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British Food Journal
Effect of modified packaging and storage time of cocoa pods on the commercial quality
of cocoa beans
S.O. Aroyeun J.O. Ogunbayo A.O. Olaiya
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S.O. Aroyeun J.O. Ogunbayo A.O. Olaiya, (2006),"Effect of modified packaging and storage time of cocoa
pods on the commercial quality of cocoa beans", British Food Journal, Vol. 108 Iss 2 pp. 141 - 151
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Effect of modified packaging and
storage time of cocoa pods on the
commercial quality of cocoa
beans
S.O. Aroyeun, J.O. Ogunbayo and A.O. Olaiya
Cocoa Research Institute of Nigeria, Ibadan, Nigeria
Abstract
Purpose – Lack of good post-harvest storage of cocoa pods has been responsible for the low
commercial quality of cocoa beans. This study aims to evaluate the effect of modified packaging and
storage time of cocoa pods on the corresponding commercial qualities of cocoa beans.
Design/methodology/approach – Preweighed cocoa pods obtained from the experimental station
of the Cocoa Research Institute of Nigeria, Ibadan, Nigeria were stored under three modified packaging
conditions, namely: black non transparent polythene film (B
NTPEF
), transparent polythene film (T
PEF
)
and N
A
(normal atmosphere environment).
Findings – The study found that there was a rise in the mean temperatures of samples in all the
storage environments up to the 12th day of storage, after which the mean temperature declined until
the end of the storage period. Cocoa butter fat, bean weights, severity of decay and mould growths
depended on the type of packaging and storage time.
Originality/value –Atp,0:05 the use of modified packaging of cocoa pods significantly affects
the commercial values of the beans. The best of these qualities was conserved in the T
PEF
.
Keywords Packaging materials, Storage management, Cocoa, Quality assessment
Paper type Research paper
Introduction
Post-harvest behaviour of cocoa (Theobroma cacao) is a major concern both locally and
internationally. High post-harvest losses are among the major problems facing the
cocoa-producing nations of the world, especially in a developing country like Nigeria
and other tropical environments. These losses are associated with incorrect packaging,
transportation and poor storage systems (Bayeri and Igbelina, 2002). These factors
cause physical, physiological and pathological disorders, which adversely affects the
cocoa bean quality and price in the international market (Robinson, 1996).
After harvest, fruits continue to carry on most of metabolic processes that were
predominant just before harvest (Wills et al., 1998) and if these processes are not
regulated, senescence soon sets in. Commercially, manipulating storage time and good
choice of packaging materials are conventional methods of extending the life of cocoa.
Cocoa of commercial values should conform to some international standards in relation
to moisture content, butter fat content, bean sizes and absence of mouldy or germinated
beans. During the last years, the influence of modified atmospheres on the physiology,
biochemistry and quality of a variety of fruits and vegetables has been reported and
The current issue and full text archive of this journal is available at
www.emeraldinsight.com/0007-070X.htm
The authors wish to acknowledge the permission granted by the director of the Cocoa Research
Institute of Nigeria, Ibadan (Professor G.O. Iremiren) to publish this paper.
Effect of
modified
packaging
141
British Food Journal
Vol. 108 No. 2, 2006
pp. 141-151
qEmerald Group Publishing Limited
0007-070X
DOI 10.1108/00070700610644951
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there is a wide range of reviews about these works (Ben-Yehoshua, 1987; Prince, 1989;
Powrie and Skura, 1991). One of the initial physiological effects of a modified
atmosphere on fruit metabolism is a decrease in respiratory intensity during the
storage period, which involves a decrease in substrate consumption, carbon dioxide
production, oxygen consumption and heat release.
Cocoa pods have been stored in jute bags, polythene, baskets and other relevant
packaging materials, but the commercial qualities in relation to the effect on the beans
were seldom reported. The storage of cocoa pods is not common in Nigeria, as farmers
processed their cocoa beans immediately after harvest. Only the beans are stored for
some months prior to shipment to consuming countries.
