Cocoa quality control for premium chocolate and cocoa production_Chemutai Job Alunga_A Review
- 1. COCOA QUALITY CONTROL PRESENTATION BY THE QUALITY ASSURANCE ASSOCIATION OF UGANDA (QAAUL) Speaker: Chemutai Job Alunga Cocoa Research Scientist (NARO-NaCORI) Member, QAAUL chemujo@yahoo.com Job.chemutai@naro.go.ug Dec, 2024
- 2. Outline Click icon to add picture • The principle of quality in cocoa and its requirements • Managing agronomic practices and post- harvest processes for quality cocoa production • Identifying the principal sources of impurities in cocoa • Classifying cocoa into grades
- 3. QUALITY Quality has been variously defined. It may come as satisfaction for a product because of: • PERCEIVED QUALITY: or value of that product in the eyes of the consumer. • PRODUCT PERFORMANCE: What a customer expect a product to do. • FEATURES: desirable characteristics of a product. • RELIABILITY: A product not breaking down • DURABILITY: A product having a long life • SERVICEABILITY: easy and cheap to repair. • AESTHECTICS: how good a product looks. • CONFORMANCE: A product meeting specified standards
- 4. WHAT IS COCOA QUALITY • For cocoa, conforming to acceptable standards is the key to QUALITY definition. • Quality of a product allows producers to access critical global markets to assure regular income while protecting consumer rights and integrity. • In the wake of consumer guarantee for quality products and global market access for producers, there have emerged various certification schemes such as Fairtrade, Rainforest Alliance, UTZ certified, geographical indications and eco-labels • EU Regulation on deforestation-free products (EUDR) (EU 2023/1115) • Sustainability Standards ISO Standards (ISO 34101 Sustainable and traceable cocoa) • ARS:1000 African regional standard for sustainable cocoa • HACCP, UNBS (EAC), ISO Standards,
- 5. Significance of quality in cocoa Chocolate sells in a very competitive market, where quality and value are paramount. Various types of cocoa beans are needed to meet the demands of a complex market for chocolate and cocoa- derived products. If the quality of the cocoa beans is poor, final products suffer and the industry as a whole loses as consumers turn to other snack foods. In the industry; food safety, traceability, efficiency and cost effectiveness are key factors alongside consumer demands for taste and quality.”
- 6. Quality starts from the beginning; • Site Selection • Land Preparation • Nursery Management • Seed Germination • Pruning • Shade Management • Weed Control • Fertilizer Application • Disease, Parasites and Pest control • Harvesting, Pod breaking and fermentation • Drying, Bagging, Storage • Post-harvest analysis and management
- 7. Quality Issues and Determination Quality of cocoa refers to the overall degree of excellence of commercial quantities of cocoa beans, including; • Purity or wholesomeness, • Yield of the cocoa nib, • Uniformity and flavor, and • Freedom from postharvest pests and moulds The highest quality beans will be uniform throughout 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 the assessment by the manufacturer.
- 8. • 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 sampling of fermented and dried beans. • If the cotyledon is slaty grey then it is totally unfermented, and if it is completely or partially purple, then the beans is under fermented. • Completely brown cotyledon means the beans is thoroughly fermented. Beans at the end of fermentation showing well defined internal ridging (right).
- 9. Cocoa inspection includes: During cocoa bag loading and stuffing: • Inspectors count and tally each cocoa cargo bag loaded, and check condition. • After completion of cocoa bag stuffing, storage doors are closed; fumigation Prior to cocoa cargo loading and stuffing: • Determination of the condition of the cocoa and cocoa packaging. • Determination of individual cocoa package weight by random basis. • Ensure cocoa storage containers are clean and dry, ready and fit for intended cocoa cargo.
- 10. Principal source of impurity in cocoa It is important that cocoa products especially chocolate shall be pure and wholesome. It follows that cocoa bean which plays a good factor shall not contain any impurities which could be injurious to the health of the consumer. The principal source of impurity are: • Pesticides • Microorganisms infections • Insects Infestation • Foreign Matters • Warehouse Sanitation
- 11. 1.Pesticides The use of pesticides on cocoa trees and in cocoa beans stored can lead to the presence of residue in the dried beans. Chocolate manufacturers require that their supplies of cocoa beans comply with these limits and will monitor closely the level of pesticides on all cocoa raw materials. Some the chemical that Quality Control Check for are: • Endosulphine • Imidacloprid • 2,4 D (2,4-Dichlorophenoxyacetic acid)
- 12. 2.Micro-organisms Excessive microbial contamination can result from too slow or inadequate drying, storage of wet beans, contamination of stored beans by birds and rodents or during drying by domestic birds and animals Others are leakage in warehouse Some of the microorganisms that they check for are; • Aflatoxins • Ochratoxins
- 13. Pool of water in a warehouse with microbial infections
- 14. Moisture Content Manufacturers requires cocoa beans to have moisture content of 6 – 7%. Over 8%, the beans become mouldy and below 5% they are brittle. The is done with a machine called “moisture meter”.
