Technical And Economic Plans For The Design Of A Factory To Produce 500,000 Metric Tonnes Of Chocolate Liquor Per Annum

ABSTRACT

Cocoa is the common name for some species in the genus Theobroma (family Theobromaceae).   Cocoa are a mixture of many substances remaining after cocoa butter is extracted from cacao beans. When sold as an end product, itmay also be called cocoa powder, cocoa, and cacao. In contrast, the fatty component of chocolate is cocoa butter. Cocoa butter is 50% to 57% of the weight of cocoa beans and gives chocolate its characteristic melting properties. Cocoa liquor or cocoa mass is a paste of roasted cocoa beans with cocoa butter and solids in their natural proportions. 

Chocolate requires the addition of extra cocoa butter to cocoa liquor, and the excess cocoa solids resulting from the chocolate industry dictate the relatively cheap supply of cocoa powder. This contrasts with the earliest European usage of cocoa where, before chocolate was popularized, cocoa powder was the primary product and cocoa butter was little more than a waste product. Cocoa solids are one of the richest sources of flavanol antioxidants. They are a key ingredient of chocolate, chocolate syrup, and chocolate confections. Natural cocoa powder has a light brown color and a pH level of 5.1 to 5.4. The processed (alkalized) cocoa powder is darker in color, ranging from brownish red to nearly black, with a pH from 6.8 to 8.1. The alkalization process reduces bitterness and improves solubility, which is important for beverage product applications. All of these pH values are considered safe for food use.

Cocoa powder contains several minerals including calcium, copper, magnesium, phosphorus, potassium, sodium and zinc. All of these minerals are found in greater quantities in cocoa powder than either cocoa butter or cocoa liquor. Cocoa solids also contain 230 mg of caffeine and 2057 mg of theobromine per 100g, which are mostly absent from the other components of the ocoa bean.

Cocoa powder is rich in flavonoids, a type of phenolic acid. The amount of flavonoids depends on the amount of processing and manufacturing the cocoa powder undergoes, but cocoa powder can contain up to 10% its weight in flavonoids. Natural cocoas are high in flavanols, but when the cocoa is processed with alkali, also known as Dutch processing or Dutching, the flavanols are substantially reduced. Tests of nine cocoa powders and nibs commercially available in the U.S. in 2014 found flavanol levels to range from 12.2 mg to 35.3 mg per gram. Flavanols are one of six compounds further classified as flavonoids. Flavanols, which are also found in fruits and vegetables, are linked to certain health benefits linked to coronary heart disease and stroke. The topic of how flavanols benefit cardiovascular health is still under debate. It has been suggested that the flavanols may take part in mechanisms such as nitric oxide and antioxidant, anti-inflammatory, and antiplatelet effects. Benefiting these mechanisms may improve endothelial function, lipid levels, blood pressure, and insulin resistance.