Chapter 1

Introduction

Cocoa is one of the most important agricultural export commodities in the world and forms the
backbone of the economies of some countries in West Africa, such as Cote dIvoire and Ghana.
Cacao beans are fruit seeds from the tropical tree Theobroma cacao L. Cacao beans are processed
into three main products: cocoa liquor, cocoa powder, and cocoa butter which depends on the
solids and fats of the beans. Cocoa liquor is an unsweetened baking chocolate made from ground
cocoa nibs, which can be transformed into cocoa powder and cocoa butter. Cocoa butter is the fat
of the cocoa nib, and may be used in lotions and pharmaceutical products. It is also the main
ingredient in white chocolate. Cocoa powder is the solid product of the cocoa nib and can be
processed to have varying fat content. The powder is used in beverages, baking, and frequently as
a dye.

The process begins with a traditional cocoa processing section, consisting of industrial scale
cleaning and destoning units, roasters, winnowers, and alkalizing units. The fruit harvest is cured
or fermented in a pulpy state during which the heat kills the seeds and turns them brown. The
enzymes activated by fermentation impart the substances that will give the beans their
characteristic flavor. The beans are then dried in the sun and cleaned in special machines before
they are roasted to bring out the flavor. They are then shelled in a crushing machine and ground
into chocolate. During the grinding, the fat melts, producing a sticky chocolate liquor, which is
filtered to remove the fat and then cooled and ground to produce cocoa powder.

The above mentioned traditional method of producing cocoa products has disadvantages including
long processing times and increased operating costs. These disadvantages in traditional methods
prompt a new design of process that will reduce processing time and decrease operating cost.

In this study, a design of a cocoa processing plant for the production of cocoa powder will be
proposed. Various process alternatives are also considered in this study to come up with a process
design that is feasible for the processing of cacao.
1.1 Objectives

The general objective of the study is to design a cocoa processing plant for the production of cocoa

powder.

Specifically, it will aim to:

1. Modify an existing process flow for cocoa production

2. Generate a process for cocoa production which utilizes waste heat and by-product

3. Determine the appropriate unit operations and parameters needed for the process

1.2 Raw Materials

1.2.1 Cocoa beans

Cocoa beans is the principal raw material. It originates as seeds in the fruit pods of the tree
Theobroma cacao. It belongs to the family Sterculiaceae and is characterized by three cultivar
groups, namely, Criollo, Frastero, and Trinitario. These different varieties of cacao may be
distinguished by the color of its beans. Raw Criollo beans are white, ivory, or very pale purple
in color and produce cocoa with a weaker but very aromatic flavor. Raw Forastero beans are
violet in cross-section and produce a strong cocoa flavor upon proper processing. Trinitario is
a hybrid of Criollo and Forastero. The beans are flat and purple in color. These three main
varieties are grown and cultivated in the Philippines. Cacao Criollo and Forastero and other
modified hybrids of cacao are cultivated in the locals of Isabela and Cagayan.
The seeds consist two cotyledons also known as the nib and a small embryo plant, that are
enclosed in a skin (the shell). The seeds are fermented which causes the chemical changes in
the pulp surrounding the seed and within the seed as well. These changes develop the chocolate
flavor and changes the color of the seeds.
1.2.3 Potassium carbonate (K2CO3)
The end product of the cacao processing is cocoa powder processes through dutching.
Cocoa powder may be processed as natural or by Dutch-process. Natural cocoa powder is non-
alkalized where the cocoa nibs are roasted and pulverized into a fine powder. Dutch-process
cocoa powder undergoes alkalization by washing the cocoa nibs with potassium carbonate
 solution. The alkalization helps to lower the acidity of the cocoa powder, increase its solubility,
darkens the color, and gives a smoother flavor.
1.2.4 Treated water
Feed preparation includes the washing of cocoa fruits. The water used in this process will
be treated in the plant.
1.3 Product Description

1.3.1 Cocoa powder

Cocoa powder is unsweetened powder produced by grinding cocoa beans and pressing out

the cocoa butter (fat). The resulting cocoa powder is low in fat, but has an intense chocolate taste.

It is most commonly used in baked goods where it is mixed with sugar and other fats, like butter,

margarine, or coconut oil (Labau 2016).

