Influence of materials damaged by cocoa tree diseases (witches' broom and black pod disease) and rotten during processing on the quality of cocoa liquor and butter

Cocoa is susceptible to several pests, including black pod rot and witches’ broom. These diseases are responsible for losses of approximately 30% of global production. The aim of this study was to evaluate the effect of combining diseased and healthy cocoa on the quality of unfermented, fermented, and dried seeds, cocoa liquor, and cocoa butter. Different combinations of healthy, diseased, and rotten fruits were subjected to processing. The results demonstrate that the material obtained from diseased and rotten fruits exhibited significant reductions (p ≤ 0.05) in sugars, organic acids, and total phenolics, indicating early metabolic degradation driven by diseases or pest infestations that damage the fruit. Although changes were observed in the fatty acid profiles of cocoa butter from damaged fruits, the solid fat content remained similar to that of cocoa butter extracted from healthy fruits. However, the results of cooling and isothermal crystallization experiments demonstrated that the presence of damaged seeds affected crystallization kinetics, likely influencing crystal growth rate, molecular mobility, and/or nucleation density. The findings suggest that a partial incorporation of damaged fruits compromises the flavour compounds of cocoa liquor and may influence the crystallization properties of cocoa butter. To ensure the applicability of this material, toxicological evaluations must be carried out. • The cocoa tree's defense system against fungal damage can alter the chemical composition of infected fruit and affect the products obtained. • Even partial inclusion of diseased or rotten fruits affects aroma quality, increasing off-flavor compounds in cocoa beans and liquor. • Cocoa butter crystallization properties are affected by the damaged cocoa seeds.