ACCRA TECHNICAL UNIVERSITY

MODIFICATION OF COCOA BEANS DRYER By

HAMMOND MICHAEL (01182918D)
RESEARCH PROJECT REPORT/ THESIS Submitted to the
DEPARTMENT OF MECHANICAL ENGINEERING FACULTY OF
ENGINEERING
in Partial Fulfillment of the Requirements for the
AWARD OF HIGHER NATIONAL DIPLOMA (HND) In
MECHANICAL ENGINEERING
SEPTEMBER 2021
                                      i

DECLARATION
This project is submitted as part of fulfillment for the award of a Higher
National Diploma in Mechanical Engineering. The work is a result of
our investigation. All section of the text and results which have been
obtained from other works/ sources are fully referenced. I understand
that cheating and plagiarism constitute a breach of Accra Technical
University and will be dealt with accordingly.
NAME
HAMMOND MICHAEL (CANDIDATE)
GOVI DANIEL (SUPERVISOR)
DR MORO ADAMS
(HEAD OF DEPARTMENT)
SIGNAMTURE ........... .........
. .................. ..
DATE ..................
..................
.................. ..................
I

I dedicate this book to the High God, my lovely parents, my siblings,

my friends and all my lecturers for their support assistance throughout
my training
II
 I will take this opportunity to show my gratitude to everyone who made
this project a success. However, it will not have been possible without
the kind support and help of my classroom colleagues. I would like to
extend my sincere thanks to all of them. I am highly indebted to my
Supervisor, HOD, Lecturer One, Lecturer Two etc. for their guidance
and constant supervision providing necessary information regarding the
project and their support in completion. I would like to express my
gratitude towards my mom for her kind cooperation and encouragement
which helped in the completion of this project.
III

TABLE CONTENTS
DECLARATION........................................................................................
.................................... I
.....................................................................................................................
.........
II ........................................................................................................III ....
.....................................................................................................................
.......VII
CHAPTER
ONE............................................................................................................
................ 1
INTRODUCTION......................................................................................
................................. 1
1.1 1.2 1.3 1.4 1.5 1.6 1.7
      BACKGROUND OF
STUDY............................................................................................... 1
PROBLEM
STATEMENT..............................................................................................
.. 4 AIMS OF
PROJECT....................................................................................................
..4
OBJECTIVES.............................................................................................
..................... 4 RESEARCH
QUESTIONS..............................................................................................
.5 SIGNIFICANCE OF
STUDY............................................................................................ 5
LIMITATION..............................................................................................
.................... 5 CHAPTER
TWO...........................................................................................................
................ 6 LITERATURE
REVIEWS...................................................................................................
........ 6
2.1 BACKGROUND TO THE
STUDY.................................................................................... 6
2.2 DRYING OF COCOA
BEANS...........................................................................................8
2. 2.1 Drying
methods.......................................................................................................
.................... 9 2.2.2 Open Sun Drying
Method................................................................................................9
Solar Drying
Method........................................................................................................
....... 10 Oven
Drying.........................................................................................................
.................... 11 Microwave
Drying.........................................................................................................
............ 12 Freeze
Drying.........................................................................................................
.................... 13 DRYING AND COCOA BEAN
QUALITY....................................................................13 QUALITY OF
COCOA
BEANS......................................................................................15
MOULD
BEANS.......................................................................................................
......16
ACIDITY.....................................................................................................
.................... 16 MOISTURE
CONTENT..................................................................................................
..18 CHAPTER
THREE........................................................................................................
.............20
METHODOLOGY......................................................................................
................................ 20 3.1
INTRODUCTION......................................................................................
......................... 20 3.2 FLOW CHART OF THE
PROJECT................................................................................... 20 3.3
DESIGN
PROCEDURE.............................................................................................
......... 21
2.2.4 2.2.5 2.2.6 2.2.6
2.3 2.4 2.5 2.6 2.7
IV

3.4 EVALUATION OF FINAL

DESIGN................................................................................ 22 3.5
SELECTION OF
MATERIALS..........................................................................................23
3.5.1
FRAME.......................................................................................................
.................... 24 3.5.2 TRAY WITH
GRATE........................................................................................................
.........24 3.5.3
ROLLERS...................................................................................................
................................. 24 3.6 CONSTRUCTION OF THE FINAL
DESIGN............................................................................ 24 3.6.1 The
Experimental
Dryer...........................................................................................................
.. 25 3.7 Cost
analysis........................................................................................................
................ 29 Table 1.0 Cost
Estimate.......................................................................................................
...... 29 CHAPTER
FOUR..........................................................................................................
............. 30 RESULTS AND
DISCUSSIONS...........................................................................................
.....30 4.1 RESULTS AND
DISCUSSION..........................................................................................
30 CHAPTER
FIVE............................................................................................................
............. 31 5.1
CONCLUSION...........................................................................................
.........................31 5.2
RECOMMENDATION..............................................................................
......................... 31
REFERENCES...........................................................................................
................................32
V

