EP2456321A2 - Process for the fermentation of cocoa beans to modify their aromatic profile - Google Patents

Process for the fermentation of cocoa beans to modify their aromatic profile

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Publication number
EP2456321A2
EP2456321A2 EP09711977A EP09711977A EP2456321A2 EP 2456321 A2 EP2456321 A2 EP 2456321A2 EP 09711977 A EP09711977 A EP 09711977A EP 09711977 A EP09711977 A EP 09711977A EP 2456321 A2 EP2456321 A2 EP 2456321A2
Authority
EP
European Patent Office
Prior art keywords
cocoa
cocoa beans
fermentation
beans
aromatic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP09711977A
Other languages
German (de)
English (en)
French (fr)
Inventor
Albertus B. Eskes
Ahnert Dario
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP2456321A2 publication Critical patent/EP2456321A2/en
Withdrawn legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
    • A23G1/00—Cocoa; Cocoa products, e.g. chocolate; Substitutes therefor
    • A23G1/02—Preliminary treatment, e.g. fermentation of cocoa
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
    • A23G1/00—Cocoa; Cocoa products, e.g. chocolate; Substitutes therefor
    • A23G1/30—Cocoa products, e.g. chocolate; Substitutes therefor
    • A23G1/32—Cocoa products, e.g. chocolate; Substitutes therefor characterised by the composition containing organic or inorganic compounds
    • A23G1/48—Cocoa products, e.g. chocolate; Substitutes therefor characterised by the composition containing organic or inorganic compounds containing plants or parts thereof, e.g. fruits, seeds, extracts
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L27/00—Spices; Flavouring agents or condiments; Artificial sweetening agents; Table salts; Dietetic salt substitutes; Preparation or treatment thereof
    • A23L27/10—Natural spices, flavouring agents or condiments; Extracts thereof
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L29/00—Foods or foodstuffs containing additives; Preparation or treatment thereof
    • A23L29/065—Microorganisms

Definitions

  • the present invention relates to a process for the fermentation of cocoa beans in order to modify the cocoa beans' aromatic profile.
  • Fermented and dried cocoa beans are used to produce cocoa liquors, chocolates and other cocoa-based food products. Fermented and dried cocoa beans that possess the potential to develop after roasting, besides the typical cocoa flavour, additional desirable flavours are often identified as "fine flavor" cocoa beans. These may be used as primary products for the manufacturing of specialty chocolates with high cocoa content, or for making blends with cocoa from other origins to create diverse or complex flavour profiles, aiming at enhancing the commercial value of the final product. Fine flavour cocoa beans may also be used as ingredients for the manufacturing of other cocoa and chocolate based high quality food products.
  • cocoa origins of cocoa beans are currently considered as fine flavoured cocoa types. This is due to a limited availability of genetic and/or geographic origins of cocoa beans that contain intrinsic fine flavour attributes. Some cocoa origins are even associated with the frequent occurrence of less desirable flavours such as excessive acidity, astringency and bitterness.
  • Cocoa manufacturers modify, with certain frequency, the flavour of chocolate through the addition of aromatic ingredients (e.g. vanilla, pieces of dried fruits and pepper) at this late stage during production.
  • aromatic ingredients e.g. vanilla, pieces of dried fruits and pepper
  • WO/2003 /037099 discloses a process for manipulating the flavour of chocolate through the addition of a non-cocoa/dairy flavour attribute to the chocolate mass.
  • WO/2007/063563 describes the addition of dehydrated fruit to chocolate to give a particular flavour and taste.
  • Another approach is to improve the quality of the beans during the fermentation process.
  • European patent application EP 0 442 421 A2 discloses an improved cocoa fermentation process comprising the treatment of fresh cocoa beans before fermentation in order to remove up to 80 wt% of pulp based on the original weight of the pulp.
  • UK patent application GB 2 059 243 A discloses a process for the fermentation of cocoa beans based on a rigorous control of fermentation parameters such as pH value and temperature.
  • WO 2008/137577 Al discloses a method of processing cocoa beans and other seeds. Typically, the methods of the state of the art try to get rid of undesirable flavours
  • the present invention allows for the development of desirable flavours, such as fruity and floral flavours, in addition to the typical flavour of roasted cocoa beans.
  • desirable flavours such as fruity and floral flavours
  • the present invention may be combined with the methods of the state of the art. Such an approach is then targeted to decrease the amount of undesirable flavours and to simultaneously increase the amount of desirable flavours, i.e. there is a synergetic effect between the methods of the state of the art and the method according to the present invention.
  • the present invention discloses a method to obtain fermented and dried cocoa beans with modified flavour through the addition of suitable aromatic substances to wet cocoa beans before, at the initiation, during or at the end of the cocoa bean fermentation process.
  • the invention can be applied to all types of cocoa varieties. Accordingly, new flavours or new flavour combinations can be added to intermediate or end products by using cocoa beans fermented according to the process of the present invention.
  • the present invention allows for the modification of the aromatic profile of any product based on cocoa beans. This allows for an increase of the commercial value of primary cocoa products (fermented and dried cocoa beans), intermediate products (e.g. cocoa masses or liquors) and end products (e.g. cocoa based food products).
  • the invention is also directed to the use of aromatic substances in a process according to the present invention.
  • Said flavourings include aromatic pulps und juices of tropical fruit.
  • the use of fruit and plants that grow in the same geographical area as Theobroma cacao L. may avoid major logistic problems that are often time-consuming and costly. Therefore, said use may result in a relatively fast and cheap way to modify the aromatic profile of cocoa beans.
  • labour costs can be reduced as the fermentation process may be applied by the cocoa farmers themselves. The latter is not necessarly true for those fermentation processes of the state of the art which require a strict control of fermentation parameters such as pH value and temperature.
