cocoa production

1. (Theobroma cacao L.)

2. presented by -
Priyanka jain
Nidhi koli
Kush modi
Nandini naik
Mysha pachhapure
Shashank paithankar
Minal Patil
Shivratna patil
1.
2.
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8.

3. INTRODUCTION
Cocoa (Theobroma cacao L.), Cocoa is an important
commercial plantation crop of the world. Cocoa is a crop of
humid tropics and so it was introduced as a mixed crop in
India in areas where the environments suit the crop. It is
cultivated in coconut and arecanut plantations large scale
from 1970 onwards. It is grown as an under- storey
intercrop with sufficient shade in southern states of India.
In India, the current production is about 12,000 Metric
Tonnes and Tamil Nadu produces about 400 Metric Tonnes.
.
1

4. Its beverage is referred to as
xocolat – hence the name
chocolate.
The sacredness of the crop
made Linnaeus to name
cultivated cocoa as
Theobroma cacao – “food of
gods”
Cocoa plantations were first
established at Martinique in
1660 and Brazil in 1754.
Theobroma cacao L
2

5. The Criollo
The Amazonian forastero
The Trinitario
Cultivated Species of Cocoa
3

6. Cultivated in Venezuela, Nicaragua,
Mexico, Colombia and Guatemala.
Most anciently cultivated.
Poor cacao vigour.
High susceptibity to diseases.
Slender cacao with green pods.
Watty, thin and soft pericarp.
Lignified mesocarp.
Plump beans, embedded in pulpy
mucilage with white cotyledons.
Fermented and dried cotyledons
are light brown.
Excellent bean flavour.
The Criollo group
4

7. Cultivated in Brazil, West Africa,
Central America, South East Asia
and Caribbean Island.
Staminodes with purple pigments.
Green and varying shapes of cocoa
pods.
Thick pericarp and very woody
mesocarp.
More or less flat beans
Dark purple cotyledons
Relatively bitter flavour and acid
taste.
West African Amelonado belongs
to this group.
The Amazonian Forastero Group
5

8. Believed to evolve from a cross
between Forastero and Criollo
groups.
Highly heterogeneous group.
Selected from Trinidad, hence the
name Trinitario.
Cultivated in Mexico, Central America,
Trinidad, Colombia, Venezuela and
some African and South East Asian
countries.
Botanical traits are intermediate
between Forastero and criollo groups
Bean flavour is also intermediate
between Forastero and Criollo
groups.
The Trinitario Group
6

9. Cocoa is cauliflorous and semi-desidous.
Height, leaf area, branches and canopy spread of cacao determined
by planting spacing.
When grown from seeds cacao attains anthesis between 24 and 36
MAT (month after transplanting) and fully matured at about 10 YAT
(year after transplanting)
A well managed cocoa continue to be economic for over 50 years.
Dimorphous root: Orthotropic taproot and Plagiotropic lateral root.
3 to 4 DAS (days after sowing) cocoa seeds start germinating
through the emergence of whitish taproot and lateral roots.
10 YAT, taproot well developed, (1.5 m) with a mass of root hairs
covering 5 – 6 m around cacao.
Botany and Agronomy of Cocoa
7

10. Stem growth is orthotropic holding the leaves.
The orthotropic growth is intermittently interrupted by the degeneration of the
terminal bud, below which branches develop – Jorquette.
Thus, there can be 1st and 2nd jorquette which form the framework of cacao
Pruning starts at the level of 2nd jorquette through the removal of excessive
orthotropic shoots – chupons.
Growth in cacao is discontinuous and in successive growth phases – flushes.
Each flush results in the production of 5 – 6 alternate leaves with short petioles
and 4 – 5 flushes occur in a year.
The young pigmented leaves may be pale-green, pink or deep blue depending
on variety, mature leaves are dark-green with 7 – 9cm petiole length.
Flowering is marked indicator of successful field establishment, and anthesis
may be attained in 2 years in improved varieties and it may take a longer period
in unimproved varieties of cocoa.
8

