Production,Processing and packaging of Cocoa
- 2. • Very unusual tree with its cultivation confined to limited areas and climatic conditions. • Processing is required both in the areas where it is cultivated and in the factory.
- 3. The emperor of Aztec (Mexico) had regularly consumed a drink called Chocolatl- made by roasting and grinding the cocoa nibs and mixed with water, maize and spices. They believed it to have divine origin and later the Swedish botanist Linnaus gave the name Theobroma – Food of the Gods. This drink had high esteem as a nuptial aid during wedding ceremonies. Originally prepared by the natives of Central America
- 4. The tree is a native of the dense tropical forest of the Amazon, growing in semi- shade, warmth and high humidity. Theobroma Cacao is the scientific name of the plant that has commercial importance. The plant has spread naturally west and northward to Guyana, Mexico and later to the Caribbean.
- 5. A powder made from cocoa (cacao) beans. It is obtained from seeds of cacao, a tropical tree 4-12 m high. It contains 25 - 40 beans rounded or flattened in shape and grey, purple or bluish in color.
- 7. Cocoa bean seeds is first put in nursery. As the tree reaches 1 to 1.5 feet the transplant to the plantation Pods grow directly on trunk on branches of tree There are 20 to 40 seeds of cocoa beans & a tree produces about 0.5Kg to 2Kg beans per year The first cocoa can be harvested after 2 to 3 years
- 8. The pods required approx 5 to 6 months to fully develop The harvest could be year long but the main crops are from November to April Pods are removed from trees with a tool which is a stick with along blade at the end The empty pods are discarded & used as fertilizers
- 9. The beans are extracted from ripe pods, heaped into mounds so that they ferment. It destroys the germ & helps to develop the flavor. They are then sorted, washed, dried & roasted.
- 11. The fermentation process takes approx 6 to 7 days The beans are turned around three times during fermentation as it leads to lot of heat being generated To check the fermentation status, some beans are cut open to see the colour of the beans that indicates if the fermentation was long enough. (brown = fully fermented, purple = not enough fermented) The beans have a humidity of 16 to 17%
- 12. The beans undergo a pre –drying process for approx 8hrs at 60º C They are filled in a round mixing drum & turned slowly to prevent sticking together The beans have a humidity content of 12 - 13%
- 13. The beans are dried by the roller drier with air to bring down the water content to approx 8%
- 14. In bags of jute or sisal usually of a (gross) weight of 60 - 65 kg, rarely of up to 100 kg. New or high quality bags should be used due to the high value of the cargo.
- 15. Transport of bagged cargo in ventilated containers (coffee containers) is possible subject to compliance with lower limits for the water content of goods, packaging and flooring. The wooden flooring of the containers must be absolutely clean and dry. If it has been washed, it must have dried completely. Water content should be 12%, corresponding to a lumber equilibrium moisture content of 70%, so that the flooring does not constitute an additional source of water vapor to dampen the cocoa cargo and container atmosphere.