Koa

Chocolate’s Journey from Pod to Bar

Chocolate is a beloved treat that brings joy to countless people around the world. Its rich, creamy texture and delicious taste make it a favourite indulgence for many. But have you ever wondered how it’s made? A fascinating journey unfolds from the moment a cocoa pod is harvested to the first bite of a chocolate bar. In this blog, we’ll take you through this delightful transformation, revealing the hard work and craftsmanship that goes into every piece of chocolate. We’ll also explore innovative approaches that maximise the use of the entire cocoa fruit, promoting a more sustainable production process.

Chocolate starts on a tree.

The delightful journey of chocolate begins in tropical regions around the globe, primarily in countries close to the equator, like Côte d’Ivoire, Ghana, Indonesia, Nigeria, Brazil, and Ecuador. These places offer the perfect warm and humid environment for cocoa trees, known scientifically as ‘Theobroma cacao’. Interestingly, the name ‘Theobroma’ is derived from Greek, meaning ‘food of the gods,’ highlighting cocoa’s cherished status since ancient times.

Cocoa plants grow slowly, especially during the first 2-3 years after planting. They require shade, well-drained soil, and plenty of moisture to develop strong and healthy roots. Typically, cocoa plants start producing their first pods within 3-5 years, influenced by temperature, humidity, soil health, and rainfall. The cocoa tree bears large, colourful, rugby-shaped pods that grow directly on its trunks and branches. These pods vary in hues from green to yellow, orange, red, and purple, primarily due to genetic diversity and the different types of cocoa trees. Inside each pod, a sweet, white pulp surrounds between 20 to 50 cocoa beans, the essential ingredient for making chocolate.  

Harvesting these pods is a hands-on process. Farmers use machetes to cut ripe pods from the trees, ensuring that neither the trees nor the pods are damaged.

From tree to sea.

Once the cocoa pods are harvested, the next step is to extract the beans. Farmers carefully open each pod and scoop out the beans, which are covered in white fruit pulp. The beans then undergo fermentation, a crucial process that enhances their distinct flavour. Fermentation typically happens in large wooden boxes or piles covered with banana leaves. Over several days, natural microbes break down the remaining pulp, generating heat and triggering chemical changes in the beans. This process not only removes the pulp but also begins to develop the rich flavours that define chocolate.

After fermentation, the beans are sun-dried to reduce moisture content, preparing them for storage and shipment worldwide. This stage marks the beans’ journey from farm to global markets.

From cocoa bean to cocoa liquor.

Once the cocoa beans arrive at the chocolate factories, they undergo a series of meticulous processes to transform them into cocoa liquor.

First, the beans are thoroughly cleaned to remove any debris. Then, they are roasted to unlock their full flavour potential. Roasting times and temperatures vary depending on the desired flavour profile. 

After roasting, machines crack and winnow the beans to separate the nibs, the edible part, from the shells. These nibs are ground into a thick, liquid paste known as cocoa mass or cocoa liquor. Some chocolate manufacturers further refine the cocoa mass to achieve an even smoother texture and finer particle size.

The end result is cocoa liquor, a liquid blend of finely ground cocoa nibs that includes cocoa solids (tiny cocoa particles) and cocoa butter. Despite its name, cocoa liquor contains no alcohol. This versatile ingredient forms the base for creating delicious chocolate treats.

From cocoa liquor to chocolate.

Once cocoa beans are transformed into cocoa liquor, the real fun begins! Cocoa liquor can be used directly in chocolate making or further processed into cocoa butter and cocoa powder. 

Cocoa butter, essential for its smooth, silky, melt-in-the-mouth texture, defines the luxurious feel of chocolate. Meanwhile, cocoa powder finds its way into various products, from baked goods to beverages.

To craft chocolate bars, manufacturers blend cocoa liquor with additional cocoa butter, sugar, and milk (for milk chocolate). This mass is then milled down to a fine particle size, ensuring a smooth texture. 

The next step involves refining and conching, a meticulous process that can span from hours to days. Conching continuously mixes and aerates the chocolate, smoothing its texture and intensifying its rich flavour.

Following conching, the chocolate is tempered – a delicate heating and cooling process that stabilises cocoa butter crystals. Proper tempering gives chocolate its glossy finish and satisfying snap. The tempered chocolate is then moulded into bars or other shapes, cooled, and carefully packaged.

From pulp to new possibilities.

Traditionally, the cocoa industry focused solely on cocoa beans, using only a small amount of the pulp for fermentation and discarding the vast majority. However, we at Koa have embraced the untapped potential of this delicious fruit pulp, which tastes nothing like chocolate. The cocoa fruit pulp is light and fruity; it carries intense sweetness and exotic acidity, offering a tropical and refreshing taste while adding depth and complexity to both sweet and savoury creations. By upcycling the cocoa fruit, we not only bring a new dimension to food and drink creations, but also support a more sustainable and holistic use of the cocoa fruit.

