Process intensification technologies for the recovery of valuable compounds from cocoa by-products

Multiscale Process Intensification of Waste Valorization Reactions

ConspectusThe central theme of this Account is the development of intensified and sustainable chemical processes for the sequestration of CO2 in synergism with the utilization of wastes of industrial, urban, and agricultural origins. A challenge when working with solid waste-fluid reactions is that mass transfer limitations across solid-liquid, solid-gas, and gas-liquid interfaces and unfavorable thermodynamics lead to slow reaction rates, incomplete reaction conversions, high energy expenditure and processing costs, and inadequate product properties. The traditional macroscale approaches to overcoming slurry reaction limitations can be effective; however, they come at a cost to the environment. In the treatment or valorization of low-grade and waste resources, such conventional approaches are often unfeasible on an industrial scale. Sustainable solutions are thus needed.In the last six years, we have been exploring and developing approaches to overcoming reaction rate limitations of slurry reactions of environmental relevance by concurrently applying process intensification strategies and multiscale engineering approaches. The scientific approach has relied on laboratory-scale experiments to test and refine the devised multiscale process intensification strategies, with thermodynamic and computational modeling work supporting the experimental work and with advanced characterization techniques being used to elucidate reaction and transport mechanisms and aid the development of nanoscale reaction models and micro- and macroscale process models. The research streams, associated with the four key references, discussed next are (a) brine carbonation; (b) mineral carbonation and enhanced weathering; (c) process intensification and integration; and (d) characterization techniques.Within the four research streams, a number of mineral carbonation processes have been investigated and can be classified as (i) ambient weathering and carbonation; (ii) gas-(wet) solid accelerated carbonation; (iii) aqueous accelerated carbonation; (iv) supercritical accelerated carbonation; and (v) CO2 mineralization from brine. In some cases, the research was aimed at producing valuable products with reduced environmental risk or a reduced carbon footprint, such as an organomineral fertilizer and zeolites. In other cases, the aim was to assess the reactivity of minerals to match the right feedstock with the right carbonation process, in view of maximizing net carbon sequestration. There were also cases where the carbonation process was reimagined by the use of innovative reaction conditions, reactors, and reagents. The experience with accelerated weathering and carbonation in engineered processes has been translated into the field of enhanced rock weathering (ERW) in agriculture, where the multidisciplinary approach used has served to advance ERW science and technology in ways that have had a resounding effect on recent commercial deployment.The completed research serves to encourage the adoption of process intensification technologies in place of conventional processes, in industry and among the research community, and to catalyze the development of the types of sustainable processes required by the chemical, metallurgical, and minerals industries (which are critical to the green transition) to reduce their environmental impact and carbon emissions. Moreover, the multiscale process intensification approaches developed may also be extended to other industrial, urban, and agricultural processes where the reduction of energy intensity, carbon intensity, and environmental footprint could be achieved.

Optimizing vacuum drying process of polyphenols, flavanols and DPPH radical scavenging assay in pod husk and bean shell cocoa

The objective of this study was to optimize different vacuum drying conditions for cocoa pod husk and cocoa bean shell in order to enhance these by-products for commercial applications. To carry out the optimization, the response surface methodology was applied using a Box-Behnken experimental design with 15 experiments for which different conditions of temperature (X1), drying time (X2) and vacuum pressure (X3) were established. The response variables were the content of total polyphenols, the content of flavanols and the radical scavenging activity evaluated in the extracts of the different experiments. Temperature (50-70 °C), drying time (3-12 h) and vacuum pressure (50-150 mbar) were considered as independent variables. The main factors affecting the response variables were temperature, followed by vacuum pressure. For the content of polyphenols, the optimal response values predicted for the cocoa pod husk was 11.17 mg GAE/g with a confidence limit (95%) of 9.05 to 13.28 mg GAE/g (optimal conditions: 65 °C, 8 h and 75 mbar), while for the cocoa bean shell cocoa was 29.61 mg GAE/g with a confidence limit (95%) of 26.95 to 32.26 mg GAE/g (optimal conditions: 50 °C, 5 h and 100 mbar). Therefore, results of this study suggest a high content of phenolic compounds obtained from these by-products that show relevance as functional ingredients for application in the food, nutraceutical, and cosmeceutical industries.