CONTENT
PAGES
LIST OF FIGURES
Fig 1.0: a. Cocoa Plant , b. Cocoa fruit, c. and d Fresh cocoa
beans........................................................2 Fig 1.1 Traditional cocoa
drying
method................................................................................................. 3
Fig 2.0: Fermented cocoa
bean.............................................................................................................
.. 7 Fig 2.1: Drying of cocoa
beans...........................................................................................................
...... 8 Fig 2.2: Open Sun Drying (method the most common method used
in Ghana).....................................9 Fig 2.3: Modernized solar drying
method............................................................................................. 10 Fig
2.4: Oven drying
method.........................................................................................................
........ 12 Fig 2.5 : Microware drying
method ......................................................................................................
13 Fig 2.6: Dried cocoa
beans...........................................................................................................
.......... 19 Fig 3.0: Flow chart of the
project.........................................................................................................
..20 Fig 3.3: Proposed
design..........................................................................................................
..............23 Fig 3.4: Measuring
process.........................................................................................................
........... 26 Fig 3.5: Cutting
process.........................................................................................................
.................27 Fig 3.6: Fabrication
process.........................................................................................................
.......... 28 Fig 3.7: Finished
structure.......................................................................................................
.............. 28 Fig 4.0: The housing unit with the solar panel and the
heating machine............................................. 30
VI

Considering drying as a key farm-based, quality determining unit

operation in the cocoa processing chain, this paper reviews recent
studies in the drying methods and quality parameters of cocoa beans.
Open sun, solar, oven, microwave, and freeze-drying methods have been
investigated at various levels in the drying of cocoa beans with
objectives to improve the drying properties and final quality of cocoa
beans. While an open sun dryer employs natural passive mechanisms,
the solar drying methods can employ a combination of passive and
active mechanisms. The oven, microwave, and freeze-drying methods
are fully active requiring electrical energy inputs. To improve drying
rates in the open sun method, dryer materials and location of drying
trays are the parameters optimized since the drying temperature depends
on solar intensity. For solar dryers, materials, angles of elevation,
heaters, and fans are manipulated to optimize energy absorption and
drying parameters. For the oven and microwave methods, drying air
properties are directly controlled by electronic systems. Moisture
content, moldiness, bean color, pH, irritable acidity, fat content, and
acetic acid concentration are the most widely evaluated bean quality
parameters.
VII

1.1 BACKGROUND
CHAPTER ONE INTRODUCTION
Cocoa has a characteristic and complex chemical composition.
Chocolate is its principal product and is generally consumed. For its
sensory quality, it has been recognized as source of bio-active
compounds with potential health benefits. In cocoa pre- processing after
harvest, cocoa beans are fermented and then dried to reduce moisture
content and water activity. The drying process interferes with
biochemical reactions initiated during fermentation, leading to a
reduction in the bitterness. Shrinkage, and acidity of cocoa beans.
Darkening cotyledons contributes to the formation of precursors for
desirable flavour in the final product. Drying may be carried out
naturally using solar or artificial energy in greenhouse. Drying
conditions can promote reactions that form new compounds that are
responsible for the developments of the distinctive chocolate colour. As
mechanical engineering student, we are enhancing the cocoa drying
process to ensure that cocoa beams get to market on time and in good
condition to help boost country economy.
Cocoa cultivation began in Ghana, according to the legend, fostered by a
blacksmith called Tetteh Quarshie, who, in 1895, returned to his farm in
the Eastern Region of Ghana with cocoa beans "in his Cocoa cultivation
began in Ghana, according to the legend, fostered by a blacksmith called
Tetteh Quarshie, who, in 1895, returned to his farm in the Eastern
Region of Ghana with cocoa beans "in his pocket" from the island of
Fernando Po (now Bioko) in Equatorial Guinea where there was already
intensive plantation production of "slave-grown" cocoa. Cocoa was first
exported at the end of the 19th century, and between 1911 – 1976
1

