Presentation during the Bureau of Agricultural Research (BAR) Seminar Series on January 23, 2020, at RDMIC Bldg., cor. Visayas Ave., Elliptical Rd., Diliman, Quezon City

1. From Seed to Bar:
CACAO
PRODUCTION &
MARKET
OPPORTUNITIES
Prepared and Presented by
Josephine V. Ramos
Bureau of Agricultural Research (BAR) Seminar Series
January 23, 2010

2. I. CACAO INDUSTRY OVERVIEW
• Beans Production & supply
• Beans Market & Price
• Trends & Forecast
C
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3. II. TECHNOLOGY & PRACTICES
Factors In Quality Cacao Beans Production
• Genetics (planting materials)
• Environment (Suitable farm site)
• Farm establishment & management (cropping
system, soil health & nutrients maintenance)
• Pest/diseases Management
• Post harvest practices (fermentation and drying)
C
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V
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A
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4. III. TRANSFORMIMG CACAO BEANS INTO
CHOCOLATES
• Beans Cleaning
• Roasting
• Winnowing
• Grinding
• Pressing, Pulverizing
• Mixing with ingredients & Conching
• Molding
C
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5. Over 70% of cocoa production takes place
in West African countries, particularly the
Ivory Coast and Ghana.
Cacao Industry Overview

6. Cacao Industry
Overview

7. December 2019 Quarterly Bulletin of Cocoa Statistics
Summary of revised forecasts and estimates
Cacao Industry Overview
Cocoa year
(Oct-Sep)
2017/2018 2018/2019 Year-on-year change
Revised
estimates
Previous
estimates a/
Revised
estimates
(thousand tonnes) (Per cent)
World production
4 651 4 849 4 834 + 183
+ 3.9%
World grindings
4 596 4 783 4 807 + 211
+ 4.6%
Surplus/deficit b/
+ 8 + 18 - 21
End-of-season
stocks
1 722 1 740 1 701 - 21
- 1.2%
Stocks/Grindings
ratio
37.5% 36.4% 35.4%

8. ICCO Monthly Averages of Daily Prices
Month US$/tonne
Jan - 2019 2263.34
Feb - 2019 2255.80
Mar - 2019 2200.49
Apr - 2019 2331.13
May - 2019 2315.07
Jun - 2019 2407.73
Jul - 2019 2416.53
Aug - 2019 2194.70
Sep - 2019 2304.40
Oct - 2019 2435.27
Nov - 2019 2519.66
Dec - 2019 2444.71
ICCO Averages of Monthly Prices
Cacao Industry Overview

9. Cacao Industry Overview

10. Trends & Forecast
Cacao Industry Overview

11. 1. GOOD GENETIC MATERIAL
What is QUALITY in Cacao?
 Technology & Practices

12. Planting materials or seedlings are the
primary investment of a farmer. Therefore,
the use of suitable planting and grafting materials is
critical.
 Technology & Practices

13. NSIC Reg. No. Variety Name Pod Color (young) Pod Color (mature)
NSIC 1999 Cc 01 ICS-40 Green Yellow
NSIC 1999 Cc 02 UIT-1 Green Yellow
NSIC 1999 Cc 03 DR-1 Green Yellow
NSIC 1999 Cc 04 P7 Green Yellow
NSIC 1999 Cc 05 BR-25 Red with Green Yellow
NSIC 2001 Cc 06 K1 Red Yellow/Orange
NSIC 2001 Cc 07 K2 Red Yellow/Orange
NSIC 2008 Cc 08 UF 18 Red with Stripe White Edges Orange Yellow
NSIC 2008 Cc 09 S5 Green Yellow
NSIC 2008 Cc 10 K9 Light Green Light Green
NSIC 2014 Cc 11 PBC123 Red Orange Red
NSIC 2014 Cc 12 USM CH 1 Red Orange Yellow
NSIC 2014 Cc 13 USM CH 2 Red Orange Yellow

15. Increases production, makes
tree maintenance easier and
reduces loses due to pest and
diseases, allowing farmers to
maximize their return.
1.0 Pruning
2. Good Agricultural Practices
 Technology & Practices