11. Flowering depends on favourable physiological, soil and climatic
conditions.
In mature cocoa, fruiting occurs twice a year in the tropics – dry
(November / December) and rainy (June / July) seasons.
Cocoa is an out-breeder and an entomophilous plant. Pollinators –
midges, ants, thrips and leaf hoppers.
Within 36 hours after pollination, fertilization occurs leading to the
formation of a young okra-sized pod – cherelle.
Cherelle continues to develop by longitudinal elongation and girth
increase to become a fully-grown mature cocoa pod.
It takes up to 150 – 180 days between fertilization and pod maturation.
Ripe pods are light-yellow in colour and thus ready for harvesting.
A cocoa pod contains 30 – 40 beans on the average and 50 – 60 pods
needed to plant an hectare of cocoa spaced 3m x 3m. 9

12. Grow to height of 8-10 m under
heavy shade but will be shorter
under full sunlight
Growth habit – vertical
orthotropic growth followed by
more horizontal plagiotrophic
growth
Later chuppon from base of tree
followed by a fan of plagiotropic
branches
Adapted to hot humid Tropics
Cocoa Adapted to hot humid Tropics
10

13. 18-32ºC (23-26ºC)
15ºC lowest tolerated
Below 10ºC damages tree
1150 – 2500 mm ( mm)
Well distributed, sensitive to water stress
Needs high humidity
Sensitive to wind damage
Adaptation of Cacao Understorey plant of tropical rain forest
Temperature
Moisture
Wind
11

14. Tolerant of shade
Maximum photosynthesis at 25% full sun
Tolerates high light as well
Well drained, no waterlogging
pH between 5.0 – 7.5
Good nutrient holding capacity
Adaptation of Cacao
Understorey plant of tropical rain forest
Shade
Soil
12

15. Cocoa is a low altitude crop, performing best within 100 – 300m above sea
level (asl). It can be grown at 700m asl.
Cocoa is sensitive to water deficiency particularly when in competition with
other plants (shade plants, wind breaks and weeds) and also to excess water
in the soil
It thrives within wide rainfall ranges of 1000 – 3000mm or more per year.
The site should enjoy an evenly distributed rainfall of 150mm/month and at
least for 9 months.
With provision of irrigation and limited occurrence of dry winds, cocoa can be
cultivated completely without rain.
Cocoa responds to temperature variations: the maximum being C while the
minimum is 18 – 210C. At a temperature lower than 100C, cacao becomes
damaged.
Site Selection
2 major factors must be considered while selecting a site for cocoa plantations
establishment: climatic and soil factors.
Climatic factors:
13

16. Cocoa enjoys high relative humidity of between of between 70 – 80%, above
which disease infection occurs and below which (obtainable in the dry season)
cocoa leaves become limp and droop, thus causing severe defoliation.
The deleterious effects of drying and strong winds is reduced through wind
breaks, shade trees or even by high density planting. This is because cacao
rooting is superficial thus offering little tolerance to strong and drying winds.
At early stage of cocoa plantation establishment, temporary shading is
indispensable. A temporary shading / a nurse plant should meet the following
conditions :
Climatic factors.
1. Easy establishment
2. Provision of good overhead shade throughout the dry season
3. Little competition with young cocoa transplants for moisture and nutrients
4. Should not serve as alternative host to cocoa disease and insect pests
5. Easy removal when no longer needed
6. Its removal should not pose any threat to the plantation.
14

17. The soil must be at least 1.5 m deep.
The soil structure must be as homogenous as possible.
It must have good water-retaining capacity, well-drained and well
aerated.
Sandy soil is not suitable except it contains high organic matter
and not under prolonged hot and dry season.
It must be of acceptable chemical properties.
It must have pH of between 5 and 8 – optimum being 6.5.
High organic matter content in the topsoil is essential for good
growth and high productivity.
Soil Factors
The soil on which cocoa will be planted should satisfy the conditions
such as:
15

