• Although the idea of maximizing the potential of the cocoa tree by reducing waste has roots that predate the current crisis in the industry, rising costs are now opening up opportunities for chocolate companies to adopt this strategy.
Starting with 2025, the leader in the production of chocolate raw materials, Barry Callebaut, offers a full range of ingredients obtained by using the entire cocoa fruit. This initiative will strongly support the use of cocoa fruit-derived ingredients in the food industry and consumer goods sector and open up new creative possibilities for cafes, restaurants and bars.
While it's not the first company to explore this approach – Lindt & Sprüngli has already collaborated with Swiss-Ghanaian startup Koa to launch a chocolate bar Excellence, sweetened with cocoa pulp – the trend demonstrates a growing demand for recycling technologies.
Cocoa bean recycling techniques
Currently, there are three main directions through which producers fully utilize the cocoa fruit: using the fruit pulp, extracting sugar from the pulp, and using the cocoa pod shell.
Confectioners use the fresh pulp that surrounds cocoa beans to produce cocoa juice. This component is increasingly present in the beverage industry and can be used as a base or sweetener in various blends.
The pulp can be dehydrated and made into dried cocoa nibs or as a base for energy snacks. It can replace dates in protein bars and chocolate bars combined with other popular ingredients, such as peanut butter, coconut oil, or almond butter.
The sugar extracted from the pulp is used as an unrefined sweetener in chocolate bars and snacks, being similar to the unrefined sugar from coconut.
The outer shell of the pod is dried and ground, and is then used in the confectionery industry to increase the dietary fiber content of chocolate and other products. This technique also adds other health-promoting functional nutrients that are abundantly found in the shell.
Economic impact
The global cocoa crisis has dominated the industry for the past three seasons, prompting producers to seek alternatives to maintain a balance between quality and cost. However, some companies began exploring the use of the entire cocoa pod before the crisis hit.
Blue Stripes, a brand focused on using the whole cocoa fruit, began its journey in 2017, focusing on reducing waste and harnessing the full potential of the cocoa pod. The culinary potential and health benefits offered by recycled components of the cocoa fruit are key factors that have driven the growing interest in using this ingredient whole.
In November 2024, Blue stripes has attracted $20 million in funding to develop products based on cocoa recycling. Another significant advantage of this process is that it increases farmers' incomes without having to expand cultivated areas. Thus, higher profits obtained from the same harvest could prevent excessive increases in the price of cocoa beans, even in the face of environmental challenges. This mechanism could help alleviate the crisis in the cocoa industry, which is mainly caused by the low income generated by traditional cultivation methods.
Rigorous research and transparency
Blue Stripes has analyzed the components of the cacao fruit in detail to identify the elements suitable for reuse. The research results show that they are highly nutritious, with superfood status, making them attractive for numerous products aimed at consumers around the world.
One of the main challenges is preserving the specific taste properties of the cacao fruit, along with ensuring an extended shelf life. Blue Stripes conducts its research in its factories in Ecuador, where it can access fresh fruit and directly test ingredients to develop high-quality products.
Another important aspect is balancing waste reduction goals with consumer preferences for taste and texture. Unlike other recycled ingredients, which may be nutritious but lack flavor, cocoa fruit and flour derived from the shell have a naturally pleasant taste and appeal to consumers.
The cocoa fruit has a sweet-sour taste, with subtle floral notes of vanilla, which makes it suitable for use both as a main ingredient and as a base for various flavor combinations. On the other hand, the flour obtained from the shell of the pod has an intense cocoa flavor, adding the specific nutrients of this superfood and emphasizing the unique taste profile of the products obtained.
Therefore, using the entire cocoa fruit not only reduces waste and contributes to sustainability, but also offers new opportunities for innovation in the industry, while maintaining the unique taste and nutritional benefits of this valuable fruit.
Article written by Gabriela Dan, Editor-in-Chief Arta Albă
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