Cocoa powder is commonly available in two varieties namely, natural cocoa powder and

alkalized or dutch-processed cocoa powder. Dutch-processed cocoa powder involves treating the

cocoa with an alkali to reduce the acidity. Also dutch-processed cocoa often has a deeper or redder

brown color, and a more palatable flavour, since some of the acidity has been removed (Robert

2003).

Chemical Properties of Cocoa Powder

i. Flammability - The cocoa powder was burning because the color of the powder started

to turn black upon subjecting to a flame. The trail of smoke is coming off the powder. The cocoa

powder will have an embers.

ii. Reactivity in acid - by adding a little vinegar with some baking soda. Add a half teaspoon

of cocoa powder to the mixture. It will produced a bubbles with that it is being reactive into

chemical.

iii. Oxidation/Sensitivity to Light putting a direct light to cocoa powder for three hours

and observed noticeable changes. Then, put it in darkness for three hours also notice some changes.
The cocoa powder did not react to light or darkness. The color remained the same. Hence, if

flashlight is put on the powder for consecutive three hours to observe the chemical property of

sensitivity to light (Minifie B. W. 1989).

Physical Properties of Cocoa Powder

Natural cocoa powder has a light brown color and an extractable pH of 5.3 to 5.8. The

processed (alkalized) cocoa powder is darker in color, ranging from brownish red to nearly black,

with a pH from 6.8 to 8.1. The alkalization process reduces bitterness and improves solubility,

which is important for beverage product applications. All of these pH values are considered safe

for food use.

Components of Cocoa Powder

Cocoa powder contains several minerals including calcium, copper, magnesium,

phosphorus, potassium, sodium and zinc. All of these minerals are found in greater quantities in

cocoa powder than either cocoa butter or cocoa liquor. Cocoa solids also contain 230 mg of

caffeine and 2057 mg of theobromine per 100g, which are mostly absent from the other

components of the cocoa bean. Cocoa solids also contain clovamide,

Cocoa powder is rich in flavonoids. Flavonoids a subset of polyphenols. The amount of flavonoids

depends on the amount of processing and manufacturing the cocoa powder undergoes.

Alkalization, also known as Dutch processing, causes its content of flavonoids to be substantially

reduced.
Benefits of Cocoa Powder

Cocoa Nutritional Benefits

A 2 tbsp. serving of cocoa powder just contain 25 calories and 1.5 g of fats. It also provides

a 3.6 g of fibres which is 14 percent of the daily value, and 8 percent of daily value of iron and 14

percent of the daily value of magnesium (Labau 2016).

Cocoa Antidepressants Effects

The cocoa powder contains substance phenethylamine, which is a neurotransmitter is found

in the brain that acts as a mood elevator and natural antidepressants (Labau 2016).

Cocoa and Antioxidants

Cocoa contains approximately 43.6 mg of flavonoids per gram. Flavonoids are part of

powerful group of antioxidants known as polyphenols.

Additional Cocoa Benefits

The cocoa may lower LDL cholesterol, reduce the risk of blood clots, increase blood flow

to the arteries, lower high blood pressure, boost cognitive performance and provide essential

mineral such as calcium and potassium (Labau 2016).

Considerations

Despite of all the possible health benefits of cocoa powder, it contain caffeine which may

have negative effects such as insomnia, on caffeine-sensitive individual. It also contain oxalates,

and increased oxalate levels that contribute to the formation of kidney stones, therefore if you are

prone to kidney stone cocoa and chocolates should not be consumed (Labau 2016).
1.3.2 Cocoa liquor

Cocoa liquor or chocolate liquor contains no alcohol, it is made by grinding the nib or meat

of the cocoa beans. Its a thick, gritty, dark brown paste that liquefies when heated. Chocolate

liquor is comprises of about half cocoa butter and half cocoa solids, cocoa solids are what remains

when the bean is ground and the cocoa butter is removed. Chocolate liquor is also called

unsweetened baking chocolate (Minifie B. W. 1989).

The quality of the cocoa liquor will depend from the cocoa beans used. Manufacturers often

blended different types of beans to gain the required quality, flavour, and taste. The cocoa liquor

can undergo further roasting and alkalisation to alter the colour and flavour which will also alter

its chemical composition. Chocolate liquor contains roughly 53percent cocoa butter (fat), about 17

percent carbohydrates, 1 percent protein, 6 percent tannins and 1.5 percent theobromine (Robert

2003).