18. Cocoa can be propagated by seeds. Seeds are to be extracted from pods. Cocoa pods
take 150-170 days from pollination to attain the harvest stage. The stage of maturity is
visible from the change of pod colour from green to yellow (Forestero) and red to
yellow (Criollo). Collection of seeds from biclonal or polyclonal seed gardens involving
superior self-incompatible parents is recommended to ensure genetic superiority of
planting materials. In TNAU coconut nursery, a poly clonal seed garden with 7
improved clones of KAU (CCRP1 to CCRP7) and Vittal cocoa clone 1 and 4 hybrids
namely VTLCH1 to VTLCH4.
Criteria for selection of mother plants for collection of seeds:
Forastero type (green- immature, yellow- ripe) having medium to large pods of not
less than 350 g weight, smooth or shallow furrows on the surface without
prominent constriction at the neck can be selected.
Husk thickness of pods should be less than 1 cm.
Pod value (number of pods to give 1 kg wet beans) should be less than 12.
Number of beans per pod has to be more than 35.
Bean dry weight to be more than 1 g.
The best seeds for sowing are those from the middle of the pod.
Propagation
1.
2.
3.
4.
5.
6. 16

19. Harvesting Extract middle beans
Harvested seed pods can be stored in shade upto one week. Viviparous
germination is reported in ripe cocoa which may affect the percentage of
germination if it is stored beyond one week. Seeds are to be sown immediately
after extraction from the pods. Viability of the beans can be extended for some
more days if freshly extracted seeds are stored in moist charcoal and packed in
polybags. Other alternative is extracting beans, removing the testa and packing in
polythene bags.
17

20. Selection of planting materials
When seedlings are used as planting, select vigorous and healthy
seedlings from polyclonal garden. The planting material should be
of 4-6 month old seedling or grafted or budded plant. The
seedling/grafted/budded plant should be planted in the centre of
the pit, not too deep. While planting grafts, polythene strip tied
over graft joint should be removed and the joint should be above
the soil.
Seedlings Budded plants Grafted plants18

21. Time and method of planting
Cocoa is a shade loving plant. During its seedling period it requires
about 50% shade and later the shade requirement is about 40%.
The plant is grown as a mixed crop with other plants like spices and
rubber mainly under rainfed conditions. Cocoa is planted as an
intercrop in coconut and arecanut gardens.
19

22. Main crop Spacing
(m)
Cocoa as inter crop
Coconut
Arecanut
Oil palm
One Cocoa row of plants at 3m interval at the center of two
Coconut rows and One Cocoa at the center of two Coconut
plants along the Coconut row. This layout will hold about
500 plants per hectare
7.5 x 7.5
2.7 x 2.7
4.5 x 4.5
One Cocoa row of plants at 2.7m interval at the center
of two Arecanut rows. Likewise alternate gaps of
Arecanut rows should be filled in. This layout will hold
about 686 plants/ha.
Five cocoa plants would come between four oil plants
resulting in 400 plants per hectare.
20

23. Cocoa under Arecanut Cocoa under Oil palm Cocoa under coconut
Pits of 50 cm x 50 cm x 50 cm are dug, allowed to weather for one month and refilled with
topsoil and 15-20 kg of compost of FYM to ground level. Tear off the polybags carefully,
place the soil ball with the seedlings in the planting hole with minimum disturbance and
press the soil around firmly. Planting should coincide with the onset of monsoon, but in
places where irrigation is resorted to, flexibility in the time of planting is possible.
Planting of cocoa seedlings 21

24. Irrigation in cocoa
Cocoa is usually grown in areas where water availability is adequate. Cocoa plants
are sensitive to drought, irrigation in such cases becomes essential. During
summer, as it exists in Southern India, the crop requires irrigation at weekly
intervals. When it is grown as mixed crop with arecanut, the crop is to be irrigated
once in a week during November-December, once in 6 days during January-March
and once in 4-5 days during April-May with 175 litres of water.
Age of the plant Water requirement
(litre/ plant / day)
1st year 3-5
2nd year 10
3rd year and later 20-25
22

