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 COCOA
MANUAL
 COCOA
MANUAL

A Source Book For

Sustainable Cocoa Production
2010

Cocoa Research Institute of Ghana

Cocoa Manual

Copyright © 2010 Cocoa Research Institute of Ghana

All rights reserved. No part of this book may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording or
otherwise, without a prior permission of the publishers. Any person who does any unauthorized
act in relation to this book will be liable to criminal prosecution and claims for damages.

An original Cocoa Research Institute of Ghana book edition, published for the first time anywhere.

Cocoa Research Institute of Ghana

Private Mail Bag,
Kotoka International Airport,
Accra-Ghana.
Telephone: +233-(0)-27-760-990-0
+233-(0)-20-201-618-6
+233-(0)-54-433-109-0
+233-(0)-54-433-109-1
+233-(0)-54-433-109-2

email: crig@crig.org/crigmailorg@yahoo.com
website: www.crig.org
Kwabena Opoku-Ameyaw

Francis Baah

Esther Gyedu-Akoto

Vincent Anchirinah

Henry K. Dzahini-Obiatey

Anthony Richmond Cudjoe

Solomon Aquaye

Stephen Yaw Opoku

A Source Book For

Sustainable Cocoa Production
2010

Cocoa Research Institute of Ghana

Cocoa Research Institute of Ghana
16
G
enerally, there are two crop seasons of cocoa within
a year, the main crop in October-March and the
mid-crop in May-August. During the harvesting
season, harvesting is done every 3-4 weeks when the pods
are ripe and yellow in colour. It is done by cutting the stalk of
the fruit with a knife as close as possible to the pod in order
not to cause injury to the tree. Pods within reach are
harvested with a cutlass whilst those on branches higher up
in the canopy are harvested with sickle-shaped knives on
long poles (Fig 16.1). Extreme care should be taken during
harvesting to ensure that the cushions carrying the flowers
and fruits are not damaged. During harvesting, diseased
pods and those damaged by rodents, are also removed. The
healthy pods are then carried to a central breaking point (Fig
16.2a). At the farmer level the central breaking point is
normally within the farm. At the end of harvesting, pod
breaking operations begin (Fig 16.2b and 16.3)
a b
Fig 16.1: Harvesting and picking of cocoa pods
Fig 16.2a: Heaped cocoa pods at a central Fig 16.2b: Heaped cocoa pods at a central
breaking point (fermentary-CRIG) breaking point (on the farm)
Pod breaking and fermentation
Pods can be broken using either a wooden club or breaking
kife (Fig 16.3). However, wooden clubs are recommended
as cutlasses may injure the beans inside the pod. The beans
are scooped out of the broken pod by hand whilst the husk
and placenta are discarded. Pod breaking should be done
within 2-3 days after harvest. Germinated, black or diseased
beans or pieces of husk and placenta fragments must be
48
Cocoa Manual version 1, 2010
HARVESTING AND POST
HARVEST MANAGEMENT
removed from the scooped beans. The beans are embedded
in a sweet, white mucilaginous pulp, which serves as a
substrate for fermentation (Fig 16.4). Fermentation begins
the same day the pods are broken. Raw cocoa has an
astringent and unpleasant flavour and must be processed
after harvest into good-tasting and good-flavour chocolate.
The importance of cocoa fermentation is to develop
chocolate precursors in the bean. The cocoa bean itself does
not undergo fermentation but the pulp surrounding it. The
pulp in an undamaged pod is microbially sterile. However,
it gets contaminated during pod breaking with
microorganisms from the surrounding environment
including pod surfaces, knives and workers' hands. Cocoa
fermentation is a spontaneous process and occurs in two
stages i.e. anaerobic and aerobic . Fermentation is normally
done in six days and it is caused by microbial succession.
Micro-organisms involved in fermentation are yeasts, lactic
acid bacteria and acetobacter.
Fig 16.3a: Breaking of cocoa pods Fig 16.3b: Breaking of cocoa pods
(on the farm) (CRIG)
Fig 16.4: Broken pods showing fresh beans with sugary pulp
Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

Anaerobic phase (stage 1)

This occurs within the first two days when the pulp does not
allow air circulation. Yeast and lactic acid bacteria
fermentations occur in this phase. Yeast fermentation
transforms pulp sugar into alcohol resulting in an increase in
temperature. The increase in temperature favours the
growth of lactic acid bacteria which produce lactic acid. The a b
pulp then breaks down, drains away and air penetrates the
beans. Fig 16.6: Covered heap

