Cocoa Powder Processing in the UK: Sanitation, pH Adjustment, and Black Cocoa Production with PerMix Vacuum Paddle Mixer/Dryers

Raising the Bar for Cocoa Powder Production in the UK

Whether you’re crafting chocolate biscuits, protein powders, premium cakes or nutritional beverages, cocoa powder is a core ingredient that demands precision in both flavour and functionality. UK food producers are increasingly seeking solutions that ensure microbiological safety, consistent pH, customisable colour, and shelf-stable powder quality — all while improving batch efficiency and reducing manual handling.

At PerMix Mixers UK, we offer a smarter way to process cocoa. Our Vacuum Paddle Mixer/Dryer brings together every essential cocoa process — sanitising, alkalising, colour adjusting, and drying — into one compact, hygienic, automated system, made to meet the exacting standards of UK food manufacturers.

Introducing the PerMix Vacuum Paddle Mixer/Dryer

The PerMix Vacuum Paddle Mixer/Dryer is a state-of-the-art system designed for the efficient mixing, thermal treatment, and drying of powders under vacuum. Its UK-compliant food-grade construction, combined with advanced automation, allows producers to meet BRC, SALSA, and FSA standards with ease.

Key Features:

• Vacuum processing for low-temperature pasteurisation
• Jacketed heating & cooling system for thermal control
• Spray nozzles for liquid additions (e.g., alkali agents)
• Optional high-speed choppers for lump-free mixing
• PLC/HMI automation with recipe storage
• Fully CIP or wash-down ready for food safety

One System. Four Functions. Full Control.

1. Vacuum Sanitisation

Cocoa is prone to microbial risks such as Salmonella and E. coli. Using vacuum, we sanitise at 80–100°C — low enough to protect flavour, but high enough to kill pathogens. The vacuum environment lowers the boiling point, allowing for efficient pasteurisation without degradation.

2. pH Adjustment (Alkalisation)

PerMix injects potassium carbonate, sodium carbonate, or other food-safe alkali through nozzles under vacuum. Optional choppers improve dispersion, while paddle mixing ensures homogeneity. This process allows you to raise the pH from ~5.0 to anywhere between 6.2 and 8.8, depending on the cocoa grade.

3. Colour Development

By altering the pH, dwell time, and alkali type, you can produce:

• Light Brown Cocoa (pH 6.2–6.6)
• Dutch-Process Cocoa (pH 6.8–7.5)
• Reddish Cocoa (pH 7.0–8.0)
• Black Cocoa (pH 8.0–8.8)

These colours are stable, batch-repeatable, and fully customisable.

4. Vacuum Drying

After pH adjustment, the cocoa is dried under vacuum to a final moisture of ≤4%, or ≤3% for black cocoa. This guarantees free-flowing consistency, prevents clumping, and extends shelf life.

Special Focus: Manufacturing Black Cocoa Powder in the UK

Black cocoa is in high demand across the UK for use in luxury baked goods, protein bars, dark biscuits, and high-end chocolates. It features a jet-black appearance, low acidity, and a neutral, smooth taste.

PerMix Vacuum Paddle Mixers are ideal for black cocoa production because they:

• Precisely raise pH to 8.0–8.8
• Maintain vacuum to prevent oxidation and colour loss
• Use high shear to disperse alkali evenly
• Dry the powder gently without overheating or caking

Alkali Used: Potassium carbonate (sometimes ammonium carbonate)
Dwell Time: 30–60 minutes
Vacuum Level: -0.9 bar
Final Moisture: ≤3%

Trusted Across the UK for Cocoa and More

PerMix equipment is used by:

• Cocoa powder manufacturers
• Bakery ingredient suppliers
• Chocolate and confectionery producers
• Nutraceutical companies
• Blenders and contract manufacturers

Whether you’re producing Dutch cocoa for a supermarket brand or black cocoa for a specialist artisan line, PerMix Mixers UK gives you engineering excellence, repeatable results, and full process control.

Benefits for UK Manufacturers

Final Word: PerMix Sets the Standard

Cocoa processing doesn’t need to be complicated. With a PerMix Vacuum Paddle Mixer/Dryer, you can achieve:

• Safer products
• Faster cycle times
• More control over colour and flavour
• Higher yields
• Cleaner operations

Upgrade your UK cocoa manufacturing line today