1.3.3 Cocoa butter

Cocoa butter contains a high proportion of saturated fats, derived from stearic and palmitic acids.

Cocoa butter, unlike cocoa solids, has no more than trace amounts of caffeine and theobromine.

Cocoa butter is mostly a saturated fat. The concentration is seen in a quantity of 57% saturated to

64% unsaturated fat. This however may differ based on the kind of butter (Ayurvedicoils 2017).

Chemical constituents of Cocoa Butter

Cocoa contains theobromine, caffeine, anandamide, flavonoids, sulphur, proteins,

magnesium, tryptophan and polyphenols including epicatechol. It also consists of numerous fatty

acids like palmitic acid, myristic acid, oleic acid, stearic acid, arachidic acid, lauric acid, linoleic

acid, glycerides and stigmasterol (Ayurvedicoils 2017).

Therapeutic attributes of Cocoa Butter

Cocoa contains high levels of anti-oxidants, as they contain polyphenol and flavonoids.

Cocoa beans are said to contain polyphenols. The butter extracted from these beans retains a

limited amount of polyphenols which help lower inflammation, improve immunity, and perk up

heart health.

Cocoa butter exhibits anti-inflammatory, anti-aging, cytotoxic, nutritive, antiseptic,

bactericidal, antispasmodic, emmenagogue, diuretic, nervine, aphrodisiac, stimulant, nervine and

anti-oxidant properties (Ayurvedicoils 2017).

 1.4Alternative Process Flow Diagrams for Cocoa Powder Production

1.4.1 ICCO Cocoa Processing Process Flow Diagram

Cocoa
Extraneous Potassium
2 Materials 5 beans 7
Carbonate
shells
Cocoa
Fermented and Nibs
Dried Cocoa 1 Cleaning and Sorting 3 Roaster 4 Winnower 6 Alkalization Reactor Grinder
8
Beans from
Cocoa Farm
Emulsifying
Sugar Milk Agents
Cocoa
16 17 18
Liquor
Cocoa Cocoa Liquid
Powder Presscake Chocolate
Cocoa Powder 13 Fine Grinder 12 10 9 14 19 20 21 Liquid Chocolate
Coarse Grinder Pressing Mixer Refining Conching
Packaging and Storage Packaging and Storage

Cocoa
Butter 15 22
11

Cocoa Butter Packaging Solid Chocolate

24 Molding 23 Tempering
and Storage Packaging and Storage
 1.4.2 Cocoa Butter, Liquor and Powder process flow diagram by Asselstine, et.al. Bunker-C
Fuel Oil
Furnace 12 Winnower 11

Coarse Stones and Cocoa

2 debris 4 Fine 6 metal 10 Shells
debris
pieces

Fermented
Coarse Fine Destoning Steam
Beans 1 3 5 7 Roaster 8 9 Winnower
Cleaner Cleaner Unit Sterilizer
Storage Silos

Water 43 13 Cocoa
18 Water Nibs

Recycled Potassium Cocoa

Butane Carbonate Liquor
Condenser 42 Decanter 44 Alkalizing Coarse
17 Mixer 19 16 Fine Grinder 14
Reactor Grinder
Recycled
Butane
41 37 24 Butane 20 15 Cocoa
Liquor
Extracted
38 Adiabatic Butter
Stripping Cocoa Liquor
Flash 36 Centrifuge 25 Mixer 23 Mixer 22 Flash Vessel Packing and
Column
Evaporator Storage

21 Excess
Solid water
Steam 40 39 Cake 26 27
Butane

Cocoa
Low-fat Low-fat
Butter w/
Cake Cocoa
Cocoa Butter Butane
Mixer 28 Filter 29 Dryer 30 Powder
Storage and
Packaging and
Packaging
Storage
31
Condenser

No-fat
Butane Cake No-fat Cocoa
Powder
32 Mixer 33 Filter 34 Dryer 35
Packaging and
Storage

