Through a brainstorming session, some problems within the
semi-finished products company have been identified.
Firstly, complaints have been received from customers
because the final product is outside the specifications
required in the technical sheet. This may be due to various
factors within the process. Additionally, the raw material
often has high ranges of microbiological loads when it
enters the plant, as the cocoa bean is exposed to different
factors from harvest to drying, which affects both the raw
material and the final producto [3].
On the other hand, during the cocoa roasting process, there
is no record of the bean's moisture, which harms the process
and generates bottlenecks due to potential reprocessing.
Having this subprocess controlled would be of great
importance [4].
The objective of this research is to establish a forecast
model for cocoa moisture control in the roasting production
process, using multivariate regression.
To achieve the objective, the first step is to identify the key
factors that influence the cocoa roasting production process.
Next, we will proceed to analyze the variability of each of
the factors that affect the cocoa roasting production process.
Finally, we will present a mathematical model that ensures
an accurate forecast for moisture control in the cocoa
roasting process, using multivariate regression.
1.1.- Cocoa Roasting.
Cocoa roasting is an exothermic process that involves
subjecting the beans to heating. It is a crucial stage that
determines the final flavor and aroma of the product. The
roasting temperature varies according to the type of bean,
being higher for the "forastero bean" and medium to low for
the "criollo bean" or "trinitario bean" [5].
This process pursues several fundamental objectives;
firstly, it facilitates the separation of the shell from the bean,
cracking it and allowing subsequent dehulling.
Additionally, it sterilizes the beans by eliminating
pathogens such as Salmonella or E. Coli, as well as other
undesirable microorganisms. It is necessary to carefully
control the temperature to avoid excessive roasting that
could negatively affect the flavor [6].
Another key objective of roasting is to reduce the moisture
content of the cocoa bean. Initially, the beans may have up
to 8% moisture, but after roasting, this percentage decreases
to approximately 2%. This moisture reduction is crucial for
the subsequent stages of cocoa processing [7].
1.2.- Food Safety and Wholesomeness
In the food industry, specifically in the production of cocoa
and its derivatives, safety and quality are fundamental
aspects. It is essential to ensure that the final products are
safe and suitable for human consumption. This implies that
the raw material, that is, cocoa beans, must be free of
impurities, contaminants, or any element that could be
harmful to the health of the end consumer [8].
To achieve this objective, it is necessary to implement strict
quality controls at all stages of the supply chain, from bean
collection to finished product packaging. Work teams must
assume responsibility for complying with applicable
national and international requirements and regulations,
both in production processes and final products. This
includes following good manufacturing practices,
implementing quality management systems, and conducting
periodic analytical tests [9].
In addition to safety, sensory quality is also a key factor in
the cocoa industry. Producers must ensure that the final
products meet the flavor, aroma, and texture standards
expected by consumers. This is achieved through rigorous
control of processing conditions, the use of high-quality raw
materials, and continuous training of personnel involved in
production. Only through a comprehensive approach to
quality and safety can consumer satisfaction and long-term
success of the cocoa industry be guaranteed [10].
1.3.- Moisture Content and Quality Criteria in Cocoa
Beans
For cocoa bean manufacturers, controlling the moisture
content of the raw material is crucial. Cocoa beans are
required to have approximately 7% moisture content. If this
percentage exceeds 8%, it can lead to several negative
consequences. Firstly, it would imply a loss of edible
material, as excess moisture can promote the growth of
molds and bacteria, representing a potential risk to food
safety. Furthermore, moisture content above 8% can affect
the yield of the production process [11].
On the other hand, if the moisture content of cocoa beans is
below 6.5%, the shell becomes too fragile and the beans
tend to disintegrate during processing. This would result in
a high proportion of broken beans, which would also
negatively impact the yield and quality of the final product.
Therefore, maintaining an optimal moisture level between
6.5% and 8% is crucial to ensure quality and efficiency in
cocoa production [12].
The excellence of cocoa encompasses various essential
elements, such as its flavor, authenticity, and physical
attributes, which directly influence production yield.
Additionally, aspects such as traceability, geographical
indications, and certification must be considered, reflecting
the sustainability of production methods and product
traceability. These factors are fundamental to ensuring
quality and consumer confidence [13].
Cocoa quality specifications include: flavor, food safety and
wholesomeness, physical characteristics (consistency and
edible material yield), cocoa butter characteristics, color
potential ("colorability"), and traceability, geographical
indicators, and certification. Each of these aspects must be