Profile of Bioactive Components of Cocoa (Theobroma cacao L.) By-Products from Ecuador and Evaluation of Their Antioxidant Activity

The aim of the study was to determine the profile of bioactive compounds in cocoa residues (mucilage and bean shells), and to evaluate their antioxidant activity in two cocoa varieties, Nacional X Trinitario type (Fine Aroma) and the variety CCN-51. The extraction of phytonutrients from the residues was carried out selectively. The characterization and quantification of the total polyphenol content (TPC), and the total flavonoid content (TFC) were determined by UV-VIS spectrophotometry. High-performance liquid chromatography (HPLC) was used to determine the phenolic profile and methylxanthines. The antioxidant activity was evaluated by the methods of 2-azinobis (3-ethyl-benzothiazoline-6-sulfonic acid) cation bleaching (ABTS), ferric-reducing antioxidant power (FRAP) and oxygen radical absorbance capacity (ORAC). The exudate mucilage samples from Nacional X Trinitario-type cocoa presented the highest content of TPC 105.08 mg gallic acid equivalents (GAE)/100 mL, TFC 36.80 mg catechin equivalents (CE)/100 mL, catechin (CAT) 35.44 mg/g, procyanidins (PCB2: 35.10; PCB1: 25.68; PCC1: 16.83 mg/L), epicatechin (EPI) 13.71 mg/L, caffeine (CAF) 0.90% and theobromine (TBR) 2.65%. In the cocoa bean shell, the variety CCN-51 presented a higher content of TPC (42.17 mg GAE/100 g) and TFC (20.57 mg CE/100 g). However, CAT (16.16 mg/g), CAF (0.35%) and TBR (1.28%) were higher in the Nacional X Trinitario cocoa type. The EPI presented no significant differences between the two samples studied (0.83 and 0.84 mg/g). The antioxidant activity values (ABTS, FRAP and ORAC methods) were higher in the samples of CCN-51 than in the Nacional X Trinitario type. The bean shell samples presented antioxidant values of 171.32, 192.22 and 56.87 mg Trolox equivalents (TE)/g, respectively, and the bean shell samples presented antioxidant values of 167.06, 160.06 and 52.53 mg TE/g, respectively. The antioxidant activity (ABTS, FRAP and ORAC) of the residues was correlated with the bioactive compounds of the mucilage and bean shells, showing a strong positive correlation (<0.99) with the procyanidins (B1, B2 and C1), EPI and CAT and a positive/moderate correlation (0.94) with methylxanthines.

Cocoa Bean Shell: A By-Product with High Potential for Nutritional and Biotechnological Applications

Cocoa bean shell (CBS) is one of the main solid wastes derived from the chocolate industry. This residual biomass could be an interesting source of nutrients and bioactive compounds due to its high content in dietary fibres, polyphenols and methylxanthines. Specifically, CBS can be employed as a raw material for the recovery of, for example, antioxidants, antivirals and/or antimicrobials. Additionally, it can be used as a substrate to obtain biofuels (bioethanol or biomethane), as an additive in food processing, as an adsorbent and, even, as a corrosion-inhibiting agent. Together with the research on obtaining and characterising different compounds of interest from CBS, some works have focused on the employment of novel sustainable extraction methods and others on the possible use of the whole CBS or some derived products. This review provides insight into the different alternatives of CBS valorisation, including the most recent innovations, trends and challenges for the biotechnological application of this interesting and underused by-product.

Plant Extraction in Water: Towards Highly Efficient Industrial Applications

Since the beginning of this century, the world has experienced a growing need for enabling techniques and more environmentally friendly protocols that can facilitate more rational industrial production. Scientists are faced with the major challenges of global warming and safeguarding water and food quality. Organic solvents are still widely used and seem to be hard to replace, despite their enormous environmental and toxicological impact. The development of water-based strategies for the extraction of primary and secondary metabolites from plants on a laboratory scale is well documented, with several intensified processes being able to maximize the extraction power of water. Technologies, such as ultrasound, hydrodynamic cavitation, microwaves and pressurized reactors that achieve subcritical water conditions can dramatically increase extraction rates and yields. In addition, significant synergistic effects have been observed when using combined techniques. Due to the limited penetration depth of microwaves and ultrasonic waves, scaling up entails changes to reactor design. Nevertheless, the rich academic literature from laboratory-scale investigations may contribute to the engineering work involved in maximizing mass/energy transfer. In this article, we provide an overview of current and innovative techniques for solid-liquid extraction in water for industrial applications, where continuous and semi-continuous processes can meet the high demands for productivity, profitability and quality.

