Establishing our Cocoa Factory at KOSI

Hello KOSI community!

Today, I’m thrilled to share with you the remarkable journey behind the establishment of our very own cocoa factory. It has been quite the adventure, filled with challenges, learning opportunities ,and, yes—lots of cocoa products!

The journey began with a simple dream: to bring high-quality, sustainably sourced cocoa products to the market. Setting up the factory was no small task, and I must say, it required a marathon of patience, teamwork, and creativity. Our goal was to process high quality cocoa beans to give back to the rural Solomon Islands communities - to improve village livelihood.

The Process of Perfection

Let’s take a little trip through the factory to showcase our cocoa transformation process – from roasting to grinding, pressing, and powdering.

1. Roasting: The journey begins with carefully selecting and roasting our cocoa beans. Finding the ideal temperature and time for roasting was a challenge, as each bean has its own unique flavour profile that we wanted to preserve. I can’t tell you how many hours we spent sampling beans and adjusting our roasting schedules before we found the perfect balance.

2. Winnowing: Once the beans are roasted, it’s time to winnow – separating the husk from the nibs. This step proved intricate, as mastering the equipment required both finesse and understanding.The first few attempts were messy affairs! But with determination and some creative problem-solving, our team nailed it, allowing us to recover more nibs.

3. Grinding: After winnowing, we grind the nibs into a thick, luscious chocolate liquor. I vividly remember the first time we powered up the grind; the rich aroma filled the factory, and it was a moment of true triumph. However, refining our grinding techniques took consistent tweaks to make sure we achieved the optimal smoothness and consistency.

4. Pressing: Next came the pressing phase, where we separated the cocoa butter from the cocoa cake. This was a especially delicate process that really tested our machinery and teamwork. The trial and error here was steep, but we finally configured the equipment to manage the output efficiently and reduce waste.

5. Cocoa Powder: Finally, the cocoa cake is ground into cocoa powder – a versatile ingredient that has endless possibilities in the culinary world. I still remember our first successful batch; we were so proud to create something that not only tasted fantastic but was also environmentally conscious and sustainable!

Challenges and Learning Curves

It’s important to acknowledge that the path was fraught with challenges. Learning to operate each piece of equipment was an ongoing process demanding hands-on experience, troubleshooting, and endless questions. Our team faced equipment malfunctions, calibration issues, and the sometimes overwhelming task of perfecting each step of the process. But together, we overcame those hurdles with grit, adaptability, and an unwavering commitment to our mission.

The most rewarding part? We processed around 20 tonnes of cocoa in our first year! This achievement is a testament to the dedication and hard work of our team. Each ton represents not just numbers, but our commitment to quality, sustainability, and innovation in every product we create.

The Future Tastes Sweet

As I reflect on this journey, I’m proud of the progress we’ve made and excited for the future. We’re continuously experimenting with new recipes and methods, striving to improve and expand our offerings—because excellence never sleeps, and neither do we!

Thank you for being a part of KOSI’s journey! The next time you enjoy our cocoa products, know that there’s a passionate team behind each flavour. Together, we’ll continue to flavour the world, one delicious bite at a time.

Warmly,

Maureen Taro

Product Manager, KOSI

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