  • a further cost saving results when aromatic substances are used which can be provided by the cocoa farmers themselves or when the aromtic substance is a dry, light substance such as a powder which can be easily transported and stored.
  • Fresh cocoa beans are covered with a white mucilage, rich in carbohydrates. Typically, this pulp is the basic substrate for micro-organisms involved in the fermentation process. Adequate fermentation of fresh cocoa beans and subsequent drying of fermented beans are fundamental processes in obtaining good quality dried cocoa beans to produce cocoa liquors, chocolates and other cocoa-based food products of high quality.
  • Fermentation of fresh cocoa beans can be carried out in different ways, e.g. by piling up fresh beans in heaps that are generally placed on banana leaves on the ground and covered with banana leaves, or by placing fresh beans in baskets, bags or wooden boxes ("sweat boxes") of variable sizes.
  • the fermentation process consists of bringing together an amount of fresh cocoa beans (beans surrounded by mucilage), extracted from ripe cocoa fruits (also called cocoa pods), sufficiently large to induce, through the activity of micro-organisms (mainly yeasts and bacteria), a chain of biochemical reactions within the mucilage and inside the cocoa beans, which is necessary to obtain cocoa beans of satisfactory industrial quality.
  • the initial anaerobic, low pH and high sugar conditions of the cocoa pulp favour activity of many yeast species, which convert sugars into alcohol and carbon dioxide.
  • yeast species which convert sugars into alcohol and carbon dioxide.
  • Bacterial activity then increases, starting with the oxidation of alcohols into lactic acid and, when conditions become more aerobic, into acetic acid.
  • These processes may produce an increase in temperature of the fermentation mass, which may reach 45°C to 50 °C during the first 24-48 hrs. Such high temperatures are maintained, with slight variations, until the fermentation is completed.
  • the high acidity and temperature kill the germs of cocoa beans during the first 24-48 hrs and sets off a series of chain reactions that are important for the development of cocoa flavour and for breaking down undesired polyphenols which are often present at high levels in unfermented cocoa beans.
  • the process of the present invention provides therefore a method to enhance quality of fermented and dried cocoa beans. These beans obtained can therefore be sold as a quality product on the national or international cocoa market.
  • One aspect of the present invention is directed to a process for the fermentation of cocoa beans, comprising the addition of at least one aromatic substance to cocoa beans before, at the initiation, during, or at the end of the cocoa bean fermentation process, wherein the addition at the end includes the early drying stages of the fermented cocoa beans.
  • the present invention is directed to a fermentation process wherein the process comprises the steps: a) providing wet cocoa beans; and subsequently b) piling up the wet cocoa beans, preferably in heaps, and optionally covering the fermentation mass comprising cocoa beans and, if present, aromatic substance(s) with a cover, wherein the at least one aromatic substance is added to the cocoa beans before, at the initiation, during, or at the end of the cocoa bean fermentation process, and wherein the addition at the end includes the early drying stages of the fermented cocoa beans.
  • Said cover which preferably allows for exchange of air, can be e.g.
  • the present invention is directed to a fermentation process wherein the process comprises the steps: a) providing wet cocoa beans; and subsequently b) putting said wet cocoa beans in an permeable container and optionally covering the fermentation mass comprising cocoa beans and, if present, the aromatic substance(s) with a cover or a lid, wherein at the least one aromatic substance is added to the cocoa beans before, at the initiation, during, or at the end of the cocoa bean fermentation process, and wherein the addition at the end includes the early drying stages of the fermented cocoa beans.
  • Said cover or lid which preferably allows for exchange of air, can be e.g. banana tree leaves, jute bags, blanket(s), tissue, bamboo or wooden mats, fleece and/or made of a polymeric material such as nylon, plastic and/or cellulose.
  • the present invention is directed to a fermentation process wherein the process comprises the steps: a) providing wet cocoa beans; and subsequently b) putting said wet cocoa beans in a reactor filled with an aqueous medium (e.g. a liquid comprising water), wherein at least one aromatic substance is added to the cocoa beans before, at the initiation, during, or at the end of the cocoa bean fermentation process, and wherein the addition at the end includes the early drying stages of the fermented cocoa beans.
  • an aqueous medium e.g. a liquid comprising water
  • the beans After fermentation the beans are dried in the sun for e.g. five to ten days or by artificial heating devices until humidity levels of about 5% to about 10%, preferably of about 8% to about 10%, are reached, before being sold by farmers on the market.
  • the cocoa beans are seperated from remaining parts of the aromatic substance(s) during, before and/or after the drying process.
  • cocoa beans with regular organoleptic quality i.e. without any undesirable flavours ("off-flavours")
  • off-flavours undesirable flavours
  • the conditions and duration of the fermentation and drying processes may depend on the type of aromatic substances used. This is because said substances may interact more or less with parameters of the fermentation and drying processes used in the prior art.
  • the use of artificial and/or concentrated dry aromatic substances may offer a certain advantage in the sense that these substances are expected to interfere less with the normal fermentation process while artificial and/or concentrated dry aromatic substances may be equally or even more effective in transferring flavours to the cocoa beans than natural aromatic substances.
  • the aromatic substance is brought together with cocoa beans.
  • the aromatic substance is surrounded by wet cocoa beans or vice versa.
  • cocoa beans and aromatic substances are well mixed
  • the aromatic substance is a liquid that is poured over the cocoa beans.
  • the cocoa beans to be fermented and, if present, the aromatic substance(s) are piled up, preferably in heaps, on a suitable floor.
  • the piled up fermentation mass may be covered by a suitable cover such as a blanket or large leaves such as banana leaves.
