Professional Documents
Culture Documents
• Cocoa is grown commercially between 20degree north and south of the Equator, in areas with a
suitable environment for cocoa.
• Main growing areas are: west africa, south east asia and south america.
• 7 largest cocoa producing countries are Ivory coast , ghana, Indonesia, nigeria, cameroon, brazil and
ecuador.
• Between them they account for 90% of the world crop.
• Huge concentration (around 70%) within west africa.
• Ivory coast produces 40%of the world crop.
• About 90% of the world’s cocoa is grown by small holders.
Top Cocoa Beans Producers
in 2010
(million metric tons)
Ivory Coast 1.242
Indonesia 0.844
Ghana 0.632
Nigeria 0.360
Cameroon 0.264
Brazil 0.235
Ecuador 0.132
Togo 0.102
Dominican Republic 0.058
Peru 0.047
World Total 4.082
• trinitario cocoa
• forastero cocoa
• Criollo cocoa
Climate Conditions
The cocoa tree will make optimum use of any light available and traditionally has been grown under shade
Soil Conditions
●
Cocoa needs a soil containing coarse particles and with a reasonable quantity of
nutrients, to a depth of 1.5m to allow the development of a good root system.
Physical properties ●
Avoid waterlogging problem and lack of water
●
Must have both water retention properties and good drainage.
●
pH in the range of 5.0-7.5;excessive acidity (pH 4.0 and below) or alkalinity (pH 8.0 and
above) must be avoided.
Chemical properties ●
high content of organic matter: 3.5% in the top 15 cm of soil.
●
35% of the total cation exchange capacity (CEC),
●
optimum total nitrogen / total phosphorus ratio should be around 1.5.
Cocoa Tree
Minerals
o Cocoa beans are rich in a number of essential minerals, including magnesium,
sulfur, calcium, iron, zinc, copper, potassium and manganese.
Vitamins
o Cocoa beans contain vitamin A, B1, B2, B3, C, E and pantothenic acid.
Polyphenols
o Polyphenols constitute one of the most numerous and widely distributed groups
of substances in the plant kingdom.
o Dietary polyphenols have received extensive attention in recent years because of
their potential health benefits such as anti-inflammatory, anti-carcinogenic , anti-
atherogenic , etc.
o Cocoa beans contain three major groups of polyphenols: catechins or flavan-3-ol
monomers (~37% of total polyphenols content), proanthocyanidins or flavan-3-ol
polymers (~58% of total polyphenols content) and anthocyanin (~4% of total
polyphenols content).
1. Catechins
2. Proanthocyanidines
3. Anthocyanins
1.Catechins
o Catechin is a flavan-3-ol, a type of natural
phenol and antioxidant. It is a plant secondary
metabolite. It is part of the chemical family of
flavonoids.
oThe two stereoisomers found in cocoa are
Catechin and Epicatechin.
o The different other enantiomers can as well be found in chocolate where
the different processes of fabrication can lead to epimerisation by heating.
o The main catechin is (-)-epicatechin with up to 35% of total polyphenol
content
o When beans are fermented there is a large loss of both (-)-epicatechin
and (+)-catechin, but also the formation of (-)-catechin. The heat of
fermentation may, in part, be responsible for the formation of this
enantiomer.
o When beans are progressively roasted at conditions described as low,
medium and high roast conditions, there is a progressive loss of (-)-
epicatechin and (+)-catechin and an increase in (-)-catechin with the
higher roast levels.
2. Proanthocyanidins
o Proanthocyanidins , refer to a larger class of
polyphenols, called flavanols.
o These are also called condensed tannins, which
are oligomers and polymers of monomeric flavans
linked through specific single (B linkages) and
double (A linkages) bonds
o These secondary plant metabolites have
substantial antioxidant activity.
3. Anthocyanins
o It is a flavonoid and imparts the purple colour
to fresh forastero cocoa beans
o It is a water soluble glycosidic compound made
up of a glycone (the sugar portion) and an
aglycone (the non sugar portion)
o During fermentation, it is enzymatically
transformed to become an anthocyanidin aglycone.