Aerobic phase (stage 2)
This occurs from day three onwards and aeration allows
strong growth of acetobacter which transform alcohol to
acetic acid. Temperature then increases up to 50o C. Acetic
acid penetrates into the bean causing the formation of
chocolate flavour precursors. At the end of fermentation the
temperature reduces causing the growth of putrefaction
bacteria and prolonged fermentation will result in the
development of hammy, off-flavours typical of over-
fermented cocoa.
Basket fermentation
This method like the heap fermentation is very simple and is
used on small-holder farms. There is no definite size for the
baskets which usually hold about 10-150 kg wet beans. The
baskets are first lined with fresh plantain leaves before
placing the wet beans in them (Fig 16.7). They are then
covered with more leaves which are held in place with small
logs (Fig 16.8). The sweatings drain from the sides and the
bottom of the baskets and air also passes through the sides
and the bottom. The fermenting mass is turned by
transferring the beans from one basket to the other.

Methods of fermentation

There are four methods of fermentation. They are the heap,

basket, box and tray methods but the most commonly used
are the heap, basket and box methods.

Heap fermentation

This method is the simplest and normally used on small

farms. It is done by spreading out fresh plantain leaves in a
circle on the ground and heaping fresh cocoa beans on them
(Fig 16.5). The mat of leaves should be punctured with a
pointed stick to create drainage holes in the mat. This allows
easy pulp drainage. The heap of beans is then covered with
more leaves and held in place by small logs (Fig 16.6 a,b).
Covering protects the fermenting beans from surface drying, Fig 16.7: Fresh beans heaped in basket
mould growth and helps to maintain the heat generated
within the heap. The size of the fermenting heap varies from
300kg -500kg.

a b
Fig 16.5: Fresh beans heaped on plantain leaves

Fig 16.8: Covered beans in a basket

49
Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

Box fermentation quality of fermented beans. Chocolates produced from

This is done in large, perforated boxes made of local
hardwood. The holes at the bottom of the boxes allow the
sweating from the pulp to drain down and air to enter.
Therefore, they are always raised above the ground level
and placed over a drain. The boxes are normally raised in
tiers so that turning is done by moving beans from a higher
box into a lower one ( Fig 16.9). The size of the box should
be large enough to take 1000 kg wet beans (1.2 x 1.2 x 1.2
m). The beans are placed in the top box and covered with a
few layers of plantain leaves. This method reduces labour in
turning beans.
heap- and tray- fermented cocoa beans have shown
differences in their key odorants.
Advantages of tray fermentation over the heap method:
. More homogenous fermentation
. Better aeration – increased acetic acid concentration
and lower levels of moulds
. Reduced loss of cocoa beans
. Better quality of the beans – higher price
. Less labor-intensive

Fig 16.9: Wooden boxes for fermentation Fig 16.10: Fresh beans in wooden trays

To facilitate uniform fermentation in the above methods,

beans are turned after 48 hours with a second turning done
after another 48 hours. Fermentation is allowed to continue
for another 48 hours or until the temperature begins to fall
and the odour of ammonia develops, when the fermentation
can be considered to have been completed. Fermentation
usually lasts between 5-7 days but the optimal duration is 6
days.

Tray fermentation

This is done by placing about 90 kg wet beans in wooden

trays of 1.2 x 0.9 x 0.1 m size. The trays have battens or mats
fixed at the bottom. About 6-12 of such trays are stacked one Fig 16.11: Covered beans in trays
over the other with an empty tray kept at the bottom to allow
for aeration and drainage of sweating (Fig 16.10). Beans in
the top most tray are covered with banana leaves (Fig 16.11).
Factors affecting fermentation
After 24 hours of setting the stacked trays, they are covered
with gunny sacks to conserve the heat that develops. There is These include the ripeness of pods, pod storage before
no need for turning and fermentation will be completed in 3- breaking, quantity of beans and pulp during fermentation,
5 days. type of cocoa, duration of fermentation, turning of the
fermenting mass, seasonal effects/climate and diseases that
This method allows aeration of the fermenting mass without affect pods.
having to turn and ensures better and more even
fermentation. Efforts are being made to encourage cocoa Over-ripening of pods can cause germination of beans.
farmers in Ghana to adopt the tray system to improve the Harvesting immature, diseased and damaged pods