However, during periods of surplus and good harvest where there is the need to
store the cocoa pods, as a result of an inability to process all the harvested pods due to
lack of facilities, an attempt is needed to study the effect of cocoa pod storage on the
corresponding commercial qualities of cocoa bean. The objective of this study is to
determine the effect of different modified packaging of cocoa pods on fermented bean
qualities.
Materials and methods
Source of raw materials
A total of 24 cocoa pods were obtained from the cocoa plantation of the Cocoa Research
Institute of Nigeria experimental station, Ibadan, Oyo State Nigeria. The pods were
healthy, well-developed and ripe with a characteristic yellow colour. The pods were
graded according to their weights. The weighed pods were packaged in black
non-transparent polyethylene films (B
NTPEF
) and transparent polyethylene films (T
PEF)
obtained from Cocoa Research Institute of Nigeria, Ibadan. Control pods were exposed
and labelled normal atmosphere (N
A
). Pods were stored in duplicates in each of the
films. After six, 12, 18 and 24 days, pods were taken from B
NTPEF
T
PEF
and N
A
,
weighed, and loss in weights of the pods was recorded. The pods were broken and the
corresponding bean weights per pod were also recorded (wet basis). The number of
beans per pod were noted and known weights of it were later taken to the fermentary
for fermentation using tray fermentation techniques and the temperature of
fermentation was recorded every 24 hours.
Fermentation
This stage is a critical stage in the development of chocolate flavour precursors. The
fermentation process generated considerable heat and a temperature close to 508C was
reached within the mass of beans during fermentation. Since the cocoa beans used in the
experiment were smaller than the minimum quantity for a normal fermentation, (about
100 kg), it became necessary to include these experimental samples in a heap of cocoa
beans to allow for an effective fermentation (CMQR, 1996). The use of a polyethylene
pouch in this study resulted in a modified atmosphere within the package. The
fermentation process took between three to five days. Constant turning was ensured to
allow uniform temperature distribution. Under- fermentation is not desirable in order to
avoid slaty beans or purple beans with consequent bitterness and astringency. Extending
the fermentation beyond five days brings a danger of over-fermentation with loss of
chocolate flavour and development of an off-flavour from putrefactio n. Fermentation is a
basic process which, if left alone, will look after itself and is best kept simple. It is more of
an art than a science and the end-point is best judged through experience when the
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external appearance of the beans indicated that they were ready to be dried. After the
completion of fermentation, the weights of the beans were taken. Weight losses during
storage were determined by weighing samples before stora ge and at various times during
the storage on a Sartorius precision balance (Sartorius Co., Gottingen, Germany). In
expressing the pod weight losses, the pod weight at the time of breaking was expressed as
a percentage of the weight at the commencement of the experiment.
Drying
This process is carried out in the sun. The drying in the sun took six to ten days and a
much longer period may allow mould to develop inside the bean leading to a
musty/mouldy off-flavour. Care was taken to avoid beans becoming contaminated with
bacteria from animals since some of these organisms may be harmful to man. The
dried weights were noted. From the dried beans, samples were taken for the
determination of mouldiness, germinated beans and black beans. Readings were taken
in duplicates and mean values were recorded. After the end of each storage period,
evaluation of browning/decay and off-odour were made for each sample. Data on
brown discoloration and subsequent decay were combined in determining percentage
of deteriorated pods.
The severity of undesirable condition was reported as severity index (SI) because
tissues began to decay after development of brown discoloration. Percentage of
browning/decay was evaluated on a rating scale (R)of0¼None, 1 ¼Slight,
2¼Moderate, 3 ¼Severe, 4 ¼Extreme. The SI is the weighted average:
SI ¼
NT4
XNiRi£100
where N
i
is the number of pods with ranking R
i
and N
T
is the total number of pods £
four scale ratings. This gives a score of severity on a scale ranging from 0 to 100
(Makita, 1985). Odour of the pods and the beans were rated on a scale of 0 ¼normal
to 4 ¼severely objectionable.
Moisture content determination and percentage fat contents were determined
according to AOAC (1998) methods.
Statistical analysis
All data generated were subjected to analysis of variance (ANOVA) using SPSS 1999
for Windows.
