Low-cost mechanized removal of cocoa bean pods
8.68 - Low-cost mechanized removal of cocoa bean pods
Valerie Monterroza Prieto, University of Guelph, Canada
Suggested citation for this chapter.
Prieto, V.M. (2026) Low-cost mechanized removal of cocoa bean pods. In Farmpedia, The Encyclopedia for Small Scale Farmers. Editor, M.N. Raizada, University of Guelph, Canada. farmpedia.org
Background
Cocoa bean is the essential ingredient used to make chocolate. Ghana, Nigeria, and Cote d'Ivoire produce the majority of the world's cocoa output (UNDP, 2025). Cocoa harvesting involves removing the pod from the bean, fermentation and drying. Traditionally, cocoa pods are cut from trees using machetes or pruning tools and then broken open manually using blunt objects or cutlasses (ICCO, 2021). Beans are typically extracted within 3-7 days after harvest and sun-dried by smallholder farmers following fermentation (see Figure 1) (Adewumi & Fatusin, 2006). These methods are effective but labour intensive (Tennhardt et al., 2024). The drudgery required is often monotonous and repetitive, causing both mental and physical strain. It can also pose safety, efficiency and quality challenges, but an alternative is low-cost machinery (Amauaku et al., 2024) which is the topic of this chapter.
Figure 1. Images of fermentation and drying of cocoa beans sample using a traditional leap heap and sun method. (Source: Ackah, E., & Dompey, E. 2021).
What is a low-cost cocoa pod removal machine and how does it work?
A cocoa pod removal machine is used to extract or remove the cocoa bean from pods using various methods such as impact (striking an object), rotation actions (objects revolve around a fixed point) and sharp incision (where a sharp edge cuts across an object) (Amauaku, et al., 2024). Most machines have a compartment where they insert the cocoa pods and a mechanism that opens the pod, often called a feeding mechanism (using impact hammers, rotating jaws with spiked teeth or beaters, and crushing plates) (Amauaku, et al., 2024). This compartment is sometimes bent at specific angles to help the flow of the cocoa pods into the opening piece until it is mostly inserted into a cylinder where the pods are stored/housed. Storage for the machine is either stationary (standing still) or rotating at different speeds. Some machines are developed with special separated compartments that are operated by electric motors and vibrators that are lined with sieves or mesh to help collect the bean (Adewumi & Fatusin, 2006). Major machine types include impact breakers that are hand operated, knife cutting systems, crushing (impact or compression), bombardment (continuous striking or impact of object), and rib-cone rotating drums (rotating cylinder placed sideways that tumbles materials inside to move them). Traditional pod breaking and many mechanized methods are highly labour intensive (Adewumi & Fatusin, 2006). Tools like the Box–Behnken design and neural networks can make machines work better and more efficiently (Srikanth et al., 2020).
Mechanism explanation by machine type
There are several designs of machines, each with a distinct mechanism
i. Manual hand operating machinery (see Figure 2)
This type of machinery is designed for farmers in rural areas without an electrical power source, making it both low-cost and accessible for those with minimal resources (Amauaku et al., 2024). Operating the machine requires two people, one to feed cocoa pods into the machine and one to collect the beans after opening (Adewumi & Fatusin, 2006). Once inserted, the pods are broken apart internally and the seeds are separated from the shell and collected in a tray below (Adewumi & Fatusin, 2006). Figure 1 shows an example of a machine operating using a simple rope and pulley system, requiring no electricity and minimal mechanical knowledge to operate.
Figure 2. Image of manual hand operated machine. Source: Adewumi, B. A., & Fatusin, A. B. 2006.
ii. Crushing machinery (see Figure 3)
There are two types of crushing machines. In the first machine's crushing method, the force acts on the pods from the side or from end to end. The forces are often impacted (when an object is struck), compressed (an object is squeezed or pressed down from more than one side), sheared (when a force causes an object to break by making its internal layers slide past one another), or dependent on the type of machine used. The two most common machines act by crushing the cocoa pods using impact (when an object is struck) or compression forces (when an object is squeezed or pressed down from more than one side) (Mabe & Sarpong, 2024). However, a disadvantage is that cocoa pods mix with the beans. The second machine cuts the cocoa pod husk by using shear force before manually separating the beans or by tumbling (Mabe & Sarpong, 2024). The pieces of the machine include a hopper (a funnel shaped container), a metering plate (a plate with specifically sized holes), a hammer and reciprocating sieve (a sieve that moves back and forth) (Adewumi & Fatusin, 2006). A hammer generates crushing impacts and breaks the cocoa pods while the vibrating screen separates the husk. Wet beans are collected through a discharge chute (a guide that is attached to the machine that separates and directs material to another location). Machines also have a problem crushing the husks into small portions that mix with wet beans and pose a problem during separation.