Ghana was the world's leading producer, contributing between 30-40%

of the world’s total output.
Due to the importance of cocoa in Ghana, both in terms of its effect over
the lives of these cocoa farmers and to the Ghanaian economy, the
government of the 1930s took over control of the industry. They set up a
buying monopoly for all the cocoa produced in Ghana. This body, first
under colonial control, and then the independent Ghanaian government,
was intended to protect the farmers from price fluctuations. Whilst it
failed to really ensure a better price to the farmers, they did receive
additional help from the other bodies set up by the government body
(now known as Cocobod) such as a Research Institute, subsidised inputs
such as fertilisers and a Quality Control Division. It is these services
that, in part, have preserved Ghana's reputation for high quality cocoa.
ab
cd
Fig 1.0: a. Cocoa Plant, b. Cocoa fruit, c. and d Fresh cocoa beans
    2

    a.
b.
c.
Fig 1.1 Traditional cocoa drying method
3

1.2 PROBLEM STATEMENT

Cocoa beans must be dried to reduce its moisture content to a safe level
of storage. The normal drying process can take about five to seven days
to the bring the moisture content of the beans from 70 % to 7 %. On
completion of fermentation, the cocoa is carried to the villages for
drying on raised bamboo mats (almost always in Ghana), on concrete
(frequently in Côte d'Ivoire). This can take from 7-10 days or even
longer in cloudy/rainy conditions. Due to the high labour needed,
children are being forced to perform the duties such as covering the
beans when there is a change in weather and driving away of pest. The
drying process of cocoa on mat or concrete floor might lead to the
contamination of the beans. We solve these problems by modifying the
cocoa drying process.
1.3
AIMS OF PROJECT
Eliminating child labour and allowing children to focus on education.
To improve the quality of the cocoa beans in terms of colour, taste,
flavour.
To ensure cocoa get to market at the appropriate time and to increase the
efficiency of dry.
OBJECTIVES
1. To design a simple machine that will eliminate the human factor
2. Construction of the machine
3. Evaluate the effects on the mechanism (less time and efficiency)
1.4
1. 2. 3.
4

1.5 RESEARCH QUESTIONS

There is no integrated equipment for cocoa production. Could there be
an integration equipment for cocoa production processes?
1.6 SIGNIFICANCE OF STUDY
The significance of study is to reduce contamination of the cocoa beans
during the drying process which will contribute to the increase in the
country GDP and to reduce wasting of time used to dry cocoa so if gets
to the world market when needed and this can help boost Ghana
economy.
1.7

LIMITATION
Insufficient financial resource to purchase the necessary equipment for
the study to obtain the actual project
Inadequate time to work on the project as planned because of individual
job affairs and our residential location.
Sample size: the project will be in a model form since the actual work is
unmovable
5

CHAPTER TWO LITERATURE REVIEWS

2.1 BACKGROUND TO THE STUDY
Fermentation of Cocoa Beans
Fermentation is the most crucial process during the preparation of cocoa
beans after harvesting. This mostly goes unnoticed by mostly the public
and the farms themselves. It is critically important to ferment the cocoa
beans to get a rich product.
Many cocoa producers perform the cocoa beans fermentation process
only because the market requires them without understanding the
importance of cocoa beans fermentation process, this because the high
market mass companies that purchase the cocoa beans do not regard if
the cocoa beans are fermented or even fermented to the right degree.
The Cocoa Beans Fermentation Process:
1. The cocoa beans are picked from the farm and carefully removed
from their cocoa pods that hold about 40 cocoa beans. Farmers who are
careful will rap the cocoa pod on a rock or a tree and the pod will easily
break this ensures that the beans are not injured.
2. The beans are then removed from the cocoa pods are collected and put
in a cocoa fermenting box or the sweat box, which are located at the
plantation. It is important to do this quickly since the beans begin to
germinate as soon as they are removed from the pods.
3. As fermentation begins immediately, the beans are exposed to air. The
spores from naturally yeast begin to settle on the sugary beans and start
to split the sugar into alcohol and carbon dioxide. The alcohol is split
further into acetic acid by the same bacteria responsible for turning wine
into vinegar.
6

4. Largest cocoa producers must separate the acetic acid that is generated
from cocoa fermentation.
5. Fermentation process occurs on both out and in the bean. During the
process, the temperatures can be as high as 122F (48°C).
6. On the second day the temperatures reach (43°C) causing the cocoa
germ to die, important chemicals changes occur as the enzymes are
released.
7. The beans are always rotated within the sweat boxes so as they get
just enough oxygen not too much and not too less, this is normally done
by transferring the beans from one sweat box to another. In conclusion,
Consistency is the key no matter the process used to ferment. While this
task may seem easy, in fact it is very difficult. The largest cocoa
producers deal with literally tons of cocoa beans production, and that
makes stirring, fermenting, and processing consistently very difficult.
Well-fermented cocoa beans are a prize for cocoa production companies.
Fig 2.0: Fermented cocoa bean
7