The rate of weight loss for all treatments was low for the first few days up to the
sixth day (0-9 per cent) according to Figure 1. A rapid increase in weight loss was
observed after the sixth day with N
A
being the greatest followed by T
PEF
and B
NTPEF
respectively. At the 12th day of storage both T
PEF
and B
NTPEF
had lost 10 per cent of
their weights. As at the 24th day, T
PEF
weight loss rose to 22 per cent while N
A
had lost
68 per cent of its initial weight.
The temperature changes during the storage periods ranged between 378C and
42.58C (Figure 2). The temperatures reached the peak for all environments at the 12th
day and subsequently declined. B
NTPEF
maintained the highest temperature
throughout the storage periods while N
A
recorded the lowest.
In Figure 3, the percentage mouldy beans were low for all the treatments at sixth
day of storage with steady increase thereafter. After the 24th day of storage, N
A
and
B
NTPEF
seemed to be equal while T
PEF
contained 70 per cent mouldy beans.
Effect of
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packaging
143
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In Figure 4, the percentage moisture contents increased in all environments from the
sixth day and reached the maximum at the 12th day. A reduction in percentage
moisture contents of N
A
,B
NTPEF
and T
PEF
was obvious also at the 18th day. Moisture
contents of N
A
and T
PEF
increased thereafter. Only cocoa beans stored in B
NTPEF
remained unchanged from the 18th day to the 24th day of storage. This may be due to
the initial moisture content of the various pods in the different environments and
probably due to non-uniform drying of beans.
Figure 1.
Percentage loss in cocoa
pod weight due to storage
Figure 2.
Temperature changes due
to storage
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In Figure 5, percentage fat content for T
PEF
was highest throughout the storage days.
Percentage fat content of pods stored in N
A
reached peak at the sixth day and later
decreased at the 12th and 18th and rose again by at 24th day. The percentage fat
content of beans from B
NTPEF
was equal at the 18th day with N
A
.
Table I showed the various weights of pods taken at the first day, the bean
numbers/pod; bean wet weights per pod and the average bean weights. The different
pods stored in different modified packages were randomly introduced into packages
used. At the end of the sixth, 12th, 18th, and 24th days, bean numbers were counted
and the bean weights per pod taken. It was found out that pod weights did not
influence the number of beans in a pod nor did it have any effect on the bean sizes.
Some pods were heavier in weights than the corresponding weights of their beans. For
instance pods stored in N
A
had an initial weight of 505 g with corresponding bean
weights of 141.36 g but B
NTPEF
weighing 525 g had bean weights of 125.27 g. In
Table II, percentage black beans and germinated beans varied with different packages
and storage periods. The rate of black bean formation was higher in pods stored in N
A
Figure 3.
Percentage mouldy beans
during storage
Figure 4.
Percentage moisture
contents of cocoa beans
after drying
Effect of
modified
packaging
145
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than others. The percentage germinated beans increased in all modified environments
with respect to storage days as shown in Table II. Pods stored in N
A
and T
PEF
maintained constant germination after the 18th day. According to Table III, the
percentage browning/decay of cocoa pods were affected by storage environment and
storage days. Beans from cocoa pods stored in B
NTPEF
increased from the sixth day till
the 24th day in browning/decay. N
A
started showing signs of decay at the 18th day and
increased thereafter till the 24th day of storage. Beans stored in T
PEF
did not have any
sign of decay throughout the periods of storage. The severity index of browning/decay
followed increasing order in all treatments except T
PEF
which had the lowest value at
the 24th day. The values obtained for odour of samples in all environments were within
0-3.5. None was severely objectionable although B
NTPEF
was objectionable at the 18th
and the 24th days than others.
Discussion
Table I shows that the cocoa pods used in the experiment varied in weights and
number of cocoa beans. It was evident that some of the pods with lower weights
contained greater numbers of cocoa beans than others with relatively greater cocoa
pods weight. At p,0:05, there were significant differences in weight of cocoa pods
and mean numbers of cocoa beans. This could mean that pods with lower cocoa bean
but larger pods weight could be richer in cocoa pod husk which might not be too
desirable for farmers whose aim is to sell their cocoa bean for chocolate manufacturer.
