Processing of cocoa
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The document discusses the cocoa tree, cocoa varieties, cocoa processing, and fermentation. It provides details on: - The cocoa tree can grow 15-25 feet tall and each tree produces 20-50 pods per year containing 20-50 beans. - There are three main cocoa varieties - Forastero, Criollo, and Trinitario hybrid. Forastero has the strongest flavor. - Cocoa processing involves harvesting, fermentation, drying, roasting, and grinding. Fermentation is key for developing chocolate flavor and takes 5-7 days. - Fermentation involves yeast, lactic acid bacteria, and acetic acid bacteria breaking down the pulp and interacting with compounds in the bean to produce
Processing of cocoa
- 2. Botanical Name: Theobroma cacao Cocoa trees grow best in the tropical rainforests The cocoa tree grows to a height of 15 – 25 ft. A single tree produce 20-50 fruits per year. 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
- 3. Varieties of cocoa trees There are three broad types of cocoa - Forastero and Criollo, as well as Trinitario, a hybrid of the two. Forastero Forastero is hardy and vigorous, producing beans with the strongest flavour. Criollo With its mild or weak chocolate flavour, Criollo trees are not hardy and produce softer red pods, containing 20-30 white, ivory or very pale purple beans. Trinitario Plants are not found in the wild as they are cultivated hybrids of the other two types.
- 6. HARVESTING: Only ripe pods are harvested. PRE FERMENTATION STORAGE: 3 to 5 days Ensures correct nib acidification Enhances pre-fermentation activity inside beans Facilitates rapid rise in temperature Imparts stronger chocolate flavor POD BREAKING AND COLLECTION OF WET BEANS: Pods are broken without causing damage to beans Only good beans are collected Diseased, germinated and caked beans are discarded.
- 7. FERMENTATION AND CURING Fermentation 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. Cocoa beans do not themselves undergo a fermentation at all It is pulp surrounding the beans which is fermented, while simultaneous ‘curing’ process takes place within the beans
- 8. Microbial aspects Micro-organisms are responsible for the breakdown of the pulp that surrounds the beans. This result in the death of the beans and 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.
- 9. Stages of Fermentation Stage 1 Anaerobic yeasts Sugar Alcohol + CO₂ 24-48 hrs (no air circulation) Rise in temperature pH < 4 acidic Low oxygen Bean death on second day occurs due to acetic acid and alcohol penetration inside the bean.
- 10. Stage 2: Lactic acid bacteria Sugar & organic acids Lactic acid LAB are present from start but only become dominant in 48-96 hrs 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
- 12. Factors influencing Fermentation Pod maturity Pod storage Quantity of beans Quantity of pulp Type of cocoa Duration Seasonal effects Pod diseases
- 13. End point of fermentation Bean color changes to brown, becomes plump and filled with a reddish brown exudate Testa becomes loose and detached from the cotyledons Longitudinal halves of cotyledons show bleached appearance in the centre with a brownish ring at the periphery When 50 % of beans show these signs, the lot can be taken out for drying
- 14. Curing High temperature and influx of acid: Kill the bean 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
- 15. Chocolate flavor precursors Proteins are degraded by enzymes to polypeptides and amino acids Reducing sugars (glucose/ fructose) are released. Reduction of astringent and bitter taste Part of polyphenols oxidized into large tannin molecules Part of polyphenols and theobromine/caffeine (20%) diffused and exudated from the bean
- 16. 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
- 17. DRYING: Extended process of fermentation Slow but progressive loss of moisture Loss of astringency & bitter taste Loosening of the shell from the bean Moisture content reduced to 6% ROASTING: Dried beans are roasted at 200˚F to 250˚F for 1-2 hours in order to develop the flavor of the beans. The beans become brown in color and friable (brittle).
- 18. GRINDING : 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 30˚C PRESSING OF NIBS Filter-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
- 19. COCOA PRODUCTS Cocoa butter also called theobroma oil, is a pale-yellow, pure, edible vegetable fat. 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.
- 20. Researches.... Improvement of Cocoa Beans Fermentation by LAB Starter Addition - M. T. A. Penia Kresnowati, Lenny Suryani, and Mirra Affifah Addition of microbial starter was thus suggested to improve the cocoa bean fermentation process. The addition of LAB starter was observed to accelerate the growth of both lactic acid bacteria and acetic acid bacteria, leading to the increase in the ethanol, lactic acid, and acetic acid concentration. Overall it increases the fermentation index and potentially shortens the fermentation time.
- 21. Dynamics of Cocoa Bean Pulp Degradation during Cocoa Bean Fermentation: Effects of Yeast Starter Culture Addition - Laras Cempaka1, Lienda Aliwarga1, Susanto Purwo & Made Tri Ari Penia Kresnowati This article discusses the effects of the addition of Saccharomyces cerevisae var. Chevalieri starter culture on cocoa bean fermentation. The dynamics in the yeast concentration, sugary pulp compounds and metabolic products were measured during fermentation. A higher fermentation index was measured for the cocoa bean fermentation with yeast starter culture, 1.13 compared to 0.84. In conclusion, this method can potentially be applied to shorten the cocoa bean fermentation time
- 22. Reference... The Functional Role of Microorganisms in Cocoa Bean Fermentation V. Thi Thuy Ho, J. Zhao, G. Srzednicki and G. Fleet www.c-spot.com - chocolate flavor profiles Harvesting and Processing Cocoa Beans 'Theobroma Cacao' – The Cocoa Tree Cocoa – production and processing -Kokou Edoh Adabe & E. Lionelle Ngo-Samnick