Condensed Condenser
butane
 1.4.3 Process Flow Diagram by Adabe and Ngo-Samnick

Cocoa
6 beans
shells
Cocoa Cocoa Cocoa
Fruit Beans Nibs
1 Pod Breaking 3 Fermentation 4 Drying 5 Crushing 7 Roasting 8 Grinding

Powdered
Cocoa Sugar Milk
2 pod Cocoa 19
husk 18
Liquor
Cocoa Cocoa
Powder Presscake
Cocoa Powder
11 Ball Grinder 10 Pressing 9 17 Mixer 20 Refining
Packaging and Storage

Liquid
16
Cocoa
Butter 12 21

Filtering Tempering 23 Conching

13
24 22

Deodorization
Liquid Chocolate
Molding / Coating
Packaging and Storage
14

Molding 25

Cocoa
15 Butter Solid Chocolate
Packaging and Storage

Cocoa Butter Packaging

and Storage
 1.4.4 MODIFIED PROCESS FLOW DIAGRAM BASED FROM THE 3 ALTERNATIVES

Cocoa
Butter
26 Filter
Packing and
Storage
Excess
Cocoa 23 Water
25 Butter Vapor

Cocoa
Powder Presscake
Cocoa Powder Flash
Packing and 28 Milling 27 Pressing 24 Evaporator 22
Storage

Potassium
Carbonate
Yeast and
Lactic Acid 20
Bacteria CO2

Alkalizing
21 Mixer 19 Water
7 8 Reactor

Fermented
Fresh Cocoa Cocoa
Cocoa 18
Cocoa Beans Beans Nibs
Fruit Mechanical Fine Liquor
Fruit 1 2 6 Fermentation 10 Dryer 11 Roaster 12 Winnower 16
Washer Pod Grinder
Storage Tank
Splitter
17
13 Cocoa
Cocoa Pod 3 Shells
Husk Water
9 Ethanol Fuel Oil
Lactic Acid 14 Mixing Cocoa
Dryer Acetic Acid Vessel Liquor
Packing and
Storage 15 Storage
4
Tank

Grinder Boiler

Animal
Feed
Storage
Fermentation and Drying

From the alternative process flow diagrams shown above, fermentation of cocoa beans is done

in the farm. Traditionally, fresh cocoa beans are placed in baskets, wooden boxes, or on the

ground for the fermentation. The beans are then covered with banana leaves and left to

ferment 4-7days. On the 2nd and 4th day, cocoa beans are mix to ensure all beans will be

fermented. The beans change color from white to brown. After the fermentation, the beans

are dried naturally. Natural/sun drying is the simplest and most popular method and it takes

8-15days.

Alkalization

There are two types of alkalization to choose from: nib alkalization and liquor alkalization. The

process could have opted either for nib alkalization, which would occur before the grinding

and milling stages, or for liquor alkalization, which would take place after these stages. Liquor

alkalization was determined to be the more effective choice, as the alkalization reagent, a 10%

by mass potassium carbonate solution fed in a 3:100 ratio with the cocoa, was much more likely

to mix well with a slurry rather than a solid stream. Complete mixing was especially important

in this scenario due to the relatively small amount of alkalizing agent, and the need for uniform

flavor throughout the cocoa (Asselstine, M., et.al., 2016).

Modified process flow diagram description

Stream 1:

Harvested cocoa fruit from the cocoa fruit storage are washed to remove dirt, soil and any

unwanted materials prior to undergoing the mechanical pod splitter.

Stream 2:

The washed cocoa fruits are conveyed via conveyor belt to the mechanical pod splitter where

the cocoa pod is separated from the cocoa beans.

Stream 3:

The waste cocoa pod husk coming out of the mechanical pod splitter is further processed and

utilized as an animal feed. It is conveyed to a dryer to reduce its moisture content. Streams 4

& 5:

The dried cocoa pod husks are conveyed to a coarse grinder to produce the animal feed. The

animal feeds produced are specifically for ruminants.