  • aromatic substances according to the present invention do not include leaves, which are placed on the top of the fermentation mass and/or underneath the fermentation mass and which are merely used for covering the fermentation mass and/or the floor underneath the fermentation mass during fermentation.
  • the cocoa beans to be fermented and, if present, the aromatic substance(s) are put in a permeable container during the fermentation process.
  • Said permeable container allows the juices formed during fermentation to flow out.
  • Suitable permeable containers can be of any size. Typically, the most suitable dimensions may also depend on the type of aromatic substance that is used.
  • Preferred containers are the usual fermentation boxes
  • normal size fermentation boxes e.g.
  • the container may be covered by a lid, blanket or leaves such as banana leaves.
  • Other suitable containers may be large bags or nets made up of jute or of polymers such as plastic and nylon.
  • the fermentation takes place in an aqueous medium in a reactor.
  • the at least one aromatic substance is added to cocoa beans e.g. in dispersion in an aqueous medium.
  • the reactor may be any kind of conventional liquid fermenter, preferably equipped with a device for agitation, for aeration, for regulating and/or measuring the temperature of the medium, for regulation and/or measuring the pH of the medium and/or for measuring the proportion of dissolved oxygen in the medium.
  • aromatic substances can be replaced or removed during the fermentation process or one or a plurality of additional aromatic substances can be added during the fermentation process.
  • aromatic substances from the beginning of the fermentation process according to the present. invention is possible but not compulsory.
  • Aromatic substance(s) can be added to the cocoa beans at any stage of the fermentation process. Preferably, aromatic substance(s) is/are added to the cocoa beans at the beginning of the fermentation process or up to 24 hrs after the start of the fermentation process.
  • aromatic substance(s) is/are added to the cocoa beans up to 24 hrs, or up to
  • Aromatic substances may be any natural, natural identical or artificial aromatic substance used in the food industry and elsewhere. This includes substances that can be smelled and/or tasted.
  • the aromatic substance may be in solid, liquid, gaseous form or a mixture thereof.
  • Preferred solid or aqueous aromatic substances are fruit pulps, aromatic leaves, roots, flowers, stems, wooden parts, such as pieces of aromatic timber, any kind of powders (such as ground aromatic powders), and oils or liquids (e.g. juices).
  • the wet cocoa bean to aromatic substance weight ratio (before fermentation and before optional pre-treatments such as drying, depulping and/or pressing) ranges from about 5000:1 to about 1:10 and is preferably between about 50:1 and about 1:2. In a preferred embodiment, the cocoa bean to aromatic substance weight ratio ranges from about 50: 1 to about 1:1.
  • liquid aromatic substances are oils such as essential oils and juices made of a plant or made of fruit pulp.
  • liquid aromatic substances are used in an amount of about 0.5% (v/v) to about 20% (v/v), based on the volume of the wet cocoa beans, before optional pre-treatments such as drying, depulping and/or pressing .
  • the preferred amount is in the range of about 3% (v/v) to about 15% (v/v).
  • the preferred amount is in the range of about 0.5% (v/v) to about 7% (v/v).
  • the preferred amount is in the range of about 12% (v/v) to about 20% (v/v).
  • Preferred gaseous aromatic substances are evaporated liquid or evaporated solid aromatic substances.
  • smoke or smoky flavours produced by burning wood or other fuels are excluded.
  • the aromatic substance can be any natural, natural identical or artificial aromatic substance (e.g. spices, aromatic wood spices and synthetic aromatic substances) capable to modify the flavour and/or aroma of the cocoa beans during the fermentation process.
  • aromatic substance e.g. spices, aromatic wood spices and synthetic aromatic substances
  • aromatic substances to modify the flavour of cocoa beans are selected from natural aromatic substances, nature-identical aromatic substances, artificial aromatic substances and mixtures thereof.
  • the natural aromatic substance is a plant or part(s) of a plant (fresh, dehydrated or dried, ground and dried or first dried and then ground).
  • a plant fresh, dehydrated or dried, ground and dried or first dried and then ground.
  • medium-sized to large leaves that are traditionally used to cover up cocoa beans during the fermentation process such as banana tree leaves.
  • medium-sized to large leaves that are traditionally used to cover the floor before cocoa beans are placed thereupon such as large banana tree leaves.
  • jute bags which are typically produced from plants in the genus Corchorus, family Tiliaceae.
  • Suitable natural aromatic substances include fresh, frozen or dried aromatic fruit, fruit pulp, juice (such as juice made of fruit pulp) and any other part of an aromatic plant (e.g. leaves, roots, flowers, stems, wooden parts, pieces of aromatic timber, dried plant parts which are ground or not ground).
  • an aromatic plant e.g. leaves, roots, flowers, stems, wooden parts, pieces of aromatic timber, dried plant parts which are ground or not ground.
  • wooden chips or chips made of bark such as chips made of oak (i.e. trees and shrubs in the genus Quercus) or made of tropical aromatic timber species are used.
  • the natural aromatic substance is a plant or is a part of a plant or is gained from a plant that grows in the same geographical area as Theobroma cacao L..
  • the natural aromatic substance is a tropical plant or is a part of a tropical plant or is gained from a tropical plant.
  • the natural aromatic substance is a plant listed in Table 1 ; or is a part of a plant listed in Table 1 or Table 2; or is gained from a plant listed in Table 1 or Table 2.
  • the natural aromatic substance is a plant or is a part of a plant or is gained from a plant wherein the plant is selected from the Annonaceae, Malvaceae, Rubiaceae and Zingiberaceae family.