16.  Technology & Practices

17.  Technology & Practices

18.  Technology & Practices

19. Integrated Pest
Management
 Technology & Practices

20. 3. Proper harvesting & Post –
Harvest Practices
Harvest pods of 75% ripeness
using machete or cutlass
 Technology & Practices

21. • Pods should be opened
using wooden baton or
devised pod splitter to
avoid injury or cutting
the seeds.
 Technology & Practices

22. Effects of Improper Pod Breaking
 Technology & Practices

23. Factors Influencing the Fermentation
 Ripeness of the pods  Quantity of beans
 Quantity of pulp  Type of cocoa
 Duration of fermentation  Turning
 Seasonal effects/climate  Pod’s diseases
 Technology & Practices

24. Slaty, underfermented (purple) and well
fermented (brown) cocoa
 Technology & Practices

25. Drying of Fermented Cacao Beans
 Sun or Solar Dried Beans is preferred by buyers .
But it may not be possible to rely solely on sun dryng due to the
changes in weather condition in most cacao growing areas in the
Philippines especially during peak harvest season.
 Reduction of moisture from 45% to 7%.
During the drying process, the excessive acidity is eliminated
through evaporation of acetic acid through the outer skin while it is
still moist.
 Drying is actually an extended part of fermentation.
As long as there is enough moisture, flavor forming reactions in the
beans continue as well browning reaction that oxidize polyphenols
and leads to reduction of astringent and bitter taste.
 Technology & Practices

26.  Technology & Practices

27. Philippine Cacao Bean Grades
(PNS/BAFPS No. 58-2007)
Grade Bean
Count
(per 100 g)
Percentage of Beans
Moldy Slaty Defects such as
insect
damaged,infested
beans, and
germinated beans
1 A < = 100 3.0 3.0 2.5
1 B 101 - 120 3.0 3.0 2.5
2 A < = 100 4.0 8.0 5.0
2 B 101 - 120 4.0 8.0 5.0
Sub-Standard > 120 > 4 > 8 > 5.0
Note: The percentages are maximum; the percentages given in the last column apply to
all the defects mentioned therein, taken together. Code 1 – 2 denotes grade based on
defective characteristics. Code A and B stands for bean counts
 Technology & Practices

28. Proper Storage
•The bags of cacao beans shall be stacked in such a way that
individual grades and lots are separated by a passage at least 60 cm
wide.
•Disinfestation by approved fumigant may be carried out.
•Prevent odor or flavor contamination
•Periodic checking of moisture level.
Proper bagging and storage of the processed beans is just as important as proper fermentation
and drying.
 Technology & Practices

29. SUMMARY
PROPER POST
PRODUCTION
PRACTICES

30. Livelihood Opportunities:
CACAO BEANS PROCESSING

31. The bean-to-bar concept involves
different methods of production,
packaging and direct shipping or sales to
high-end outlets. Bean-to-bar enables a
small number of producers to add
significant amounts of value to their
cocoa production. This value addition for
cocoa producers is mainly done through
quality branding and packaging, and by
offering superior cacao qualities.

33. CLEANING
to remove all extraneous material
Linisin ang mga buto ng Cacao.
The first step to actual manufacturing is cleaning.
This is done by removing dried cacao pulp, pieces of
pod and other extraneous material that had not been
removed earlier. In the science of chocolate making,
the proper selection of beans for processing is critical.

34. ROASTING
Isangag ang mga buto ng Cacao
Depending upon the variety of the beans and the desired
end result, the roasting lasts from 30 minutes to an hour
at temperatures of 90-120 degrees Centigrade. As the
moisture content drops, the color changes to a rich brown
and the characteristic aroma of chocolate becomes
evident.