50
Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

produces poor quality beans for fermentation. The time

between harvesting and pod breaking affects fermentation
and ultimate bean quality. Storing the pods for more than six
days causes the pulp surrounding the beans to dry up. Pulp
and beans can contain more water during the wet seasons
and too much pulp affects aeration of the fermenting mass
and bean acidity. Turning aerates the fermenting mass to
avoid uneven temperature and oxygen distribution. a b
Fig 16.13: Drying of cocoa beans
Drying of cocoa

At the end of fermentation, drying begins. It is done the same

day fermentation ends. Drying is the reduction of moisture
in fermented beans from about 55% to 7%. After
fermentation, the beans are carried to the drying area and
spread thinly on raised mats (Fig 16.12 a,b). These mats
ensure uniform drying; drying should not be done on the
bare floor or asphalt roads. The beans must be stirred a b
frequently to pick out germinated, flat and black beans, Fig 16.14: Covering of cocoa beans to protect them
placenta and any foreign materials. There are two methods from the rains
of drying – sun drying and mechanical drying. Mechanical
drying is generally not recommended because it is Storage of cocoa beans
expensive, there is the danger of smoke contamination and
After drying the cocoa beans are cleaned of any extraneous
high acid retention in beans. Sun drying is best for good
matter and packed into clean, strong jute bags (Fig 16.13).
quality beans and this is because during sun (slow) drying
The great care to achieve optimum quality from harvest to
acetic acid, which is volatile, evaporates through the shells.
drying must continue during storage. The dry beans are
Lactic acid, which is non-volatile, is partly transported by
stored in a well ventilated storage room with relatively low
water from the bean to the shell. There is also the oxidation
humidity to avoid re-humidification of the beans. The bags
(browning) of polyphenols resulting in the reduction of
of cocoa must be packed on wooden pallets to avoid rodents
astringency and bitterness. More flavour forming reactions
and insect pests. Storage must also not be in close proximity
also occur during sun drying. The beans are covered every
to any strong odours. Fire should not be made in the room
evening to protect them from possible showers and dew.
where cocoa is stacked. Forced air, fumigation and good
When it rains during the day, the beans must be covered to
sanitary practices all contribute towards optimal storage
protect them from the rains. Uncover the beans early in the
conditions. With a moisture content of 7%, cocoa beans can
morning or after immediately after the rains. The beans are
keep for many years under ideal storage conditions.
dry when they produce a 'cracking' sound after pressing
them lightly in the fist. Do not stop drying until the beans are
well dried. The minimum period of drying is 7 days. Fire
should not be made under or close to the beans during
drying as it will give the beans a bad taste or smell. The fresh
bean to dry bean ratio will be 3:1. Well -fermented and
well- dried beans are brown in colour.

Fig 16.15: Cocoa beans in jute sacks stacked on a wooden pallet

Fig 16.12: Fresh cocoa beans being transported from the farm
to drying area.

51
Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

COCOA BEAN QUALITY

17 AND ITS ESTIMATION

Q uality of cocoa means the overall degree of

excellence of commercial quantities of cocoa beans.
Cocoa quality is determined by four fundamental
areas: purity or wholesomeness, yield of cocoa nib,
uniformity and flavour and functional potential. The highest
quality beans will be uniform through out the lot, possess the
desired flavour and functional potential for the intended use,
have a high level of purity, and provide a yield superior for
the particular grade. These are the key criteria for assessment
by the manufacturer. There is an international standard for
the assessment of cocoa bean quality which defines that
cocoa of merchantable quality must be:
a. Fermented, thoroughly dry, free from smoky beans, free
from abnormal or foreign odours and free from any
evidence of adulteration.
b. Reasonably uniform in size, reasonably free from broken
beans, fragments and pieces of shell and be virtually free
from foreign matter.
Cocoa Inspection
1. Prior to cocoa cargo loading and stuffing:
· Determination of the physical condition of the cocoa and
the packaging
· Determination of individual cocoa package weight by
random sampling.
· Ensuring cocoa storage containers are clean and dry,
ready and fit for intended cargo.
2. During loading and stuffing of cocoa:
· Inspectors count and tally each cargo bag loaded and
check the physical condition.
· After completion of bag stuffing, storage doors are
closed.

