POST HARVEST PROCESSING FACILITY - TUMACO COLOMBIA

´´Optimizing the quality of cocoa.´´

To meet the ever-increasing quality demands of the int. cocoa market we have taken a leap

forward and developed a high-end processing facility, creating new opportunities for those

companies looking for the highest quality standards.

BACKGROUND

We understand that the success of a Single-origin chocolate largely depends on the quality

consistency and long-term sustainability of the grain quality. Our focus therefore is to bring to

market Single-origin cocoa that meets the highest post-harvest standards, using the most optimal

mechanisms available.

MAIN OBJECTIVE

The main objective of this project is to create value for our customers, by improving the

quality consistency and long-term sustainability of our cocoa products.

SPECIFIC OBJECTIVES

Ensure the quality (consistency), safety and traceability of the cocoa beans, based on the

fermentation and drying protocol "Flor de baba", according recommendations of the expert

Ing. Ms. Gladys Ramos and specific customer requirements.

Establish a work plan in which small and medium farmers who currently struggle to correctly

process their cocoa are involved. Often they do not have the infrastructure, work force and

time to do it.

Contribute to overall cocoa quality and improve processing techniques in the area of

Tumaco, Nariño, Colombia, so that the unique characteristic of each cocoa type are

optimally expressed.

APPLIED STRATEGIES

Identifying the correct region: The climate and genetics of the Tumaco area allowed

us to develop this project. Tumaco is also interesting because of the low cadmium

levels and farming practices. For example, no agrochemicals are used on the crops

by the farmers, which makes the cocoa practically organic.

Identify production areas that could be involved in the project by providing wet cocoa.

Defining the structure, stages and mechanisms of the project, developing a postharvest processing infrastructure on which we can project long-term growth, considering a growing demand. All done with expert advice and guidance from Fine Aroma Cocoa Ing. Ms. Gladys Ramos.

DEVELOPMENT OF THE PROJECT

Pre-operational stage: For a period of six months, we were developing construction works.

Adaptation of the land area, establishing the settlement and then the first installations. In

this stage, we have completed a first module, which is ready for the start of our testing

phase.

Teste stage: During the month of June 2015, the first module will operate in the presence

and supervision of Ing Ms. Gladys Ramos, who develops training and implementation for

operating the facility, records parameters, and applies protocol-established fermentation

and drying. During this stage, possible improvements will be identified and applied to the

four remaining modules that will be installed.

Operational Stage: Once the test phase is successfully completed, we will proceed to the

operational phase of our project.

GENERAL INFORMATION

Location: The facility is located in ‘Inguapi del Carmen’, 22Km from the main road

connecting several villages in the rural area to the urban area of Tumaco. It also connects

with other municipalities in the department of Nariño.

Hydrography: The hydrography of the region makes it one of the most interesting cocoa

areas of Colombia, the Mira and Patia rivers are the most important ones, but there are also

small rivers such as the Caunapí, Chagui, planks and Mexico, many of them are surrounded

by mangroves and high plant and animal biodiversity deltas. Cocoa plantations naturally

benefit from the geographical and hydrological characteristics of the area.

Production areas: The main producing areas are Los Robles, Tablón Dulce, Tablón Salado,

Shawi and Rosario

Production capacity: In recent years, the production has maintained between 2700-2800

MT a year. Production will increase due to the plantation of new crops.

Colombia, Tumaco Region

CHARACTERISTICS OF THE PROCESSING FACILITY

Superficies: The facility has a total area of 1,754 square meters, divided into 5 areas. A

fermentation room, drying area, cellar area, gardens, planting area and access area.

Fermentation area: The fermentation room has an area of 150 m2, divided into two areas, the reception area and fermentation area. The design of the spaces ensures a homogeneous fermentation, preventing temperature changes that can disrupt the process. It relies on a proper ventilation system to provide good working conditions for operators and to run the drainage system for the cocoa slime.

The fermentation area is divided into 5 modules. Each module has 12 boxes of 85 cm x 2.80 cm x 0.70. Capacity 7,500 Kilos in wet.

Amount of boxes Capacity of Baba cocoa (Approx.)

Module 1 12 6.000 Kg

Module 2 12 6.000 Kg

Module 3 12 6.000 Kg

Module 4 12 6.000 Kg

Module 5 12 6.000 Kg

TOTAL 60 30.000 Kg

Drying area: For the drying of the cocoa, we chose a tunnel shaped solar drying parabolic of 29 m x 3.87 m x 2.10 m, with a wooden structure. The drying beds are made of 100% plastic for a slow dehydration of the fine cocoas. The top has a plastic-polyethylene cover with low density (gauge 6 and tubular support).

The five drying tunnels will have a total area of 900 square meters each.

Amount of bed Capacity of Dry cocoa (Approx.)

Tunnels 1 2 700 Kg

Tunnels 2 2 700 Kg

Tunnels 3 2 700 Kg

Tunnels 4 2 700 Kg

Tunnels 5 2 700 Kg

TOTAL 10 3.500 Kg

TRACEABILITY SYSTEM, SAFETY AND QUALITY Sourcing wet cocoa beans: We have a careful harvest planning in place running a weekly collection schedule for each farm participating in the project. Participating farmers commit too:

Weekly harvesting.

Use appropriate tools to prevent damage to the pods at the time of harvest.

Harvesting fruits on full physiological maturity.

Separate the sick pods from the healthy.

When separating the placenta from the pods, check if they are free of sick almonds, black or germinated, as well as remains of placenta.

Avoid injuring the almonds.

The collecting happens the same day of the harvest and is held in plastic tanks with lids, taking care of the mucilage. Vehicles are used for the collection. Farmers will be encouraged to work this way because they receive the same prices as for dry Fine flavor cocoa.

Photos by: Ing. MS. Gladys Ramos

FERMENTATION When the cocoa arrives at the facility, it undergoes its fermentation and drying protocol. The specific protocol is adjusted according the type of cocoa and customer requirements. Spreadsheets are used to guarantee the traceability of each batch when it enters for the first time into the facility. This documentation contains all necessary information regarding the exact origin and timing of the processes.

DRYING In layers of maximum 5 cm the drying is controlled, in order to ensure the elimination of acidity and reduce the moisture content to 8%. The designated personnel shall frequently move the mass for optimal processing. The final product obtained after these processes; enables easy removal of the shells of the kidney-shaped grains.

PACKAGING AND STORAGE We have built a warehouse with a storage area and a small laboratory. We store the cocoa according optimal requirements and conditions until transported to the harbor of Buenaventura.

CREATING VALUE FOR OUR CUSTOMERS The post-harvest process is a crucial stage in terms of organoleptic quality for the cocoa beans. We have therefore developed this professional fermentation and drying processing facility and trained qualified teams to assist the local farmers. The farmer therefore has more time to take care of his pods and harvest and we can bring more value to our customers.

TRACEABILITY MAP