  • the natural aromatic substance is a plant or is a part of a plant or is gained from a plant wherein the plant is selected from Theobroma grandiflorum (cupuacu), Annona muricata (sour sop, gravida or guanabana), Genipa americana (genipa), and Zingiber officinale and is preferably the pulp and/or the juice of said plants such as the juice made of Zingiber officinale (ginger) rhizomes.
  • Annona muricata as aromatic substance is excluded.
  • Suitable separation processes to gain natural aromatic substances from an aromatic plant include extraction, distillation, compression, drying, roasting, fermenting, and enzymatic and/or microbiological processes.
  • natural aromatic substances are purified, naturally occurring aromatic substances, extracted from aromatic plants or from parts of an aromatic plant.
  • any nature-identical aromatic substance can be used.
  • the nature-identical aromatic substance is identical with or derived from a natural aromatic substance gained from plant of List 1 or List 2.
  • Table 1 Examples of aromatic fruit species
  • the nature-identical aromatic substance is identical with or derived from a natural aromatic substance gained from a tropical plant such as a plant of the Annonaceae, Malvaceae, Rubiaceae and Zingiberaceae family.
  • the nature-identical aromatic substance is identical with or derived from a natural aromatic substance gained from Theobroma grandiflorum (cupuacu), Annona muricata (sour sop, graviola or guanabana), Genipa americana (genipa), Zingiber * officinale (ginger rhizomes).
  • Artificial aromatic substances include, among others, flavouring substances used in the food and confectionary industry, such as diacetyl, isoamylacetate, cinnamicaldehyde, ethylpropionate, limonene, ethyl-(E,Z)-2,4-decadienoate, allylhexanoate, ethylmaltol and benzaldehyde.
  • flavouring substances used in the food and confectionary industry such as diacetyl, isoamylacetate, cinnamicaldehyde, ethylpropionate, limonene, ethyl-(E,Z)-2,4-decadienoate, allylhexanoate, ethylmaltol and benzaldehyde.
  • the content of said Register (in particular the names of the flavouring substances and the respective CAS numbers insofar these had been attributed or made available) is herewith incorporated by reference in its entirety.
  • the aromatic substance is a mixture of natural aromatic substance(s) and/or nature-identical aromatic substance(s) and/or artificial aromatic substance(s).
  • the present invention is also directed to the use of aromatic substances in fermentation processes of the present invention.
  • aromatic substances are included.
  • the fermentation mass is preferably turned around one to six times to allow for adequate aeration, hi a preferred embodiment, the fermentation mass is turned at regular intervals of 24 hours, of 36 hours or of 48 hours, wherein the fermentation mass is preferabyl turned over for the first time about 24 hours after the initiation of the fermentation process. In another embodiment, the fermentation mass is turned over about 24 hours, about 48 hours, about 72 hours, about 96 hours and/or about 120 hours after the initiation of the fermentation process.
  • At least a part of the cocoa beans are pre-treated before fermentation in order to decrease the amount of undesirable flavours (such as excessive acidity, bitterness and astringency).
  • such pre-treatment can be combined with the addition of at least one aromatic substance to cocoa beans before, at the initiation, during or at the end of the fermentation process.
  • the cocoa beans are pre-treated before the actual fermentation process in order to reduce the amount of pulp.
  • Such an approach enables the subsequent fermentation to proceed in more aerobic conditions, favouring acetic acid bacteria over lactic acid bacterial activity, causing the pH to remain above 5 during the fermentation which results in cocoa beans with low acidity.
  • a preferred method of treating fresh cocoa beans before fermentation comprises passing the fresh beans dynamically through a depulper to remove up to 80% by weight of pulp based on the original weight of the pulp.
  • the depulper may be operated mechanically or by other means e.g. ultrasonically.
  • a depulper may be preceded or replaced by the use of a pressing device such as a hydraulic press in order to squeeze the wet cocoa beans.
  • the pulp juice obtained by the press and/or depulper can then be used to make natural cocoa pulp juice that can be sold as a fruit juice.
  • the latter approach will make the herein disclosed process more profitable.
  • at least a part of the cocoa beans are dried or pre-dried before the actual fermentation process. This operation may be or may not be preceded by a reduction of pulp as described above.
  • air with a temperature between ambient and 70°C, preferably between ambient and 5O 0 C is forced through the cocoa beans for 0.5-5 hours, depending on the amount of cocoa beans.
  • the pre-drying step may be carried out in any conventional hot air dryer, such as a circular drier, or using any alternative drying system such as sun drying.
  • At least a part of the cocoa beans is perforated or pierced before the actual fermentation process. This operation may be or may not be preceded or followed by a reduction of pulp and/or a pre-drying step as described above. It is believed that such perforation is useful to decrease the amount of undesirable flavours (such as polyphenol compounds). Perforation facilitates the transport of fluids and gases from the interior of the seed across shell to the exterior environment. In particular, perforation allows for aeration of cocoa beans and of cocoa cotyledons, favouring aerobic processes that are necessary to decrease the amount of undesirable flavours. In one embodiment the cocoa beans are perforated during or after fermentation.
  • the perforation of cocoa t ⁇ eans before or during fermentation may increase the uptake of aromatic compounds that are added to the fermentation mass. Therefore, in a preferred embodiment, the amount of undesirable compounds such as polyphenol is decreased by perforating cocoa beans prior to fermentation, wherein the effect of the additon of at least one aromatic substance(s) to cocoa beans during the fermentation process is simultanously enhanced.
  • pierce generally refers to forming an opening in a cocoa bean, while leaving the portion of the cocoa bean surrounding the opening substantially intact.
  • Intact generally refers to unitary or whole.
  • a pierced cocoa bean may be a perforated cocoa bean.
  • a "perforated” cocoa bean refers to a cocoa bean pierced in one, two or more locations to form openings.
  • the openings may be substantially uniform in size and/or shape.