There is also the 'Code of Practice' which has been accepted

internationally and covers grade standards, inspection,
sampling, testing, bagging, storage and infestation of cocoa
beans. The worldwide standard for cocoa and its products is
obtained in volume 7 of the Codex Alimentarius. The degree
of fermentation in cocoa is assessed by a cut-test on a
random sample of fermented and dried beans. If the
cotyledon is slaty grey, then the bean is totally unfermented,
and if it is completely or partially purple, then the bean is
under-fermented. Completely brown cotyledon means the
bean is thoroughly fermented.

Cocoa Testing and Inspection

Fig 17.1: Loading of cocoa from warehouse

This is done by the Quality Control Division of the Ghana

Cocoa Board. Trained and professional field staff is located
in key cocoa producing regions in Ghana for testing and
inspection. Cocoa inspection services include:

· Loading and discharge inspection (Fig 17.1)

· Cocoa weight and quantity verification
· Inspection of loading, discharge and storage facilities
· Representative sampling for lab tests (Figs 17.2-17.4)
· Certification of quantity and quality
· Truck inspection
· Cocoa warehousing and stock monitoring
Fig 17.2: Physical assessment of cocoa beans

52
Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

Fig 17.3: Chemical assessment (fat extraction) Fig 17.4: Entomological assessment of nibs

Cocoa cargo is graded on the basis of the count of defective Table 17.2 Cocoa laboratory analysis includes the
beans in the cut test. following:

Table 17.1 Defective beans should not exceed the
following limits:
Grade I cocoa beans
Mouldy beans, maximum
3% by count
Slaty beans, maximum
3% by count
Insect-damaged, germinated or
flat beans, total maximum 3%
by count
Grade 2 cocoa beans
Mouldy beans, maximum
4% by count
Slaty beans, maximum
8% by count
Insect-damaged, germinated
or flat beans, total maximum
6% by count
Physical assessment Entomological assessment
Chemical assessment Essential oils testing
Moisture content Aflatoxin testing
pH of cocoa beans Microbiological analysis
Fat content Pesticide residue testing
Cocoa quality can also be ensured by the farmer at the farm
level through good post harvest practices. The farmer can
assess the different types of defects in cocoa using the
physical means.

Table17.3 Physical assessment of cocoa at the farm level includes the following:

Mouldy/mildewed beans – badly dried beans

These are the worst defects of cocoa, which lead to the reduction in the value of cocoa. However, the defects are easily avoidable.

Description - The bean is mouldy on the inside and when cut or broken, a blanket of mould of
variable colour (from black to white through brown and yellow) will be seen.
- The bean is affected by moulds after the fermentation process.
- The bean will still be considered mouldy even if a small part of it is affected.
- This defect cannot be repaired.

Causes - Inadequate drying of cocoa beans

- Storage of inadequately dried beans in a sack
- Storage of dry cocoa beans in a poorly ventilated room results in the uptake of
moisture by the beans.

Consequences - If the beans are poorly dried or stored in a poorly ventilated room, the mould can
spread quickly to infect the entire pile of cocoa beans.
- One bag of mouldy cocoa beans can reduce the value of a whole truck load.
- The presence of mouldy beans in chocolate production will result in a chocolate
with a bad flavour.

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Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

How to avoid it - Infection by mould can be prevented during drying of the beans.
and test it - The beans must always be thoroughly dry before bagging.
- To test for mouldy beans, the beans must be crushed in the hands and if the
shells do not crack then they are not well-dried.

Insect damaged/moth-eaten beans

Description - The beans are damaged by insects (moths/mites) and their larvae that feed on
them.
- The moth can still be in the bean or left the bean after feeding, it is still
considered as insect damaged.

Causes - Long storage periods of cocoa

- Poorly dried cocoa beans.

Consequences - When the cocoa is stored for long periods, the insects multiply and spread
quickly in the store room.
- Untreated insect infested cocoa beans will also affect cocoa in other countries
when exported

How to avoid it - Ensure that storage rooms are free of insects (moths/mites).
and test it - Fumigation of store rooms with recommended fumigants.

Slaty beans

Description - The bean shows a slaty colour (dark gray) on the inside when cut.

Causes - Under fermentation or no fermentation at all.