2.2 DRYING OF COCOA BEANS

Cocoa beans must be dried to reduce its moisture content to a safe level
for storage. The drying process is also a continuation of the oxidative
stage of fermentation of the beans, thus, further reducing the shrinkage
and bitterness of the product. Methods of drying the beans are usually by
sun-drying and artificial or, forced air drying, depending on some
socioeconomic considerations, and prevailing climatic conditions. Sun
drying is simple and cheap, not requiring the expensive mechanical
devices used in the artificial dryers, but it is also labour- intensive and
there is much concern for a stable weather condition. Fundamental
works on the thin layer drying characteristics of cocoa beans are limited
and are not related to the bean quality (Bravo and McGraw, 1974;
McDonald et al., 1981). Although, experimentation on slow drying using
the ambient air had produced beans of acceptable quality, there was
over- fermentation of the beans with inadequate heat and air movement
(Thien and Yap, 1994). In the humid tropics, slow drying with ambient
air is not sufficiently attractive because the prevailing environmental
conditions of about 29-32°C and 80% relative humidity result in low
drying potential. The drying process involves both heat and mass
transfer. The moisture to be removed may exist both on the surface and
within the product and drying is normally examined in terms of moisture
removal at these two levels (Garg and Bhargava 1989; Menon and
Mujumdar 1987; Sukha 2009).
Ab
Fig 2.1: Drying of cocoa beans
  8
2. 2.1 Drying methods
Methods of drying cocoa beans are usually by sun-drying, artificial or
forced air drying, depending on some socioeconomic considerations, and
prevailing climatic conditions.
2.2.2 Open Sun Drying Method
Sun drying, that is exposing the product directly to sunshine. This is the
most widely used form of solar energy in the post-harvest processing of
crops and several factors hampers it. These include slow drying rates,
low efficiency in the use of space and poor quality (Minka 1986; Arime
1986). Sun drying is simple and cheap, not requiring the expensive
mechanical devices used in the artificial dryers, but it is also labour-
intensive and there is much concern for a stable weather condition. It
however, appears that the traditional sun drying, though with some
limitations, is the most appropriate method for producing cocoa beans
with the best quality attributes. The beans are heaped up at sunset, stored
away from dew and covered with thick tarpaulin over-night. It is,
therefore, a rest period type of drying. It is necessary to keep the beans
at higher temperature than the ambient, to eliminate the occurrence of
moisture re-absorption.
Fig 2.2: Open Sun Drying (method the most common method used in
Ghana)
9

2.2.4 Solar Drying Method

Solar drying is the method in which the sun's heat is managed and
utilized for drying while protecting for the product. Many authors have
reported the potential for solar drying in the tropics (Arinze 1986; Sodha
et al., 1987).
Solar driers may be classified primarily according to the mode of heat
collection employed and secondarily on the mode of heat transfer
(Sodha et al., 1987). Solar thermal technologies have been used in
various applications as natural convective type dryers, or with forced
ventilation in the drying of cocoa. A direct-mode solar drier is a closed
chamber that contains the product, covered by a transparent sheet of
either glass or plastic and ventilated by a series of holes. Thus, heating is
by direct absorption of radiation by the crop (Bhatnagar and Ali 1989).
In an indirect-mode drier, the air is heated in a collector and is directed
to a dehydration chamber containing a batch or batches of the product
(Maulbauher 1986). Where an air-heating collector is coupled with a
drying chamber that exposes the product to solar radiation the drier is
termed "mixed-mode".
Fig 2.3: Modernized solar drying method
10

2.2.5 Oven Drying

A drying oven is a type of low-temperature convection or forced air
oven used primarily in laboratory settings. Specimens, tools, and
temperature-sensitive chemicals are placed inside a drying chamber to
remove moisture slowly and evenly. An electric dehydrator is a self-
contained appliance with a heat source, a fan for circulation, and
multiple trays for drying many foods at one time. Better quality
dehydrators also have thermostats and double-walled construction for
more efficient energy usage. As such, any researcher can dry any
produce at any temperature for experimental purposes.
A local firewood oven dryer was constructed in Fako, Cameroon, with
bricks and cement plastered and a tilting platform to support the
suspended heating and combustion chamber above the ground. To
control the effect of smoke, the combustion chamber was separated from
the drying chamber with 2 m heat/air conveying ducts (the kiln), in
which dry wood was burnt to generate heat. The drying mat was
perforated to facilitate the free circulation of air in the drying chamber.
The rotation rates of the cocoa beans during the drying process and the
rate of free exit of saturated air were the same as the rate of entry of
hot/dry air into the drying chamber. Although this gave encouraging
results (7% within 96 hours of continuous drying), the difficulty to
control smoke and maintain the drying temperatures at 35-40°C and
equality in the distribution of heat were some of the risks observed in the
experimental process. Further studies are still expected on the
dimensions of other cocoa bean quality parameters such as PAHs,
acidity, mould content, and OTA content in Cameroon; over 40% of total
cocoa productivity is dried using firewood ovens.
11