  • An area of the openings may range between about 0.5 mm 2 and 15 mm 2 . In some cases, an area of the opening may be smaller than 0.5 mm 2 or larger than 15 mm 2 .
  • the openings may have shapes including, but not limited to, circular, rectangular, oval, or star-shaped, cocoa bean may be pierced in a variety of methods, such as piercing with a solid object, piercing with a fluid jet, piercing with droplets of enzymes or acids, piercing with electromagnetic radiation, or combinations thereof.
  • Piercing with a solid object may include piercing with a sharpened metal cylinder.
  • the sharpened metal cylinder may be, for instance, a solid or hollow needle.
  • Piercing with a fluid jet may include, but is not limited to, piercing with an air jet, a water jet, or a jet of gas including, but not limited to, argon, nitrogen, oxygen, carbon dioxide, and combinations thereof.
  • Piercing with droplets may include, but is not limited to, piercing with liquid droplets of cellulases or pectinases or acids such as hydrochloric acid or hydrogen peroxide or combinations there of.
  • Piercing with electromagnetic radiation may include piercing with visible laser radiation.
  • the process according to the present invention can be further modified by the addition of at least one adjuvant before, during or at the end of the fermentation process.
  • Possible adjuvants are bacteria (e.g. lactic acid bacteria, and acetic acid bacteria), enzymes (e.g. Ultrazym®, a pectinase available from Novozymes A/S, Bagsvaerd, Denmark), pH-regulating, oxidizing and reducing agents.
  • a rigorous control of the fermentation parameters, such as temperature and humidity may be recommendable.
  • a modified fermentation process may be used: Preferably in the period of day 0 to day 2 of the fermentation process, preferably for a duration of about 20 to 30 hours, cocoa beans may be dispersed in an aqueous medium, with agitation and/or aeration, at a temperature of about 30-40°C and/or at a pH of about 3.0 to 4.5, and/or with addition of a strain of yeast of relatively high pectinolytic activity. Possible strains of yeast of relatively high pectinolytic activity comprise Saccharomyces chevalieri, Saccharomyces spp., S. cerevisiae, S. cerevisiae var. chevalieri Candida zeylanoides, Candida spp.
  • cocoa beans are further fermented, preferably in an aqueous medium, with agitation and/or aeration, at a temperature of about 40-about 50°C and/or at a pH of about 4 to about 5, and/or with addition of a strain of acetic bacterium.
  • Any strain of acetic bacterium capable of converting ethanol into acetic acid can be used. The most valuable strains include Acetobacter rancens and Acetobacter xylinum.
  • the at least one aromatic substance can be added and/or removed in any form at any stage of the fermentation process.
  • the pH can be adjusted by use of any acid such as citric acid (i.e. citric acid is not used as aromatic substance according to the present invention, but as pH regulating agent) and/or by use of any base such as (NH 4 ) 2 HPO 4 .
  • an aqueous medium it also acts as culture medium and may therefore contain glucose and/or any other sugar, i.e. glucose, sucrose, fructose, maltose and other carbohydrates are not used as aromatic substance according to the present invention, but as agent to influence the growth of bacteria.
  • any other sugar i.e. glucose, sucrose, fructose, maltose and other carbohydrates are not used as aromatic substance according to the present invention, but as agent to influence the growth of bacteria.
  • fruit juice as aromatic substance is excluded.
  • the aqueous medium may content a pH buffer.
  • cocoa bean can be used in all fermentation processes according to the present invention. However, for economical reasons, it is preferred to enhance the aromatic qualities of bulk cocoa beans which are usually sold at cocoa markets for lower prices than beans from fine flavoured cocoa varieties.
  • “Bulk cocoa”, meaning "mass-produced cocoa” is cocoa that generally expresses low or insignificant levels of fine flavour attributes.
  • cocoa origins are associated with occurrence of less desirable flavours such as excessive acidity, astringency and bitterness due to the inherent traits of the cocoa variety or due to inadequate post-harvesting processing.
  • the most commonly grown bulk cocoas are traditional "Forastero" cocoa varieties, such as Amelonado varieties, modern hybrid cocoa varieties or cocoa types derived from these varieties. "Forastero” varieties make up the majority of the cocoa varieties grown worldwide.
  • the cocoa beans are the seed of a
  • Theobroma cacao L. cocoa tree variety that is cultivated in any cocoa producing country, such as Ivory Coast, Ghana, Cameroon, Nigeria, Madagascar, Brazil, Ecuador, Venezuela, Dominican Republic, Trinidad and Tobago, Indonesia, Papua New Guinea and/or Malaysia.
  • the cocoa bean variety to be used is characterised by the shape of the fruit and is designated as Amelonado, Angoleta, Cundeamor or Calabacillo.
  • the cocoa bean variety is a Criollo type ( ancient cocoa variety cultivated in Central America before arrival of the Spanish), a Forastero type (including Upper Amazon and Lower Amazon Forastero cocoa types) or a Trinitario type (derived from hybridization between Criollo and Forastero).
  • Criollo type ancient cocoa variety cultivated in Central America before arrival of the Spanish
  • Forastero type including Upper Amazon and Lower Amazon Forastero cocoa types
  • Trinitario type derived from hybridization between Criollo and Forastero
  • the cocoa beans are the seed of a "Forastero" cocoa tree variety such as Amelonado, modern hybrid cocoa varieties or cocoa types derived from these varieties or Nacional cocoa types.
  • cocoa beans from traditional Amelonado cocoa varieties from South Bahia, Brazil e.g. Cons, Para, Parazinho and
  • Fine flavoured cocoa varieties can also be used in the fermentation process according to the present invention.
  • traditional cocoa varieties such as Criollo and Trinitario.