25. Soil nutrient management
Soil nutrient management is critical to the general health of the tree,
particularly where cocoa is grown on poor soils with low nutrient
levels. The fertility of soils under cocoa plantations with complete
canopy formation can be maintained or sustained for a fairly long time
due to the ability of cocoa fallen leaves to recycle nutrients back into
the soil and decomposition of leaf litter. However, continuous
harvesting will eventually result in loss of soil nutrients
23

26. Fertilizer schedule for cocoa
An annual application of the following schedule should be
applied in two equal splits, the first dose in April- May and
the second dose in September- October i.e. pre and post
monsoon applications.
24

27. Method of application
Fertilizer may be applied uniformly around the base of the tree up to a
radius of 30 cm during the first year, forked and incorporated into the soil.
For grown up plants the best method is to rake and mix the fertilizers with
soil in shallow basins of around 75 cm. This radius may be increased
gradually upto 150 cm after third year. Care should be taken not to spill
the inorganic fertilizers on the trunk, branches or leaves of young trees in
order to avoid burning.
Fertilizer application 25

28. Nutrient management in cocoa
Sixteen plant nutrients are essential for proper crop development. Each is equally
important to the plant, yet each is required in vastly different amounts. These
differences have led to the grouping of these essential elements into three
categories; primary (macro) nutrients, secondary nutrients, and micronutrients.
Primary (macro) nutrients
Primary (macro) nutrients are nitrogen, phosphorus, and potassium. They are the most frequently required in a crop
fertilization program. Also, they are need in the greatest total quantity by plants as fertilizer.
Secondary Nutrients
The secondary nutrients are calcium, magnesium, and sulphur. For most crops, these three are needed in lesser amounts
that the primary nutrients. They are growing in importance in crop fertilization programs due to more stringent clean air
standards and efforts to improve the environment.
Micronutrients
The micronutrients are boron, chlorine, cooper, iron, manganese, molybdenum, and zinc. These plant food elements are
used in very small amounts, but they are just as important to plant development and profitable crop production as the
major nutrients. Especially, they work "behind the scene" as activators of many plant functions like chlorophyll production,
carbohydrate formation, cell division and starch formation etc.,
26

29. Pest management
1. Mealy bugs (Planococcus lilacinus, Planococcus citri, Paracoccus marginatus and Rastrococcus
iceryoides)
It colonizes on the tender parts of the plant such as growing tips of the shoots, the terminal buds, the
flower cushions, the young cherelles and mature pods. Feeding of mealy bugs induces cherelle wilt.
Following control measures are recommended.
Planococcus lilacinus Paracoccus marginatus Rastrococcus iceryoides
27

30. When the infestation is lesser: Spraying of Neem Oil 3% or fish oil rosin soap 25g/litre
In case of severe incidence, spraying of any one of the following chemicals is recommended :
Dimethoate (2 ml/litre) , Profenophos (2 ml/litre), Chlorpyriphos (5 ml/litre), Buprofezin (2
ml/litre), Imidacloprid (0.6 ml/lit), Thiamethoxam (0.6g/litre)
In the area where P. marginatus alone occurs, field release of Acerophagus papayae, the
encyrtid parasitoid @ 100 per hamlet is recommended as the best management strategy.
Acerophagus papayae
28

31. 2. Tea mosquitoe bugs (Helopeltis antonii)
Infested pods develop circular water soaked spots around the feeding
punctures. These punctures subsequently turn pitch black in color.
Deformation of pods occurs because of multiple feeding injuries.
Tea mosquitoe bug
Damage symptom
When the infestation is lesser: Spraying of Neem Oil 3% is
recommended.
In case of severe incidence, spraying of any one of the following
chemicals is recommended: Imidacloprid (0.6 ml/lit) , Thiamethoxam
Management
29

