From tree to factory: Everything You Need to Know About the Journey of Your Favourite Chocolate

Chocolate is one of the ultimate comfort foods. Present in our homes throughout the year as an indulgence. Yet behind a simple square of chocolate lies a long and complex supply chain that starts far away.

Every year, approximately 110,000 tons of cocoa beans arrive at Italian ports destined for the national confectionery industry—a steady flow connecting Italy to the world’s main cocoa-producing regions.

Origin and Harvest of Cocoa Beans

Almost all imported beans come from West Africa, particularly Ghana and Ivory Coast, with smaller shares from Nigeria and Ecuador. The plantations are either owned by confectionery companies, international traders, or local cooperatives that aggregate the work of local producers.

Cocoa pods, large and elongated, are harvested manually and opened directly on-site. The seeds inside—the beans—are left to dry for several days before being packed in 60-kilogram jute sacks, ready for maritime transport.

Transport: A Tradition That Endures

For more than twenty-five years, cocoa bean transport methods have remained largely unchanged. Jute remains the preferred packaging material because it allows natural ventilation, essential to protect the beans from moisture, one of cocoa’s main enemies.

With their woody consistency, the beans are particularly sensitive to mould and rot. Containers are fitted with cardboard dunnage, to protect from condensation due to temperature fluctuations between loading and unloading.

Over time, shipping companies have proposed alternative solutions to reduce moisture risks, but the sector continues to favour the traditional approach, supported by both the jute lobby and cocoa operators.

    Arrival in Italy and Quality Control

    Imports are mainly managed by traders, who supply batches to confectionery companies. The approximately 4,500 containers destined for the Italian market arrive primarily between December and May, each carrying around 25 tons.

    Since the cargo is not palletized, unloading is done manually, and containers undergo fumigation to prevent infestation. Introducing a single contaminated batch into large warehouses could cause significant damage, which is why quality checks are extremely stringent.

    From Port to Factory

    From Italian ports—primarily Genoa, followed by La Spezia and Vado Ligure—cocoa beans continue their journey by road to intermediate warehouses. The cargo is then opened and cleaned using hopper-like machinery that removes impurities such as stones, leaves, twine or metal fragments.

    Depending on the needs of individual recipients, the beans can then be:

    • transferred into one-ton bags;
    • palletized
    • or transported directly in tanker trucks to production facilities.

    From this point, the transformation begins that will ultimately produce the finished product: chocolate.