Researchers at ETH Zurich aimed to address nutritional, environmental, and socio-economic challenges in conventional chocolate production by repurposing cocoa pod components.
The result is a type of whole-fruit chocolate that, in place of traditional sugar from sugar beets, uses cocoa fruit jelly made from typically discarded parts of the cocoa plant. Better yet, taste is not sacrificed, according to the researchers who say the chocolate has the same sweet taste as traditional chocolate.
The study, published in Nature Food, presents a novel approach to chocolate production. Alongside improved nutritional value compared to conventional chocolate, the whole-fruit formulation has the potential to reduce the environmental impact often associated with chocolate and offer socio-economic benefits for cocoa farmers.
Cocoa pod and cocoa bean pulp combined to create a fruit jelly
Conventional chocolate production uses a mixture of refined sugar and cocoa mass (cocoa beans and a small amount of cocoa pulp), with most of the pulp being discarded. In contrast, the whole-fruit formulation utilises this typically wasted pulp by transforming it into cocoa fruit jelly. This jelly replaces refined sugar in the formulation, combining it with the cocoa mass to create a more sustainable product.
To create the formulation, the team first extracted, dried, and milled the endocarp – the innermost layer of the cocoa pod – into a fine powder. Next, the cocoa bean pulp was harvested and pressed to extract the juice, which was then concentrated to enhance its sweetness and functionality. In the final step, the endocarp powder and the concentrated pulp juice were mixed and heated to form the cocoa fruit jelly.
The cocoa fruit jelly, besides imparting sweetness, enables the whole-fruit chocolate to have a higher fibre content compared to traditional dark chocolate – 15 grams per 100 grams, compared to 12 grams. It also has a reduced saturated fat content – 23 grams per 100 grams compared to 33 grams.
A panel of experts consulted to develop the perfect formulation
Creating the recipe for the whole-fruit chocolate was no easy feat. The scientists at ETH Zurich experimented with various compositions, aiming to balance sweetness and texture. Too much of the extracted fruit juice led to clumpy chocolate, while too little resulted in a product that was not sweet enough. To find the ideal blend, the team adjusted the ratio of endocarp powder and cocoa pulp juice concentrate.
The refined formulations were then put to the test by a panel of trained tasters from the Bern University of Applied Sciences. The panellists conducted sensory evaluations, comparing the chocolate's sweetness and mouthfeel against conventional varieties with differing levels of powdered sugar. Their feedback helped to ensure the sweetness of the whole-fruit chocolate could match the familiar taste of traditional chocolate.
Circular benefits to whole fruit chocolate: sustainable income and lower emissions
The whole-fruit formulation has the potential to reduce food waste. Utilising the entire cocoa pod, including the pulp, rather than outsourcing sugar, offers circular benefits and promotes a more sustainable production cycle. This process cuts down the emissions associated with growing, processing, and transporting sugar beets.
The formulation could also provide additional income streams for smallholder farmers, who could sell pulp juice and endocarp powder alongside cocoa beans, potentially leading to more sustainable income for cocoa-producing regions.
Declining cocoa production calls for chocolate innovation
Although whole-fruit chocolate has potential, it may take some time before it reaches grocery store shelves. ETH Zurich has filed a patent for the recipe, marking the first step toward commercialisation.
And while this type of chocolate may offer a more sustainable alternative to traditional chocolate, the outlook for chocolate is not so certain. Cocoa production in West Africa – where most of the world’s cocoa is harvested – is declining, according to the International Cocoa Organisation’s (ICCO) 2024 market review. The decline has led to global cocoa production being down nearly 11% this year, which will likely force brands to change their formulations by reducing the size, price, or amount of chocolate in their product.
Alongside whole-fruit chocolate, another potentially promising avenue for sustainable chocolate production comes from cellular agriculture technology or cell-based cocoa. Kokomodo, a startup based out of Israel, recently received a $750,000 investment to produce cell-based cocoa, while in the US, startup California Cultured recently announced a ten-year commercial partnership with Meiji, Japan’s biggest chocolate company. The agreement will integrate California Cultured’s cell-cultured cocoa products into Meiji’s packaged products. Other cell-based cocoa companies innovating in the space include Fazer, based out of Finland, and Israel-based Celleste Bio.