Figure 3. Image of crushing machine. Source: Amauaku et al. (2024) Link
iii. Knife cutting machinery
This style of machinery uses mechanized sharp-edged blades placed at specific angles to open cocoa pods from both sides (see Figure 4) (Amauaku, et al., 2024). The pods are placed between the blades of the knife, and a handle is pressed to split the pods into 2 pieces. The machine is made up of an included rectangle that is separated into five temporary compartments. The cocoa pods move using the force of gravity along the angled paths into corresponding compartments. A pair of knives cuts the placenta (the white spongy part in the middle). The separation of the two sides of the pods is performed by another pair of knives. After splitting the side into halves, the beans are separated from the empty cocoa pods at the bottom of the collector (a box that collects the beans) under the machine (Amauaku, et al., 2024).
Figure 4. Image of knife cutting machine. Source: Amauaku et al. (2024) Link
iv. Rotary drum machinery
This method uses a machine comprised of 2 rolling cylinders moving in an anticlockwise or reverse orientation (see Figure 5) (Srikanth et al., 2020). The rolling cylinders serve as the main opening mechanism. Due to the orientation, they can break open cocoa pods moving directly towards the cylinder (Srikanth, V., et al., 2020).
Figure 5. Image of rotating drum machine design. Source: Srikanth, V., et al. (2020).
Critical Analysis
Cost
The cost of machinery ranges in price on wholesale retailers like Alibaba.com depending on the machine and function. Please see the 'Helpful Hints and Links to Get Started' section. The machines listed do not directly connect to the types of machinery explained above however. The following explains the types of machines available to order online:
A sorting and separation machine can be bought starting at $4000 USD. A shell and bean separator machine is available for purchase ranging from $2860 to $3420 USD. A hydraulic cold press is sold starting at $1320 USD. A processing line starts at $4500 USD. A peeling and de-husking machine is available in pieces starting at $4500 USD. A peeling specific machine is available in sets starting at $4000 with customization.
Even at these base prices, the financial barrier is significant. Overall, these machines are both expensive and difficult to access for smallholder farmers, especially in rural areas lacking electrical power (Tennhardt et al., 2024; Zhou, n.d.). In West Africa, cooperatives such as the Farm Machinery Cooperative (FMC) in Benin, Nigeria, offer one potential pathway to shared ownership (FNCuma, n.d.). The FMC was modelled after the French system of the Coopérative d'utilisation de matérial agricole (CUMA) (FNCuma, n.d.). However, purchasing mechanized equipment remains very difficult even within a cooperative model. Farmers may lack access to credit, so they work together to save money within the group, but this can take several years. It is also difficult to find affordable and accessible machinery. As a result, most CUMAs depend on intermediaries like NGOs or government funds to acquire and transport equipment (Daum & Birner, 2020).
Taking all these factors into account, the manually operated machines (Figures 2-5) and locally fabricated machines remain the most practical options (FNCuma, n.d.).
Logistics and Transport
In addition to the costs of machinery, there are logistical issues involved with transporting this equipment to a smallholder or subsistence farm. There are several steps to access equipment by the farmer. The 'first mile' is the journey from the farm to a checkpoint to access transport into a city or port, often found at a fork of a drivable road (Muhia, 2016). Farms use their own transportation such as head loading (carrying items on the heads of a person), backloading (carrying items on a person's back), animal carts, bicycles or sometimes motorcycles (Muhia, 2016). The intermediate transport segment includes more affluent farmers and transporters who then transport to markets through main road networks (African Development Bank, 2015).
