Cocoa is derived from a plant called Theobroma cocoa that is born in South America and from which the seeds of the fruits are obtained.

These seeds undergo a fairly complex processing divided into several stages:

• Fermentation. The seeds are collected and piled into baskets and wooden vats and then exposed to a temperature of between 40 and 50 degrees. At this stage the sugars turn into acids and eliminate what is left of the pulp and lower the bitter taste of the seeds.
• Drying. Exposure to the sun or through jets of hot air makes the product lose half its weight.
• Toasting. The temperature is kept around 100/150 degrees.
  Various shelling, crushing and cleaning procedures. 
• Grinding. At this stage you mix different qualities of cocoa to get the desired taste and quality.

At the end of the processing you get a dough that will serve for all subsequent processing, but especially for the most important the :

Cocoa paste or cocoa mass

From this pasta that results in a very bitter taste, they are made with various processes:

• Cocoa butter : obtained by pressure and heat
• Cocoa powder : with fine grinding until you get a soluble powder in water.
• Chocolate : with complex and articulated processing.

Cocoa (Theobroma cacao L., Malvaceae)

Cocoa encompasses seeds (beans/nibs) and derivatives obtained from processing Theobroma cacao: cocoa liquor (mass), cocoa butter, and powders (natural or Dutch-processed/alkalized). It is used as a flavoring, functional, and lightly coloring ingredient in foods and beverages; in cosmetics as an emollient (butter), gentle exfoliant (powders), and antioxidant extract.

Caloric Value (Per 100 g Of Product)

Roasted beans/nibs: ~570–620 kcal/100 g.
Cocoa liquor (mass): ~580–650 kcal/100 g.
Cocoa powder 10–12% fat (natural/Dutch): ~220–260 kcal/100 g.
Cocoa powder 20–22% fat: ~360–450 kcal/100 g.
Cocoa butter: ~880–900 kcal/100 g.
Unsweetened cocoa beverage (ready-to-drink): ~0–15 kcal/100 g (depends on dissolved solids).

At practical use levels, energy contribution depends on form and recipe; sugar additions markedly raise calories.

Key Constituents

Polyphenols: flavanols (catechin, epicatechin) and B-type procyanidins; phenolic acids. They contribute color and bitterness/astringency and show in-vitro antioxidant activity (TPC as a global indicator; profile via HPLC).
Xanthine alkaloids: theobromine (major) and trace caffeine; responsible for bitter note and mild stimulation.
Lipids (derivatives/residual): cocoa butter with typical fatty acids—stearic (SFA — saturated fatty acids; high oxidative stability, dietary balance advisable), oleic (MUFA — monounsaturated fatty acids; often favorable for oxidative stability), palmitic (SFA), and small linoleic (PUFA — polyunsaturated fatty acids; functional but more oxidation-prone).
Dietary fiber: high in powders and nibs.
Minerals: magnesium, potassium, iron, copper (variable); regulated metals (e.g., cadmium) must be monitored.
Volatiles: pyrazines, aldehydes, esters formed through fermentation/roasting.
Analytical markers: TPC, flavanol/xanthine profile by HPLC, moisture/aw, color (Lab*), pH; for powders, particle size and fat content.

Production Process

Harvest & fermentation: pod opening; pulp/seed fermentation (2–7 days) to develop aroma precursors.
Drying: moisture reduction for stability and storability.
Roasting: aroma development and microbial reduction.
Winnowing (dehulling): shell/nib separation.
Grinding: production of cocoa liquor; optional pressing to separate cocoa butter and press cake, then milled into powder.
Alkalization (Dutch process): carbonate treatment (pH ↑, darker color, lower acidity; potential polyphenol reduction).
Quality controls: moisture/aw, pH, total fat, TPC/HPLC, mycotoxins (e.g., OTA), metals (e.g., Cd), pesticides, PAHs; packaging per GMP/HACCP.

Sensory And Technological Properties

Aroma/color: roasted-cocoa, nutty, caramelized notes; Dutch powders are darker and less acidic.
Functionality: brown coloration, in-vitro antioxidant activity, contribution to body and texture; cocoa butter provides structure and gloss in coatings/creams.
Compatibility: in protein beverages, polyphenol–protein complexes can cause haze/precipitation; alkalization improves dispersibility but may reduce TPC.

Food Applications

Chocolate & fillings: liquor/butter per standards of identity.
Beverages & RTD: 1–4% powder (higher for Dutch); stabilize with hydrocolloids.
Bakery: 1–6% in flours/doughs; consider pH for chemical leavening.
Dairy/ice cream: 1.5–5% powder; contributes color, bitterness, and body.
Cereals/snacks/spreads: dosage per sensory target and fat/water binding.

