BACKGROUND AND RESEARCH

the cocoa pod

COCOA PODS

• Cocoa pods are the dried vessels that contain cocao beans.
• When opened, the pod contains a fruity, edible pulp.
• To continue the chocolate-making process, this pulp containing the cocao beans is removed, fermented, and dried.

COCOA PRODUCTION

• 4.82 million tons produced in 2019-2020
• Chocolate industry makes $103 billion annually
• Only 10% of the total cocoa fruit weight is used commercially, leaving the remaining 90% to be discarded as waste and left to decompose

PRODUCTION ISSUES

• Global waste estimated at 700 thousand tons per year
• Continuous deposition of waste has resulted in detrimental environmental issues including, but not limited to, silting, blockage of water drainage systems, flooding of rivers, water pollution, pests, and diseases.

SOCIAL ISSUES

• Ghanaian farmers don’t make much money from the sale of their crop due to the set farmgate price and high taxes.
• Besides cultivating the crop itself, there aren’t many other industries within Ghana that provide the farmers with ways to use the cocoa they produce.
• Oftentimes, middle men and large chocolate corporations make most of the money at the end of cocoa’s lifecycle.

Through material research, it was discovered that cocoa pod husk fibers can be turned into paper products, which would help combat this abundance of waste.

additional MATERIALS AND PROCESSES

While bar soap has many environmental benefits, consumers are often deterred from purchasing soap in this form because they find issues with its convenience. The two largest struggles consumers face are dropping the soap when in use and figuring out where to store the bar in the shower.₈

SOCIAL ISSUES

Companion planting is when certain plants are grown together in a symbiotic relationship, thereby improving each other’s health and yields.

benefits

Regulation of Shade

Increase of
natural supporters

Improved plant and soil health

Improved weed suppression

Companion planting is when certain plants are grown together in a symbiotic relationship, thereby improving each other’s health and yields.

SHADE-GROWN COCOA

Promotes biodiversity

Improves soil fertility

Builds resistance to weather

Provides ideal habitats

AFRICAN BLACK SOAP

African black soap is an all-natural product made from cocoa pod ash and is a widely beneficial alternative to traditional store-bought face soap.
Originating in the Yoruba communities in Benin, Toga, and Nigeria, this product has since become popular with citizens all across Western Africa.

INGREDIENTS

• Plantain skins: rich source of vitamins A & E and iron
• Cocoa pod ash: contains antioxidants and anti-inflammatory properties
• Palm oil: rich in antioxidants and two forms of vitamin E

BENEFITS

• Improves skin tone
• Promotes healing
• Deep cleansing
• Gentle exfoliation
• Soothes skin irritation
• Anti-inflammatory properties

BANANA FIBERS

One of the world’s strongest natural fibers, banana fibers are made from the stem of the banana plant. Thicker, sturdier fibers come from the outer sheaths, while inner sheaths contain softer fibers. Banana fibers are used to make a wide variety of textiles with different weights and thicknesses.
Banana fiber production includes methods of cultivation, extraction, processing, and sorting. This product is generally woven in small communities on non-electric looms, which produces an abaca fiber that is low impact, low (mechanical) energy, and requires no chemicals to grow or process.

BENEFITS

• Biodegradable
• Incredibly durable
• Better spin ability, fineness, and tensile strength than alternative natural fibers

PAPER-MAKING

Cocoa pods are the dried vessels that contain cocao beans. When opened, the pod contains a fruity, edible pulp. To continue the chocolate-making process, this pulp containing the cocao beans is removed, fermented, and dried.

soap research and analysis

FACE SOAP ISSUES

• The average liquid face soap container only holds 6-8oz of actual wash.
• Dermatologists recommend using face soap 2-3 times a day, resulting in consumers rapidly running out of soap and needing to buy it more often.
• Due to the constant use coupled with a misunderstanding of the proper amount needed, consumers tend to use an excess amount of face soap per wash.

The levels of wasted packaging produced by the beauty industry is so high that it is estimated that at the current rate of our consumption, by 2050 there will be 12 billion tonnes of plastic in landfills₉.

BAR SOAP BENEFITS

The increasing amount of plastic could be prevented if the less popular alternative to liquid soap, bar soap, was popularized.

Although it’s not as common to use, bar soap has a lower environmental impact than liquid soap in various important categories including:

• carbon footprint
• ecotoxicity
• ozone depletion potential
• eutrophication potential.₇

BAR SOAP ISSUES

While bar soap has many environmental benefits, consumers are often deterred from purchasing soap in this form because they find issues with its convenience. The two largest struggles consumers face are dropping the soap when in use and figuring out where to store the bar in the shower.₈

IN STORES

When soap is sold at stores like Walmart, they are packaged in chipboard boxes and then wrapped in plastic.

BULK PACKAGING

When soap is sold in bulk, each bar is individually packaged in chipboard boxes and then the whole pack is wrapped in plastic. Once the box is open, you can’t reseal it.

USER ERROR

Since it’s hard to find places to put bar soap, users will bring the box in the shower, leading to it disintegrating and the soap getting dirty.

We want to focus on these issues, and promote the more environmentally friendly bar soap, as well as the high potential of the cocoa fruit. This brings us to our project, and how we plan to connect the worlds of cocoa and soap together. That begs the question:

How might we leverage complementary natural material sources and reconstruct them within soap packaging to improve the convenience of bar soap in order to satisfy the liquid face soap user market?

Read about our process here!

MAKING COCOBERRY

making cocoberry

the cocoa pod

cacao preparation

Preparing the cocoa pod for use in papermaking started by cutting them in half and removing the pulp covered beans. This left the pod shell, which had to be scraped on the inside to separate it from the soft memrane layer. We then cut the shell into pieces and placed them in ziploc bags to soak in water for a couple days.

Cooking the Fibers

in the kitchen

Banana leaves, banana stalks, and palm fibers also needed to be cut into smaller pieces and left in bags to soak in water. This soaking of fibers and pod pieces prepared them for the cooking process. The fibers were separated into large pots containing water and soda ash and cooked for several days to break them down further.

Cooking the Fibers (con't)

cooking fibers

After being cooked for days, the fibers needed to be washed thoroughly to remove the soda ash. As they were rinsed, the small bits of fibers were kept in buckets of water to keep them wet and separated. Once this process was over, the fibers were placed in a hollander beater to be dispersed and mixed together.

creating the mold

mold

In two parts with large draft angles. Based on previous prototypes, we had to cut down on complex geometry and keep all the curves simple in the base and lid.

part

The lid slots into the walls of the bowl, and the lid has a boss on the top to allow your fingers to grip and raise the lid.

stretching the paper

POUR

After the fibers are prepped, it's time to pour the fibers into a sheet-form.

DECKLE

The deckle is used to hold the fibers in place so that they take the shape we want and don't run too thin.

mold

After the fibers are poured and pressed, we can mold the paper by hand around the form that we want!

Proposed Industrial Proccess

Read about our product background here!

BACKGROUND AND RESEARCH