  • some of the less commonly grown Forastero types may also produce fine-flavour cocoa (such as is the case for the Ecuador “Nacional” type.
  • the duration of the cocoa fermentation process varies between about two and to about twelve days.
  • “Forastero” varieties are generally fermented 6 to 8 days, while the traditional “Criollo”, “Trinitario” and “Nacional” varieties are fermented between 3 and 5 days.
  • a prefered embodiment of the present invention is directed to a fermentation process wherein the process comprises the steps: a. providing wet cocoa beans b. before the start of the fermentation, optionally applying a pre- treatment such as using a de-pulper and/or a pressing device, and/or by pre-drying, and/or by perforating the cocoa beans c. putting the mixture, i.e. the fermentation mass, in a sweat box or piling up the mixture, preferably in heaps, wherein the mixture is optionally covered with a cover such as banana leaves, or placing the mixture in sealed containers such as a reactor or liquid fermenter, for about 2 to about 10 days, d.
  • the cocoa beans with at least one aromatic substance e. optionally turning the mixture at regular interval, e.g. every 24 or 48 hrs, f. optionally adding adjuvants, such as microorganisms or enzymes g. optionally applying a treatment to enhance aeration of the inside of the beans, e.g. by perforating the cocoa beans before or during drying h. drying of the beans, preferably with ambient air, through exposure to the sun, with artificial heated air or through a combination thereof and wherein, if applicable and if necessary, the fermented cocoa beans are seperated from the aromatic substance(s) before and/or after drying.
  • adjuvants such as microorganisms or enzymes
  • a prefered embodiment of the present invention is directed to a fermentation process wherein the process comprises the steps: a. providing wet cocoa beans b. optionally perforating the cocoa beans c. suspending the cocoa beans and the at least one aromatic substance in water, using a reactor such as a conventional liquid fermenter d. optionally adding a strain of yeast, enzymes and/or glucose e. keeping a temperature of about 30 0 C to about 4O 0 C and a pH of about 3.4 to about 4.1 for a duration of about 20 to about 30 hours f. raising the temperature to about 40°C to about 50°C and raising the pH to about 4 to about 5 g. optionally adding a strain of acetic bacterium and/or enzymes h. keeping the fermentation going for another about 36 to about 48 hours i. optionally separating the fermented cocoa beans from the mixture j . drying the fermented cocoa beans
  • a prefered embodiment of the present invention is directed to a fermentation process wherein the process comprises the steps: a. providing wet cocoa beans b. removing parts of the pulp with a suitable mean c. optionally perforating the cocoa beans k. suspending the cocoa beans in water in water, using a reactor such as a conventional liquid fermenter d. optionally adding a strain of yeast and optionally glucose e. keeping a temperature of about 30°C to about 4O 0 C and a pH of about
  • the objective of the present invention is to obtain cocoa-based food and non-food products, which possess enhanced and diversified aromatic qualities. This is achieved by using as primary ingredient cocoa beans that are fermented according to the claimed process.
  • Food products include products such as cocoa liquor, chocolate, chocolate powder or cocoa butter.
  • the present invention also provides a process for preparing chocolate and cocoa products comprising roasting the dried cocoa beans fermented as hereinbefore described in accordance with the invention, cracking the shells of said cocoa beans, winnowing to remove the shells and to produce the nibs which are ground to give cocoa liquor.
  • the cocoa liquor may be used to prepare e.g. chocolate that may be further processed.
  • the present invention also provides for a process wherein roasted and winnowed cocoa beans or said cocoa liquor is pressed to extract cocoa butter, wherein the residual cake is pulverised, cooled and shifted to produce cocoa powder.
  • semi-finished and finished products of the cocoa industry prepared from cocoa beans fermented as hereinbefore described in accordance with the invention may also be used to manufacture non-edible substances, such as saponified cocoa butter. Therefore, the present invention is also directed to non-edible products such as lubricants, pharmaceuticals, ointments, cosmetics and toiletries comprising saponified cocoa butter prepared from cocoa beans fermented as hereinbefore described in accordance with the invention. Definitions
  • Fermentation is a chain of biochemical reactions, which occur when cocoa beans are brought together in sufficient quantity, and which are responsible for the necessary industrial quality of cocoa beans. Fermentation includes the oxidation of organic compounds such as the pulp. "Micro-fermentation” means the fermentation of a small quantity of cocoa beans, generally within a bigger mass of cocoa beans that ferment simultaneously, or within small containers, for research purposes.
  • the “fermentation process” is the process of fermenting cocoa beans during a certain number of hours or days e.g. by piling the beans up in heaps, or by putting them in a permeable container or in a reactor of variable sizes, wherein the cocoa beans are preferably covered and are preferably being turned around at least once, preferably at regular time intervals, to allow for aeration of the cocoa fermentation mass and to allow for uniform fermentation of the cocoa beans.
  • Day 0 refers to the beginning of the fermentation process.
  • the “fermentation mass” comprises cocoa beans to be fermented and, if present, at least one aromatic substance.
  • Drying or the “drying process” as used herein means drying of cocoa beans during a variable number of hours or days, preferably by exposing the cocoa beans to ambient air, to the sun, or to air heated by an energy source (fuel, wood, sunlight, etc.).
  • an energy source fuel, wood, sunlight, etc.
  • a "plant” is any plant at any stage of development.
  • a “tropical plant” is a plant that naturally grows (i.e. that grows outdoor) in the equatorial regions of the world, limited in latitude by the Tropic of Cancer in the northern hemisphere at approximately 23°26' (23.4°) N latitude, and the Tropic of Capricorn in the southern hemisphere at 23°26' (23.4°) S latitude.
