Technical Feasibility, Quality and Environmental Impact of a Partial Replacement of Cocoa Nibs with Cocoa Bean Hulls in Chocolate Bars

This study examines the feasibility of incorporating cocoa bean hulls (CBH) into chocolate in order to improve the resource efficiency of the cocoa value chain. The substitution of cocoa nibs with pre-milled cocoa bean hulls without adjustment of fat content was investigated in dark chocolate. The reference R100.0 (dark chocolate, 0% CBH) was compared with V75.25 (25% of cocoa nibs replaced; 16.25% CBH total) and V50.50 (50% replacement; 32% CBH total). Increasing CBH significantly elevated viscosity and yield stress, and firmness rose correspondingly. Both effects align with the literature attributing such increases to higher solids loading and reduced fat content. Colour analysis (ΔE) showed distinct differences between R100.0 and V50.50. Environmental impact was reduced by 16% for V75.25 and 32% for V50.50. According to the EU Novel-Food-Status-Catalogue, CBH is not classified as novel food. While CBH is typically regarded as an underutilized by-product, this study demonstrates its potential as a functional, cost-reducing ingredient in dark chocolate formulations when applied at optimized inclusion levels.