32. 3. Flatid Plant hoppers
Nymphs and adults suck the sap from flowers, tender shoots and pods. They
excrete honey dew resulting in the development of sooty mould fungus on the
leaves and pods.
Flatid Plant hopper nymphs Flatid Plant hopper Adults
Management: Foliar application of a newer molecule Thiacloprid
@ 2 ml/litre twice at 5 days interval is recommended for the
management of these flatid plant hoppers.
30

33. 4. Aphids (Toxoptera aurantii and Aphis gossypii)
They colonize on the underside of tender leaves, succulent stem, flower buds and
small cherelles. Heavy infestation may occur during hot summer and after rainy
season which brings about premature shedding of flowers and curling of leaves.
Toxoptera aurantii
Management : Spraying of dimethoate @ 2 ml
per litre
31

34. 5.Hairy caterpillars (Lymantriya sp., Euproctis sp.,
Dasychira sp.,)
They cause serious leaf damage on seedlings and young
trees.
Defoliation
Management: Foliar spray of acephate @ 2g/litre of
water 32

35. 6. Stem Girdler, Sthenias grisator
Damage was done by female beetle which girdles the branches and inserts whitish
spindle shaped eggs singly into the tissue in a slanting manner. Due to mechanical
injury caused by girdling and oviposition, the branches above the girdle wither and dry.
Damage by stem girdler Adult stem girdler
Swab Coal tar + Kerosene @ 1:2 or carbaryl 50 WP 20 g / litre (basal portion of the trunk - 3 feet height) after
scraping the loose bark to prevent oviposition by adults.
Hook out the grub from the bore hole and apply monocrotophos 36 WSC 5 to 10 ml/ bore hole (or) one celphos
tablet (3 g aluminum phosphide)/bore hole (or) apply carbofuran 3G 5 g/bore hole and plug with mud.
Injection of dichlorvas (DDVP) + monocrotophos solution into bore holes after removing the webs and
subsequently sealing of the holes with clay gives satisfactory control of the pest.
Management
1.
2.
3. 33

36. 7. Non- Insect pests
Rats (Rattus rattus) and squirrels (Funambulus trisriatus and F. palmarum) are the
major rodent pests of cocoa. They cause serious damage to the pods. The rats usually
gnaw the pods near the stalk portion whereas squirrels gnaw the pods in the center
Rat damage Squirrel damage
The rats can be controlled by placing 10 g bromadiolone (0.005%) wax cakes or ripe banana
stuffed with carbofuran on the branches of cocoa trees twice at an interval of 10-12 days.
Squirrels are best controlled by trapping with wooden or wire mesh single catch ‘live’ trap
with ripe coconut kernel as the bait.
Management
34

37. Diseases
1. Seedling blight (Phytophthora palmivora)
The symptom develop on the leaves and stem of seedlings or budded plants. On
leaves, small water soaked lesions appear which later coalesce in the blighting of
leaves. On stem, water soaked lesions develop initially and later turn to black colour.
Stem infection develop any point on the stem causing the death of seedlings.
Management: Remove and destroy the affected seedlings. Spray with 1 percent
Bordeaux mixture or 0.2% copper oxychloride just before the onset of monsoon and
thereafter at frequent intervals.
35

38. 2. Black Pod rot (Phytophthora palmivora)
Infection appears as chocolate brown spot, which spreads rapidly and soon occupies the entire
surface of the pod. As the disease advances, a whitish growth of fungus consisting of fungal
sporangia is produced over the affected pod surface. Ultimately, the affected pods turn brown to
black. The internal tissues as well as the beans become discolored as a result of infection. The
beans in the infected pods approaching ripeness may escape infection because they are separated
from the husk on ripening
Management: Periodically remove the infected pods. Spray 1 per cent Bordeaux mixture with on set of
monsoon and also frequent intervals. Provide frequent drainage and regulate shade to increases aeration.
Pseudomonas fluorescens (Pf1) liquid formulations @ 0.5% as soil and foliar spray (3 times per year- June,
October & February) was found to be effective in reducing the Cocoa Pod rot and Stem canker.
36