Effect of drying method on the production of in vitro short-chain fatty acids and histone deacetylase mediation of cocoa pod husk

We evaluated the effect of cocoa pod husk (CPH) processing (microwave [MW], forced-air drying [FAD], and FAD plus extrusion [FAD-E]), and in vitro gastrointestinal digestion on the in vitro human colonic fermentation metabolism, in vitro bioactivity on human HT-29 colon cancer cell, and the in silico mechanism of selected compounds. CPH as a substrate for human colonic microbiota significantly decrease local pH (MW -0.7, FAD -0.2, and FAD-E -0.3, 24 h) and modifies their metabolic activity (short-chain fatty acids [SCFAs] production). FAD-E generated the highest butyric (7.6 mM/L, 4 h) and FAD the highest acetic and propionic acid levels (71.4 and 36.7 mM/L, 24 h). The in vitro colonic fermented FAD-E sample (FE/FAD-E) caused HT-29 colorectal cancer cells death by inducing damage on membrane integrity and inhibiting (up to 92%) histone-deacetylase (HDAC) activity. In silico results showed that chlorogenic acid, (-)-epicatechin, and (+)-catechin, followed by butyric and propionic acids, are highly involved in the HDAC6 inhibitory activity. The results highlight the potential human health postbiotic benefits of CPH consumption, mediated by colonic microbiota-derived metabolites. PRACTICAL APPLICATION: The enormous amount of CPH (10 tons/1 ton of dry beans) generated by the cocoa industry can be used as a removable source of bioactive compounds with physicochemical functionality and health bioactivity. However, their potential applications and health benefits are insufficiently explored. CPH represents a serious disposal problem; practical and innovative ideas to use this highly available and affordable material are urgent. Research exploring their potential applications can increase the sustainability of the cocoa agro-industry. This paper highlights the value addition that can be achieved with this valuable industrial co-product, generating new functional products and ingredients.

An Innovative, Green Cascade Protocol for Grape Stalk Valorization with Process Intensification Technologies

Valorization of agri-food residues to produce bio-based platform chemicals will enhance the transition to the bio-economy era. To this end, a sustainable process has been developed for the overall valorization of grape stalks (GS) according to a circular approach, starting from the lignin fraction to further deal with the cellulose-rich residue. This non-conventional protocol fully adheres to green chemistry principles, exploiting the so-called enabling technologies—mainly ultrasound and microwaves—for energy-saving innovative processes. Firstly, ultrasound-assisted extraction (UAE, 40 kHz, 200 W) demonstrated to be an excellent technique for GS delignification combined with natural deep eutectic solvents (NaDESs). Delignification enables isolation of the pertinent lignin framework and the potential to obtain a polyphenol-rich liquid fraction, focusing on the valorization of GS as source of bioactive compounds (BACs). Among the NaDESs employed, the combination of choline chloride (ChCl) and levulinic acid (LevA) (ChLevA) presented noteworthy results, enabling a delignification higher than 70%. LevA is one of the top-value biobased platform chemicals. In this work, a flash microwave (MW)-assisted process was subsequently applied to the cellulose-rich fraction remained after delignification, yielding 85% LevA. The regeneration of this starting compound to produce ChLevA can lead to a further biomass delignification cycle, thus developing a new cascade protocol for a full valorization of GS.

UHPLC-MS Characterization, and Antioxidant and Nutritional Analysis of Cocoa Waste Flours from the Peruvian Amazon

Cocoa (Theobroma cacao) is a food product used worldwide and a key raw material for chocolate manufacturing. Cocoa possesses bioactive compounds such as methylxanthines, flavonoids, procyanidins, and related molecules with medicinal or health-promoting properties. Cocoa shell and pod husk have been proposed as a by-product with several interesting bioactivities, and the gummy residue or glue (a sticky, gluey by-product known as “mucilage” in Spanish) is used to produce liquors and is eaten as a food in Perú. However, little is known about the chemical composition and bioactivity of flours made from Peruvian cocoa ecotype wastes such as those from the vein and pod husk of the fruits. This study aimed to characterize the in vitro antioxidant properties and nutritional values of flours made from the waste from a special ecotype of cocoa (CCN-51). The chemical fingerprinting was performed using UHPLC–HESI orbitrap mass spectrometry and allowed the detection of 51 compounds. GC-FID was used for the determination of individual fatty acid contents, and the antioxidant activity was assessed by several assays (DPPH, FRAP, and ABTS). The flours obtained were composed of a good amount of dietary fiber, carbohydrates, and minerals, as well as several bioactive polyphenolic compounds, fatty acids, and amino acids with nutraceutical properties, making the flours a rich and promising food as well as a good source for the preparation of functional foods or nutraceuticals.