Nutrition And Health

Cocoa provides polyphenols with in-vitro antioxidant activity; in foods, health claims require authorization. Theobromine and caffeine warrant attention in sensitive individuals; the product is not suitable for pets. Nutritional impact depends on context (added sugars, fat level).

Quality And Specifications (Typical Topics)

Key parameters: moisture (often ≤8%), aw, total fat (10–12% or 20–22% in powders), pH (natural ~5.2–6.0; Dutch ~6.8–8.1), color Lab*, particle size.
Composition: TPC/HPLC (flavanols), theobromine/caffeine, ash.
Safety: mycotoxins (OTA), metals (Cd/Pb) within limits, pesticides, PAHs compliant; microbiology to spec.
Sensory: free from moldy, rancid, overly smoky notes.
Traceability & hygiene: GMP/HACCP compliance.

Storage And Shelf Life

Protect from humidity, light, and oxygen (DO); use low-permeability barrier packs.
Powders: control RH/aw to avoid caking and aroma loss; reseal well.
Butter/liquor: limit oxidation (cool temperature, low light, low oxygen); avoid thermal shock.
Apply FIFO rotation.

Allergens And Safety

Cocoa is not a major allergen, yet cross-contact (milk/tree nuts) can occur in facilities. Verify labeling where required for theobromine/caffeine and compliance with mycotoxin/metal limits.

INCI Functions In Cosmetics

Typical entries: Theobroma Cacao (Cocoa) Seed Butter; Theobroma Cacao Extract; Theobroma Cacao (Cocoa) Seed Powder.
Roles: emollient (butter), antioxidant and skin conditioning (extracts), gentle physical exfoliant (powders), masking.

Troubleshooting

Excess bitterness/astringency: high dose or tannin-rich fraction → reduce dose, choose “softer” powders, balance with fats/sugars, optimize pH.
Haze/precipitates in beverages: polyphenol–protein or Ca/Mg complexes → clarification, fine filtration, mild chelants; check water hardness.
Underpowered color: low-pH natural powder → consider Dutch powder (higher pH) or higher dose; note possible TPC decrease.
Over-limit Cd/OTA: non-compliant raw material → change origin/supplier, tighten intake screening, reinforce CCP.

Sustainability And Supply Chain

Valorization of co-products (shells for extracts/fiber, biochar/compost), effluent management to BOD/COD targets, recyclable packaging, and controlled temperature/humidity logistics reduce environmental impact. Provenance traceability and responsible farming practices support sustainability.

Conclusion

Cocoa offers a complex aroma profile, a useful polyphenolic matrix, and broad technological functionality. Performance and stability depend on raw-material quality, pH/process choices (alkalization), protection from humidity/oxygen, and analytical standardization.

Mini-Glossary

TPC — Total phenolic content: Folin–Ciocalteu global, non-specific phenolic indicator.
HPLC — High-performance liquid chromatography: quantitative analysis of flavanols and xanthines.
SFA — Saturated fatty acids (e.g., stearic/palmitic): high oxidative stability; dietary moderation advisable.
MUFA — Monounsaturated fatty acids (e.g., oleic): often favorable for lipid profile and stability.
PUFA — Polyunsaturated fatty acids (e.g., linoleic): functional but more oxidation-prone; protect accordingly.
DO — Dissolved oxygen: lowering it limits oxidation and aroma loss.
RH — Relative humidity: control to prevent caking and degradation.
aw — Water activity: “free” water fraction tied to stability and microbiology.
GMP/HACCP — Good manufacturing practice / Hazard analysis and critical control points: preventive quality systems with defined CCP.
BOD/COD — Biochemical/chemical oxygen demand: effluent organic-load indicators.
PAHs — Polycyclic aromatic hydrocarbons: regulated contaminants in roasted matrices.
CCP — Critical control point: step where a control prevents/eliminates/reduces a hazard.

Cocoa studies

References__________________________________________________________________________

Montagna MT, Diella G, Triggiano F, Caponio GR, De Giglio O, Caggiano G, Di Ciaula A, Portincasa P. Chocolate, "Food of the Gods": History, Science, and Human Health. Int J Environ Res Public Health. 2019 Dec 6;16(24):4960. doi: 10.3390/ijerph16244960. 

Abstract. Chocolate is well known for its fine flavor, and its history began in ancient times, when the Maya considered chocolate (a cocoa drink prepared with hot water) the "Food of the Gods". The food industry produces many different types of chocolate: in recent years, dark chocolate, in particular, has gained great popularity. Interest in chocolate has grown, owing to its physiological and potential health effects, such as regulation of blood pressure, insulin levels, vascular functions, oxidation processes, prebiotic effects, glucose homeostasis, and lipid metabolism. However, further translational and epidemiologic studies are needed to confirm available results and to evaluate other possible effects related to the consumption of cocoa and chocolate, verifying in humans the effects hitherto demonstrated only in vitro, and suggesting how best to consume (in terms of dose, mode, and time) chocolate in the daily diet.