35. Behmor 1600
Proper roasting completely kills any potential
surface contamination that may be present,
makes them safe to eat and develops the
flavors associated with chocolate.
Roasting

36. Subject the cocoa beans to a high temperature initially,
slowly reduce the temperature and stop the roast when
the beans are "cracking", but well before they start to
burn.
The initial high heat lets the beans gain some thermal
momentum and allows for a good separation of the husk
and nibs as the beans expand. You lower the ambient
temperature so as not to burn the outside of the bean,
but let the interior continue to roast. Finally, the cocoa
beans will start to pop and crack as water vapor is
explosively released. This happens when the cocoa bean
temperature is around 250 F. This is your sign you are just
about done roasting. Experience and smell (you don't
want any burned smell) are the key indicators when the
beans are roasted.

37. The roasted beans pass through a
WINNOWINGmachine
to separate and remove the shells,
and leave just the cacao NIBS.
Pag tatanggal ng balat ng buto
ng cacao

38. Sylph Winnower
© 2020 Chocolate Alchemy.
Bean Cracking and
Winnowing
After your beans are
cracked, the husks
need to be separated
from the nib.

39. GRINDING
The nibs are then milled to create
CACAO LIQUOR
The degree of milling varies according to the type of nib
used and the product required.

40. Grinding After your beans have been
roasted, cracked and
winnowed , the next step in
cacao processing is to grind
them until they liquefy into
cocoa liqueur

41. The processing now may go in
three (3) different directions.
1. Cacao Liquor into ‘tableas’
which are molded either by
hand or molders

42. TABLEA

43. 2. The cacao liquor is pressed to
extract the CACAO BUTTER,
leaving a solid mass called
cacao cake.
NutriChef Oil Press

44. The cacao butter is used in the
manufacture of chocolates,
cosmetics and pharmaceuticals.
The cacao cake is PULVERIZED
to form CACAO POWDER.

45. Rico grinder
650 W motor works well
to grind down nibs into
smaller powder

46. 3. Cacao liquor is used to
produce chocolate (addition of
other ingredients such as
sugar, milk, emulsifying
agents and cacao butter)

48. Chocolate makers in the speciality
segment will only be interested in fine
flavour cocoa products of very high
quality, in specific and outstanding
flavours (possibly from micro lots or
small batches), with proven traceability
and in accordance with their standards
and specifications. These criteria can be
related to the level of cocoa bean
fermentation and cocoa nib roasting,
but they can also include specific niche
requirements such as Organic
certification, for example. Chocolate
makers will only outsource processing
activities when they can make sure that
the products do not deviate from their

49. Conching
The process involves heating and mixing for several
hours to several days the ingredients of chocolate -
cocoa, cocoa butter, sugar, lecithin and and any
"flavoring" such as vanilla or essential oils.
• For milk chocolate, dry milk powder is also included
in the mix. (don't try to use liquid milk, it will seize
on you).
• During conching, the chocolate is heated to
temperatures of 110 to 180° F, to allow the lactose
crystals to transition into amorphous lactose. This
transition is often why milk chocolate has that soft
and silky mouth feel.

50. The mixture is then tempered, or passed
through a heating, cooling and reheating
process. Tempering allows you to solidify
chocolate in a way that keeps it glossy,
causes it to break with a distinctive snap
and allows it to melt smoothly in your
mouth.

51. The mixture is then poured into moulds and cooled in a cooling
chamber. Once cooled, the chocolate is demoulded, packaged for
distribution and is ready for savoring.

52. Dark chocolate and
ONLY dark chocolate
contains high
concentrations of
flavonoids, which are
actually antioxidants.
Flavonoids In 1.25
ozs of cocoa
products:
Milk chocolate 300 mg
Dark chocolate 700 mg
Cocoa powder 1,300
mg

53. • “Focus production to FINE
FLAVOR cacao”
• Pursue
processing
• Aside genetic difference, the farming practices
strongly influence several quality parameters of
the finished chocolate.
• Engaging storytelling to highlight chocolate’s
journey from the bean to the finished bar
• Add value to
production

54. • Product consistency is key for repeat
purchases.
• Opportunity to enrich cocoa producer
livelihoods around the world, principally
by promoting ‘differentiated’ cacao at
higher prices.

55. Livelihood Opportunities:
PRODUCTION OF PLANTING
MATERIALS

77. JE VOUS REMERCIE
THANK YOU!!
GRACIAS!!!
DAGHANGSALAMAT…