Bioactive Compounds from Cocoa Husk: Extraction, Analysis and Applications in Food Production Chain

Cocoa husk is considered a waste product after cocoa processing and creates environmental issues. These waste products are rich in polyphenols, methylxanthine, dietary fibers, and phytosterols, which can be extracted and utilized in various food and health products. Cocoa beans represent only 32–34% of fruit weight. Various extraction methods were implemented for the preparation of extracts and/or the recovery of bioactive compounds. Besides conventional extraction methods, various studies have been conducted using advanced extraction methods, including microwave-assisted extraction (MAE), ultrasonic-assisted extraction (UAE), subcritical water extraction (SWE), supercritical fluid extraction (SFE), and pressurized liquid extraction (PLE). To include cocoa husk waste products or extracts in different food products, various functional foods such as bakery products, jam, chocolate, beverage, and sausage were prepared. This review mainly focused on the composition and functional characteristics of cocoa husk waste products and their utilization in different food products. Moreover, recommendations were made for the complete utilization of these waste products and their involvement in the circular economy.

Cocoa extract with high content of flavan 3-ols, procyanidins and methylxanthines

The health benefits of cocoa depend on the flavan 3-ols, procyanidins, and methylxanthines, which decrease from the early stages of cocoa bean processing. The objective of this research was to obtain a cocoa extract high in these compounds with (-)-epicatechin as the primary reference. An evaluation of two pretreatments of cocoa beans with a control after harvesting was made: A (untreated/control), B (Frozen), and C (Polyphenol oxidase inhibition), all followed by dehydration at 45 °C until obtaining a cocoa powder. In terms of (-)-epicatechin content, the best pretreatment was put on to a hydroalcoholic extraction. Flavan 3-ols, procyanidins, methylxanthines, and total polyphenols content (TPC), were quantified in the cocoa powders and the hydroalcoholic extract. The results showed that the control (A), significantly conserves the (-)-epicatechin (24.964 ± 0.400 mg/g) ca. 7 times more than conventionally sun-dried and fermented beans (3.742 ± 1.977 mg/g) ca. The hydroalcoholic extraction increased the (-)-epicatechin ca. 3 times more based on pretreatment A (84.738 mg/g).

Pulsed Electric Field-Assisted Extraction of Aroma and Bioactive Compounds From Aromatic Plants and Food By-Products

In this work, the effect of pulsed electric field (PEF) pre-treatment on the extractability in green solvents (i. e., ethanol–water mixture and propylene glycol) of target aroma and bioactive compounds, such as vanillin from vanilla pods, theobromine and caffeine from cocoa bean shells, linalool from vermouth mixture, and limonene from orange peels, was investigated. The effectiveness of PEF as a cell disintegration technique in a wide range of field strength (1–5 kV/cm) and energy input (1–40 kJ/kg) was confirmed using impedance measurements, and results were used to define the optimal PEF conditions for the pre-treatment of each plant tissue before the subsequent solid–liquid extraction process. The extracted compounds from untreated and PEF-treated samples were analyzed via GC-MS and HPLC-PDA analysis. Results revealed that the maximum cell disintegration index was detected for cocoa bean shells and vanilla pods (Z_p = 0.82), followed by vermouth mixture (Z_p = 0.77), and orange peels (Z_p = 0.55). As a result, PEF pre-treatment significantly enhanced the extraction yield of the target compounds in both solvents, but especially in ethanolic extracts of vanillin (+14%), theobromine (+25%), caffeine (+34%), linalool (+114%), and limonene (+33%), as compared with untreated samples. Moreover, GC-MS and HPLC-PDA analyses revealed no evidence of degradation of individual compounds due to PEF application. The results obtained in this work suggest that the application of PEF treatment before solid–liquid extraction with green solvents could represent a sustainable approach for the recovery of clean labels and natural compounds from aromatic plants and food by-products.

Added-value biomolecules' production from cocoa pod husks: A review

Cocoa beans are produced through on-farm processing where residual biomass is discarded, including cocoa pod husks (CPH), cocoa bean shells and cocoa sweatings. CPH represents about 80% of these residues that are generated during the initial cocoa bean processing steps and their disposal occupies large areas, causing social and environmental concerns. In the last decades, the lignocellulosic composition of CPH has attracted the attention of the scientific and productive sector. Recently, some studies have reported the use of CPH in the production of medium to high value-added molecules, with potential applications in food and feed, agriculture, bioenergy, and other segments. This review presents biotechnological approaches and processes for the exploitation of CPH, including pre-treatment methods for the production of different biomolecules. Great perspectives and innovations were found concerning CPH exploitation and valorisation, but still more efforts are needed to valorise this potential feedstock and give support to producers in-development countries.