In another perspective, the lower weighted pods with correspondingly higher number
of cocoa beans might be due to the small size of the cocoa beans in the pod which might
be lower in standard than acceptable cocoa in the international market. With the new
cocoa areas being opened up, there is an increasing variation in bean size from a
greater diversity of planting materials. It is becoming more important that beans are
sold not only on the basis of the agreed quality standards, but also on the basis of the
agreed bean size criterion so that manufacturers know what they are buying and the
sellers’ reputation is protected (Wood and Lass, 1985; Dand, 1993; Aroyeun, 2004).
Figure 5.
Percentage fat contents of
cocoa beans as a result of
cocoa pod storage
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6121824
Quality parameters
a
B
NTPEF
N
A
T
PEF
B
NTPEF
N
A
T
PEF
B
NTPEF
N
A
T
PEF
B
NTPEF
N
A
T
PEF
Pod weight 310 505 400 450 400 265 525 350 350 454 300 454
Bean no./pod 46 48 49 38 40 50 56 47 45 54 44 54
Bean wet weight/pod 95.62 141.36 127.1 68.69 36.82 88.2 125.27 97.2 91.3 117.6 55.8 117.6
Average bean weight (g) 2.08 3.0 2.6 1.80 2.2 1.80 2.23 1.6 2.02 2.2 1.3 2.2
Note:
a
Values recorded were means of six pods per treatment
Table I.
Weights of cocoa pods,
bean wet weight and
bean numbers in different
storage environments
Effect of
modified
packaging
147
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Day(s)
6121824
Parameters B
NTPEF
N
A
T
PEF
B
NTPEF
N
A
T
PEF
B
NTPEF
N
A
T
PEF
B
NTPEF
N
A
T
PEF
% black beans – – – 6.3 5.20 5.7 15.1 40.8 21.2 17.4 81.2 22.6
% germinated beans 0.3 0.1 0.2 0.7 0.3 0.5 0.8 0.9 0.8 0.9 0.9 0.8
Notes: B
NTPEF
: black non transparent polythene film; N
A
: normal atmosphere; T
PEF
: transparent polythene film
Table II.
The percentage
germinated and black
cocoa beans
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Weight loss
According to Figure 1, the longer the pods were stored, the higher the weight losses.
However, pods stored in B
NTPEF
lost more weights than in N
A
and T
PEF
.B
NTPEF
lost 68
per cent of its initial weight as at the end of the storage period. Total weight loss of
both N
A
and T
PEF
were lower than B
NTPEF
. These differences might be due to
differences in carbon losses in respiration and moisture (Roy et al., 1996) or due to
histology of tissues. Those in B
NTPEF
were in a more advanced stage of senescence as
noted by the deteriorated condition, which probably made them more susceptible to
water loss. The reasons for the significant rise in weight loss as a result of the type of
packaging used might not be unconnected to the elevation of carbon dioxide in the
storing package (Al-Redhaiman, 2002). The reduced weight of B
NTPEF
and N
A
pods
might be due to increased cell integrity, (Al-Redhaiman, 2002). According to Figure 2,
there was a gradual rise in the mean temperature up to the 12th day of storage, after
which the mean temperature declined till the end of storage for all treatments. Up to the
24th day of cocoa pod storage, slightly higher mean temperature was recorded for pods
stored in B
NTPEF
than others. Black beans (Table II), apparently due to mould, were
encountered only after pod had been stored for more than six days in all treatments
and greatest in samples stored in N
A
. Percentage germinated beans also increased in
the entire packaging atmosphere with rise in the storage days. There appeared to be an
association between percentage black beans and length of pod storage. This result was
in conformity with the findings of (Hotchkiss and Banco, 1991), who reported that
production of undesirable colour resulted from high O
2
concentration in the package.
The incidence of germinated beans also seemed to be associated with the storage
period and appeared to be more favored in B
NTPEF
stored cocoa pods (Table II). In
Figure 3, there is a sharp increase in the number of mouldy beans in B
NTPEF
and N
A
than T
PEF
which increases with rise in storage period, T
PEF
being the lowest. The
atmosphere where the mouldiness is lowest is highly modified. This finding was in
agreement with the reports of (Cappellini et al., 1987) who stated that mouldiness is
inevitable in an unmodified package.