Caffeine
o It is a xanthine alkaloid substance found in
cocoa beans and many other plants.
o The cocoa bean contains between 0.1-
0.7% caffeine, 0.2% being the most
common amount found.
o Caffeine is also present in lesser amounts
in the husk that surrounds the cocoa beans,
usually from 0.05% -0.3%.
• Pyrazines (20%)
• Aldehydes
• Alcohols
• Ketones
• Esters
o Some of these compounds are influenced by
fermentation time, others are not.
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Fermentation and Curing
• The process has to be carried out within 24-48 hours after breaking the
cocoa pod.
• It takes about 5-7 days on average and varies according to the species.
Forastero- 5-7 days
Criollo- 1-3 days
• It is responsible for the chocolate flavor and aroma in cocoa and also
external browning of beans.
Fermentation and drying
• Fermentation and drying are the last operations carried out on-farm before trading the dried beans.
• Fermentation and drying are the last operations carried out on-farm before trading the dried beans.
Fermentation is essential for the development of chocolate flavour (further developed during roasting).
After extraction, the wet beans are bulked together and gradually heat up as a result of exothermic
chemical reactions in the pulp caused by the activity of microorganisms (yeasts and acetic and lactic acid
bacteria). Initially, the mucilage is broken down and drains off as 'sweatings'. After 36-72 hours the beans
are killed and a series of chemical changes take place inside the bean, some of which continue during
drying.
• Fermentation methods are simple. Fermentation is carried out in specially constructed wooden boxes, in
heaps covered by banana leaves or in baskets. Much of the heat generated is retained by insulation, but
this is more difficult with small quantities of beans and a minimum of about 90 kg is required when using
traditional heap or box methods. The process usually takes from five to seven days to complete
depending on the type of cocoa being grown and local practice. The mass of beans is turned or stirred at
least once for aeration.
• Fermented beans are then dried in the sun or artificially until suitably dry (6-7% moisture content dry
basis) for storing and transporting. Artificial drying can cause beans to be very acidic if they are dried too
quickly. Dried beans are hand sorted or mechanically sieved and winnowed to remove defective beans
and debris.
Fermentation and Curing
•Coca beans do not themselves undergo a fermentation at all
•It is pulp surrounding the beans which is fermented, while an almost
simultaneous ‘curing’ process takes place within the beans
Fermentation Curing
Site: In the pulp Site: inside the beans
Carried out by Carried out by enzymes
microorganisms Occurs after
Immediate and initial process fermentation
after breaking of pods Purpose: flavor
Purpose: removal of pulp development & partially
out of the pod responsible for the brown
colour
Microbial Aspects of Fermentation
• Micro-organisms are responsible for the breakdown of the pulp that
surrounds the beans.
• Their activities result in the death of the beans and they create the
environment that enables the formation of cocoa flavor precursors
• The pulp is an excellent medium for the growth of micro-organisms since it
contains 10-15% of sugars.
• When the beans are removed from the pods, the pulp is inoculated
naturally with a variety of micro-organisms from the environment.
There are 3 stages of fermentation:
Stage 1-
Anaerobic yeasts
• Sugar Alcohol + CO₂
• 24-36 hrs
• Rise in temperature
• pH < 4 acidic
• Low oxygen
• Bean death on second day occurs due to acetic acid
and alcohol
Stage 2:
Lactic acid bacteria (LAB)
• Sugar & organic acids Lactic acid
• LAB are present from start but only become dominant
in 48-96 hrs
Pulp composition
Components Percentage
Water 82-87
Sugar 10-15
Pentosans 2-3
Citric acid 1-2
Salts 8-10
Stage 3:
Acetic acid bacteria
• Also present from start but become significant at the
end when the aeration increases
• Alcohol acetic acid
• Exothermic reaction
• Increases temperature to 50˚C
Pulp sugars
Fermentation
Respiration yeasts
aeration
yeasts
Aeration
Acetic acid
bacteria
Lactic acid bacteria
Methods of fermentation
1. Heap
2. Baskets
3. Boxes
4. Batch processes
Fermentation
• The pulp around the beans is sticky and needs to be separated.
