1.2. La Responsabilidad Social Empresarial desde su idea filantrópica
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Harvesting, pod storage and breaking
Adapted from: 1STCP: Farmer Training Guide on ICPM Cocoa
Importance of correct harvesting practices
• Harvesting is the start of the post-harvest process that determines the quality of the beans to be sold, which will be used by the cocoa and chocolate industry. Getting any of the post-harvest steps wrong can lead to poor quality beans
• If you harvest too early, or too frequently, you are likely to collect unripe pods. Pods that are still green or partly green have more solid pulp (with less sugar content) and the beans may be hard to break up. Unripe pulp gives rise to clumps of beans and leads to poor fermentation
• Harvesting early in the season and at the end can mean that you will not have enough pods/beans to make a good fermentation heap
• Harvesting too late leads to overripe pods with the pulp drying up, and in extreme cases, the beans may start to germinate. Lack of pulp will not give a good fermentation. Also, germinated beans will not ferment well, and the hole caused by the emerging shoot will allow mould inside the bean
• Before fermenting, you can store unopened pods for no longer than 5 - 7 days as storage allows the pulp to increase in sugar content, which causes faster fermentation. Storing pods for longer than 7 days may allow mould to damage the beans and/or encourage the beans to germinate.
Farmer practices
• Some farmers harvest pods too early for various reasons including the desire to sell their cocoa quickly to get money. This leads to poor fermentation. Other farmers delay harvesting due to lack of labour, waiting for the rains to stop or for other reasons. Harvesting late may lead to poor fermentation and loss of beans as a result of mould and germination. Leaving over-ripe pods on trees also encourages disease
• Some farmers damage the beans when using a cutlass for pod breaking by cutting too deeply. Damaged beans should be thrown away. It is better not to use a cutlass at all
• Children should never use cutlasses to break pods, as they may injure themselves. They may be involved in pod breaking after school, using a short stick
• Many farmers store pods for too long which may cause the beans to start to germinate.
Best practices
Harvest the whole farm at least every two weeks
If possible, avoid the use of a machete to open pods, because of the danger of damaging beans and cutting the hand. Use a short stick, a stone or a piece of angle iron, filed to form an edge that is about the same depth as the
thickness of the husk of an average cocoa pod.
See: Discovery learning activity 7: Impact of harvesting time on fermentation and cocoa quality
Fermentation
Importance
• Proper fermentation is important because it stops germination and gives the beans a good taste when roasted
• Fermentation is necessary to begin the process of developing the cocoa/chocolate flavour needed by chocolate manufacturers
Cocoa/chocolate flavour develops fully when beans are roasted. When you roast unfermented beans, the beans taste horrible!
• Flavour development begins when the temperature of the beans is raised to a high enough level during fermentation
• The level of heat required to start the flavour development process only occurs in fermentation heaps/baskets with at least 50 pounds of wet beans. The temperature does not get high enough to start flavour development in a fermentation heap with a smaller quantity of beans • The first part of the fermentation is done by bacteria that do not need air.
Therefore the first two days the heap is not mixed. The second part of the fermentation process is done by bacteria that do need air. Therefore, after the first two days the heap must be turned/mixed thoroughly every day to allow air to reach all the beans
• Ferment beans for a total of 7 days (this is to be confirmed by experiment).
Well fermented
Under fermented
The table below shows the relationship between colour, degree of fermentation and flavour.
Colour of beans Degree of fermentation Flavour of roasting
Brown Fully fermented Strong cocoa flavour, balance of acidity, astringency and bitterness
Brown/purple (mauve)
Partly fermented Good cocoa flavour, higher acidity, astringency and bitterness
Purple Low fermentation Low cocoa flavour, strong acidity, astringency and bitterness
Greyish or black Unfermented Absence of cocoa flavour, predominantly acid, astringent and bitter. Overall sour
flavour
Farmer practices
• Some farmers don’t ferment their cocoa at all and simply dry the beans in the sun. Others ferment for only 1 or 2 days. They may do this because they are impatient and want to sell their beans quickly. From the outside you can’t tell whether a bean has been fermented. You can only tell if a bean has been fermented by cutting it open and looking at the colour.
