Nestlé unveils cocoa production technique to boost yields amid global shortages 

SWITZERLAND – Nestlé has unveiled a patented technique designed to transform cocoa production, with the potential to increase cocoa fruit yields by up to 30%. 

The innovation comes at a critical time, as global cocoa shortages and record price surges continue to disrupt supply chains and impact the livelihoods of farmers. Nestlé’s method is aimed at enhancing both sustainability and economic returns by maximising the use of the entire cocoa fruit. 

Traditionally, only the cocoa beans extracted from pods are used in chocolate manufacturing, leaving pulp, placenta, and pod husks largely underutilised.  

Nestlé’s approach collects all parts of the fruit as a wet mass, which undergoes natural fermentation to unlock chocolate flavours. The mass is then roasted, ground, and dried into chocolate flakes, suitable for use in confectionery. 

Louise Barrett, head of Nestlé’s Research and Development Center for Confectionery in York, UK, emphasised the significance of this technique, particularly in the face of climate change challenges.  

“We are exploring solutions that could help cocoa farmers maximise the potential of their harvests,” Barrett said. “This groundbreaking technique utilises more of the fruit while enabling us to provide delicious chocolate to our consumers.” 

By improving extraction efficiency, the method also allows farmers to dedicate more time to essential agricultural practices, such as pruning, which further enhances yields. This dual impact could play a vital role in improving farmer livelihoods and strengthening the cocoa supply chain. 

The innovation arrives amid what experts describe as a severe cocoa crisis. Over the past 18 months, cocoa crops have been hit by disease and adverse weather, with global warming posing an additional long-term threat. Prices have soared as a result. 

On the London commodities exchange, a tonne of cocoa priced at around US$2,560 in January 2023 rose to US$4,430 a year later, before surging above US$10,494 by December 2024. 

In response, companies across the food sector have been developing alternatives to reduce dependence on traditional cocoa supplies. In October 2024, T. Hasegawa USA launched a Cocoa Powder Replacer, an alkalised low-fat flavour solution for food and beverage manufacturers.  

In May 2025, Ardent Mills introduced Cocoa Replace, a wheat-based ingredient that can substitute up to 25% of cocoa powder in baked goods. 

Cargill also recently announced a commercial partnership with Voyage Foods, a start-up specialising in cocoa-free chocolate, to meet demand for sustainable confectionery. 

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