2026.11.13 Views:19
In New Caledonia, chocolate manufacturer Les Cacaos du Pacifique (LCCP) set out to extend its operations upstream by producing cocoa powder and cocoa butter in-hous.
With more than four decades of chocolate-making experience, LCCP had a clear understanding of the flavour and quality required from its finished products. Processing directly from cocoa beans, however, meant mastering an entirely new set of technologies and production parameters
The project therefore needed to answer three critical questions: How should the processing parameters be defined? How could the desired cocoa flavour and product quality be achieved consistently? And how could the new production line be brought into operation smoothly?
GELGOOG began with process trials and sample evaluation, using the validated results to guide equipment selection and complete line design. Through on-site installation, commissioning, production trials and operator support, GELGOOG helped LCCP establish an integrated, in-house cocoa processing capability.
“For many years, we had been looking for a stable, reliable and efficient solution to strengthen our production capabilities, and GELGOOG provided exactly what we needed.
The GELGOOG technical team demonstrated a high level of professionalism throughout the installation and commissioning process. The equipment is fully functional and meets all our original technical requirements. Both the output and quality of the cocoa powder and cocoa butter fully satisfy our production needs.
We can confidently say that choosing GELGOOG was the right decision.”
— Mr. Yann HOFFMANN, Project Director, LCCP
Founded in 1979 under the name Biscochoc, the company has been producing chocolate bars, chocolate spreads and other chocolate products for more than 40 years. On 1 October 2025, it officially changed its name to Les Cacaos du Pacifique.
Its extensive chocolate-making experience has given LCCP a well-defined understanding of product flavour and quality. The company’s next objective was to extend this expertise upstream and gain greater control over cocoa ingredients by processing directly from cocoa beans.
Entering a new processing field required the LCCP team to understand how cocoa beans change at each production stage and how these changes influence the final products.
Based on LCCP’s quality expectations, GELGOOG conducted process trials and comparative sample evaluations. Through repeated testing, sample assessment and parameter adjustment, the two teams progressively clarified the production requirements.
This process-first approach ensured that equipment selection and line design were based on verified product results, giving LCCP greater confidence before investing in the complete processing system.
For an experienced chocolate manufacturer such as LCCP, bringing cocoa processing in-house created an opportunity to control flavour from a much earlier stage.
Roasting is one of the most important steps in developing the aroma and flavour of cocoa. A key focus of the project was therefore to reproduce the roasting conditions established during process trials in daily industrial production.
GELGOOG’s independently developed cocoa roaster played a central role in meeting this requirement. Precise temperature control and adjustable roasting parameters allow the process conditions identified during testing to be consistently applied during production.
After roasting, the cocoa beans are cooled promptly to control the post-roasting condition and preserve the required flavour characteristics for subsequent processing.
With this system, the LCCP team can manage changes in cocoa flavour more effectively and translate its product expectations from laboratory samples into repeatable industrial production.
GELGOOG supplied an integrated processing solution covering cocoa bean pre-treatment, cocoa liquor production, pressing and separation, and the downstream processing of cocoa powder and cocoa butter.
During pre-treatment, cocoa beans are cleaned, roasted and cooled before the shells are removed through cracking and winnowing. The resulting cocoa nibs are ground into cocoa liquor, which can be used directly as an ingredient in chocolate production or transferred to the pressing section for further separation.
After pressing, the cocoa cake is crushed and milled into cocoa powder. The separated cocoa butter proceeds to downstream treatment and refining.
Through unified process planning and properly matched equipment capacities, each stage operates in coordination with the next. This enables the production line to maintain a consistent processing rhythm from raw cocoa bean intake through to finished cocoa powder and cocoa butter.
Building on the completed line, GELGOOG is also conducting process research and trials for cocoa powders with different fat contents and for alkalised cocoa powder. This provides technical support for LCCP’s future product diversification and potential equipment expansion.
Producing cocoa powder and cocoa butter from cocoa beans involves multiple closely connected processing stages. For the LCCP team, clear visibility into equipment status and critical process parameters is essential for managing daily production efficiently.
GELGOOG integrated automated control and production data management into the complete line. Centralised monitoring provides operators with a clear overview of equipment status, while the collection of key process data supports more consistent production management.
The system helps to:
Reduce manual intervention;
Improve coordination between processing stages;
Monitor critical production parameters;
Record production data for review;
Support process optimisation;
Facilitate troubleshooting and maintenance;
Improve operational efficiency and production consistency.
As LCCP continues to build its cocoa-processing expertise, reliable production data gives the team a stronger basis for decision-making, process adjustment and day-to-day factory management.
Delivering a production line involves more than installing individual machines. The equipment, process conditions and operator practices must work together as one complete system.
For LCCP, professional on-site support was essential to move successfully from equipment familiarisation to stable production.
GELGOOG provided an integrated project-delivery service covering on-site installation, complete line commissioning, operator training and production ramp-up trials. During actual production, the technical team verified equipment coordination, process parameters and finished-product performance while helping LCCP’s operators become familiar with the complete production process.
By conducting production trials and adjustments together with the customer’s team, GELGOOG ensured that the process conditions validated during the earlier testing stage were successfully transferred to the factory. The on-site support also helped LCCP develop the practical operating and troubleshooting experience required for long-term production.
The production line has now completed installation, commissioning and acceptance and has officially entered operation. According to the customer, both the output and quality of the cocoa powder and cocoa butter meet the project’s expectations.
With the new line in operation, LCCP has established an integrated in-house processing capability—from cocoa bean handling to the production of cocoa liquor, cocoa powder and cocoa butter.
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