• Some farmers use black plastic sheets to cover the fermentation heap. They may do this because they think black plastic is more “modern”, plastic sheets can be reused, or because there aren’t any banana trees around.
• Black plastic should not be used as it almost “seals” the heap and doesn’t allow air to circulate during fermentation. This causes rotting rather than fermentation and does not allow the flavour development process to take place. By contrast, banana leaves allow air to penetrate into the heap.
• Some farmers ferment in wooden boxes or in plastic trays. The use of wooden boxes should really only be used when there are very large quantities of cocoa beans to ferment; they are not really suitable for small farmers, baskets with leaves are best!
Best practices
After splitting the pod, scoop the beans directly in the basket
Cylindrical baskets are the best. They allow the heat to develop evenly. Traditional baskets with a broad top let too much heat escape and are not suitabley.
Leave the beans ferment for 2 days. Than mix them thoroughly every day for five days. Total fermentation time: 7 days (this is to be confirmed by experiment).
See: Discovery learning exercise 8: The effect of different lengths of fermentation times
See: Discovery learning exercise 9: The effect of different quantities of beans on the fermentation process
Drying
• Fermented cocoa must be dried. Drying cocoa beans reduces the growth of mould and helps improve the flavour. Dried cocoa beans are easier to store and to transport.
• In the rainy season beans dry more slowly than in the dry season. There is no fixed drying time. Dry as long as necessary to get the beans dry!
• A properly fermented and dried bean should be brown in colour when you cut the bean in half.
Farmer practices
Some farmers think cement drying floors are better because they are more modern. But drying floors do not let air pass and get too hot: the beans “boil”. Also there is a risk that goats or children walk through over the beans and damage them.
Best practises
Put mats on sticks. Spread the beans in a thin layer on the mat. Whenever you pass and see a bad bean, pick it off the mat.
Advantage of using mats: if it suddenly starts raining you can easily scoop the beans up and bring them inside. With the mats on sticks, the beans also dry faster.
Dry until the beans are dry!
Discovery learning exercise 7: Impact of harvesting time on fermentation
and cocoa quality
Source: 1STCP: Farmer Training Guide on ICPM Cocoa
Several factors account for the poor quality of cocoa produced by some farmers. These include harvesting pods at the wrong time, poor fermentation and drying methods. Farmers harvest cocoa pods at the wrong time for many reasons including the desire to get income quickly, lack of knowledge about the quantity of fresh beans needed for fermentation and the relationship between harvesting time and quality. Learning objective
Improve understanding of the maturation stages of cocoa pods and the physical aspects of cocoa quality
Materials
• Flip chart paper • Markers
• 30-40 kg of fresh cocoa beans, preferably of the same variety, collected from the following types of pods:
1st lot: Immature, green pods
2nd lot: Ripe pods, that is, pods that are half or 3/4 yellow 3rd lot: Over ripe pods, that is pods that are orange 4th lot: Pods attacked by black pod disease
Note: It is preferable to use beans from participants’ own farms rather than from the FFS plots so as not to affect the harvest data
• Materials usually used for fermentation • Fresh banana leaves
• Four trays
• 1 very sharp pocket knife
• Labels for the four fermentation lots
• Materials usually used for sun drying, for example, a cement or raised platform
Procedure
At harvest time, tour the FFS plot with participants, asking them to point out which pods are ready for harvesting and which are not.
Return to a central place. List on a flip chart the factors farmers consider when deciding when to harvest. Discuss to what extent each factor provides flexibility for harvesting later.
Cover the four lots of beans to be fermented with the banana leaves and place heavy objects on top of each pile.
Ferment and dry as usual for the specific varieties.
After drying, randomly select 100 seeds from each lot and put them on the four trays. With the pocket-knife, cut each bean longitudinally and observe physical aspects. Observations
Take a handful of dried beans from each lot and squeeze between your fingers. Note which beans make a cracking sound.