Ferri C, Desideri G, Ferri L, Proietti I, Di Agostino S, Martella L, Mai F, Di Giosia P, Grassi D. Cocoa, blood pressure, and cardiovascular health. J Agric Food Chem. 2015 Nov 18;63(45):9901-9. doi: 10.1021/acs.jafc.5b01064. 

Abstract. High blood pressure is an important risk factor for cardiovascular disease and cardiovascular events worldwide. Clinical and epidemiological studies suggest that cocoa-rich products reduce the risk of cardiovascular disease. According to this, cocoa has a high content in polyphenols, especially flavanols. Flavanols have been described to exert favorable effects on endothelium-derived vasodilation via the stimulation of nitric oxide-synthase, the increased availability of l-arginine, and the decreased degradation of NO. Cocoa may also have a beneficial effect by protecting against oxidative stress alterations and via decreased platelet aggregation, decreased lipid oxidation, and insulin resistance. These effects are associated with a decrease of blood pressure and a favorable trend toward a reduction in cardiovascular events and strokes. Previous meta-analyses have shown that cocoa-rich foods may reduce blood pressure. Long-term trials investigating the effect of cocoa products are needed to determine whether or not blood pressure is reduced on a chronic basis by daily ingestion of cocoa. Furthermore, long-term trials investigating the effect of cocoa on clinical outcomes are also needed to assess whether cocoa has an effect on cardiovascular events. A 3 mmHg systolic blood pressure reduction has been estimated to decrease the risk of cardiovascular and all-cause mortality. This paper summarizes new findings concerning cocoa effects on blood pressure and cardiovascular health, focusing on putative mechanisms of action and "nutraceutical " viewpoints.

Jean-Marie E, Jiang W, Bereau D, Robinson JC. Theobroma cacao and Theobroma grandiflorum: Botany, Composition and Pharmacological Activities of Pods and Seeds. Foods. 2022 Dec 8;11(24):3966. doi: 10.3390/foods11243966. 

Abstract. Cocoa and cupuassu are evergreen Amazonian trees belonging to the genus Theobroma, with morphologically distinct fruits, including pods and beans. These beans are generally used for agri-food and cosmetics and have high fat and carbohydrates contents. The beans also contain interesting bioactive compounds, among which are polyphenols and methylxanthines thought to be responsible for various health benefits such as protective abilities against cardiovascular and neurodegenerative disorders and other metabolic disorders such as obesity and diabetes. Although these pods represent 50-80% of the whole fruit and provide a rich source of proteins, they are regularly eliminated during the cocoa and cupuassu transformation process. The purpose of this work is to provide an overview of recent research on cocoa and cupuassu pods and beans, with emphasis on their chemical composition, bioavailability, and pharmacological properties. According to the literature, pods and beans from cocoa and cupuassu are promising ecological and healthy resources.

Tan TYC, Lim XY, Yeo JHH, Lee SWH, Lai NM. The Health Effects of Chocolate and Cocoa: A Systematic Review. Nutrients. 2021 Aug 24;13(9):2909. doi: 10.3390/nu13092909. 

Abstract. Chocolate has a history of human consumption tracing back to 400 AD and is rich in polyphenols such as catechins, anthocyanidins, and pro anthocyanidins. As chocolate and cocoa product consumption, along with interest in them as functional foods, increases worldwide, there is a need to systematically and critically appraise the available clinical evidence on their health effects. A systematic search was conducted on electronic databases such as MEDLINE, EMBASE, and Cochrane Central Register of Controlled Trials (CENTRAL) using a search strategy and keywords. Among the many health effects assessed on several outcomes (including skin, cardiovascular, anthropometric, cognitive, and quality of life), we found that compared to controls, chocolate or cocoa product consumption significantly improved lipid profiles (triglycerides), while the effects of chocolate on all other outcome parameters were not significantly different. In conclusion, low-to-moderate-quality evidence with short duration of research (majority 4-6 weeks) showed no significant difference between the effects of chocolate and control groups on parameters related to skin, blood pressure, lipid profile, cognitive function, anthropometry, blood glucose, and quality of life regardless of form, dose, and duration among healthy individuals. It was generally well accepted by study subjects, with gastrointestinal disturbances and unpalatability being the most reported concerns.

Schwan RF, Wheals AE. The microbiology of cocoa fermentation and its role in chocolate quality. Crit Rev Food Sci Nutr. 2004;44(4):205-21. doi: 10.1080/10408690490464104. 