Streams 6, 7, 8 & 9:

The fresh cocoa beans from the mechanical pod splitter are conveyed to a fermentation tank

where it undergoes two-phase fermentation process. Yeast and lactic acid bacteria are added

to the fermentation tank (Stream 7). The first phase of fermentation is anaerobic and the yeast

dominate the population inside the fermentation tank. Cocoa beans are coated by a sweet fruity

pulp with water and sugar as its main components. The yeast is responsible for converting the

pulps sugar of the cocoa beans into alcohol (ethanol). The breakdown of the pulp makes it

possible for air to penetrate the cocoa beans. The population of the yeast peaks for about 24

hours. After that, yeast population starts to decline and the lactic acid bacteria begin to briefly

take over the fermentation process. This second phase of the fermentation process is aerobic

and this means that the tank must be aerated. Lactic acid bacteria convert the ethanol into

lactic acid. After lactic acid bacteria population has declined, the acetic acid bacteria start to
take over. They convert the ethanol into acetic acid bacteria. During this phase, the

temperature in the fermenter can reach up to 50C. The acetic acid penetrates the bean and

causes biochemical reactions that are responsible for the formation of chocolate flavor

precursors. By-product CO2 is vented to the atmosphere (Stream 8) and the liquid juices

coming out of the fermenter (Stream 9) goes to a storage tank for further utilization.

Stream 10:

The fermented cocoa beans coming out of the fermenter are conveyed to the dryer where its

moisture content is reduced.

Stream 11:

The dried beans are conveyed to the roaster to produce the desired flavor and aroma. In here,

moisture of the beans is furtherly reduced.

Stream 12:

After roasting, the beans are conveyed to the winnower. The winnower is responsible for the

removal and separation of cocoa shells from the nibs. As stated before, the waste cocoa shells

(Stream 13) are mixed with fuel oil (Stream 14) in a 9:1 ratio and is combusted in the boiler

(Stream 15) to produce steam.

Stream 16:

The nibs which are separated from the shells is conveyed to a fine grinder where it is ground

producing a highly viscous cocoa liquor. About 30 % of the cocoa liquor can be stored (Stream

17) and packed since it can be sold as one of the secondary products.

Stream 18:

The rest of the cocoa liquor is further processed. It is pumped into the alkalizing reactor

(Stream 21) and combines with pre-mixed Potassium carbonate (Stream 20) and water

(Stream 19) in a 1:10 ratio. The mixture will be mixed until the desired pH is achieved. Desired

pH of about 7 is set in able to reduce the acidity and the bitter taste of the cocoa liquor.
 Stream 22:

After the cocoa liquor is alkalized, it is pumped to a flash evaporator to remove the excess

water vapor (Stream 23).

Stream 24:

The cocoa liquor is pumped to a pressing machine where it is pressed to separate the cocoa

press cake and the cocoa butter.

Streams 25 & 26:

The cocoa butter is pumped to a filtering machine and is stored in a storage vessel ready to be

packed and sold as another secondary product.

Streams 27 & 28:

The cocoa press cake coming from the pressing machine is conveyed to a milling machine

where it is grind into fine-sized powder called cocoa powder.

1.5 Process Anatomy

Fermentation
Waste Waste By-product
By-products

Raw Material Feed Preparation Reaction Product Post- Product Product Storage Sales
Storage Processing Separation

Stage 1. Raw Material Storage

Cocoa fruits are stored in storage silos near the feed preparation.

Stage 2. Feed Preparation

The feed preparation includes the washing of the cocoa fruit and the separation of the cocoa

fruit pods from the cocoa beans via mechanical pod splitter. At this stage, waste produced is

the cocoa fruit pods which are further utilized as animal feeds.
Stage 3. Reaction

The reactor is a fermentation tank. This is the most important part of the process. Without

fermentation, there will be no chocolate flavor precursors in the cocoa beans. Fermentation

by products include carbon dioxide, water, acids and alcohols.

Stage 4. Product Post-Processing

These includes the drying, roasting and winnowing and grinding of the fermented cocoa beans.

The waste at this stage is the cocoa beans husk. These wastes are further utilized as a fuel for

the boiler. Also, after the grinding process, cocoa liquor is produced.

Stage 5. Product Separation

The cocoa liquor mainly composed of fats and cocoa mass. The fats which is a byproduct, can

be separated from the cocoa mass by the used of the pressing machine. This fat is what we call

the cocoa butter and the cocoa mass is further grinded to cocoa powder.

Stage 6. Product Storage

The cocoa powder is the main product in the process while the cocoa liquor and cocoa butter

are secondary products. These are separately packed and stored.