With the opening of its new store on the Sunshine Coast, Noosa Chocolate Factory brings its freshly made chocolates from its factory to a discerning public.
There is a warm, nostalgic feeling associated with a chocolate factory. Romanticised by books and films as “magical”, a chocolate factory brings out the inner child for those who crave freshly made chocolates. In the heart of Noosaville, Noosa Chocolate Factory brings the art of chocolate-making back to its roots with handcrafted techniques and innovation.
With a goal to create flavourful chocolates using only fine ingredients, Noosa Chocolate Factory was born in 2009 by founders Pam and Gordon Thomson. What started in a small kitchen to create handmade batches of chocolate flourished into a large-scale factory with more than 65 dedicated team members carrying on the tradition for its specialty in panned, slab and moulded chocolates.
Under the leadership of brand ambassador Andrew Thomson, the business has been revitalised and is now positioning itself for both regional expansion and international recognition. Opening its sixth store in the Sunshine Coast, Thomson explained that the shop is no ordinary outlet, but a “concept” driven one.
“We wanted to operate like a Build-A-Bear business,” said Thomson.
For an immersive and interactive experience for customers, Thomson outlined the vision for the store to deliver customised chocolate products on the spot. The model allows customers to personalise hampers and hot chocolate drinks. They can select from jars of flavoured chocolate to create customised hot drinks and design hampers suited to their tastes or dietary preferences.
Fresher ingredients and chocolates
A central principle of the business is freshness. Thomson highlighted that a fresh product starts with the ingredient itself. The business sources its fruit and nuts from Australian growers where possible – strawberries from Bundaberg, macadamias from the Sunshine Coast hinterland, peanuts from Kingaroy, pecans from Boyne River, QLD, Almonds from South Australia.
This close relationship with suppliers not only supports local growers but also guarantees ingredient traceability and a reduced environmental footprint.
“Everything we bring in is Australian sourced,” said Thomson. “All of our ingredients from macadamias, strawberries, raspberries and mango pieces are from Australia.”
The Noosaville factory operates largely on solar power, drawing on grid energy only at night. Unlike many large-scale chocolate producers, whose products can sit in storage for a year or more before reaching consumers, Noosa Chocolate Factory operates on a much shorter cycle. It has a short stock turn period of 45 days, meaning customers are consistently purchasing fresher chocolate.
“The chocolates you have could be 12 months old by the time you purchase it,” said Thomson. “Any Noosa chocolate you eat is typically less than two months old.”
He explained that the company’s approach to manufacturing and storage systems is what allows its chocolate to retain premium quality.
Manufacturing to perfection
Thomson believes the disciplines of process management, precision and quality in manufacturing are universal.
“In my view, manufacturing is manufacturing,” Thomson said. “There’s not a lot of difference between manufacturing machines and chocolate.”
He emphasised the importance of Noosa Chocolate Factory’s workflows and systems. Being in the business since high school, he highlighted the company’s approach through its modern production systems, commitment to traditional craftsmanship, and its quality ingredients, which are key to its success, resulting in a high return rate from customer.
“We have 90 per cent returning customers across our business and 92 per cent in Brisbane,” Thomson added.
For each product, multiple pairs of “eyes” are involved in checking every stage, from chocolate making to packaging, labelling, and delivery. Staff involvement ensures consistent quality, safety and hygiene across operations.
So, what does the development process of Noosa chocolates involve?
Tempering, coating, marbling
Chocolate making is a blend of artistry and science. For Noosa Chocolate Factory’s products, having an effective tempering process is required.
“Chocolate manufacturing is all about time and temperature,” said Thomson.
Chocolate tempering is a temperature-sensitive process where consistent heating and cooling is required to achieve the “glossy” appeal and “snappy” break.
With tanks that sit at 46°C, the chocolate requires constant monitoring for temperature. Consistent monitoring is important especially when raw ingredients are added in for mixing where the temperature must be lowered. If done correctly, oils from the cocoa butter, an emulsifier, will not escape – preventing the forming of undesirable “white haze” in chocolates. After tempering, chocolates destined for Noosa Chocolate Factory’s packaged products are coated.
A chocolate coating is the outer layer of chocolates that is hardened. While there are multiple application methods, the chocolate company utilises a panning machine for the coating process. The panning machine slowly rotates raw ingredients in a large dome pan. Layers of chocolate are dripped on the pan with a “dripper”, creating even coatings.
“The centrifugal force coats everything exactly the same,” added Thomson.
This method allows nuts, fruit and other inclusions to be coated evenly. Finishing touches include dustings of strawberry or decorative marbling, where hazelnut paste is drizzled over chocolate-coated nuts as they slowly rotate, creating swirled patterns for aesthetic appeal.
Overcoming temperature challenges
This year alone, Noosa Chocolate Factory has processed around 120 tonnes of products. With thousands of products moving between the factory and shops, maintaining consistent quality is not without its challenges. Thomson pointed out that the temperature and humidity in Queensland are constant operational hurdles.
“Summer is a big problem,” he said. “If you try to deliver to stores on a 40°C day, it’s a bit of a nightmare.”
With the company’s focus on freshness, the Noosaville facility is carefully sealed and fitted with heat curtains. To keep the ambient temperature of the factory at 18°C, the company works with external contractors on call to manage air conditioning and refrigeration systems. These measures are essential in an environment where excess heat or moisture can damage chocolate’s structure and appearance.
He added that no product leaves the factory from start to finish until it is ready to sell. From the factory to its retail stores, deliveries are made three times a week using temperature-controlled vehicles, ensuring chocolate maintains its texture, flavour and quality.
“It is a real challenge to keep humidity down to 60 per cent or below,” Thomson added. “The operational challenge for us is making sure the factory is a sealed environment, minimising people coming in and out.”
Another way the company wants to manage temperature-related challenges in its operations include expansion into Sydney and Melbourne where it would likely require localised manufacturing to maintain freshness and consistency.
Root rots
The business also faces broader industry challenges, particularly in the global cocoa market. Cocoa plants are grown in equatorial regions such as West Africa and Ghana.
“A lot of plants are dying due to root rot,” said Thomson.
“Root rot” is a plant disease where roots deteriorate due to lack of oxygen. Cocoa plants, according to Thomson, are dying from this crop disease caused by climate change and soil conditions, increasing supply shortages and price spikes. These issues have placed pressure on chocolate manufacturers worldwide.
Despite this, Thomson remains optimistic.
“The upside is that we’re starting to see a lot of manufacturers seeking alternatives,” he said.
To stay afloat during predicaments, and to safeguard against volatility, the company has established supply contracts that guarantee volumes for each year, supporting more accurate forecasting and stability.
What’s in store
Looking ahead, Noosa Chocolate Factory is planning to expand its business with new stores scheduled to open in Chermside and on the Gold Coast, with further growth mapped across Southeast Queensland in the lead-up to the 2032 Olympics. The company’s vision is to ensure its chocolate is accessible to every tourist visiting the region during the games.
With its focus to provide more handmade and “honest” chocolate in Queensland, Thomson plans to raise awareness around the brand.
“Given the brand’s quality and loyal following, it’s really just been the case of getting the brand out there,” he said.
Building its reputation on sourcing locally, manufacturing with care, and delivering chocolate at its freshest, Noosa Chocolate Factory remains committed to extend its family legacy through craftsmanship.