nutella factory, the cocoa beans are roasted in ovens, a process that releases internal moisture and develops the aromatic and flavor compounds characteristic of chocolate. Given that cocoa beans contain up to 50% cocoa butter, they must be roasted to convert it into a liquid form. This cocoa butter is then removed using large presses, yielding pure cocoa discs weighing 7 kg each, which are further processed into cocoa powder, a key ingredient in Nutella.

Nutella production requires around 700 tons of cocoa and 500 tons of powdered milk annually. While cocoa butter is not used in Nutella, it is a valuable byproduct utilized in various chocolate products manufactured at the factory.

Palm oil, essential for achieving Nutella's ideal consistency, is produced in Malaysia from high-quality palm fruits. The cultivation of palm oil is noted for its high productivity and efficiency in oil yield per hectare, making it a cost-effective option compared to other vegetable oils. The fruits undergo pressing and refining processes to produce high-quality oil free from impurities, ensuring it does not alter Nutella's flavor.

Once all ingredients are in the factory and quality control tests are completed, the mixing process begins. It starts by combining hazelnuts with palm oil to create a rich, creamy base. Cocoa powder is then carefully added to enhance the chocolate flavor, followed by the incorporation of sugar, completing the basic Nutella mixture.

The essence of Nutella is derived from hazelnuts, cocoa, and oil. To maintain consistency and prevent solidification, skimmed milk powder is added as a stabilizer. The aroma is enhanced with vanilla extract, which boosts the cocoa flavor and adds a distinctive touch. All these ingredients are meticulously combined in a large tank to achieve a homogeneous integration of flavors and textures.

After the initial mixing, the resulting paste undergoes refining to ensure a smooth and creamy texture. This refining process is crucial for creating the exquisite consistency of Nutella, guaranteeing an unparalleled sensory experience with each spoonful.

Once all ingredients are mixed, the final blend goes through a quality control process to ensure it meets the standards of the original Nutella that consumers expect. This step is vital for maintaining product integrity.

Simultaneously, glass jars for packaging are produced using recycled glass. Enormous furnaces create tons of containers daily, with molten glass being shot into molds that shape the jars while ensuring there are no imperfections. The newly formed jars are then subjected to flames to eliminate any small holes before being rapidly cooled and stored for two days at 30 degrees Celsius.

Once the Nutella mixture is ready, it is transferred to a dosing machine that fills each jar with the exact amount of Nutella. The dosing pump, made from food-grade aluminum, injects the mixture at high pressure. Each filled jar is automatically capped, with a hermetic seal applied using glue around the rim to ensure freshness.

The filled jars then proceed to an automated labeling process, ensuring each jar is marked with the product's distinctive label. After labeling, the jars are packed into boxes, which are then distributed wholesale from the factory to businesses and stores for public availability.

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