UK - German food manufacturing giant Döhler has joined hands with Nukoko, a British start-up behind the “world’s first” cocoa-free, bean-to-bar chocolate, to scale up the production of Nukoko’s innovative chocolate alternative, made from fava beans. 

“We are excited by our collaboration with Döhler, one of the world’s leading fermentation experts. Their support is crucial in helping us achieve industrial-scale production and bring our revolutionary chocolate alternative to market,” Ross Newton, co-founder of Nukoko, expressed excitement about the partnership which aims to bring the product to market by 2025. 

Sustainable solutions

Nukoko’s chocolate alternative is created using a patent-pending fermentation process that mimics the traditional fermentation of cocoa beans, allowing fava beans to replicate the rich flavors associated with chocolate. 

The company’s innovation addresses several pressing issues in the chocolate industry, including volatile cocoa prices, the environmental toll of cocoa farming, and socio-economic challenges tied to cocoa production. 

Nukoko claims its cocoa-free chocolate produces 90% fewer carbon emissions compared to conventional chocolate, offering a significant reduction in the industry’s environmental footprint. Additionally, its product boasts 40% less sugar and higher levels of protein, fiber, and antioxidants, making it a healthier alternative without sacrificing taste.

With Döhler’s expertise in fermentation scale-up and ingredient systems, Nukoko is on track to increase its production capacity from pilot-scale 500 kg batches to industrial-scale 10,000-liter fermentation batches by 2025. This expansion will significantly boost output, enabling Nukoko to produce thousands of tonnes of its sustainable chocolate alternative each month.

“Nukoko’s technology presents a groundbreaking solution for the food and beverage industry. We are proud to support the scale-up of its cocoa-free chocolate, which aligns with our mission to drive sustainable food innovations,” Rodrigo Hortega de Velasco, representing Döhler Ventures, highlighted the potential impact of the partnership.

Rising demand for cocoa alternatives

Nukoko’s cocoa-free chocolate enters the market at a time of heightened awareness around the environmental and social issues linked to cocoa farming. 

Extreme weather events in major cocoa-producing countries like Ivory Coast and Ghana have led to fluctuating cocoa yields and record-high prices in 2024. These disruptions, coupled with deforestation concerns, have driven the search for alternative ingredients and processes that can mitigate the industry’s environmental impact.

Nukoko is not alone in this endeavor. Several other companies are also working on innovative chocolate alternatives that aim to reduce dependence on cocoa, each employing different strategies and ingredients.

Another British start-up, Win-Win Food Lab, has taken a similar approach to Nukoko, developing cocoa-free chocolate using carob and sunflower seeds. These ingredients provide a robust, climate-resilient alternative to cocoa, with a fraction of the carbon emissions. 

Like Nukoko, Win-Win is leveraging fermentation techniques to replicate the rich taste of chocolate while maintaining sustainability at the core of its production process.

Germany-based Planet A Foods has also developed a product called Nocoa, a cocoa-free chocolate made from fermented oats and legumes. This alternative is designed to address environmental concerns and resource-intensive cocoa production, offering consumers a more eco-friendly chocolate option without compromising flavor.

Meanwhile US-based Voyage Foods has introduced a cocoa-free chocolate alternative made from a blend of ingredients such as sunflower seeds and other plant-based elements. Like Nukoko, Voyage Foods’ mission is to create climate-resilient products that are less susceptible to the environmental and economic risks associated with cocoa farming.

Cell-based chocolate solutions

While many companies are focused on plant-based cocoa alternatives, some innovators are taking a different path. 

Israeli startups Celleste Bio and Kokomodo, along with California Cultured in the US, are pioneering the development of lab-grown, or cell-based, chocolate. 

These companies are cultivating real cocoa cells in laboratory environments, bypassing traditional farming altogether. This technology holds the potential to produce authentic chocolate while drastically reducing land and water use, as well as avoiding deforestation.