Table 1. Efficiency ranking based on machine mechanism (created by Valeria Monterroza Prieto)
Key Problems with Machine Designs and Cost
Farmers must take into consideration the cost and limited accessibility of advanced machines, along with power and infrastructure limitations (Adewumi & Fatusin, 2006). Complex machines often require expensive components restricting accessibility. Many designs are prototypes without rigorous optimization. Some machines are heavy and stationary, limiting mobility on farms. Electric powered machines are impractical for many farmers. The machinery is also sometimes inefficient and problematic (see Table 1 chart).
Machines may open pods well but still require manual cleaning. They also may collect both beans and husks, contaminating sieves or collection containers mixing contents requiring further time and energy separating contents after beans have been processed through machines (Adewumi & Fatusin, 2006). Poorly controlled cutting can cause shell fragments to mix with beans and increase bean breakage, potentially reducing quality. There is still typically a high labour input required with some designs, needing two operators (feeding the beans into the machines and collecting the beans) (Salcedo-Puerto et al., 2024; Mweemba & Kaut, 2024).
Environmental and sustainability considerations
There is potential to divert waste from cocoa bean production and to use it as potential biofuel (Salcedo-Puerto et al., 2024). Cocoa pod husks (CPH), a major by-product of pod breaking, can be converted into bio-oil, biochar, hydro char and syngas (Salcedo-Puerto et al., 2024). CPH also contains valuable compounds such as dietary fiber, antioxidants and complex carbohydrates which can be used for food, pharmaceutical, and cosmetic applications (Salcedo-Puerto et al., 2024).
Cooperatives when functional can help with sustainability. Cooperatives offer an entry point for corporations to target their sustainability programs within cooperatives in order to reach a larger range of farmers. In practice, cooperatives give farmers collective access to training, subsidized inputs, and certification support that individual smallholders cannot access alone (Wadham, 2025).
For example, a co-op could partner with a chocolate company's sustainability arm to receive agroforestry training or fair-trade certification as a group, reducing the cost and administrative burden on any single farmer (Foundjem-Tita et al., 2017). Unfortunately, very few cooperatives can function properly due to factors such as a lack of funds, knowledge, poor infrastructure, and mistrust of institutions (Schulte et al., 2020). In order for farmers to implement sustainable practices requires knowledge of modern farming techniques. Access to education can improve a farmer's capacity to adapt to the effect of climate change (Schulte et al., 2020).
Helpful links to get started
References
Ackah, E., & Dompey, E. (2021). Effects of fermentation and drying durations on the quality of cocoa (Theobroma cacao L.) beans during the rainy season in the Juaboso District of the Western-North Region, Ghana. Bulletin of the National Research Centre, 45(1), 175. Link
Adewumi, B. A., & Fatusin, A. B. (2006). Design, fabrication and testing of an impact-type hand operated cocoa pod breaker. Agricultural Engineering International: The CIGR Ejournal, VIII. Link
Amauaku, R., Amoah Asante, E., Bobobee, E. H. Y., & Kwasi Amano, G. (2024). Mechanised removal of cocoa beans from the pod and strategies to optimize the technique: A review. American Journal of Agriculture and Forestry, 12(3), 185–194. Link
Anoraga, S. B., Shamsudin, R., Hamzah, M. H., Sharif, S., & Saputro, A. D. (2024). Cocoa by-products: A comprehensive review on potential uses, waste management, and emerging green technologies for cocoa pod husk utilization. Heliyon, 10(16), e35537. Link
Foundjem-Tita, D., Degrande, A., Donovan, J., Stoian, D., & Kouamé, C. (2017). Baseline for assessing the impact of fairtrade certification on cocoa farmers and cooperatives in Côte d'Ivoire. World Agroforestry Centre. Link
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Srikanth, V., Rajesh, G. K., Kothakota, A., Pandiselvam, R., Sagarika, N., Manikantan, M. R., & Sudheer, K. P. (2020). Modelling and optimization of developed cocoa beans extractor parameters using box Behnken design and artificial neural network. Computers and Electronics in Agriculture, 177, 105715. Link
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Wadham, R. (2025, December). Co-operatives build a better world for cocoa farmers: How co-operatives drive change for cocoa farmers in West Africa: Evidence from 2024–25. Fairtrade. Link
Zhou, Y. (n.d.). Agricultural mechanization in West Africa. WATHI. Link