• The pulp starts loosening from the bean in the 1st microbial stage.
• Turning of the beans aids to the fermentation process
• In 1st 2 processes the temperature rises due to the exothermic
reactions to almost 49-54˚C
• By the end of 3rd stage, the temperature drops rapidly and most of the
pulp has drained away as a liquid.
External appearance of cocoa beans
Temperature profile
Curing
• Acetic acid penetrates into testa (husk) of cocoa beans.
• High temperature and influx of acid:
1. Kill the bean
2. Disrupt the internal structure
• Cocoa beans are composed of white cells (fats, proteins)
and purple cells (polyphenols)
• Due to the disruption compounds in the beans mix and
interact within themselves.
• Reactions between storage proteins, enzymes
(proteolytic, polyphenol oxidase, invertase) and
polyphenols result in formation of the crucial chocolate
flavor precursors
Chocolate flavor precursors Components Percentage
•Proteins are degraded by Water 32-39
enzymes to polypeptides and Cellulose 2-3
amino acids Starch 4-6
•Reducing sugars (glucose/ Pentosans 4-6
fructose) are released.
Sucrose 2-3
Fat 30-32
Protein 8-10
Reduction of astringent and
bitter taste Theobromine 2-3
•Part of polyphenols oxidized Caffeine 1
into large tannin molecules Polyphenols 5-6
•Part of polyphenols and Acids 1
theobromine/caffeine (20%)
diffused and exudated from the Salts 2-3
bean
Importance of fermentation & curing
• There is no chocolate flavor in cocoa bean without
fermentation
• Chocolate flavor precursors are formed during fermentation
which help in further flavor development
Importance of fermentation & curing
• Fermentation helps in the separation of pulp and beans
• Omission of fermentation prevents the possiblity of ever
developing a true chocolate flavor and defect cannot be
removed by later attempts of fermenting
• With lower temperatures the putrefaction bacteria will start
to proliferate and longer fermentation would cause hammy
off-flavors typical for over fermented cocoa beans
Factors affecting fermentation
• Extent of ripeness of pod
• Pod storage
• Quantity of beans
• Quantity of pulp
• Type of cocoa
• Duration of fermentation
• Seasonal/ climatic effects
• Pod’s disease
By products
• Shell
In African countries, it is used as manure due to its
fibrous content
• Fermented pulp
Use of liquid fermented pulp for manufacturing of
vinegar has been proposed by many. But practical
application has not been tried yet.
Drying
• Extended process of fermentation
• Superficial browning in cocoa beans continues to
deepen
• Slow but progressive loss of moisture
• Loss of astringency & bitter tasteloosening of the shell
from the bean
• Shrinking of furrowed cotyledons into 2 almost
separate halves
• Moisture content reduced to 6%
• The enzymatic action as evidenced by colour changes
in the bean should be allowed to proceed to
conclusion
Drying
• If the beans are dried too quickly some of the
chemical reactions started in the fermentation
process are not allowed to complete their work and
the beans are acidic with a bitter flavor.
• If the drying is too slow moulds and off flavors can
develop.
• Temperature should not exceed 65˚C
• Types of drying:
sun-drying
mechanical drying
Slaty, underfermentated (purple) and
well fermented (brown) cocoa
Sun-drying
• Fermented beans are spread in a thin layer (1-2 inch
deep
• Exposed to sun until dry
• Beans are occasionally turned for uniformity
• Sundrying can be carried out on small as well as on
large scale basis
• Traditionally there is also a method call dancing the
beans which serves the purpose of drying and
removal of shell
Large scale sun drying
• One of the important reaction for flavor development is the Maillard reaction or
carbonyl-amine reaction.