2.2.6 Microwave Drying

Fig 2.4: Oven drying method
Microwave drying is a process that basically works in the same way as
when we heat food in a microwave oven. The microwaves cease at the
same moment as the drying machine or microwave oven is switched off.
The responses of a lossy food product to dielectric heating result in rapid
energy coupling into the moisture and lead to fast heating and drying. A
significant reduction in drying time in microwave drying is often
accompanied by an improvement in product quality, making it a
promising food dehydration technology. The need for improvement in
engineering design and process optimization for microwave drying has
stimulated the development of computer simulation techniques to predict
temperature and moisture history and distribution in the product to be
dried. Despite the experimental successes that this method may achieve
in the drying of cocoa beans, it is limited to very small-scale drying and
practically unsuitable for unelectrified rural areas and large-scale
production of cocoa.
Microwave drying relies on additional energy being supplied that is
preferentially absorbed by the solvents in the process to enhance
evaporation. Microwaves are a form of electromagnetic energy (300
MHz–300 GHz), generated by magnetrons under the combined force of
perpendicular electric and magnetic fields.
12

2.2.6 Freeze Drying

Fig 2.5: Microwave drying method
Freeze drying is a special form of drying that removes all moisture and
tends to have less of an effect on a food’s taste than does normal
dehydration. In freeze drying, food is frozen and placed in a strong
vacuum. The frozen water in the food turns to vapour (sublimation).
Although this method has been proven suitable in the experimental
drying of cocoa beans, it seems practically impossible to be used in the
large-scale drying of cocoa beans due to its high electrical and technical
inputs.
2.3 DRYING AND COCOA BEAN QUALITY
Drying practices influence market quality, the development of flavour,
final bean acidity, moldiness, and the presence of off-flavour in the
beans. Under adverse weather conditions, the slow rate of sun drying
results in moldiness and the development of off-flavour (Ghosh and
Cunha 1975). The beans are also more likely to be adulterated by dust
and other debris
13

during sun drying. Artificially dried beans are inferior to sun dried beans
in chocolate flavour development (Quesnel and Jugmohunsingh 1970;
Shelton 1967). Artificial drying increases brittleness and produces a high
proportion of cracked and broken beans (Urquhart 1961; Ghosh 1972;
1973) and beans with a wrinkled appearance (Bravo and Mc Gaw,
1974). Many authors, with an emphasis on reducing acidity (DeVos,
l956), have investigated the causes of the inferior quality of artificially
dried beans. Quesnel and Jugmohunsingh (1970) found that under
certain 12 conditions temperatures from 600 C to 900 C gave
unacceptable product. Chocolate flavour development, which begins
during fermentation, continues during drying and the mediating enzymes
are destroyed by temperature over 600 C (Quesnel and Jugmohunhsingh,
1970). The drying process is also a continuation of the oxidative stage of
fermentation of the beans, thus, further reducing the contingency and
bitterness of the product. Properly dried beans, usually at about 6-8%
moisture content (wet basis) have reduce acidity and are characterized
by the familiar „chocolate‟ brown colour. The high temperatures used in
artificial driers, cause rapid drying of the testa and case hardening
preventing outward migration of acetic acid from the beans, (Jinap et al.,
1994). Literature points to the physical loss of acidity through outward
migration (Jinap et al., 1994), but this may not be the most important
process. Laiu (1978) provided much evidence that the reduction of
acidity during drying is mainly an oxidation process brought about the
enzymes. Consequently, factors, which inhibit enzyme activity, e.g., high
temperature and reduced moisture, contribute to acid retention. Thus, the
rate of moisture removal and the temperature employed should be
balanced so that adequate acid removal and flavour development are
both assured. Jinap et al. (1994) found the pH of sun-dried beans not
significantly higher than that of beans that were air-blown for 72 hours
and subsequently heated at 600°C . The pH of mould-affected, shade-
dried beans was higher than that of sun-dried beans. Despite the higher
pH, the mouldy beans had higher total volatile acidity than sun-dried, or
air blown beans in addition to an objectionable flavour. Beans, which
were oven dried at 13 600°C had a significantly higher
14

total volatile acidity. The practical consensus is that temperatures beyond

600°C generally impair cocoa quality Thus, drying practice may
influence the development of flavour, bean acidity, mouldiness, and the
presence of off-flavours (Jinap and Dimick, 1994). Acidity of cocoa
liquor as measured by pH was found to be positively related to acidity
scores obtained from taste tests (Baigrie and Rumbelow 1987). Several
studies have found that the main factor in acidity of cocoa is volatile
acidity of which acetic acid forms 95%. Rapid drying at high
temperature is known to lower the pH of the dried beans (Shelton 1967).
However, artificial drying method reduces the dry matter and causes
increase in energy cost (Arinze et al., 1996) while quick drying prevents
the chemical processes started during fermentation to be completed.
Also, the rate drying is critical to final quality of raw cocoa. The
removal of moisture from cocoa beans is slower in natural method, and
faster in the artificial and mixed drying methods. The differences may be
explained by several factors such as exposure time and temperature of
drying air, nature of drying airflow and the speed with which moisture
migrated from the inner cocoa beans structures to their surface. These
observations are in accordance with the studies obtained by Franke et al.
(2008). The natural drying process was slower due to the limitations the
method imposes.
2.4 QUALITY OF COCOA BEANS
The grading criteria and quality categories of commercial cocoa beans
are specified in the International Cocoa Ordinance (Wood and Lass
1985). International cocoa trading bodies define quality in terms of
degree of fermentation and the extent of defects present. Criteria at
fermentation, proportion of broken beans, and the degree of moulding
and insect infestation and other adulteration (Wood and Lass 1985;
Crespo 1985).
15

