SHERIDAN, WYOMING - November 25, 2025 - Nestlé is piloting a novel, patented cocoa processing technique that uses up to 30% more of each cocoa fruit, aiming to boost farmer yields, reduce waste and create new product opportunities for the global food processing and ingredients industry. By turning traditionally underused parts of the cocoa pod into chocolate flakes, the company is testing a more resource-efficient model for chocolate production in the face of climate pressure on cocoa supply.
Turning more of each cocoa pod into value
Conventional chocolate production relies almost exclusively on cocoa beans, leaving pulp, placenta and husk largely underutilized. Nestlé's R&D organization has reframed that paradigm by developing a method that leverages all of the edible material inside the pod, not just the beans. In doing so, it directly addresses both raw material efficiency and the economic potential of each harvested fruit.
The core idea is simple but strategically powerful: if more of the cocoa fruit can be transformed into a chocolate ingredient without compromising taste, farmers can generate more sellable output from the same plot of land, and manufacturers gain a more resilient and diversified feedstock. For procurement and sustainability teams, this aligns closely with yield optimization, waste reduction and ESG targets.
From beans-only to whole-fruit processing
In the new process, everything inside the cocoa pod is collected as a wet mass that ferments naturally, unlocking the characteristic chocolate flavor. The mass is then ground, roasted and dried into chocolate flakes that can be used as a base for chocolate products, similar to conventional cocoa ingredients.
This contrasts with the classic value chain, where:
- Beans are extracted and the rest of the pod is largely discarded or underused
- Beans alone go through fermentation, drying, roasting and grinding
- Utilization rates of the overall fruit remain relatively low
By integrating pulp and placenta into the process, Nestlé's technique raises the share of the fruit that becomes an ingredient, while still meeting sensory expectations for taste.
Pilot-stage innovation with farmer-centric benefits
The initiative is being led from Nestlé's Research and Development Center for Confectionery in York, UK, with a clear focus on the realities of cocoa farming.
Louise Barrett, Head of the Nestlé Research and Development Center for Confectionery in York, UK, says: "With climate change increasingly affecting cocoa yields around the world, we are exploring innovative solutions that could help cocoa farmers maximize the potential of their harvests. This groundbreaking technique utilizes more of the fruit, while enabling us to provide delicious chocolate to our consumers. While this project is still at a pilot stage, we are currently exploring how to apply this innovation at a larger scale."
Beyond higher material utilization, the simplified extraction process could free up time for farmers by reducing manual handling steps. Nestlé notes that additional time can be redirected into good agricultural practices such as pruning, which is already proven to support better yields and long-term farm productivity.
Strategic implications for the food processing and ingredients industry
For chocolate manufacturers, brand owners and ingredient suppliers, this kind of process innovation has several potential business impacts:
- Yield efficiency: More usable cocoa material per fruit can help buffer supply volatility and support portfolio planning.
- Cost and margin dynamics: Higher conversion rates from fruit to ingredient may improve economics over the medium term, particularly in climate-stressed regions.
- ESG and sustainability positioning: Demonstrable reductions in waste strengthen narratives around responsible sourcing and circular use of agricultural raw materials.
- Innovation pipeline: Whole-fruit cocoa flakes could enable new product formats or claims, especially in premium or sustainability-focused segments.
If successfully scaled, the technique could become an important lever in securing long-term cocoa supply for global chocolate and confectionery markets while differentiating brands on sustainability and resource use.
Next steps: from pilot to scalable practice
The project remains at pilot stage, with Nestlé evaluating how to industrialize the method and integrate it into existing cocoa processing and sourcing frameworks. Key questions for the next phase include scalability, farmer adoption models, integration with local fermentation and collection infrastructure, and alignment with certification and sustainability programs.
For stakeholders across the cocoa value chain-from cooperatives and traders to branded manufacturers-this pilot underscores how processing innovation can complement agronomy, breeding and sourcing initiatives to build a more resilient global cocoa ecosystem.
For full details on this patented cocoa processing technique and Nestlé's wider cocoa sustainability work, visit https://www.nestle.com/.