Nestlé’s breakthrough technique aims to redefine cocoa production potential

Nestlé has announced the development of a novel, patented method that allows for up to 30% more cocoa fruit to be used in chocolate production — all while maintaining exceptional taste quality.

Traditionally, cocoa processing has relied solely on extracting beans from inside the cocoa pod. After harvesting, the beans undergo fermentation, drying, roasting, and grinding to produce the chocolate liquor used in manufacturing. However, a large portion of the cocoa fruit — comprising the pulp, placenta, and pod husk — has historically been discarded or underutilised, leading to waste and missed opportunities for increased yield.

Recognising the untapped potential of these parts, Nestlé’s research and development team has pioneered a technique that harnesses the entire cocoa fruit.

The new process involves collecting all components of the cocoa pod as a wet mass, which naturally ferments to develop the rich chocolate flavour. This mass is then ground, roasted, and dried into chocolate flakes, enabling the production of high-quality chocolate without sacrificing flavour or quality.

Louise Barrett, head of the Nestlé Research and Development Center for Confectionery in York, UK, emphasised the significance of this innovation amid the challenges posed by climate change.

“With climate change increasingly affecting cocoa yields around the world, we are exploring innovative solutions that could help cocoa farmers maximise the potential of their harvests,” she said. “This ground-breaking technique utilises more of the fruit, while enabling us to provide delicious chocolate to our consumers.”

Currently in the pilot stage, Nestlé is exploring ways to scale this technique for broader application. The approach promises not only to increase the amount of cocoa material available to farmers but also to streamline the harvesting process, freeing up valuable time for agricultural practices such as pruning — an activity known to enhance yields.

By improving efficiency and reducing waste, Nestlé’s innovation could play a pivotal role in supporting cocoa farmers worldwide, promoting sustainable practices, and ensuring a steady supply of quality chocolate for consumers. As the company advances this technology, it marks a significant step forward in sustainable confectionery production.