- Insufficient fermentation heap size.
- Outside temperature too low (harmattan)

Consequences - Slaty beans give chocolate a bad taste (bitter or musty).

- They also reduce the market value of cocoa.

How to avoid it - Good fermentation practices

and test it · Ferment under shade
· Heap size of at least 300 kg
· Ferment on banana leaves and cover with banana leaves
. Ferment for 6 days

Black beans and beans with high free fatty acid (FFA) content
Description - Black beans have low bean weight and high FFA content.
- FFA cannot be seen with the naked eye but can be determined by chemical
tests.
Causes - Diseases such as black pod and brown rot (pourriture brune).
- Pods that have been left on trees for a long time before harvesting.
- Improper storage or long storage of cocoa beans can also cause an increase in
FFA.
Consequences - Reduction in the market value of cocoa.
How to avoid it - Harvest pods regularly.
and test it - Remove diseased pods from healthy ones.
- Avoid long storage of cocoa.

54
Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

Germinated beans

Description - Germinated /sprouted beans have a small point/hole at one end of the bean,

Causes - Over-ripening or leaving pods on the tree for a long time before harvesting
- Leaving an opened pod for a day or two can also cause germination of beans.

Consequences - Facilitates the entry of moulds through the ripped hull of the bean.
How to avoid it - Harvest regularly
and test it - Ferment beans immediately after pod breaking.
- Do not mix sprouted beans with other beans to prevent the spread of moulds

Chipped beans
Description - Beans with injury

Causes - Breaking of pods with cutlass or sharp object

Consequences - Facilitates the entry of moulds through the wounded area

How to avoid it - Breaking of pods with wooden clubs

and test it - Do not mix injured beans with other beans to prevent the spread of moulds

Purple beans
Causes - Harvesting of unripe or green pods
- Under fermentation
Consequences - Bitter chocolate
- Reduction in market value
How to avoid it - Harvesting of mature or ripe pods
and test it - Fermentation for 6 days

Brown beans, black spots

Causes - Over-fermentation

Consequences - Taste of rot

- Reduction in market value

How to avoid it - Fermentation for 6 days

and test it

Smoked beans

Causes - Drying or storage of beans in contact with smoke

Consequences - Taste of smoke

How to avoid it - Avoid bean contact with smoke from the fireplace.
and test it

55
Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

Bean debris and foreign matter

Description - Small pieces of broken beans mixed with good beans
- Foreign matter include:
- Small stones
- Pieces of pod husk
- Pieces of placenta
- Pieces of metal
Causes - unsorted cocoa or sorting not well- done
- place of drying not clean
- farmer cheating the buyer by adding pieces of stones and metals to the bag of
cocoa to increase the weight

Consequences - Reduction in the market value of cocoa.

- Gives extra work to the exporter by sorting before marketing.

How to avoid it - Ensuring proper bean sorting

and test it - Keep areas of drying clean, use raised mats.

Low graining and flat beans

Description - Low graining is due to small bean size
- Flat beans have cotyledons which are completely atrophied due to
malnourishment from the tree.
Causes - The size of the tree is related to the development of pods on the tree.
- Lack of water and nutrients or disease infection affect the size of beans and
number of pods on a tree.

Consequences - Large beans have more cocoa butter and manufacturers prefer them to small
beans.
- Reduction in the market value of cocoa.
How to avoid it - Good agronomic practices
and test it . Mulching
. Correct spacing
. Spraying against diseases.