Moisture content
In the international market, cocoa of merchantable quality must be thoroughly dried by
all means; the moisture content need be reduced to between 6 and 7 per cent. In
Figure 4, moisture content of B
NTPEF
at sixth day of storage, ambient and T
PEF
fell
% of pods with
browning/decay
d
Severity index (SI) of
browning/decay
e
Odour
f
Treatment 6
g
12 18 24 6 12 18 24 6 12 18 24
B
NTPEF
4.16
a
8.30
a
8.30
a
16.7
a
1.04
a
5.20
a
25
a
31.25
a
0.1
a
0.5
a
2.1
a
3.5
a
N
A
0
b
0
b
4.16
b
8.30
b
0
b
4.16
b
7.2
b
25.0
b
0
a
0.3
b
0.5
b
1.6
b
T
PEF
0
b
0
b
0
c
0
c
0
b
0
c
0
c
4.17
c
0.1
a
0.1
c
0.3
b
1.2
c
Notes:
abc
means with different superscripts in the same column are significantly different (p,0:05);
d
(Number of browned and decayed pods £100)/number of observed pods;
e
((number of slight
pods £1Þþðmoderate pods £2Þþðsevere pods £3Þþðextreme pods £4Þ£100Þ=ðnumber of
observed pods £4);
f
Rated on a scale of 0 to 4, with 0 ¼normal and 4 ¼severely objectionable;
g
Days in storage
Table III.
Physiological changes in
cocoa pods during
storage
Effect of
modified
packaging
149
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within acceptable range for properly dried beans. Other moisture values less than 5 per
cent such as in B
NTPEF
at sixth day storage, T
PEF
at 18th day storage and B
NTPEF
at the
24th day will cause the shell to be too brittle and the beans may distingerate, giving
high levels of broken beans (CMQR, 1996). Since chocolate manufacturers require cocoa
beans to have a moisture content of 6-7 per cent, if it is above 8 per cent there is not only
a loss in edible material, but also a rise of mould and bacterial growth (CQMR, 1996).
According to Table III, cocoa pods developed brown discoloration and decay during
storage. Percentage and severity of browning/decay were less under T
PEF
than B
NTPEF
and N
A
. Low oxygen or high carbon dioxide atmosphere might have resulted in
reduced browning via inhibition of phenolics production and polyphenol oxidase
activity. These results followed the trend of the reports of Siriphanish and Kader (1985)
and Minamide et al. (1980) for lettuce and shiitake mushroom. The decay/browning as
evident from the B
NTPEF
and N
A
might be due to increased metabolic activities of the
tissues (Kader, 1986). Nevertheless the low oxygen atmosphere was helpful in reducing
the amount of browning /decays (Mencarelli et al., 1983). Thus in commercial
film-packaged pods especially in B
NTPEF
, the reduced oxygen levels caused by MA
would be desirable in retarding development of browning/decay. Pods held in N
A
developed an off-odour on day 24 due to decay, while those in T
PEF
only had a slight
off-odour.
Fat contents
According to Figure 5, there was a significant difference (p,0:05) among all the
samples stored in various MA due to storage. Although there are standard
specifications for fat meant for export, only beans stored in T
PEF
was able to maintain
the level despite the steady decrease in fat due to storage. There was a sharp decrease
in percentage fat content of samples stored under N
A
than B
NTPEF
.
However, only values obtained for T
PEF
fell within the international standard (55-58
per cent) (CQMR, 1996).
Conclusion
The use of modified packaging of cocoa pods in transparent polythene films conserved
the commercial qualities of the cocoa beans such as cocoa butter, percentage moisture
content, reduced mould growth and severity of decay. The values obtained for all these
parameters in T
PEF
fell within international standard for cocoa beans.
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Further reading
Al-Redhaiman, K.N., Al-Humaid, A.I. and El-Rayes, D.A. (2002), “Effect of modified atmosphere
treatments on fruit quality and respiration rate of ‘Tristar’ strawberry fruits”, Zagazig
J. Agric. Res., Vol. 29 No. 5, pp. 1503-12.
Effect of
modified
packaging
151
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