Chocolate production is a complex process during which numerous chemical reactions occur. The most important processes, involving most of the reactions important for development of the proper chocolate flavor, are fermentation, drying and roasting of cocoa bean, and chocolate conching. During fermentation, formation of important precursors occurs, which are essential for further chemical reactions in the following processes of chocolate production. Roasting is one of the most important processes due to the occurrence of Maillard’s reactions, during which aroma compounds are formed. In this paper, we have reviewed the most important chemical reactions that occur with proteins, carbohydrates, lipids, and polyphenols. Additionally, we present other components that may be naturally present or form during the production process, such as methylxanthines, aldehydes, esters, ketones, pyrazines, acids, and alcohols.

The cocoa and chocolate industries have huge problems with the utilization of waste generated during the production process. Waste material generated during production include cocoa pod husk, pulp, and cocoa bean shell. Cocoa shell is a by-product that has great potential because of its composition. It consists of dietary fibers, proteins, polyphenols, methylxanthines, etc. However, despite its favorable composition, cocoa shell often cannot be used directly in food production because it may contain components that are harmful for human health. Cocoa shell can carry mycotoxins, different microorganisms, polycyclic aromatic hydrocarbons, and heavy metals. High voltage electrical discharge presents a novel non-thermal method that has great potential for the decontamination of waste materials and can also be used for extraction of valuable compounds from cocoa shell.

Chocolate is considered as both caloric and functional food. Its nutritional properties may be improved by addition of fiber; however, this may reduce polyphenols content. The aim of this research was to determine the influence of cocoa shell addition (as a source of fiber) and its combination with different ingredients (cocoa butter equivalents (CBE), emulsifiers, dairy ingredients) on polyphenols of dark and milk chocolates. Total polyphenol (TPC) and total flavonoid (TFC) contents were determined spectrophotometrically, identification and quantification of individual compounds by high pressure liquid chromatography and antioxidant capacity by ferric reducing antioxidant power (FRAP) assay. Results showed that even though addition of cocoa shell to chocolate results in reduced contents of TPC, TFC, and individual compounds, it is not significant compared to ones reported by other authors for commercial chocolates. Other ingredients influence determined values for all investigated parameters; however, additional research is needed to reveal exact mechanisms and implications.

Cocoa shell is a by-product of the chocolate industry that is rich in dietary fiber and bioactive components. In this research, the influence of high voltage electric discharge (HVED) treatment on chemical and physical characteristics of the cocoa shell, i.e., the effects of applied time and frequencies on grinding ability, water binding capacity (WBC), dietary fibers and tannin content was investigated. HVED had a significant influence on the chemical and physical properties of cocoa shell, all of which could be linked to changes in fiber properties. Along with the fiber content, grinding ability and water binding capacity were increased. These properties have already been linked to fiber content and soluble/insoluble fiber ratio. However, this research implies that change in fiber properties could be linked to tannin formation via complexation of other polyphenolic components. Additional research is needed to verify this effect and to establish mechanisms of tannin formation induced by HVED and its influence on fiber quantification.