  • This definition includes plants naturally growing the following countries: Ivory Coast, Ghana, Cameroon, Nigeria, Madagascar, Brazil, Ecuador, Venezuela, Dominican Republic, Trinidad and Tobago, Indonesia, Papua New Guinea, Peru, Grenada, Jamaica, Madagascar, Saint Lucia, Sao Tome and Principe and/or Malaysia.
  • Pulp is the soft moist part of a fruit from a plant. Fruit juice is typically made by squeezing the pulp of fruit(s). Pulp of cocoa beans is sometimes refered to as "mucilage”.
  • Cocoa bean is the seed of any cocoa tree variety.
  • Wet cocoa beans or “fresh cocoa beans” are cocoa beans with at least parts of the fresh pulp/mucilage still attached.
  • Pod is a mature or ripe cocoa fruit or seed case. As used in the present invention, the pod encloses the cocoa beans and the pulp/mucilage.
  • nibs are pieces of crushed dried cocoa beans without shell.
  • a “leaf is a usually green, flattened, lateral structure attached to a stem and functioning as a principal organ of photosynthesis and transpiration in most plants.
  • medium-sized leaves can reach an average surface of more than ca. 400 cm 2 .
  • Large leaves are leaves can reach an average surface of more than ca. 600 cm 2 .
  • Aromatic as used herein relates to a distinctive pleasant smell and/or taste.
  • Aromatic substance as used herein is any substance that modifies the aromatic profile of fermented and dried cocoa beans when added to wet cocoa beans before, at the initiation, during or at the end of the cocoa bean fermentation process, wherein adding at the end includes the early drying stages of the fermented cocoa beans.
  • Aromatic substances include substances perceived by tasting, substances perceived by smelling, and substances perceived by tasting and by smelling.
  • Aromatic substances include flavourings, aromas and mixtures thereof. Enzymes and microorganisms are not considered as aromatic substances in the meaning of the present invention.
  • aromatic substance means one single aromatic substance or a plurality of aromatic substances.
  • a "natural aromatic substance” as used herein is an aromatic substance which occurs in nature and can therefore, if necessary, be obtained from natural substances by physical, microbiological and/or enzymatic processes. Included are also whole plants and parts of a plant.
  • Natural aromatic substance include substances perceived by tasting, substances perceived by smelling, and mixtures thereof.
  • a “nature-identical aromatic substance” as used herein is an aromatic substance which occurs in nature, but is produced artificially by synthesis or isolated through a chemical process. "Nature-identical aromatic substance” include substances perceived by tasting, substances perceived by smelling, and mixtures thereof.
  • an “artificial aromatic substance” as used herein is an aromatic substance which does not occur in nature and can therefore not be isolated from any natural material.
  • “Artificial aromatic substance” include substances perceived by tasting, substances perceived by smelling, and mixtures thereof.
  • Substance is anything which has mass and occupies space.
  • a “semi-finished product”, a “half-finished product” or an “intermediate product” is a product that is not sold as such to the consumers, but is rather modified or further processed before being sold.
  • Cocoa liquor or “cocoa mass” is an often smooth liquid when heated above 35°C, made of roasted, de-shelled and ground cocoa beans. Like the roasted cocoa nibs from which it is produced, it contains cocoa solids and approximately 50% cocoa butter.
  • a “finished product” or an “end product” is any product that is directly sold to a customer/consumer.
  • Such end-products include also chocolate bars with high cocoa content and other cocoa-containing food products produced by chocolate and confectionary industries or by artisans, such as pastries, cakes, desserts, ice-creams and chocolate "bon-bons" such as
  • the term "chocolate” comprises standard dark chocolate, milk chocolate as well as substitute chocolates such as used in compounds, Trus or ice-cream coatings.
  • Standard dark chocolates are generally obtained by mixing cocoa liquor with cocoa butter and sugar, followed by refining, conching and tempering.
  • Milk chocolates are prepared in a similar way but with the addition of milk.
  • the cocoa butter may be partially or totally replaced by cocoa butter replacements such as stearines, coconut oil, palm oil, butter or any mixture thereo. Chocolates prepared in this way are also called substitute chocolates.
  • “Saponified cocoa butter” is cocoa butter that is, typically under basic conditions, hydrolyzed to form products like various types of alcohols and carboxylic acids.
  • Permeable container as used herein is any container permitting exchange and draining of fluids, gases and/or solids.
  • Said container can be any type of bag, box or basket as long as it permits good exchange and exit of fluids.
  • a permeable container in the shape of a wooden box is often referred to as "sweat box”.
  • "Micro-fermentation bags” are relatively small permeable containers placed within a large cocoa fermentation mass. In a preferred embodiment a netted polystyrene bag is used.
  • reactor refers to any device or system that supports a biologically active environment.
  • a reactor is a vessel in which is carried out the fermentation process.
  • the reactor is cylindrical, ranging in size from liters to cubic meters, and is typically made of stainless steel or a polymeric material.
  • the invention is explained by the following examples.
  • the inventors have utilised aromatic pulps from two tropical fruit species, Theobroma grandiflorum (cupuacu) and Annona muricata (sour sop, "graviola” or “guanabana”), to demonstrate the validity of the principle of the invention.
  • Five treatments of micro-fermentation were applied using a fermentation mass made up of fresh cocoa beans from a mixture of the Amelonado Forastero cocoa varieties ("Comun”, “Para”, “Parazinho” and “Maranhao") traditionally grown in the South of Bahia, Brazil.
  • These Amelonado cocoa varieties are known to produce bulk cocoa quality.
  • the duration of fermentation was six days and the fermentation mass was turned at 48 hrs, 72 hrs, 96 hrs and 120 hrs after the initiation of the fermentation process to allow for adequate aeration.
