Unlocking cocoa potential: Nestlé taps fermentation and upcycles fruit parts to transform waste into flavor

The cocoa industry is reeling from the effects of climate change, leading to lower yields and higher production costs. In response, Nestlé’s novel technique to boost cocoa fruit yields by up to 30% unlocks the “untapped potential” of the pulp, placenta, and pod husk — parts that are largely unused during chocolate production.

The patented method helps farmers get more yield and value from cocoa, especially as climate change affects production and increases prices. In West Africa, nearly 90% of cocoa farms in Ghana are impacted by climate change, but only about 25% of farmers are taking steps to adapt.

“In light of the growing impact of climate change worldwide, transformative changes are needed in how we produce and source agricultural raw materials,” Louise Barrett, head of the Nestlé Research and Development Centre for Confectionery in York, UK, tells Food Ingredients First.

“That is why we are actively exploring solutions to build resilience in the future supply of raw materials we source, such as cocoa, coffee, and dairy.”

Increasing the cocoa extraction process’s efficiency minimizes waste and helps farmers get “more value from their cocoa harvests.” This could free up some time for farmers, giving them more time to focus on good agricultural practices such as pruning.

“We are still exploring the full potential of this technology, including the benefits for the farmer,” Barrett adds.

Flakes to chocolate

Traditionally, chocolate production relies solely on the cocoa beans, underscores Barrett. These beans are harvested, fermented, dried, roasted, and ground into a liquor that is used to make chocolate. 

Nestlé’s method of using all cocoa fruit components to create chocolate flakes could revolutionize chocolate production, says Barrett.“In contrast, this innovative and streamlined method collects the entire contents of the cocoa pod — comprising the pulp, pith, and cocoa beans — as a single wet mass.”

“This mass then undergoes natural fermentation, unlocking a rich chocolaty flavor. Following fermentation, the wet mass is ground, roasted, and dried into cocoa flakes, which are then used to make either milk or dark chocolate,” she explains.

While the concept of utilizing alternative parts of the cocoa fruit, such as the pulp, to minimize waste is “not entirely new,” Barrett emphasizes that the novel approach of combining all the components of the cocoa fruit to create these flakes could “revolutionize the way chocolate is produced.”

Elevating taste

Rich flavor and taste in foods continues to top consumer demands, with nearly 40% of those surveyed globally agreeing this makes their food experiences “impressive,” Innova Market Insights’ data suggests. This makes the need to maintain chocolate’s taste profile critical for companies.

“Great tasting chocolate is a priority for our consumers. Using our R&D expertise in confectionery innovation, we conducted trials to develop and optimize the technique, and we also conducted sensory testing to ensure the cocoa flakes deliver the desired flavor notes,” says Barrett.

“We can then blend the cocoa flakes with other ingredients that are normally used in chocolate making to develop great-tasting milk or dark chocolate without compromising the taste.”

Targeting cocoa sustainability

Nestlé is currently in the “pilot phase” and is exploring various applications that could leverage more of the cocoa fruit, Barrett notes.

Nestlé’s method boosts extraction efficiency, giving farmers more time for practices like pruning.The company is also assessing the potential of the new technique while considering key factors such as impact on sustainability, supply chains, costs, and production, as well as the impact on farmers.

“Cocoa is a key ingredient in our confectionery products, especially chocolate. In light of the growing impact of climate change worldwide, there is an urgent need to ensure the sustainable supply of cocoa.”

“As part of the Nescafé Cocoa Plan, we are actively helping farmers improve their crops and livelihoods by supporting best practices, providing resources, and incentivizing them to adopt regenerative agricultural methods.”

Through training programs for farmers, the company aims to help minimize crop disease, improve bean quality, rejuvenate plantations, and manage land more sustainably. 

“Beyond this work, we are also exploring the possibility of breeding improved cocoa varieties with higher yields, which are also disease resistant and climate resilient,” Barrett concludes.