Reducing Process Variation of Cocoa Powder With Color Spectrophotometers

The process of turning raw cocoa beans into powder takes many steps. Slight variations throughout any stage could create differences in the final product. As a quality manager in the manufacturing of cocoa, you look to avoid process variations that could decrease cocoa powder quality. 

A spectrophotometer is a powerful tool for cocoa quality control. It allows you to quantify the color of the powder and its raw ingredients to identify any differences. Assessing color data throughout various stages lets you see where variations arise so you can more knowledgeably adapt your processes. 

Understanding Process Variation in Cocoa Powder Production

Process variation refers to fluctuations during production that may cause deviations from the expected outcome. In cocoa powder production, variations might include a higher roasting temperature, which creates a darker powder. Some types of process variations happen naturally and won't cause a significant change in the final product. In more severe cases, a variation could lead to substantial changes, which may require disposing of a batch or spending additional time fixing it. 

Where Does Process Variation Appear? 

Cocoa powder production involves numerous stages, where even a slight change in each may influence the outcomes. Process variation occurs for different reasons, including a lack of standardization, human error, or random fluctuation. 

Some examples of process variations that influence appearance include:

• Raw materials: Cocoa beans have a natural genetic variety that influences color. 
• Processing: Changes in time, temperature, or other factors during fermentation, drying, roasting, and grinding could change the appearance. 
• Chemical treatments: Dutch-process cocoa powder undergoes alkalinization, which makes it appear darker. Changes in the alkalinization may influence the lightness. 
• Equipment standardization: Roasters and grinders perform differently depending on contamination from previous batches or setting changes.
• Environmental factors: Temperature, humidity, and other factors influence appearance when introduced during drying and storage.

How Variation Influences the Final Product

Production variations could influence product quality and customer satisfaction with the final product. For example, too much sunlight during storage could lighten cocoa powder's color, lowering customers' perceptions of the product quality and influencing buying decisions.

The next time they choose this baking ingredient, they might avoid a particular brand due to the variation they experienced in their last purchase. Consistent, high-quality cocoa powder manufacturing helps you stand out in a competitive market. Consumers will respect your brand and choose it more readily for their baking requirements. 

Reducing Process Variation in Cocoa Production With the ColorFlexL2 Spectrophotometer

Some variation will naturally appear in cocoa powder production, but adding a color spectrophotometer like the powerful ColorFlex L2 to your workflow helps you remain within a set standard. This solution enables you to measure the color of samples throughout your production processes, from the raw beans to the final powder. 

We've designed the ColorFlex L2 as the ultimate quality assurance partner in cocoa powder manufacturing, with unrivaled features and value. Among its many benefits, this equipment offers:

• Exceptional ease of use: Our next-gen color spectrophotometer is ready to measure straight out of the box, and simplified onboard training guides let your users confidently operate it within minutes with minimal training. 
• Support for faster quality control decisions: The built-in high-resolution camera and image recording capability allow for rapid, data-driven quality decisions that reduce production bottlenecks and material waste potential.
• Stand-alone functionality: The ColorFlex L2 is a fully independent color workstation — it's not necessary to connect extra PCs or laptops.
• Improved Essentials 2.0 software: We've upgraded the built-in software for analysis of multiple tristimulus and spectral data sets.
• Unparalleled connectivity: Data migration and export to Statistical Process Controls (SPCs) and Laboratory Information Management Systems (LIMS) is seamless with a full selection of connectivity options.
• Long-lasting durability: Like all HunterLab color measurement solutions, the ColorFlex L2 is built to withstand demanding production environments. Our latest color measurement solution comes with industrial glass and a sealed, spill-proof case.
• Reliable performance: Onboard diagnostics capabilities are included to help keep your device in peak performance and ensure dependable long-term operation.

How to Implement the ColorFlex L2 Into Every Production Stage

Our innovative ColorFlex L2 spectrophotometer unleashes value at every stage of production with an extensive built-in library of the industry's most widely used scores and indices. All you need to do is select the right one for your application, press the button, and determine if your product falls within tolerances in as little as a few seconds. Here's how you can leverage this tool at various stages of cocoa bean processing.

1. Raw Beans

The initial color of raw beans provides a baseline profile. Noting significant color variations in raw beans can tell you if and where you may need to adapt your processes.

2. Fermentation

In this stage, color changes occur as the pulp drains away and flavor begins to develop. Regularly evaluating samples during fermentation allows for a greater understanding of variations arising in color development so you can adjust your strategies as necessary.

3. Drying

During this stage, the beans lose most of their moisture content as they undergo heat exposure. The ColorFlex L2 helps optimize drying processes to ensure even drying and consistent color outcomes.

4. Roasting 

If your manufacturing process starts with dried beans, performing a color assessment before roasting supports better sourcing and quality assurance in raw materials. Beans that pass evaluation are ready to move forward in production, where you can retest each batch for conformance with tolerances. Unexpected data allows for early process adjustments so you can achieve the desired appearance while minimizing wastage.

5. Grinding

In this stage, the nibs undergo numerous changes, such as alkalizing to reduce acidity and create a darker color. The ColorFlex L2 helps you check spectral data consistency throughout every step, from the pulp to the powder stage. Its color measurement capabilities can reveal issues like inconsistent grinding, which can cause differences in appearance. When creating Dutch or black cocoa, this equipment ensures you get the deep color consumers expect.

6. Packaging and Storage

Once you have the finished powder, sample the color of each batch using the ColorFlex L2 to check for any variations introduced during packaging. 

If the powder remains in storage for some time before shipment, periodically test the color again to ensure it maintains chromatic quality. You can adapt storage temperature, humidity, and light as needed to help reduce variation. 

Add the ColorFlex L2 to Your Production Processes

At HunterLab, we're industry experts with over 70 years of color measurement expertise. Our ColorFlex L2 helps ensure accurate and objective color quality decisions in cocoa powders so producers can reduce process variations. Contact us online for more details or ordering guidance.