  • the micro-fermentations were carried out by placing samples of 1 (one) kg of fresh cocoa beans, alone or in mixture with 1 kg of one of the two aromatic pulps used (cupuacu and sour sop), in netted polystyrene bags permitting good exchange of fluids between the fermentation masses inside and outside the bags.
  • the polystyrene bags were inserted in the middle of the Amelonado fermentation mass in the box at two different timings: 24 hrs or 48 hrs after the start of the fermentation process. The following treatments were applied each with two replicates (two filled netted bags):
  • ⁇ Treatment 1 (control). Micro-fermentation of a sample of 1 kg of fresh cocoa beans without addition of aromatic pulp. The cocoa bean sample was obtained by placing beans from the Amelonado cocoa fermentation mass into two micro-fermentation bags (replicates) 24 hrs after the beginning of the fermentation process. The two micro- fermentation bags were then inserted in the middle of the fermentation mass.
  • ⁇ Treatment 3 Micro-fermentation of a mixture cocoa beans and cupuacu pulp, as in treatment 2, but with addition of the cupuacu pulp to cocoa beans taken from the fermentation mass 48 hrs after the start of the fermentation process.
  • Treatment 4 As treatment 2, but with addition of pulp of sour sop ⁇ Annona muricata) to the cocoa beans in the micro-fermentation bags instead of pulp of cupuacu.
  • Treatment 5 As treatment 3, but with addition of pulp of sour sop ⁇ Annona muricata) to the cocoa beans in the micro-fermentation bags, instead of cupuacu pulp.
  • the micro-fermented beans were sun-dried for seven days attaining 8 to 10% moisture content.
  • the dried cocoa bean samples and chocolates produced with beans from these five treatments were evaluated by two experts with large experience in sensory evaluation of cocoa beans, cocoa liquors and chocolates. One of these experts was familiar with the typical flavours of cupuacu and sour sop pulp. Preferences for the chocolates made with the beans of the five treatments were provided by approximately 20 chocolate amateurs, part of whom were familiar with the typical flavours of cupuacu and sour sop pulp.
  • the flavour of the nibs (pieces of crushed dried cocoa beans without shell) obtained in the control treatment 1 was similar to that of nibs from normally fermented Amelonado-type beans (low acidity, quite bitter and no fruity notes).
  • Fruity flavours were detected in the nibs of treatments 2, 3, 4 and 5 with treatments 2 and 3 demonstrating fresh-fruit flavours with strong resemblance to that of the cupuacu pulp.
  • the fruity flavour of the beans of treatments 4 and 5 was less pronounced and more delicate, and showed resemblance to that of the fresh sour sop pulp.
  • Example 2 The inventors applied separate fermentations of Amelonado cocoa beans (the same as used in Example 1) alone or mixed with four natural flavourings.
  • the four flavourings used were three juices made with fresh pulp of aromatic fruits species (Theobroma grandiflorwn or cupuacu, Annona muricata or sour sop and Genipa Americana or genipa) and one juice made with ginger rhizomes ⁇ Zingiber officinale).
  • the fermentations were carried out in polystyrene boxes, the bottoms of which were pierced to allow fermentation fluids to drain away. Small holes were also present in the lateral walls and in the lids of the boxes to allow for adequate aeration during the fermentation process.
  • the size of the boxes was 28 1 for the mixed cocoa/fruit-juice fermentations and 8 1 for the mixed cocoa/ginger-juice fermentation as well as for the control treatment (fresh cocoa beans alone).
  • the fruit pulps and ginger rhizomes were transformed into concentrated juices in a blender by using a minimum amount of water.
  • the juices were added to the cocoa beans 48 hrs after the start of the fermentation process in the amounts of 10% (v/v) for the fruit juices and 5% (v/v) for the ginger juice.
  • the cocoa beans were turned three times, at 24 hrs, 48 hrs and 96 hrs after the start of the fermentation. After 6 days (144 hrs) the fermentations were stopped and the cocoa beans were dried in the sun for 8 days until reaching about 8% humidity.
  • the above results constitute a demonstration of the invention's principle that makes it possible to modify flavours in cocoa nibs and in chocolates through the addition of aromatic substances to the cocoa beans before, at the initiation, during or at the end of the process of fermentation.
  • the optimal conditions for application of the invention will vary according to the type or variety of cocoa beans used, to the type of aromatic substance(s) added, to the timing of the addition of aromatic substance(s) as well as to general parameters applied during the fermentation and drying processes (e.g. size of fermentation mass, duration of fermentation, number and timing of turns, type of drying, etc.).

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EP09711977A 2008-02-22 2009-02-19 Process for the fermentation of cocoa beans to modify their aromatic profile Withdrawn EP2456321A2 (en)

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BRPI0800944-9A BRPI0800944A2 (pt) 2008-02-22 2008-02-22 método para obtenção de amêndoas de cacau (treobroma cacao l.) e massa de cacau torrado ("liquors"), para fazer chocolate, com sabor diversificado através da adição de ingredientes aromáticos à polpa do cacau antes ou durante o processo de fermentação de sementes frescas de cacau
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BR112014010562B1 (pt) 2011-11-03 2020-12-15 Chr. Hansen A/S Método de fermentação de sementes de cacau empregando pichia kluyveri
GB2525555B (en) 2013-02-20 2018-05-09 Mars Inc Methods of processing cocoa
CN104263515B (zh) * 2014-10-10 2019-10-15 中国热带农业科学院热带作物品种资源研究所 番荔枝花香精及其应用
WO2021048869A1 (en) * 2019-09-14 2021-03-18 Lovely Professional University A novel double fermentation process for fruit flavored chocolate with antioxidant properties
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