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Nestlé has developed a new patented technique aimed at revolutionising cocoa production, potentially increasing cocoa fruit yield by up to 30%.

This innovation not only addresses sustainability concerns within the cocoa supply chain but also promises to enhance the economic viability for cocoa farmers by maximising the value derived from their harvests.

Traditionally, chocolate production relies solely on cocoa beans extracted from the pods, leaving a substantial amount of the cocoa fruit – including pulp, placenta and pod husk – largely unused.

Nestlé's new method seeks to leverage these underutilised components, and in doing so, minimise waste and improve the overall efficiency of cocoa extraction.

The process involves collecting all parts of the cocoa fruit as a wet mass, which then undergoes natural fermentation. This method unlocks essential chocolate flavours without compromising taste.

The resulting mass is subsequently ground, roasted and then dried into chocolate flakes, ready for use in chocolate production.

Louise Barrett, head of the Nestlé Research and Development Center for Confectionery in York, UK, highlighted the importance of this innovation in light of climate change's effects on cocoa yields.

“We are exploring solutions that could help cocoa farmers maximise the potential of their harvests,” Barrett stated. “This groundbreaking technique utilises more of the fruit while enabling us to provide delicious chocolate to our consumers.”

The implications of this development extend beyond just yield enhancement. By streamlining the cocoa extraction process, farmers can allocate more time to essential agricultural practices, such as pruning, which has been shown to further improve crop yields.

This dual benefit of increased efficiency and enhanced agricultural focus could significantly elevate the livelihoods of cocoa producers.

More innovative solutions for cocoa production

🍫 Barry Callebaut

Barry Callebaut has teamed up with the Zurich University of Applied Sciences (ZHAW) to research the potential of cocoa cell culture technology. The initiative aims to explore new ways of producing chocolate while strengthening supply chain resilience.

The collaboration will combine Barry’s expertise in chocolate manufacturing with ZHAW’s research led by professors Tilo Hühn and Regine Eibl-Schindler, both recognised for their work in cell culture technologies.

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🍫 T. Hasegawa USA

In October last year, T. Hasegawa USA introduced a new product aimed at addressing the ongoing global cocoa shortage that has significantly impacted food and beverage manufacturers across multiple categories, including confectionery, snacks and sports drinks.

The company’s Cocoa Powder Replacer is an alkalised, low-fat cocoa flavour designed to serve as a substitute for traditional cocoa powder. This innovation allows manufacturers to reduce their reliance on raw cocoa while maintaining the desired flavour profile in their products.

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🍫 Mars

In a move to bolster its cocoa supply chain amid growing challenges, Mars – the manufacturer of global brands such as M&M’s, Snickers and Dove chocolate – recently entered into a licensing agreement with agricultural gene-editing firm Pairwise.

This partnership aims to leverage advanced CRISPR technology – a gene-editing tool that allows scientists to precisely alter DNA sequences in living cells and organisms – to develop more resilient cocoa plants, addressing the pressing issues of climate variability, plant diseases and environmental stresses affecting cocoa production.

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🍫 Ardent Mills

In May, Ardent Mills introduced Cocoa Replace, a wheat-based ingredient designed to replace up to 25% of cocoa powder in baked goods like cakes, cookies, brownies and muffins.

The product addresses ongoing challenges with cocoa supply, rising costs and clean-label demands.

Cocoa Replace is a single-ingredient, non-GMO, vegan and kosher-certified solution that simplifies reformulation for manufacturers. It allows for minimal label changes in wheat-based products, offering a cost-effective alternative amid cocoa price volatility.

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🍫 Cargill

Last spring, Cargill announced a commercial partnership with cocoa-free chocolate start-up Voyage Foods, aiming to meet global demand for sustainable confectionery.

Voyage, based in California, uses plant-based ingredients to develop sustainable and dairy-free alternatives to popular products that face ‘uncertain futures’ due to their sourcing challenges – including chocolate.

Alongside its alternatives to cocoa-based products, it also provides nut-free spreads made without common nut or dairy allergens, such as peanut and hazelnut, formulated to taste like their traditional counterparts thanks to the company’s proprietary technology.

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