Well fermented cocoa beans Unfermented cocoa beans

Fig 17.5: Cross section of fermented and unfermented

cocoa beans

56
Cocoa Research Institute of Ghana
19
Uses of cocoa
Cocoa is grown mainly because of the beans and the three
products from the beans are chocolate and its products,
cocoa butter and cocoa powder.
Chocolate and its production
Chocolate is a worldwide passion and a famed mood-
booster, which fulfils consumer cravings. Hundreds of
chocolate and chocolate products are made in the US and
for Valentine's Day alone, over $1 billion worth of
chocolate is purchased. In 2001 chocolate lovers in the UK
alone spent over £4 billion ($7.5 billion) on well over half a
million tonnes of chocolate products including biscuits, etc.
In the same year consumers in the U.S. spent more than $10
billion (£4½ billion) on 1.3 billion kilogram of chocolate
alone (not including coated biscuits, etc), representing
about half of the world's entire chocolate production.
The world production of cocoa during the period of 2004/05
was 3,327,000 tonnes and that of Ghana for the same period
was 740,000 tonnes. About 95,000 tonnes out of the
740,000 tonnes was processed into semi-finished products
such as cocoa mass and cocoa butter, and chocolate
products in Ghana. Ghana is far from being a major
consumer of chocolate. However the overall chocolate
market has been growing slowly but steadily and this is
because of the growing evidence of the health benefits of
cocoa in fighting against many diseases including cancer,
hypertension, stroke, diabetes, aging and erectile
dysfunction.
Producing chocolate is a time consuming and complicated
process which involves the following:
· The first step involves cleaning and sorting of cocoa
beans.
· Roasting in special equipment at a temperature of
130-150 °C. Waste moisture and acid compounds
evaporate during the roasting process, and the beans
become a uniform shade of deep-brown. Cocoa roasting
is a very important stage of the whole manufacturing
process, and the future quality of the chocolate, and its
smell and taste depend on it just as much as they do on
fermentation. Sometimes different grades of cocoa (or
cocoa of one grade, but grown in different countries) are
mixed for roasting.
· After roasting, the shells are removed and the cocoa
beans are crushed separating the cocoa nibs from the
shells.
· At this stage most manufacturers put the cocoa nibs
through an alkalization process to help develop flavour
68
Cocoa Manual version 1, 2010
USES OF COCOA AND
ITS BY-PRODUCTS
and colour. However, some purists producing the finest
chocolate prefer to rely on the quality of the beans and
natural processing to produce the best colour and
flavour.
· The nibs, which are very high in fat or cocoa butter
(54%), are then finely milled and liquefy in the heat
produced by the milling process to produce cocoa
liquor. Then the cocoa liquor, otherwise known as cocoa
mass, is allowed to cool and solidify. The finer the
ground cocoa nibs, the fuller and finer the chocolate.
· At this point the manufacturing process splits according
to the final product. If the end product is chocolate, some
of the cocoa liquor is reserved; the rest is pressed to
extract the cocoa butter leaving a solid residue called
press cake. Press cake is usually kibbled or finely ground
to produce cocoa powder.
· The retained cocoa liquor or solid cocoa mass is blended
with cocoa butter and other ingredients to produce the
various types of chocolate.
· The blended chocolate then goes through a refining
process involving heavy rollers, which grinds down
and blends the particles to smooth mass and improves
the texture.
· The mass then undergoes a process called “conching”.
A conch is a type of container in which the refined and
blended chocolate mass is continually kneaded and
further smoothed (Fig 19.1); the fractional heat
produced by this process keeps the chocolate liquid.
The length of time given to the conching process
determines the final smoothness and quality of
chocolate (Fig 19.2).
· Because cocoa butter exhibits an unstable
(polymorphous) crystal structure, the chocolate must
go through a very precise cycle of heating and cooling
to encourage the stable crystal formation needed to
produce the desirable properties for good tasty
chocolate. This final process is called Tempering.
· The tempered chocolate can be used as coverture, for
coating biscuits and other products, or poured into
moulds and cooled for sale as the finished product such
