Design of Automatic Cocoa Fermenter Based on a Traditional Process

Abstract

The cocoa fermentation process is a crucial factor to ensure the quality of the product and it is the key device for a successful fermentation. In rural populations, the fermentation process is made with simple wooden devices which results in a lot of hand labor with low production rates. In this project, we collect the experiences of the traditional procedures used by the cocoa artisans to design a prototype that fits their requirements. The design of the container starts with the appropriate selection of the wood so that it does not impregnate the product with aroma or flavor. Also, we should be capable to monitor important parameters of the process such as temperature and pH of the ferment. In order to carry out a mixing procedure in the same container by means of several movement patterns and achieve a uniform rearrangement of the seeds, it is avoided manual removal of the seeds that usually end up beaten and mistreated, thus reducing the quality of the final product. The movement also allows keeping the seeds aerated during fermentation and is based on information from the sensors and the action of an electrical motor to control such movement. Smallholder farmers are responsible for roughly seventy percent of total global cocoa production and most of this production occurs in areas of high biodiversity. Trials were conducted based on this prototype and the process for fermentation was developed with the new design. We can say then that the goals set for this project are to get a better control of the processing parameters, a reduction in hand labor, a raise in production rate and better income and life conditions of rural population dedicated to this economic activity. Finally, to give greater added value to the product, promoting the incorporation of more cocoa farmers, including native communities.