In our innovative cocoa value chain, the cocoa pulp is extracted right after harvesting, making sure no part of the fruit goes to waste. Farmers receive their beans back promptly, along with mobile money payments that are 100% traceable through blockchain technology. This approach provides farmers with a new source of income, which they use to create jobs on their farms, cover their children’s school fees, or save for future investments like building a house. Furthermore, the pulp can even be reintroduced into the final stages of chocolate production, blending with cocoa liquor and cocoa butter to add a natural sweetness or fruity crunch inclusion.

Renowned global chocolate manufacturers Lindt & Sprüngli and Confiserie Sprüngli have already embraced these innovative approaches in their chocolate production. Lindt & Sprüngli uses Koa Flakes to add a natural sweetness to their Cocoa Pure bars. Meanwhile, Confiserie Sprüngli incorporates Koa Pure into the ganache of their Grand-Cru Bâtons, enhancing the flavour with a touch of tropical delight. By integrating the cocoa fruit in its entirety, both companies help the environment through upcycling and support farmers in Ghana with an extra income stream.

At Koa, we’re committed to transforming the cocoa value chain in West Africa. We’re the first and so-far only company in the world processing the fresh cocoa fruit in cooperation with many smallholders in rural Ghana. Through our activities, the farmers increase their income significantly and upcycle an additional 40% of the cocoa pulp. As a B Corp™, we believe in creating positive change, one upcycled cocoa fruit at a time. From farmers to the planet, we’re here to make a difference that matters, where it matters most. Because caring is cool, and making the world a better place is even cooler. 

The cocoa fruit is the chocolate industry’s hidden gem and we are on a mission to uncover its juicy secrets. We’re all about making food and drinks so tasty, you’ll want to share it with your grandma (and she’ll probably ask for seconds). Whether it’s the best ice cream, a refreshing soda, or a scrumptious snack, we believe taste buds are meant to dance with joy. And we’re sure the cocoa fruit will make them go wild! 

In recent years, we have established a robust value chain and, by opening the world’s largest cocoa fruit processing factory in Ghana, we laid the foundations for growth. Now, it’s all about spreading the word taste, creating exciting product concepts which will leave people grinning from ear to ear – like love at the first taste. 

Where you can buy cocoa fruit pulp ingredients.

Indulge in the world of cocoa fruit pulp products, designed to elevate the world of gastronomy and cater to the discerning needs of industry professionals.

Gastronomy professionals

We offer a variety of cocoa fruit pulp products to cater for different culinary preferences. Whether you’re a chocolatier, confectionery expert, ice cream artisan, bakery master or mixologist, Koa Pure cocoa fruit juice or Koa Flakes dried cocoa fruit pulp can give your dishes a refreshing and exotic taste, offering a new twist to various recipes. Here’s where you can purchase them:

Germany and Austria:

Confis-Express: Confis-Express is a German supplier that caters to confectioners, pastry chefs, chocolatiers, bakers, and all those with a passion for finesse. Trusted by top establishments for 25 years, Confis-Express offers more than 10,000 products, with many available for delivery within 24 hours.

Switzerland:

Felchlin: Felchlin has been the leading producer of noble Swiss chocolate and semi-finished products for more than a hundred years. Felchlin works directly with cacao farmers and partners around the world to ensure their standards of quality, transparency and sustainability are met throughout all our processes, from cacao planting to our finished products.

The Netherlands:

Vanilla Venture: Since its foundation, Vanilla Venture has been the market leader and a leading supplier of high-quality gourmet products in the Netherlands. Vanilla Venture offers delicatessen and fresh products for the quality-conscious gastronomy. The products are sourced from small, authentic producers worldwide. Vanilla Venture focuses on organic and ethically sound products.

Industry professionals

Our dedication to food innovation extends to a wide array of industry professionals, including beverage companies, ice cream manufacturers, chocolate producers, and beyond within the Food & Beverage industry.

From the pure essence of cocoa fruit juice in Koa Pure, to the crunchy dried cocoa fruit pulp in Koa Flakes and Koa Choco Flakes, to the honey-like richness of Koa Concentrates – each product is carefully crafted to aid industry professionals across diverse specialities. 

Interested to learn more about using Koa’s cocoa fruit pulp products in your creations? Click the ‘Request a Sample’ button at the bottom of your screen to get started with a sample of our cocoa fruit pulp ingredients. Alternatively, if you have any questions or want to explore further, feel free to send us an e-mail. We’re here to help you integrate cocoa fruit pulp into your recipes and enhance your food and drink creations.