as solid chocolate bars. However, every time it is a l l o w e d
to harden and is re-melted it will have to be re- tempered.
· Well tempered chocolate has a good shiny gloss, a
snappy or brittle bite and a smooth tender melt on the
tongue, coating the palate with long lasting flavour and
generally tasting wonderful.
Cocoa Research Institute of Ghana
Fig 19.1: A conch for chocolate production
Cocoa butter
Cocoa butter is the cream-coloured fat extracted from cocoa
beans and used to add flavor, scent, and smoothness to
chocolate, cosmetics, tanning oil, soap, and a multitude of
topical lotions and creams. Cocoa butter is also known as
the ultimate moisturizer, and is used to keep the skin soft and
supple. It is one of the most stable, highly concentrated
natural fats known, and melts at body temperature so that it
is readily absorbed into the skin. Cocoa butter is often
recommended for treatment of skin conditions such as
eczema and dermatitis. When applied topically, it creates a
barrier between sensitive skin and the environment and also
helps retain moisture. In addition, cocoa butter contains
cocoa mass polyphenol (CMP), a substance that inhibits the
production of the immuno globulin IgE which is known to
aggravate symptoms of both dermatitis and asthma.
Pregnant women have long used cocoa butter formulations
to prevent and treat stretch marks, but this pleasant-smelling
substance is added to countless other topical preparations as
well. Lotions and oils containing cocoa butter are often used
in aromatherapy massages to promote feelings of relaxation
and well-being. Recent research indicates that massaging
the skin with cocoa butter may help relieve stress, boost the
immune system, and even prevent cancer. This is its CMP
content. Researchers in Japan reported that CMP inhibits the
growth of cancerous cells and tumors by reducing active
oxygen levels in the body, and concluded that CMP inhibits
the oxidation of low density lipids (LDP) or good cholesterol
and the production of inflammatory cells. There is also some
evidence that the CMP in cocoa butter may also help
prevent heart disease and ease arthritic symptoms.
Cocoa powder
Cocoa powder is essentially used as flavor in biscuits, ice
cream, dairy drinks and cakes. Apart from its use as flavor, it
is also used in the manufacture of coatings for confectionery
or frozen desserts. Cocoa powder is also used by the
beverage industry for the preparation of beverages such as
chocolate milk.
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Cocoa Manual version 1, 2010
Fig 19.2: Chocolate products
By-product utilization
Research on the commercial exploitation of fresh cocoa pod
wastes started in Central America, where cocoa is cultivated
on large accessible plantations. In Ghana, efforts to intensify
research in the field of cocoa by-products were made in
1964 at the Cocoa Research Institute of Ghana (CRIG), Tafo
in collaboration with the Universities and other Research
Institutions. The cocoa fruit is grossly under-utilized
considering that the beans, which are the basic product of
commerce, comprise only about 10% of its weight. Another
10-20% of the weight of the cocoa fruit is lost through the
sugary pulp juice or sweatings during natural fermentation
with the remaining 70-80% as pod husk. The actual amount
of waste generated is difficult to assess due to the diversity in
the characteristics of the planting material. However, it has
been calculated that 1 tonne dry cocoa beans leaves about
400-425 kg of pulp. Therefore, value addition to cocoa
wastes will increase the income-generating capacity of the
cocoa industry. These wastes and other by-products from
cocoa processing are being processed commercially into
useful products such as animal feed, fertilizer, food
products, cosmetics and soap at CRIG. Commercial
processing of these wastes will also provide employment
and income for the rural people.
Products from cocoa pod husk
Animal feed production
Cocoa pod husk (CPH) (Fig 19.3) has high nutritional value
and can be used to feed animals but their use is restricted by
the theobromine which is toxic to livestock up to certain
levels. CPH has a high polysaccharide content of about 42%
on dry weight basis, crude fibre content of 24-35% and
crude protein content of 6.35%. It is normally sliced (Fig
19.4a,b) and used for both wet and dry feed production.
While wet feeding is appropriate for direct or on-farm
feeding on day-to-day basis during the harvest season, dry
Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

