Coco processong

PROCESSING AND VALUE ADDITION OF COCOA

P C VengaiahScientist (Food Science &Technology)

Horticltural Research StationPandirimamidiDr.Y.S.R Horticultural University

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COCOA (Theobroma cocoa) A small tree native to America tropicsNow grown in all tropical regions of the worldChief cocoa producing countries Ghana, Nigeria, Ivory Coast and BrazilKerala, Karnataka, Tamil Nadu and Andhra Pradesh in India

The pods are 10-18 cm in diameter, having thick leathery rinds containing 20-50 beans inside in rows

The seeds are embedded in white or pinkish pulp

Seeds are the principal source of cocoa or cocoa powder highly prized as a nutritious beverage, and chocolate used as food all the world over

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FRESH POD WITH PULP

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WHY COCOA IS PROCESSED ? Raw cocoa is bitter, astringent and devoid of chocolate flavour The original taste, flavour and colour of the chocolate are due to the interplay of about 600 different chemicals developed during processing Biochemical processes for development of chocolate flavour start during fermentation and continue during drying, roasting and conching.

QUALITY OF INDIAN COCOA CURRENT STATUS`At present, more thrust is given on value addition, so farm level processing is relevant.Knowledge of farmers on processing techniques is inadequateThe area expansion on cocoa is very extensive and India will become an exporter of cocoa in the next decade.Adoption of improper processing technology can lead to branding of Indian cocoa as poor quality in international market

Thank YouCocoa pods when mature, are yellow in some varieties and red in others

1. Post harvest processing A. Primary processingB. Secondery processing

2. Value added productsA. Cocoa mass/liquerB. Cocoa butterC. Cocoa PowderD. Chocolate E. By product utilisation

PRIMARY PROCESSING PRESENT STATUS Above 90% of cocoa is sold as pods or as wet beans Quality of beans processed by growers is poor due to Wrong choice of the method of fermentation Indiscriminate mixing of diseased, germinated and caked beans Adulteration practices Improper turning and lack of insulation during fermentation Under fermentation and consequent acidity problems Too rapid drying in artificial dryers Contamination by smoke and mould

FACTORS INFLUENCING QUALITY OF COCOA Pre harvest factorsPost harvest handling methods Environmental conditions during growthVariety GrownAgrotechniques adoptedFermentationDryingStorgae

HARVESTOnly ripe pods are harvested

Primary ProcessingMatured pods are removed from the tree by machetes or by a similar knife attached to a long pole for the higher branches

After a day or two, the pods are split open with the machete and the beans and pulp removed by hand or by hand implements

Beans are subjected to natural fermentation to assist in removing the adhering pulp and to prepare the beans for drying

Fermentation generally takes for 5-10 days

At the end of fermentation, the pulp breaks down and there is a change in color of the seeds from pale yellow or violet to brown

The endogenous enzymes, activated by the heat of fermentation bring about changes in proteins and polyphenols in the Kernel and there is also a reduction in the astringency of the kernel

The beans are then dried to 6-8% moisture level in sun or in artificial dryers

The bean is then ready for export or further processing to manufacture cocoa products

PRIMARY PROCESSING SOME TIPS FOR BETTER QUALITYHarvest ripe podsPre fermentation storage of 3-5 days is essentialUse only good beans Choose method depending upon the quantity Allow smooth drainage of sweatingsInsulate the fermenting mass properlyTurn on alternate daysAvoid too small quantitiesAvoid over or under fermentationTake out for drying after judging the end pointAs far as possible sun dry fermented cocoa If artificial dryers are used, adjust temperature to less than 600C, stir at regular intervals and adjust rate of air flow so that drying is complete in 3-5 days.