Abstract. The first stage of chocolate production consists of a natural, seven-day microbial fermentation of the pectinaceous pulp surrounding beans of the tree Theobroma cacao. There is a microbial succession of a wide range of yeasts, lactic-acid, and acetic-acid bacteria during which high temperatures of up to 50 degrees C and microbial products, such as ethanol, lactic acid, and acetic acid, kill the beans and cause production of flavor precursors. Over-fermentation leads to a rise in bacilli and filamentous fungi that can cause off-flavors. The physiological roles of the predominant micro-organisms are now reasonably well understood and the crucial importance of a well-ordered microbial succession in cocoa aroma has been established. It has been possible to use a synthetic microbial cocktail inoculum of just 5 species, including members of the 3 principal groups, to mimic the natural fermentation process and yield good quality chocolate. Reduction of the amount of pectin by physical or mechanical means can also lead to an improved fermentation in reduced time and the juice can be used as a high-value byproduct. To improve the quality of the processed beans, more research is needed on pectinase production by yeasts, better depulping, fermenter design, and the use of starter cultures.

Cárdenas A, Mojica L, Coronado-Cáceres L, Castillo-Herrera GA. Unlocking the Alkaloid Biological Potential of Chili Pepper (Capsicum spp.), Cacao (Theobroma cacao L.), and Coffee (Coffea spp.) Byproducts: Characterization, Non-Conventional Extraction, Applications, and Future Perspectives. Molecules. 2025 Sep 18;30(18):3795. doi: 10.3390/molecules30183795. 

Abstract. Chili peppers (Capsicum spp.), cacao (Theobroma cacao L.), and coffee (Coffea spp.) are important crops worldwide. Nearly 35%, 80%, and 45% of the respective fruits are underutilized or discarded, representing a considerable economic loss. This work reviews and analyzes the environmental factors that influence the concentration of the main alkaloids in these crops, including capsaicin, theobromine, and caffeine. Their reported anti-inflammatory, cardioprotective, neuroprotective, and cytotoxic properties are also reviewed. This work explores strategies for the revalorization of these crops, comparing alkaloid extraction methods that use non-conventional techniques, including supercritical fluid extraction (SFE), ultrasound-assisted extraction (UAE), high-pressure and -temperature extraction (HPTE), pressurized liquid extraction (PLE), pressurized hot water extraction (PHWE), enzyme-assisted extraction (EAE), and pulsed electric field-assisted extraction (PEFAE), and their combination to enhance the recovery of capsaicin, theobromine, and caffeine, leading to sustainable and innovative uses of these crops' byproducts. Capsaicin, theobromine, and caffeine alkaloids are promising ingredients for the development of functional foods, cosmeceuticals, and pharmaceuticals.

Díaz-Valderrama JR, Leiva-Espinoza ST, Aime MC. The History of Cacao and Its Diseases in the Americas. Phytopathology. 2020 Oct;110(10):1604-1619. doi: 10.1094/PHYTO-05-20-0178-RVW. 

Abstract. Cacao is a commodity crop from the tropics cultivated by about 6 million smallholder farmers. The tree, Theobroma cacao, originated in the Upper Amazon where it was domesticated ca. 5450 to 5300 B.P. From this center of origin, cacao was dispersed and cultivated in Mesoamerica as early as 3800 to 3000 B.P. After the European conquest of the Americas (the 1500s), cacao cultivation intensified in several loci, primarily Mesoamerica, Trinidad, Venezuela, and Ecuador. It was during the colonial period that cacao diseases began emerging as threats to production. One early example is the collapse of the cacao industry in Trinidad in the 1720s, attributed to an unknown disease referred to as the "blast". Trinidad would resurface as a production center due to the discovery of the Trinitario genetic group, which is still widely used in breeding programs around the world. However, a resurgence of diseases like frosty pod rot during the republican period (the late 1800s and early 1900s) had profound impacts on other centers of Latin American production, especially in Venezuela and Ecuador, shifting the focus of cacao production southward, to Bahia, Brazil. Production in Bahia was, in turn, dramatically curtailed by the introduction of witches' broom disease in the late 1980s. Today, most of the world's cacao production occurs in West Africa and parts of Asia, where the primary Latin American diseases have not yet spread. In this review, we discuss the history of cacao cultivation in the Americas and how that history has been shaped by the emergence of diseases.

Martin MÁ, Ramos S. Impact of cocoa flavanols on human health. Food Chem Toxicol. 2021 May;151:112121. doi: 10.1016/j.fct.2021.112121. Epub 2021 Mar 13. PMID: 33722594.

Kerimi A, Williamson G. The cardiovascular benefits of dark chocolate. Vascul Pharmacol. 2015 Aug;71:11-5. doi: 10.1016/j.vph.2015.05.011. Epub 2015 May 27. PMID: 26026398.