39. Preparation of 1% Bordeaux mixture
The mixture of copper sulphate and lime was known as Bordeaux mixture
Procedure:
Dissolve one kilogram of copper sulphate in fifty litters of water in a plastic bucket
Dissolve one kilogram of lime in fifty litters of water separately in a plastic bucket
Pour copper sulphate solution into the lime water slowly with constant stirring using a wooden stick
Test the mixture before use for the presence of free copper, which is harmful to the plant by dipping a polished knife in it.
If the blade shows a reddish colour, add more lime till the blade is not stained when dipped afresh in the mixture.
Always use wooden or earthen or copper vessels for the preparation of Bordeaux mixture.
Bordeaux paste
Bordeaux paste consists of same constituents as that of Bordeaux mixture, but it is in the form of a paste as the quantity of water
used is too little. It is prepared by mixing 1 kg of copper sulphate and 1 kg of lime in 10 liters of water. The method of mixing
solution is similar to that of Bordeaux mixture. 37

40. 3. Stem Canker (Phytophthora palmivora)
The cankers appear either on the main trunk, jorquettes or fan branches. The earliest
symptom is the appearance of a greyish brown water soaked lesion on the outer bark.
A reddish brown liquid oozes out from these lesions, which later dries up to form
rusty deposits. The tissues beneath the outer lesion show reddish brown
discoloration due to rotting.
Management:
It can be controlled in the initial stages by the excision of diseased
bark followed by wound dressing with Bordeaux mixture or copper
oxychloride paste .Wilted branches should be cut and removed.
38

41. 4. Vascular Streak Dieback (VSD)
It is reported from some parts of Kerala. The first indication of the disease is a
characteristic yellowing of one or two leaves on the second or third flush behind the
growing tip. Diseased leaves fall within a few days of turning yellow and the other
leaves on the shoot show similar symptoms. When the infected shoot is split
lengthwise there is always a characteristic brown streaking.
Management: The disease can be controlled by disposing diseased branches and regular
pruning of chupons on the trunk. Cocoa nurseries should not be located near the diseased
area. Avoid getting seedlings from diseased tracts. Kerala Agriculture University has
developed some VSD resistant and high yielding varieties CCRP-1 to CCRP-7. 39

42. 5.Cherelle wilt
The shriveling and mummifying of some young fruits are a familiar sight in all
cocoa gardens. In the early stages the fruits lose their lustre and in four to
seven days they shrivel. The fruits may wilt but do not abscise. Many other
factors like insects, diseases, nutrient competition and over production may
also be associated with this problem. Hence, remedial measures will depend
upon the nature of the causative factors involved.
Cherelle wilt 40

43. It takes 150 – 180 days between pollination and ripening in cocoa, depending
on varieties.
Only mature and ripe pods are harvested, diseased and damaged pods must
not be processed for markets.
Harvesting should be regular and frequent in order to avoid damage due to
over-ripening, disease and animals.
In a case of irregular / delayed harvesting, the beans start germinating in-situ,
such cocoa is unsuitable for marketing.
Harvesting of unripe cocoa pods results in poor-quality beans with low
aromatic compounds after fermentation.
During harvesting flower cushion must not be damaged, if damaged,
subsequent years’ harvests will be reduced.
Cocoa pods must not be pulled off in order to avoid any damage to flower
cushions.
Pods are ready for harvesting when colour changes from green to
yellow/pink/red, depending on varieties.
Harvesting and post-harvest handling of cocoa
41

44. In order to be sold as cocoa beans, the fresh cocoa removed from
pods have to undergo two very important processes – Fermentation
and Drying.
The main aim of which include:
Preparation of Commercial Cocoa
1. To remove the mucilaginous pulp which surrounds the beans.
2. To cause the death of the embryo and consequently prevents it from
germinating.
3. To bring about complicated biochemical changes inside the
cotyledons, leading to a reduction in the bitterness and astringency thus
enabling the precursors of the chocolate flavour to develop.
4. Finally, to reduce the water content of the fermented beans from
approximately 60% to 6 – 7%, in order to block the enzymatic reactions
and to enable the commercial product to be stored safely, free from
pests and diseases.
42