Observe and compare the difference in colour between the different lots of cocoa
.Observe and compare the physical aspects of the cut seeds and determine the number/percentages of:
Brown/purple or purple, compact beans Germinated beans
Flat beans
Guide questions for discussion
1) Are there colour differences between the beans from the different lots? What is the difference?
2) Which lots have the worst quality beans?
3) What do you think explains the defects that you observe?
4) Do the differences between the lots of cocoa affect price? How? 5) What have you learned from this exercise?
6) What is the ideal amount for a fermentation heap? Why is the amount in a fermentation heap important?
7) What can farmers who harvest small quantities at a time do to increase their fermentation load?
Discovery learning exercise 8: Impact of duration of fermentation on
bean quality
Farmers often feel under pressure to sell their cocoa as quickly as possible so they do not ferment the beans properly. Only good quality, well fermented cocoa can be sold for export and it is important that the cocoa is fermented properly.
Learning objective
To improve understanding of the fermentation process and learn how to recognise when beans are properly fermented.
Materials
• Flip chart paper • Markers
• 90 kg (200lbs) cocoa beans from properly ripe pods • 2 cylindrical fermentation basket
• Banana leaves • Sharp pocket knife Note
Use beans from participants’ own farms rather than from the FFS plots so as not to affect the harvest data
Procedure
Allow the participants to select properly ripe, healthy pods, these should be split and the beans prepared for fermentation in the normal way (removal of damaged beans, pod debris etc.).
Line the cylindrical baskets with banana leaves and fill them with equal quantities of cocoa beans.
Allow to ferment for 2 days (48 hours).
Stir the beans in each basket very thoroughly using hands (carefully because the mass of beans will be very hot) or a wooden paddle. Do not use any metal tools. Re-cover the tops of the baskets with the banana leaves.
After a further 24 hours stir the beans again, very thoroughly.
Remove a sample of 100 beans from each basket, do not take the beans from just one place but from everywhere in the mass of beans. The sample beans will be very messy and sticky. Re-cover the baskets to allow fermentation to continue.
Keep the 2 samples separate S1 and S2) and using the pocket knife cut the beans in half lengthwise. Examine the cut beans and record the numbers of each colour found.
Repeat the mixing of the beans, the removal of samples and the ‘cut test’ each day until the ninth day after fermentation was started (7 samples examined)
Observations
• Count the number of beans that fall into each category as described in the section concerned with fermentation:
Grey/black → unfermented Purple → low fermentation Brown/purple → partly fermented Brown → fully fermented
• Record the results in a table similar to the one below
Grey/Black Purple Brown/purple Brown
Test num ber duration of fermen- tation S1 S2 Av S1 S2 Av S1 S2 Av S1 S2 Av 1 3 2 4 3 5 4 6 5 7 6 8 7 9
• Calculate the percentages of each category and relate them to the number of days of fermentation
• Record the prevailing weather conditions throughout the period of fermentation (hot and sunny; raining and cool etc.)
Guide questions for discussion
1) Do the percentages of each ‘fermentation category’ change as the time of fermentation increases?
2) Which period of fermentation do you think gave the best result? 3) Is this the same as the time of fermentation you use on your farm?
4) Do you think you need to change anything when you ferment cocoa on your farm?
5) Do you think anything besides time can affect fermentation? 6) If so, what are these other factors?
Discovery learning exercise 9: Impact of quantity of beans on the
fermentation process and cocoa quality
This exercise should be carried out after the correct fermentation time has been established with Exercise 8
Cocoa trees that are very old or badly maintained do not yield many pods, this
means that some farmers have only a small quantity of beans to ferment, particularly if they harvest at irregular intervals, whenever they think they have the time between other tasks, such as harvesting their rice.