• The reactions may be conveniently seperated into three stages
-initiation
-intermediate
-final
• INITIATION:
FORMATION OF ADDITION COMPOUNDS
Reducing sugars + amino acids glucoslyamines or fructoslyamines
(depending upon initial reducing sugars)
ISOMERISATION
The isomerizaion product formed during the initial phase are primarily addition
compounds formed from amino acids and sugars
• INTERMEDIATE
moisture is evaluated by hygrometer probe.
ERH > 40% - very light roast
ERH = 28-30% - average roast
ERH < 20% - very dark roast
Composition of roasted cocoa bean
Components Percentage
moisture 1-4
Organic acid 5
Nib/shell 8-14
Importance of roasting
• Non uniformity in moisture content, age, ripeness, fermentation and
curing
• To convert flavor precursors into the type and intensity of chocolate
flavor desired
• Roasting duration and temperature varies for different species as well
as for different products
Cocoa products
Main products obtained from Cocoa beans
are
-Cocoa powder
End product of cocoa solids which are low-
fat
components and are rich in flavonoids
-Chocolate
A food preparation in the form of a paste or
solid block made from roasted and ground
cacao seeds, typically sweetened.
PRODUCTION OF COCOA POWDER & CHOCOLATE
FERMENTED CACAO BEANS
CLEANING
ROASTING
CRUSHING SHELL,GERM,ROOTLETS
CACAO NIBS
DISINTEGRATON
GRINDING
ROLLING
LECITHIN REFINING
CONCHING
MOLDING
COCOA POWDER
CHOCOLATE
Cocoa products
1)Cocoa liquor :
After roasting and drying , the cocoa nib is disintegrated and milled in order to rupture
the cell walls of aggregates and expose the cocoa butter. The resultant product is a
homogeneous mobile paste, a flowing cocoa mass or cocoa liquor
COCOA BUTTER
Pressing
Press cocoa cake
(COCOA
COCOA LIQUOR POWDER)
Mixing with
Grinding and
sugar, fat and
refining
milk powder
COCOA BUTTER
• Cocoa butter is the natural fat of the cocoa bean .Cocoa butter (hydraulic
expression of cocoa nib) is a light yellow fat, exhibiting a distinct brittle fracture
>20°C, a fairly sharp complete melting point about 35°C, with an incipient fusion
or softening around 30-32°C.
• The completely liquid fat displays mark tendency to super cool,(which means that
the liquid fat in an undisturbed condition will remain in the liquid state well below
its melting point.) which must be taken into account during chocolate enrobing
and molding
• Cocoa butter is composed of number of glycerides of stearic, palmatic and oleic
fatty acids with a small proportion of linoleic.
• The cocoa butter has important functions. It not only forms part of every recipe,
but it also later gives the chocolate its fine structure, beautiful lustre and delicate,
attractive glaze.
COCOA BUTTER
COCOA BUTTER
• It is the fat obtained • Cacao nib is steamed • extracted from the cake
from good quality and expeller pressed residue after expeller
cocoa nib by means to remove cocoa pressing.
of mechanical butter • It is always subjected to
(hydraulic) pressing • Flavor obtained is refining (de-odorization,
• No refining other very mild and floral, de-gumming)
than filtration is if raw beans used.
done • If substandard raw
material is used then
resultant cocoa
butter has to be
subjected to a
refining process
COCOA POWDER
• The cocoa mass/liquor is converted into cocoa powder , the cocoa fat is reduced by
pressing, by means of hydraulic, mechanical pressing or preferentially , horizontally- run
expeller press at a pressure of 400- 500 bar and temperature of 90-100 degree C
• The cocoa powders are divided according to the extent of defatting
• Cocoa powder is widely used in the manufacture of other products e.g. cake fillings,
icings, pudding powders , ice creams, and cocoa beverages
The process involves use of simply The process involves use of alkalized
unsweetened cocoa powder. unsweetened cocoa powder.
Cocoa powder reacts with baking powder Doesn’t react with baking powder
used in recipes So not used in recipes
Lighter in colour than dutch process powder. Neutralization of acidity makes it dark in
colour