45. 43

46. To get the proper taste, colour and flavour associated with cocoa products.
To kill the embryo and stop germination.
To remove pulp/mucilage so that the beans may dry properly.
To loosen the skin from the cotyledon thereby allowing easy and proper de-
shelling during processing.
Heap fermentation
Basket fermentation
Sweat box fermentation
Tray fermentation.
Fermentation
Fermentation a process by which mucilaginous pulp surrounding the beans is
removed under the gradual influence of heat and pressure for the purpose of
removing the beans’ bitter taste and the development of acceptable bean
flavour and colour.
It is necessary to ferment cocoa beans in order to fulfill the following
conditions:
Cocoa is fermented by different methods of fermentation which include:
44

47. The degree of ripeness of cocoa pods.
Healthiness of cocoa pods.
Types of cocoa: Criollos ferment at a shorter periods compared to Forasteros and
Trinitarios.
Climatic and seasonal variations:
Low temperature of high altitude (800 m asl) slows the rate of fermentation.
The weight of pulp and sugars per bean depend on growing conditions.
Bean has limited amount of pulp during the dry season.
Quantity of cocoa:
Duration of fermentation:
A complete fermentation gives the bean a uniform brown colouration.
Inadequately fermented cocoa bean has purple colour and this gives a bitter and astringent
product.
An excessively long fermented cocoa bean runs the serious risk of having a very bad taste
due to the commencement of putrid fermentation.
Factors Affecting Fermentation of Commercial Cocoa.
1.
2.
3.
A minimum quantity of about 70 – 90 kg of fresh bean is needed per fermentation unit in order
to have a satisfactory fermentation.
1.
2.
3.
45

48. Box method
The boxes of 60 cm X 60 cm X 45 cm made of wood and having reapers at the
bottom to allow the sweating from the pulp to drain out and provide aeration
are used. The boxes could be arranged in tiers for transferring beans from
one to the next in line below. Two detachable wooden planks are provided on
one side of the box for transferring (mixing) the beans by removing the
planks.
The beans are loaded on fermentation box and covered with banana leaves or
gunny bags. The mixing of beans is effected while transferring to the next box
after 24 hours. The temperature of the fermentation mass will rise to 45 –
550C after about 48 hours of fermentation.
Every alternate day the beans under fermentation have to be properly mixed
for uniform fermentation. This has to be continued for 6 days.
46

49. 47

50. box method fermentation
48

51. Basket methods
In this method, Bamboo or cane baskets of suitable size could be
used for fermenting small quantity of beans. One or two layers of
banana leaves are placed at the bottom with provision to drain the
sweating. The basket is filled with the beans and the surface is
covered with banana leaves. A small weight is placed over the
banana leaves. The basket is placed over a raised surface to
facilitate drainage of the sweating for one day. Later the basket is
covered with thick gunny bags. The beans are mixed thoroughly on
the 3rd and 5th days and again covered with gunny bags. The
fermentation will be completed at the end of 6th day and the
beans withdrawn for drying.
49

52. basket method of cocoa fermentation
50

53. End point of fermentation
Well fermented beans will be plumpy and filled with
reddish brown exudates. The testa becomes loosened
from the cotyledons. When cut open, the cotyledons
will have a brownish colored with lots of ridges and
furrow appearance in the centre with a brownish ring in
the periphery. When above 50 per cent beans in a lot
show the above signs, it can be considered as properly
fermented. 51

54. fermented cocoa beans
52

55. Drying
During fermentation the cocoa flavour develops and the beans
turn brown. After fermentation, the beans can be dried by sun
drying. The fermented cocoa beans have considerable moisture
(55 -69 %) and the drying rate is depend upon temperature and
the airflow. Sun drying should be adopted as far as possible, as
it gives superior quality produce compared to that by artificial
drying. The moisture content of well dried beans is around 6 – 7
%. Slow drying is preferable for better quality of the beans.
53

