Cocoa roasters: Keys to efficient implementation in the cocoa industry

In today’s chocolate industry, the choice of the right cocoa roasters determines not only the final quality of the product, but also the profitability and sustainability of the entire operation. With the global industrial chocolate market valued at over $58.6 billion and projected growth of 12.5% annually, investing in the right roasting technology becomes a critical strategic decision.

Cocoa processing has undergone a radical transformation in recent years. Europe and Latin America are leading this revolution, with countries such as Spain, Germany and Ecuador positioning themselves as leaders in industrial processing technology.

The European market accounts for 45% of global chocolate consumption, while Latin America accounts for 60% of cocoa bean production. This dynamic has created a perfect ecosystem for innovation in processing machinery, where companies such as TecAIRE have developed specific solutions for each link in the chain.

In Spain, the chocolate sector generates more than 2.8 billion euros per year, with a growing demand for equipment to guarantee:

• Full traceability from grain to final product
• Energy efficiency over 85%.
• Operational flexibility for different origins of cocoa
• HACCP and FDA compliance

Vertical integration has become the dominant strategy. The main reasons include:

1. Full control of the flavour profile: Allows for the development of unique aromatic signatures
2. Cost reduction: Up to 30% savings compared to buying pre-processed cocoa.
3. Market flexibility: Ability to adapt quickly to consumer trends
4. Competitive differentiation: Premium products with authentic stories

Roasting is the decisive moment when cocoa is transformed from a simple bean into the precursor of the chocolate we know. It is not just a thermal process, it is controlled alchemy.

During roasting, more than 600 simultaneous chemical reactions occur:

Maillard reactions: These develop between 140°C and 165°C, creating the characteristic aroma compounds. A modern industrial cocoa roaster can control these reactions with an accuracy of ±1°C.

Caramelisation: At 160°C and above, the natural sugars are transformed, bringing sweet and complex notes.

Pyrolysis: Controlled process that eliminates astringency and develops the body of the chocolate.

Evaporation of volatile acids: Reduces excessive acidity and balances the sensory profile.

The best industrial cocoa roaster must control these parameters with millimetre precision:

Temperature: Specific ranges depending on the type of cocoa:

• Trinitario cocoa: 120–135°C for 20–25 minutes
• Forastero cocoa: 135–150°C for 15–20 minutes
• Criollo cocoa: 115-130°C for 25-30 minutes

Time: The roasting curve must be progressive and controlled, avoiding thermal shocks that compromise quality.

Residual moisture: Target 2-3% for optimal preservation and further processing.

The choice of the type of cocoa roaster determines the quality, efficiency and profitability of the whole process.

Cocoa roasters for beans process the whole bean in the shell, which is the traditional and most widespread method in the industry.

✅ Advantages:

• Total process control: from the green grain to the final product.
• Flexibility of origin: Adaptation to different varieties and qualities
• Increased aromatic development: Whole grain allows for gradual and complex development.
• Traditional process: Method validated by decades of industry experience
• Industrial capacities: JCP BEANS Range 60-500 kg per cycle

❌ Limitations:

• Longer processing time: 15-30 minutes per cycle
• Higher energy consumption: Need to heat the shell
• Requires subsequent shelling: Additional process required

Technical specifications JCP BEANS Series:

• Capacity: 60-500 kg cocoa beans per cycle
• Working temperature: 120-160°C
• System: Perforated drum with controlled convection
• Material: Food grade stainless
• Control: PLC with automatic profiles

Cocoa roasters for nibs process only the edible part of the bean, previously shelled, optimising efficiency and quality.

✅ Advantages:

• Superior energy efficiency: Only the useful part of the grain is heated.
• More homogeneous roasting: Elimination of shell variability
• Short cycle times: 8-15 minutes per cycle
• Improved quality control: Processing of already selected product
• Higher capacities: JCP NIBS Range 1,000-3,000 kg per cycle

❌ Limitations:

• Pre-processing required: pre-shelling necessary
• Higher initial investment: More expensive full line
• Less flexibility: Depends on the quality of shelling

Technical Specifications JCP NIBS Series:

• Capacity: 1,000-3,000 kg cocoa nibs per cycle
• Working temperature: 110-150°C
• System: Specialised drum with optimised air flow
• Efficiency: 25% less energy consumption vs. beans
• Productivity: Up to 3 tonnes/hour

For whole grains (60-500 kg/cycle):

• Recommendation: TecAIRE JCP Series drum toasters
• Application: Processors seeking full profile control

For cocoa nibs (1,000-3,000 kg/cycle):

• Recommendation: Controlled convection systems
• Application: High-volume production with premium standards

For mixed processing:

• Recommendation: Modular lines with automatic exchangers.
• Application: Flexible plants processing multiple products

The nominal capacity may differ significantly of the actual operating capacity:

Reduction factors:

• Grain variability: -15% with irregular grains
• Scheduled maintenance: -10% uptime
• Format changes: -20% during transitions

TecAIRE recommendation: Dimension with a 30% margin over current needs for future growth.

A modern mass-market cocoa roaster must be adapted to:

Main origins:

• Ecuador National: Light roasting, 120-130°C
• Ghana: High profile, 135-145°C
• Madagascar: Progressive roasting, complex curves
• Venezuela Criollo: Sensitive process, maximum control

Necessary technical characteristics:

• Temperature range: 100-180°C with ±1°C accuracy
• Variable time: Cycles of 10-40 minutes
• Partial load: Efficient operation from 30% capacity

Consistency is key for premium brands:

Critical parameters to be monitored:

• Drum temperature: Temperature sensor inside the bass drum
• Air temperature: Multiple measuring points
• Rotation speed: Variable control 1-20 rpm
• Air pressure: Automatic regulation
• Output humidity: Continuous control

TecAIRE control system:

• Unlimited storable profiles
• Automatic load-dependent self-adjustment
• Repeatability: ±2% in all parameters

Levels of automation:
Level 1 – Semi-automatic: Manual operation with parameter control.
Level 2 – Automatic: Automatic process with supervision
Level 3 – Fully integrated: Full line with SCADA

In a market where differentiation is increasingly complex, cocoa roasters become the differentiating element that allows brands to develop unique and recognisable profiles. Investment in roasting technology is not simply a purchase of machinery, it is a strategic commitment to the future.

Companies that have integrated advanced roasting systems report:

• Gross margin increase: 15-25% on average
• Reduced wastage: Up to 8% less waste
• Improved customer satisfaction: +35% in sensory evaluations
• Access to premium markets: Higher standards and certifications

Leading brands in the sector have realised that control of the roasting process allows them to:

1. Develop proprietary aromatic signatures that are impossible to replicate
2. Adapting quickly to market trends and regional preferences
3. Optimising costs through direct control of the value chain
4. Ensuring the consistency demanded by premium consumers
5. Complying with sustainability and traceability standards

At TecAIRE, we have been perfecting the art of cocoa roasting for over 45 years. Our experience with more than 400 installations in 30 countries allows us to say that each project is unique, but the fundamental principles remain the same: uncompromising quality, maximum energy efficiency and total control of the process.

The best industrial cocoa roaster is not necessarily the most expensive or the most technologically advanced. It is the one that adapts perfectly to the specific needs of each customer, that grows with their business and that guarantees consistent results year after year.

Are you ready to take the next step in your cocoa production process?

The decision to invest in your own roasting technology will make the difference between being just another processor in the market or becoming a trend-setting brand. At TecAIRE, we are here to accompany you in this transformation, because we know that behind every great chocolate, there is a great roaster.