Successful fermentation depends on the mass of cocoa beans becoming hot very quickly and this is not possible if there is only a small quantity of beans in the basket. Learning objective
To find out what quantity of cocoa beans is required to obtain successful fermentation and produce good quality cocoa
Materials
• Flip chart paper • Markers
• 160 kg (350 lbs) cocoa beans from properly ripe pods • Scale
• 3 cylindrical fermentation baskets • Labels for baskets
• Banana leaves • Sharp pocket knife Note
Use beans from participants’ own farms rather than from the FFS plots so as not to affect the harvest data
Procedure
Allow the participants to select properly ripe, healthy pods; these should be split and the beans prepared for fermentation in the normal way (removal of damaged beans, pod debris etc.).
Line the 3 cylindrical baskets with banana leaves, label them 50, 100 and 200 and put 50lbs, 100lbs and 200lbs of fresh cocoa beans into the appropriate basket. Cover as for normal fermentation.
Allow to ferment for 2 days (48 hours) and then stir the beans in each basket very thoroughly using hands (carefully because the mass of beans may be very hot) or a wooden paddle. Do not use any metal tools. Re-cover the baskets with the banana leaves.
After a further 24 hours stir the beans again very thoroughly and re-cover. Stir the beans thoroughly every 24 hours until the number of days that gave the best result in Discovery Learning Exercise 8 have passed from the time the beans were first
placed in the baskets (likely to be around 4 stirrings)
Day 1 Day 2 Day 3 Day x Day
x+1 Day x+2 Day x+3 Add beans Allow heat to generate
Stir Stir Stir Stir
Remove beans and test
On the final day remove 3 samples of 100 beans from each basket and using the sharp knife, cut the sample beans in half lengthwise. Examine the beans and record the numbers of each fermentation category present; this is determined by colour, as explained in the section concerned with Fermentation and Discovery Learning Exercises 7 and 8.
Observations
• Count the number of beans in each sample that fall into each category as described in the section concerned with fermentation:
Grey/black → unfermented
Purple → low fermentation
Brown/purple → partly fermented
Brown → fully fermented
• Record the results in a table similar to the one below Basket
size
Sample no. Grey/black Purple Brown/purple Brown 1 2 3 50 lbs Average 1 2 3 100 lbs Average 1 2 200 lbs 3
Average
• Calculate the percentages of each category and relate them to the weight of beans in the basket
• Record the prevailing weather conditions throughout the period of fermentation (hot and sunny; raining and cool etc.)
Guide questions for discussion
1) Do the percentages of each ‘fermentation category’ differ according to the weight of cocoa beans in the fermentation basket?
2) Which weight of cocoa gave the best result?
3) Why do you think the quantity of beans in the basket might affect the fermentation?
4) What weight of coca beans (size of basket) do you use on your farm?
5) Do you think you should change the way you ferment your cocoa to improve the quality?
6) Do you know of any other ways that you can ferment your cocoa?
7) What do think the advantages or disadvantages of these alternative methods might be?
If the quantity of cocoa beans to get good fermentation is important, how will you ensure that you have the correct quantity after each harvest?
Discovery learning exercise 10: Drying cocoa on raised mats
Adapted from: 1STCP: Farmer Training Guide on ICPM Cocoa
Proper drying is important for ensuring good cocoa quality. While drying on cemented floors is common among cocoa farmers in West Africa, the process can be improved through simple technologies such as using raised, covered mats.
Learning objective
To dry cocoa faster and protect drying cocoa from contamination, dew and rain
Materials
• Cement floors (at least 2 m x 2 m size)
• Mats made from the rachis of palm fronds (at least 2 m x 2 m size) raised1.2 m from the ground on wooden supports
• About 100 pounds of well fermented cocoa beans • 2 cocoa bean mixing paddles
• Flip chart and markers
Procedure
Introduce the subject of drying and the objectives of the exercise.
Ask participants to form two groups. One group will dry their cocoa on a cement floor; the other will dry cocoa on a raised mat.
Ask each group to spread out at least 25 kg of beans (with a thickness of 3-4 cm) to dry using the relevant method. During the first two days, each group should mix the beans every hour and then three or four times per day. Ensure that the group