Manufacture
Aero bars are manufactured in nut-free facilities in England and Canada. However, in Australia where they are manufactured, they do have traces of nuts. They are made in a number of discrete stages beginning with deposition of unaerated shell chocolate into the bar moulds. A frozen cone shaped to fit into the bar is then pushed down to spread the liquid chocolate into the entire mould and set it. The aerated chocolate is then deposited into the centre and the moulds are shaken to distribute the chocolate evenly in the cavity. This is then chilled to set the bubbly chocolate in place before a final backing off deposit is created to give the back. The moulds are then shaken again to get a flat even back. The moulds are specially shaped to ensure that no meniscus is formed on the bottom, which can give the chocolate a scuffed appearance and also cause issues with the machines when they break off and build up. The bars are then chilled again for a longer period. This helps to make the chocolate contract for easier demoulding. The moulds are then tipped over and hammered to demould the bars, which then go to the packaging section.
Read more about this topic: Aero (chocolate)
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