• Chocolate consists of the basic ingredients cacao mass, cacao butter, sugar, and milk powder.
  • The milk powder is supplied in enormous bags, so called Bigpacks. Each bag weighs 750 kilos, as much as a cow.
  • The ingredients are weighed and mixed in the chocolate production.
  • Rolling mills crush the chocolate mass. Thereby, the sugar crystals are broken.
  • A powdery mass results from this, which is transported to the conche on a conveyor belt.
  • The chocolate gets stirred (conched) in the conche for several hours.
  • The temperature in the conche is 60 degrees. After conching, the chocolate is done.
  • In order for the chocolate to become a real advent calendar, we need a form, basically the insides of a calendar. A machine pushes in the plastic forms, into which the chocolate is later poured and puts them onto a conveyor belt.
  • In technical jargon, these forms are called blisters.
  • The forms go through 24 little nozzles.
  • Each one of the 24 forms is filled with about three grams of chocolate.
  • So that the chocolate does not get stuck in the pathways, it was given a defined pouring temperature. We also call that being tempered.
  • In order for as many calendars as possible to be made in as little time as possible, there is a trick.
  • The plastic forms, running side by side, pass the nozzles four at a time. There is an infinite line behind each of them.
  • The chocolate goes through a huge cooling tunnel for about 20 minutes.
  • By the time it comes out at the other end of the tunnel, it is solid.
  • The forms that are still lying next to one another are automatically put on a conveyer belt and brought to the packaging facility.
  • The plastic inserts filled with chocolate are now pushed into the calendar. A machine glues the flaps, so that the plastic forms will not fall out.
  • The calendar is wrapped in foil for protection.
  • The finished advent calendars are packed into boxes. Closing the lid and they are done!
  • The advent calendar can now be sent all around the world. Rübezahl sells more than 30 million advent calendars each year.