2.5 MOULD BEANS

Prolonged drying during the rainy season in the humid tropics is also a
very important factor and Wardsworth (1958) has attributed most mould
growth affecting quality to this problem. Beans dried in the solar driers
had few signs of external moulding. Bonaparte ET AL., 1998 surface
moulding is a function of very high humidity and low air movement.
Sun-dried beans, especially those dried on the wooden surface, recorded
some levels of mould growth.
2.6 ACIDITY
Drying practice have been reported to influence the development of
flavour, bean acidity, moldiness, and the presence of off flavours (Jinap
and Dimick 1994). Acidity of cocoa liquor as measured by pH was
found to be positively related ta acidity scores obtained from taste tests
(Baigrie and Rumbelow 1987). Several studies have found that the main
factor in acidity of cocoa is volatile acidity of which acetic acid forms
95%. Rapid drying at high temperature is known to lower the pH of the
dried beans (Shelton 1967). However, artificial drying method reduces
the dry matter and causes increase in energy cost (Arinze et al., 1996)
while quick drying prevents the chemical processes started during
fermentation to be completed. Also, the rate drying is critical to final
quality of raw cocoa, many reports have referred to the high acidity and
poor flavour development of artificially dried beans compared to sun-
dried beans with similar levels of fermentation (Shelton 1967; Jinap et
al., 1994). Quesnel and Jugmohunsingh (1970) examined the effect of
high temperature on browning reactions during cocoa processing. They
concluded that these flavour development reactions are enzymatic and
are inhibited at drying temperatures beyond 600 C. Furthermore, it
appears that rapid moisture loss inhibits the enzymatic breakdown of
acids (Liau 1978). Acidity of cocoa liquor, as measured by pH, has been
correlated to acidity scores obtained from parallel taste tests (Baigrie and
Rumbelow 1987). The pH of mould-affected, shade-dried beans was
higher than
16

that of sun-dried beans. Despite the higher pH, the mouldy beans had
higher total volatile acidity than sun-dried or air-blown beans in addition
to an objectionable flavour. Beans, which were oven dried at 600C, had
a significantly higher total volatile acidity (Fagunwa et al., 2009).
According to Barel (1998), too rapid a drying rate results in excessively
acid beans with case hardening. A high production of acidity in cocoa
beans produces unsuitable raw cocoa for chocolate manufacture and
leads to the reject of cocoa at the market. Zahouli et al. (2010) reported
pH values of fermented cocoa beans comprised roughly between 3.8 and
4.5, while natural drying processes and mixed drying methods produce
less acidic cocoa beans with pH up to 4, artificial method gives high
acidic cocoa beans with pH around 3.7 Volatile acidity content of
fermented cocoa beans was largely dependent on drying methods
(Zahouli, 2010) 16 Most studies have shown that removal of moisture
from beans induce the increase of their acidities. Sun dried beans
showed pH 4.6the pH of sun-dried beans is usually higher (less acidic)
than artificially and mixed dried beans due to the slow and gentle drying
process that enable the evaporation of more acetic acid during solar
drying (Hii et al., 2009). According to Hii et al. (2009), low pHs are
always associated with high acidic beans. Analyses of fermented beans
showed that sun drying method, artificial method and mixed drying
processes produce the same higher volatile acidity cocoa beans than
other methods. This might be because the loss of these volatile acidities
during fermentation was induced by exudation of acidic liquid and not
by chemical degradation. Most studies have shown that generally acetic
acid is removed as volatile acidity from fermented beans during a slow
and gentle drying process as natural process. However, artificial drying
process would dry faster and break the diffusion path of the acetic acid
with moisture (Jinap et al., 1994). Hence, artificial drying method
cannotavoid0 retention of excessive acids and most of the acids remain
inside the beans and because excessive sourness notes to the beans. For
this reason, Jinap et al. (1994) have recommended that drying of cocoa
should be performed at temperature not exceeding 60oC. The practical
consensus is that temperatures beyond 60 0 c
17