feed production is done for storage and integration with

animal production in suitable locations. Dry animal feed
pellets (Fig 19.5a,b) from sliced fresh husks have been used
successfully as a substitute for wheat bran to feed pigs and
rabbits. Quick processing and fast drying of pellets prevent
rotting and loss in nutritional value. On-farm processing for
very small farms (< 5 ha) has also been found to be
unprofitable. The recommended levels of dry CPH in
different animal feeds are as follow:

Cattle, sheep and goats up to 60%

Pigs 45%
Poultry (layers) 15%
Poultry (broilers) 10%

In Cameroon, a fish food partially made from powdered

CPH has been developed and has been demonstrated to be a Fig 19.5a: Slicing of CPH with a slicer
suitable feed alternative for tilapia (Oreochromis niloticus).
This alternative feed is protein-rich and cheaper compared
to the conventional tilapia food which is a blend of
cornmeal, wheat bran and rice.

Cocoa pod

Pod breaking
Cocoa pod husk

Selection of fresh unblemished

pod husk

Slicing of fresh pod husk

Drying of sliced husk to about

60% moisture
Pelletizing of dry sliced husk
Fig 19.5b: Sliced CPH
Drying of CPH pellets to about
12% moisture
Mixing of pellets with other feed
ingredients

Fig 19.3: Steps involved in the production of animal feed from

cocoa pod husk

Fig 19.6a: Pelletizing of sliced CPH

Fig 19.4: Fresh CPH for animal feed production

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Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

Fig 19.6b: Drying of CPH pellets

Fig 19.8: Drying of CPH for burning
Potash production

CPH can also be sun-dried (Fig 19.6) and incinerated in an

ashing kiln or a truncated metal drum. Although the potash
can be used as fertilizer, the majority of it is being used for
soft soap manufacturing. Production of potash is labour
intensive, making it uneconomical for farms located in
remote areas. However increasing demand has made
production a viable process provided a minimum quantity
of 15 tonnes of fresh pod husk is processed. Potassium forms
about 3-5% of dry CPH and about 30-40% of the ash. For the Fig 19.9a: CPH ash for Fig 19.9b: Extracted potash for
preparation of soft soap, caustic potash is extracted from potash extraction alata samina
CPH ash by dissolving in water and evaporation (Fig
19.7a,b). The soft soap (Fig 19.8) is prepared using the
traditional method . Because of the relatively high potash
content of CPH, it can be used to manufacture potash
fertilizer or potash compost. Many years ago, WACRI
recommended 8 cigarette tins of the ashe per cocoa tree,
half a tin per maize plant and 2 tins per square yard (0.836
m2) for smaller plants. However, the possibility of spreading
black pod disease has discouraged the idea of using CPH as
compost.

Cocoa pod

Pod breaking

Cocoa pod husk

Collection and drying

Dry cocoa pod husk
Incineration of dry pod husk Fig 19.10: Alata samina (soft soap)

Cocoa pod husk ash

Suspension in water and leaching

Filtrate from ash

Evaporation and crystallization

Potassium salt from cocoa pod

husk

Fig 19.7: Steps involved in the extraction of potassium salt from

cocoa pod husk

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Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

Cocoa pulp juice

The sugar content of fresh cocoa pulp juice (”sweatings”)
varies from 10-15% (w/v). These sugars form the substrate
for yeast population which initiates fermentation. During
fermentation of fresh cocoa beans, excess juice always
drains off and this may be collected as by-product with no
adverse effects on the fermentation process (Fig 19.9a,b).
The pulp juice is used for the production of alcoholic
beverages such as the local gin (akpeteshie), wine, gin and
brandy. For the production of alcohol, the “sweatings” is
fermented for 4 days and the alcohol distilled using the
traditional distillation unit (Fig 19.10). The alcohol is then
refined using a fractional distillation unit and blended into
gin and brandy (Fig 19.11a,b). Jams and marmalades are also
produced from the “sweatings”. The production of these
products has been found to be viable.

Cocoa “sweatings” contains about 1% pectin which Fig 19.12: Fermentation of sweatings
compares favourably with commercial pectin produced
from apple, lemon and pawpaw. This pectin can also be
extracted from cocoa “sweatings” and used in the
pharmaceutical, cosmetic and food industries.

Fig 19.13: Traditional distillation unit

Fig 19.11a: Collection of sweating using the polytank method a (Gin) b (Brandy)

Fig 19.14: Alcoholic products from cocoa sweatings

Extraction of cocoa butter from discarded beans

Although cocoa butter is widely used in cosmetics around

the world, little is actually produced in most West African
cocoa producing countries. Fat extracted from discarded
beans (Fig 19.15) is used in the production of soap and
cosmetics. Discarded beans are extracted from rejected
insect and or rodent damaged pods as well as pods suffering
from blackpod infection. Discarded beans also include
Fig 19.11b: Fresh cocoa sweating extracted from fresh beans

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Cocoa Research Institute of Ghana Cocoa Manual version 1, 2010

mouldy, slaty/unfermented, germinated and flattened/small

beans. They may also be dried and unfermented. The
extraction of fat is done using the local extraction method,
which involves roasting, milling and boiling to extract the
fat.

Discarded cocoa beans

Sorting of good beans

Cocoa
COCOA beans
BEANS without
WITHOUT foreign
FOREIGN MATTmatter

Roasting of cocoa beans

Roasted cocoa beans

Milling of cocoa beans

Milled cocoa beans

Addition of water and boiling Fig 19.16: Extracted cocoa butter from rejected beans
Boiled cocoa bean mass with top
oil
Skimming of oil and leaving
overnight
Raw cocoa butter

Fig 19.15: Steps involved in the production of cocoa butter

from discarded beans

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