- 15. Cocoa storage (moisture content control
- 16. Good warehouse for storing cocoa
- 17. Well arranged cocoa in the warehouse
- 18. 3.Insect infestation • Cocoa beans frequently become infested at origin by several species of insects. • If not controlled by effective pre-shipment fumigation, the infestation will spread to cocoa stores which will destroy finished goods. • Chemical Used for Fumigation is Phosphine Some of the pest are; 1. Tropical warehouse moth-Ephestia cautella 2. Cigarette beetle-Lasioderma serricone 3. Corn sap beetle-Carpophilus dimidiatus 4. Rusty grain beetle-Cryptolestes ferrugineus 5. Coffee bean weevil-Araeocerus fasciculatus 6. Red flour beetles-Tribolium castaneum 7. Rodent-Rattus spp. Insect trap in a warehouse
- 19. 4.Foreign matters The presence of foreign matters such as pieces of pod husk, placenta, stone, broken wood in bulk cocoa may contaminate the product, affect the flavor or cause damage to plants or machinery apart from reducing the proportion of edible material.
- 20. GRADING COCOA BEANS Cocoa beans are graded, according to the proportion of defective beans determined by the method of test specification The test specification mostly used is the cut test Unfermented bean Partially fermented bean
- 21. GRADE TYPES GRADE I: Cocoa which is thoroughly dry, free from foreign matter, smoky beans and any evidence of adulteration, and which contains not more than 3% by count of mouldy beans, not more than 3% by count of slaty beans, and not more than 3% by count of all other defects. GRADE II: Cocoa which is thoroughly dry, free from foreign matter, smoky beans and evidence of adulteration, and which contains not more than 4% by count of mouldy beans, not more than 8% by count of slaty beans, and not more than 6% by count of all other defects. SUB GRADE: Cocoa which fails to reach the standard of Grade II. This is unacceptable to be purchased. Only grades I and II cocoa are purchased at the full price.
- 22. The table below describes grade standards Mouldy Slaty Insect Damage, Germinated, flat Grade I 3 % 3% 3 % Grade II 4% 8% 6%
- 23. Germinated beans Description • Germinated /sprouted beans have a small point/holes at one end of the beans Causes • Over ripened 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 contaminants through the ripped hull of beans How to avoid it and test it • Harvest regularly • Ferment beans immediately after pod breaking • Do not mix sprouted beans with other beans to prevent the spread of mould
- 24. Chipped beans Description • Beans with injury Causes • Breaking of pods with cutlass or sharp object Consequences • Facilitates the entry of the moulds through the wounded areas. How to avoid it and test it • Breaking of pods with wooden clubs • Do not mix injured beans with other beans to prevent the spread of moulds
- 25. Purple beans Causes • Harvesting of unripe or green pods • Under fermentation Consequences • Bitter chocolate- • Reduction in market value How to avoid it and test it • Harvesting of mature or ripe pods • Fermentation for 6 days
- 26. Brown beans, black spots Causes • Over-fermentation Consequences • Taste of rot • Reduction in market value How to avoid it and test it • Fermentation for 6 days
- 27. Smoked beans Causes • Drying or storage of beans in contact with smoke Consequences • Taste of smoke How to avoid it and test it • Avoid bean contact with smoke from the fireplace.
- 28. Beans 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 Clumped beans 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 exporter by sorting before marketing How to avoid it and test it Ensuring proper bean sorting Keep areas of drying clean, use raised mats.
- 29. Low graining and flat beans Description • Low graining is due to small beans size • Flat beans have cotyledons which are completely artrophied 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 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 and test it • Good agronomic practices • Mulching • Correct spacing • Spraying against disease
- 30. GOOD QUALITY CONTROL MEASURES At the pre harvest level • Climatic conditions such as rainfall can affect pod development which may lead small bean sizes. • Ambient temperature, Evidence from brazil indicates that the cocoa butter from beans which develop during cooler months contains more unsaturated fatty acids and it is therefore softer. • Check planting materials, go for good quality planting materials. They are vigorous, are also disease tolerant and high yielding.
- 31. • The types pesticides to use – especially those that will not leave residues in the tree affecting the pods. • The time of harvest can also affect bean quality, this should be done at interval of 1-2 weeks. • After harvesting pods should not be left for a long period before breaking, this brings about germination which can reduce quality • Use wooden baton to open pods instead of machete
- 32. At the post harvest level • Deep box fermentation, multiple turning and too much rapid drying can lead to excessive acid taste • Lack of fermentation can also lead to excessive bitterness and astringency • Do not dry more than needed unless necessary • Preventing moulds Check prolonged fermentation Adequate drying Don’t store under high humid conditions • Do not dry in smoky environment
- 33. • Do not store in warehouse closer to smoke • Store in a clean dry environment well stacked on pallets. • Check the pesticides for controlling insect infestation to prevent residues in the beans
- 34. Summary of quality requirements, Cocoa beans shall be: Be properly fermented and dried whole seed of a tree botanically known as "Theobroma cacao linnaeus Be reasonably uniform in size and shape Be reasonably free from broken beans, fragments and small pieces Be free from foreign matter
- 35. Be free from beans of abnormal odour or flavor Be free from admixture of any other seeds and impurities The dried beans should have a moisture content of 6 – 7%. Over 8% the beans become mouldy and below 5% they are brittle. Conform to the provisions under Rules 57, 57A and 65 of the Prevention of Food Adulteration rules, 1955 in respect of metallic contamination, crop contaminants and pesticide residue
- 37. Conclusion Summary Cocoa Quality is a Key driver of success along the cocoa value chain Applying standardisation and systemisation ensures consistency and builds trust Call to Action Engage the Quality Assurance Association (QAAUL) for your business growth and development Focus on Quality at every stage, invest in certification, and leverage marketing tools to compete globally.