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Conventional dark chocolate production methods that are applied in the industry consist of several steps, which require equipment with big investment costs. There are however few cost-effective alternatives suggested for small-scale production. Meanwhile, knowledge on these alternative equipment/techniques are insufficient to promote miniature production of high quality chocolates, either for research purposes in an industrial context, or for producers in developing countries, where the cost of investing in conventional equipment seems to be an impediment. The aim of this study was two-fold; first, to assess the feasibility of utilizing the ECGC-12SLTA CocoaTown melanger as an alternative to the conventional 3-roll refiner at different settings and fat content. Thereafter, one optimal setting was selected for each equipment for further investigation on the impact of the refining on some quality attributes of the final dark chocolate (70% cocoa). Secondly, the Stephan mixer; being used to mimick a conching-like process, was assessed with respect to two processing factors; the dry conching temperature (60 °C, 80 °C) and the duration of vacuum pump connection (0, 30, 60 min). The latter was to facilitate adequate moisture removal. The melanger proved to be a suitable alternative to the 3-roll refiner, provided that refining was carried out at moderate/high (ca. 40%) fat content, as is often the case for “high-percentage-cocoa” chocolates. Refining for 180 min with the mini drum at 40% resulted in D (v,0.9) significantly (p

The impact of pod storage (PS) and roasting temperature (RT) on the aroma profiles of dark chocolates were evaluated. Cocoa liquor samples comprised of ten different combinations of PS and RT, whilst keeping the roasting time fixed at 35 min. Additionally, commercial cocoa liquors from renowned origins (Ecuador, Madagascar, Venezuela, Vietnam, Ivory Coast and Ghana) were acquired for comparison. From these, 70% dark chocolates were produced under the same conditions after which they were subjected to headspace solid-phase microextraction-gas chromatography–mass spectrometry (HS-SPME-GC–MS) analysis. Although both PS and RT were found to influence the aroma volatile concentrations, the impact of RT over PS seemed to be greater. An agglomerative hierarchical clustering (AHC) of all chocolates on the basis of their aroma profiles revealed a similar impact as earlier observed, where major clustering of the chocolates was in accordance with the intensity of the roasting process applied. However, within each group, the dissimilarities owing to PS among the chocolates was clearly depicted. Comparatively, chocolates with low (100–120 °C), instead of moderate to high (135–160 °C) RT's, rather showed a low dissimilarity with those from the commercial cocoa liquors of the different origins. Although from the same beans, the diversity of aroma profiles of these chocolates as well as the similitude of some treatments to some chocolates from commercial grade cocoa liquors, unequivocally underscores the possibility for steering diverse distinct flavors from ‘bulk’ cocoa through PS and roasting, with beneficial implications, both from an application and an economic point of view.

The use of alternative equipment for chocolate production is gaining attention in recent times in many countries. This is due to the lower cost of investment and maintenance, multi-functionality, and lower throughput. This study was conducted to investigate the applicability of two of such equipment; melanger and Stephan mixer. In the first set-up, the possibility of refining chocolate with the melanger in comparison with the conventional 3-roll refiner was explored. Whereas in the second set-up, the applicability of the Stephan mixer (aided with a vacuum pump) for a conching-like application was also investigated. From each set-up, 70% dark chocolates produced through various alternative means were then evaluated on the basis of their flavor profiles. Specific groups of volatiles such as aldehydes, ketones, terpenes and terpenoids, showed significant (p 0.05) preference for these representative chocolates from the clusters. These findings stimulate various practical application possibilities for tuning chocolate flavor through alternative processing for both industries and various artisans worldwide.

The impact of pod storage (PS) and roasting temperature (RT) on the quality parameters and the sensory profiles of dark chocolates were evaluated. Dark chocolates (70%) from ten liquors of different PS and RT combinations as well as six liquors of different origins (Ecuador, Ghana, Ivory Coast, Madagascar, Venezuela and Vietnam) with variable genetic groups were produced under identical conditions and compared. To a greater extent, the range of chocolate quality attributes underscored the generally minimal effects of PS, RT and origin of liquor on the processing conditions. Although with a few exceptions, generally, chocolate acidity (pH and TA) decreased with increasing PS and vice versa in the case of RT. Furthermore, results from a balanced incomplete block design (BIBD) involving a 16-member expert panel also revealed the impact of the applied treatments (PS and RT) on the final flavor profiles of the chocolates irrespective of the origin or genetic groups of the cocoa beans. The same was confirmed when instrumental aroma results were correlated with the sensory data using partial least squares (PLS) regression models. Thus, this study demonstrates the possibility of creating diverse flavor profiles (even towards ‘fine’ flavor) from ‘bulk’ cocoa beans through an optimized combination of PS and RT. The findings are therefore expected to challenge the status-quo, especially in the way ‘bulk’ cocoa is currently processed and consequently priced, thereby, possibly fostering a win-win situation between cocoa producers and industries.