generally impair cocoa quality Artificially dried beans are described as

brittle and are said to lack lustre (Urquhart 1961) due to the high drying
temperatures. The broken beans, which result present problems during
roasting (Urquhart 1961) and in storage, are more liable.17 The pH of
the sun-dried beans is different from the pH of the best flavoured beans
sourced generally from West Africa, which is around 5.5 (Franke et al.,
2008).
2.7 MOISTURE CONTENT
Fagunwa ET AL. (2009) reported that intermittent solar dryer is
appropriate for drying cocoa beans to safe moisture level (3.6%, w.b)
within 72 hours. The essential quality attributes of the beans are
comparable with the product from the traditional sun drying.
Microbial Diversity and Population
The cocoa fermentation is a spontaneous process. The pulp is sterile, but
as soon as the beans are removed from the pod, the pulp is inoculated
with yeasts and bacteria from the surroundings (Jespersen et al., 2004;
Nielsen et al., 2006; Takrama & Adomako 1996). As fermentation of the
pulp starts, ethanol and acetic acid are produced and penetrate the beans
(Doyle et al., 2001). Yeasts and LAB dominate the first 24 – 36 hours
(Nielsen et al., 2006). Yeasts mainly convert sugars in the pulp into
alcohol and CO2. Enzyme activities and maceration of the pulp makes
the acidy juices run off as sweating, which result in a rise of pH
(Takrama & Adomako, 1996). The yeast cell counts decrease after 24 –
36 hours while LAB remain high throughout the fermentation (Nielsen
et al., 2007) Both homo- and hetero fermentative LAB species are
observed, metabolizing glucose to respectively lactic acid and lactic
acid, alcohol, acetic acid, and carbon dioxide (Takrama & Adomako,
1996). Turning the heap, makes conditions more aerobic, and increases
the population of AA. These bacteria
18

species oxidize ethanol to acetic acid, which is an exothermic process

that rises the temperature to nearly 50°C (Camu et al., 2008; Takrama &
Adomako, 1996) 18 Spore forming Bacillus species are dominant at the
end of the fermenting period and while drying (Nielsen et al., 2006;
Ardhana, 2003). These bacteria form some undesirable short fatty acids,
giving an off-flavor to the final chocolate (Doyle et al., 2001)
ab
Fig 2.6: Dried cocoa beans
    19

3.1 INTRODUCTION
CHAPTER THREE METHODOLOGY
This chapter consist of the processes for the project to be achieved, and
the materials needed for the project.
3.2 FLOW CHART OF THE PROJECT
Design Procedure
Selection of material
Construction of final design
Test and evaluate
Cost of Material
Fig 3.0: Flow chart of the project
                      20

3.3 DESIGN PROCEDURE

The drying of cocoa beans plays an important role in cocoa processing.
The modification of cocoa beans dryer designed shall enhance in the
drying and preservation of cocoa beans for consumption and other uses.
The design procedure comprises of the exiting design and the new
design.
A design methodology was used, which utilized the following steps:
 Identify problems with previous designs
 Generate ideas to solve the problems
 Implement various improved prototypes
 Use a method to derive the most suitable design
 Build and test the final design
    a. front view of the design
b. Wire view
21

    c. Top View d. 3D View

Fig 3.2: a. Front view, c. Wire view, d. 3D view. 3.4 EVALUATION OF
FINAL DESIGN
The intent was to enhance the traditional method of drying cocoa beans
by replacing it with this modified cocoa beans dryer. The drying floor or
the tradional cocoa mat will be replaced with a sliding tray grate on
which the cocoa will be placed, a closed housing that allows air
circulating at night, in addition a heat blower to produce heat in the night
to aid reduction of moisture of the cocoa bean. Also minimization of
manual labor and time taken for the drying process. This housing unit
can be used for drying during day and night. The alternative source of
energy for the heat blower is solar energy .
The choice of design (see fig. 3.4) was based on affordability and the
place of use. The design is a model of the actual structure,since the
actual structure is not mobile. This design is used to show how the actual
stucture looks like .
22

Fig 3.3: Proposed design

3.5 SELECTION OF MATERIALS
The selection of materials as part of the steps in the process of designing
a structure is to minimize cost while meeting performance and
requirement.
The materials needed for the construction of the design are
 Mild steel for framework
 Rollers for the sliding tray
 Wooden (Bamboo strip) grate as platform for drying
 Solar panel
 battery
 aluminium roofing and tapeline
23

3.5.1 FRAME
The material selection was mild steel for the frame, due to it high tensile
strength and its durability.
In addition to it durability and high tensile strength, mild steel has
another numerous advantage which include.
a. Light in weight
b. Usable at high temperatures
c. Heat dissipation properties
d. Durable and tough
3.5.2 TRAY WITH GRATE
The Tray houses the bamboo grate on which the cocoa beans is dried.
Wood (Bamboo strip) does not have negative effect in the drying of
cocoa beans compared to a metal grate. Grate was used to improve the
circulation of air in the cocoa house.
3.5.3 ROLLERS
Rollers was used to allow the free movement of the tray in and out of the
cocoa house at both side of housing unit.
3.6 CONSTRUCTION OF THE FINAL DESIGN
24