PRE FERMENTATION STORAGE (3-5 DAYS) Ensures correct nib acidification Enhances pre-fermentation activity inside beans Facilitates rapid rise in temperature Imparts stronger chocolate flavour

POD BREAKING & COLLECTION OF WET BEANS Break pods without causing damage to beans Collect good beans Discard diseased, germinated and caked beans

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BREAKING OF RIPED PODS

Heap method Heaps of reasonable quantity (50-500kg) Slanting floor to ensure drainage Use banana leaves for heaping & covering Insulate adequately Turn on alternate days Retain for 6-7 days

FERMENTATION - TRADITIONAL METHODS

STARTING A FERMENTATION HEAP

HEAP READY TO FERMENT

FERMENTATION IS FINISHED

COCOA BEANS IN BASKETS READY FOR FERMENT

Box methodTW boxes of 1.2 x 0.95x 0.75m)Small scale

Tray methodTW Tray of 90x 60x 13 cm to hold 45 kg wet beansLarge scale Small scale

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Basket method

On drying platforms Gunny bags

Pod maturityPod storageQuantity of beansQuantity of pulpType of cocoaDurationTurningSeasonal effectsPod diseases

FACTORS INFLUENCING FERMENTATION

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Bean colour changes to brown, becomes plump and filled with a reddish brown exudate

2. Testa becomes loose and detached from the cotyledons3. Longitudinal halves of cotyledons show bleached appearance in the centre with a brownish ring at the periphery4. When 50 % of beans show these signs, the lot can be taken out for dryingEnd point of fermentation

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DRYING Sun dryingArtificial dryingMoisture content reduced from 55% to 6-7%Sun drying is the best as it ensures lower acidity, astringency, bitterness and better chocolate flavourThe beans are to be skin dry in first 24 hours3-4 days drying is desirableTemperature of the dryer should not exceed 600c Avoid contamination by smoke

Large scale Sun Drying

Small scale sun drying

Mechanical drying

STORAGERemove flat beans, foreign matter and broken beans Beans are packed in gunny bags lined with polytheneHumidity of store not to exceed 80 %

4. Store to be made clean and insect free5. Avoid nearness to smoke, fumes, bad odour etc.

FARM LEVEL SECONDARY PROCESSINGAlkalizationReduces acidityImparts attractive colour to cocoa powderImproves dispersability of cocoa powder

Soak beans in 1.0% Sodium bicarbonate solution for 3 hours

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ROASTING ( 20-30 MINUTES)Large scaleRoasterWinnowerSmall scaleUruli roaster

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Roasting of Cocoa BeanRoasting develops the characteristics flavor

A large number of compounds have been identified in coca and chocolatethat form during roasting

Roasting also causes changes in the chemical structure of polyphenols, producing less astringent compounds

In choosing a roast, attention is given to the ultimate product being made, its use, and the kind of beans being used

Roasting temperatures depend upon the type of roaster used and the location of the measuring instrument

Roasters traditionally were of batch design but modern manufacturing practice calls more and more for the continuous roaster

While roasting, the beans are processed through corrugated rollers to break their shells and removed by winnowing

The cotyledons are known as Nibs

Usually there is some blending of the nibs from different varieties of cocoa before they are processed further

REMOVAL OF SHELLNibShell

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Large scaleSmall scaleGRINDING NIBS TO A FINE PASTELarge scaleSmall scale

Grinding of Pressed CocoaAs cocoa loaves drop from the presses, they are passed through breakers to form a kibbled cake of less than 1 size

The higher fat cocoa break down to a smaller size than do the lower fat cocoas because of the presence of extra cocoa butter

The cocoa then requires further grinding or pulverizing to be used commercially

Traditionally pulverized cocoa has been passed over screens to obtain the proper size

Grinding of NibsThe nibs are ground using stone mills or other suitable mills to a fine paste or liquor

The heat produced during grinding causes cocoa fat to melt and the melted fat carries with it, in suspension, finely ground particles of cocoa

This is known as Cocoa mass, Chocolate liquor or Bitter chocolate

This mass solidifies at about 30C

Cocoa mass is very rich (50-55%) in fat and can not be used directly for the preparation of any beverage

Pressing of NibsFilter-pressing to separate out a major part of fat (cocoa butter)

The amount of fat left in the pressed cake can be varied by the conditions of pressing

The pressed cake is used for producing cocoa powder

The fat content of cocoa used for beverage is fixed by law

According to ISI specifications, cocoa used for beverage should contain 20 % cocoa fat

Medium fat cocoa, containing between 10 20 % fat, and low fat cocoa, containing less than 10 % fat are made

Flavoring substances like vanilla and cinnamon are generally incorporated into cocoa powder

Large scaleSmall scaleEXTRACTION OF COCOA BUTTER

Separates cocoa butter from cocoa powderPresses are large, hydraulic, expensive, and contain steel filter screens The first part of the press cycle separates the butter from the solids