COCOA QUALITY CONTROL IN GHANA AND BEYOND
- 1. COCOA QUALITY CONTROL By D. OWUSU BOATENG (polonium90@yahoo.com) BUNSO COCOA COLLEGE Nov, 2014 COCOA HEALTH & EXTENSION DIVISION
- 2. WHAT IS 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
- 3. WHAT IS 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 product and global market access for producers have emerged various certification schemes such as Fairtrade, Rainforest Alliance, UTZ certified, geographical indications and eco-labels
- 4. 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
- 5. INTRODUCTION The importance of a consistently high standard of quality in cocoa beans cannot be over emphasized since chocolate is very competitive on the markets. If the quality of the beans are poor, final product suffers and the industry as a whole looses as consumers turn to other snacks foods. Through out the food industry, and with most of the other methods of cocoa production, quality control is changing from inspection to the application of Good Agricultural Practices (GAP)
- 6. • Ghana is highly reputed on the world market for the high quality of its cocoa. ‘Ghana Cocoa’ is the standard mark for the grading of the quality of raw cocoa beans from all producing countries. • Ghana Cocoa Board is determined to maintain quality of every exportable crop under its schedule. • The subsidiary of the Board which is responsible for preserving quality of exportable cocoa is the Quality Control Division now Quality Control Company Ltd. • The Board insists on cocoa always being of the highest quality. There are at present, three grades, namely grades I, II and sub-grade.
- 7. QUALITY ISSUES AND DETERMINATION Quality of cocoa means the overall degree of excellence of commercial quantities of cocoa beans, areas; Purity or wholesomeness, Yield of cocoa nib, Uniformity and flavour and Free from postharvest pest 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 intentionally 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, 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.
- 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 storage can be 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 in all cocoa raw materials. Some of 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 results 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 the aqua boy
- 15. WAREHOUSE FOR STORING COCOA
- 16. WELL ARRANGED COCOA IN THE WAREHOUSE
- 17. 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.
- 18. 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.
- 19. 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
- 20. 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 not purchased by the Board. Only grades I and II cocoa are purchased at the full price.
- 21. The table below describes grade standards Mouldy Slaty Insect Damage, Germinated, flat Grade I 3 % 3% 3 % Grade II 4% 8% 6%
- 22. GERMINATED BEANS Description Germinated /sprouted beans have a small point/holes at one end of the beans Causes Over ripen 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 beans 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
- 23. 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 are 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
- 24. 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
- 25. BROWN BEANS, BLACK SPOTS Causes Over-fermentation Consequences Taste pf rot Reduction in market value How to avoid it and test it Fermentation for days
- 26. 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.
- 27. 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 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.
- 28. 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
- 29. 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 the hybrid which is a cross of the Amazon which is know to produce bulk cocoa as compare rest. They are also disease tolerant and high yielding.
- 30. The types pesticides to use, that is these that will not leave residue 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 pod should not be left for a long period before breaking, this bring about germinated once which can reduce quality Use wooden baton to open pods instead of machete
- 31. 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 drying more than the fermentation period unless necessary Preventing moulds Check prolong fermentation Adequate drying Don’t store under high humid conditions Do not dry in smoky environment
- 32. 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 residue in the beans
- 33. SUMMARY OF QUALITY REQUIREMENT, Cocoa beans shall be- Be properly fermented and dried whole seed of 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
- 34. 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. Be 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
- 35. QUALITY CONTROL EXPECT AT WORK PERFORMING EFFICACY TEST