From tree to bean

June 10, 2006

Before a cocoa bean is shipped off to the factory, it obviously must be grown and harvested from the pod. What is not very obvious is the complexity of the processes in between. A cocoa tree (theobroma cacao) grows from a seedling to pod-bearing maturity in 4 to 5 years. The tree is classified as an evergreen and may be harvested year round; however there are typically two large harvest periods.


Cacao Seedling (Corbett)

When the pods are harvested, great care must be taken to prevent damage to the tree or other pods. The harvested pods are collected in piles and broken open to reveal the pulpy seeds. The seed mass is extracted from each pod and collected into a large pile, usually in wooden bins, to ferment for up to 7 days.


Cacao Pod Bisection (Corbett)

The fermentation process is crucial to flavor development and to breaking down many of the bitter tasting compounds in the fresh bean. This process also kills the seed germ inside the bean. During the fermentation process the bean mass heats up, and the white flesh surrounding the seeds runs off as a liquid. Often, this liquid is collected and made into a very sustaining (sometimes alcoholic) drink.

As the fermentation process progresses the beans need to be stirred, at least once a day to provide even fermentation and to prevent bean spoilage. When the beans reach optimal fermentation, they are removed from the bins, washed, and dried.


Harvested beans on their way to fermentation. (Sacco)

To ensure healthy shipment and storage, and to prevent rot and mold growth, the beans must be thoroughly dried immediately following fermentation. This is often accomplished by laying the beans out in the sun, or in a plantation setting, by spreading the beans out over propane heated drying tables. The beans must be dried to a maximum of 10% moisture content, and ideally down to 8% moisture for proper shipment and storage stability.


Fermented beans spread out to dry in the sun. (Sacco)

Once the drying is complete, the beans can finally be bagged and sold. For some perspective, it takes about 200 beans (5 or so pods) to make 1 pound of cocoa paste that is mixed with sugar and other ingredients to make a chocolate bar.

So, next time you bite into your favorite chocolate bar you'll know what kind of human energy went into each one before it even leaves the farm.

Coming soon:
From farm to factory - a look at the cocoa trade