56. 54

57. to reduce the water content of fermented cocoa beans from about 60 % to 8 %.
to ensure that cocoa is kept under good conditions for storage and transportation.
If drying is slow, mould may develop.
If drying is too rapid, oxidation may be prevented, acetic acid may be retained in the
cotyledon resulting in excessive acidity of the cocoa beans.
Flat beans, germinated beans and broken beans as well as foreign bodies must be removed.
Sun-drying
Drying autobus
Movable roof dryer.
Simple dryers
Mechanical dryers
Automated workshops.
A well-dried cocoa bean will crack when squeezed between the fingers.
Cut through the sample beans with a knife, if properly dried, the cotyledon will separate
easily.
Drying
The aim of drying:
Methods of drying:
Test for dryness:
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58. Grading and storage
The flat, slate, shrivelled, broken and other extraneous
materials are removed. The cleaned beans are packed
in fresh polythene lined (150 – 200 gauge) gunny bags.
The bags are kept on raised platform of wooden
planks. The beans should not be stored in room where
spices, pesticides and fertilizers are stored as they
may absorb the odour from these materials.
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59. Grade 1 cocoa: less than 3 % slaty, mouldy and defective beans each.
Grade 2 cocoa: less than 5 %, 4 % and 5 % slaty, mouldy and defective beans respectively.
The international standards state that the net weight of a cocoa bag must be 62.5 kg, (16
bags makes a ton).
Sorting and elimination of flat, broken, germinated beans and other impurities.
The beans are packed in jute bags.
Polythene bags must not be used for bagging cocoa.
The international standards stipulate the following conditions.
The ambient humidity must not exceed 70 %.
The bags must be stored at least 7 cm above the ground in order to allow air circulation.
There must be at least a passage of 60 cm between the walls and the bags and between
bags of different types of cocoa.
Disinfect by fumigation. Protection against rodents and other pests must be carried out as
and when due.
Steps must be taken to avoid contamination by odour, off-flavours or dust.
Periodic checking of the moisture content of each lots must be carried out.
Grading of cocoa.
Cleaning and bagging of cocoa.
Storage of commercial cocoa.
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60. Bean quality
Cocoa quality depends on various factors, but primarily on the
cocoa variety and the post-harvest handling. Generally, fine or
flavour cocoa beans are produced from Criollo or Trinitario
varieties, while bulk cocoa beans come from Forastero trees.
Before fermentation Fermented beans
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61. Poor post-harvest handling can cause cocoa beans to be mouldy and/or germinated which reduces or
diminishes the cocoa quality. Mouldy cocoa beans should be rejected on two counts, namely the
tainting and off-flavours to the beans and possible contamination by mycotoxins (including 59

62. Fully ripe, correctly fermented
Firm beans of uniform size
Loose and undamaged shell
Brown color
Readily crumbled, fragile kernel
Bean quality Good qualities:
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63. Unripe and poorly fermented beans
Mouldy cocoa beans
Purple color (underfermented)
Black color (overfermented)
Insect infested cocoa beans
Germinated cocoa beans
Smokey smell, obtained from smoke by fire drying
Bean quality Bad qualities:
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64. Fine cocoa (F = jenis mulia)
Bulk cocoa (B = jenis lindak)
Mutu I
Mutu II
Mutu III
Cocoa bean grades
Cocoa beans can be classified by:
There are 3 types of quality:
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65. AA: maximum of 85 beans per 100 gram
A : beans per 100 gram
B : beans per 100 gram
C : beans per 100 gram
S : over 120 beans per 100 gram
cocoa bean grades
The 3 types of quality have sub-categories for bean
count (number of beans per 100 gram sample):
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66. Cocoa beans shall be free from live insects
The moisture content shall not exceed 7.5 %
The beans shall be free from smoky smell and other
objectionable odor
The beans shall be free from foreign matter
cocoa bean grades
General conditions:
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