The dryer was conceived as low cost, easy to fabricate and easy to
operate equipment, using available local material to make it suitable for
most peasant farmers with little or no formal education.
3.6.1 The Experimental Dryer
The experimental dryer (fig 3.4) was made mainly of metal and
consisted of the following major component: housing unit, tray with
grate, rollers, heat blower and solar panel.
The tray with grate serves as the drying chamber, the tray of 108mm and
92mm wide to form the storage chamber, the housing unit, which is the
frame 115mm length, height of 121mm breath of 93mm. The roof of
height 15mm from the frame and length of 66mm from the apex. The
surface of the drying chambers was covered with palm font trips to
allow the circulation of air, since air also is needed in the drying of
cocoa beans. The rollers fixed under the tray to allow the movement of
the tray in and out of the housing unit according the adverse of the
weather condition. A sheet metal cover 1mm thick for roofing and
tarpaulin for side covers.
The proposed design was fabricated in Accra technical university
mechanical engineering welding shop.
The proposed design was contracted using various fabrication process.
The fabrication process are as follows.
a. Making out process
25

To ensure accuracy, parts to be cut were marked out to correct

measurements by using tape measure in mm.
Fig 3.4: Measuring process
b. Cutting process
After marking out follows cutting, various pieces of metals were in sizes
to join to form one complete unit.
    26

Fig 3.5: Cutting process

c. Joining process and grinding process
As part of the assembly process, various cut out part were joined
together, and grinding was done to obtain smooth surface.
    a. Joining of metals
b. Grinding
c.Welding process
27

Fig 3.6: Fabrication process

Fig 3.7: Finished structure
28
3.7 Cost analysis
Table 1.0 Cost Estimate NO COMPONENTS
1 Angle bar
2 Square pipe
3 Rollers
4 Electrode
5 Cutting disc
6 Grinding disc
7 Wooden grate
8 Oil Paint
9 Roofing sheet
10 Tape measure
11 Heat blower
Total
QUANTITY
DIMENSIONS
COST(GHȻ)
385
25
150
40
30
15
160
35
66
5
70
= 981
11
1
5 pair
1 pack
10
3
16
Milo tin
2 1- 1-
1 inch 1 inch
1mm 3mm 44* 46
--
- 8feet
29

CHAPTER FOUR RESULTS AND DISCUSSIONS

4.1 RESULTS AND DISCUSSION
Although, the beans were apparently wet there was no free surface water
on the bean. The open sun drying was carried out by spreading the beans
on the grate during the sunshine. The beans are manually turned
regularly, and the was no need to carry the beans to the shade in case of
rain, since the housing unit has a tray that can be slide in during bad
weather condition, drying also continuous in the housing unit due to the
circulation of air or ambient temperature in the unit, and a heat blower to
blow the heat to aid drying during bad weather condition. The Solar
panel install on the top of roofing provides energy which is store in
battery and used at night to power the heat blower to warm the housing
unit at night. Drying cocoa takes five to ten days when the weather
conditions is good, in forest region or areas where climate is very moist,
cocoa beans do not dry at all. With the use of our construction the cocoa
bean dried for a period of 5 to 7 days. With the traditional drying method
drying do not take place at night because at night the cocoa beans are
being gathered so no aeration takes, please, this process slows the drying
process. With the modification mechanism, the drying process take
places all round.
Fig 4.0: The housing unit with the solar panel and the heating machine
    30

5.1 CONCLUSION
5.2 RECOMMENDATION
CHAPTER FIVE
The solar drying, open sun drying, oven, microwave drying, and freeze
dryers have been widely effective in the drying of cocoa beans, at
various levels. The open sun drying method utilizes only natural means
of drying the cocoa beans which is dependent on the sun and weather
conditions. Also using the artificial methods such oven drying, freezing
drying, solar drying, microwave drying affect the quality of the cocoa
bean, among the method of the drying the open sun drying is considered
as the best.
Whereas our project utilizes the open sun drying method and an
advancement of the traditional method by using a heat blower at night
and when the weather condition is bad (raining season), hence, reducing
time for drying and increasing it efficiency Our design has an advantage
of reducing labor, in terms of farmers gathering to pack or cover the
beans in the case of weather changes. This has been achieved by the
application of the tray mechanism which can be done by a single person.
Though there are new improvements on the method of drying of cocoa
but the use of open sun drying with a source of heat to keep the place
warn at adverse weather condition. I recommend this project to cocoa
farmers, some little improvement of the heat source to be controlled by a
sensor to regulate the heat produce so that the seed are drying without
affect the quality of the cocoa beans.
31

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            32

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