The various products made from cacao and processing technologies used in chocolate manufacturing.

1. College of Food Processing Technology and
Bioenergy,
Anand Agricultural University
Submitted by~ Kratika Khede
(07-0221-2015)

2. • A cocoa pod (fruit) has a rough,
leathery rind thick filled with sweet
pulp with a lemonade-like taste
enclosing 30 to 50 large seeds that
are fairly soft and a pale lavender to
dark brownish purple color.
• The three main varieties of cocoa
plant are Forastero, Criollo, and
Trinitario.

3. • The husks of cocoa pods and the pulp
and the cocoa bean shells can be used.
Some examples of these uses are:
• Animal feed from cocoa husk.
• Production of soft drinks and alcohol –
In the preparation of soft drinks, fresh
cocoa pulp juice (sweatings) is collected,
sterilised and bottled. For the production
of alcoholic drinks, such as brandy, the
fresh juice is boiled, cooled and fermented
with yeast. After 4 days of fermentation
the alcohol is distilled.

4. • Potash from cocoa pod husk
• Cocoa pod husk ash is used mainly for soft soap
manufacture.
• It may also be used as fertiliser for cocoa,
vegetables, and food crops.
• To prepare the ash, fresh husks are spread out in
the open to dry for one to two weeks. The dried
husks are then incinerated in an ashing kiln.

5. • Jam and marmalade - Pectin for jam and
marmalade is extracted from the sweatings by
precipitation with alcohol, followed by distillation
and recycling of the alcohol in further extractions.
• Mulch - Cocoa bean shells can be used an organic
mulch and soil conditioner for the garden.

6. • After fermentation and
drying:
• Cocoa butter –
• use :
• manufacture of chocolate
• cosmetic products such as
moisturising creams and soaps.
• Cocoa powder –
• Use: as an ingredient in almost
any foodstuff.(chocolate flavoured
drinks, desserts such as ice
cream and mousse, chocolate
spreads and sauces, and cakes
and biscuits.)
• Cocoa liquor –
• Used: to produce chocolate to
form confectionery products.

8. • Step 1. Cleaning
• Step 2. Roasting(to bring
out the chocolate flavour)
Small roasters

9. alkalization Roaster +winnower
Step 3. A winnowing machine is used to remove the shells from the beans
to leave just the cocoa nibs.
Wind winnowing is a method for separating grain from chaff.

10. • Step 4.grinding:The beans' cocoa butter melts and the so-
called cocoa nibs turn into liquid cocoa mass(cocoa liquor).
• Alkalisation is the addition of alkali salts such as potash or
sodium carbonate to develop the flavour and colour.Fat is
more easily separated from the cocoa mass.

11. Step 7. the cocoa mass is pressed in a press for 10
to 15 minutes at a temperature of about 100
degrees Celsius and the fat runs off as golden yellow
cocoa butter.

12. • Step 8. The processing now takes two
different directions. The cocoa butter is
used in the manufacture of chocolate.
The cocoa presscake is broken into small
pieces to form kibbled presscake, which
is then pulverised to form cocoa powder.
What is left over is the cocoa press cake,
which is then pulverised. The cocoa
butter is also deodorised.
• Deodorization is process in which steam
is passed for a given period of time
through hot oil at a low pressure. Hence,
volatile components are removed.
• Step 9. Cocoa liquor +cocoa butter+
sugar, milk, emulsifying agents _these
are mixed. The proportions depend on
type of chocolate.

13. • Step 10. The mixture then
undergoes a refining process by
travelling through a series of
rollers until a smooth paste is
formed. Refining improves the
texture of the chocolate.
• Step 11. The next process,
conching, further develops
flavour and texture. Conching is a
kneading or smoothing process.
The speed, duration and
temperature of the kneading
affect the flavour. An alternative
to conching is an emulsifying
process using a machine that
works like an egg beater.

14. • Step 12. The mixture is then
tempered or passed through a
heating, cooling and reheating
process. This prevents
discolouration and fat bloom in
the product by preventing
certain crystalline formations
of cocoa butter developing.
• Step 13. The mixture is then
put into moulds or used for
enrobing fillings and cooled in
a cooling chamber.
• Step 14. The chocolate is then
packaged for distribution to
retail outlets.