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.

Cocoa shell is one of the by‐products obtained in chocolate industry which was considered as waste for a very long time. Recently, the presence of high‐valuable bioactive components in cocoa shell was recognized, and research on the pallet of food products enriched with cocoa shell is increasing. The most abundant bioactive components of untreated cocoa shell (UCS) are theobromine (3.906 ± 0.070 mg/g), caffeine (0.646 ± 0.055 mg/g), and (+)‐catechin (0.290 ± 0.005 mg/g), followed by gallic acid (0.147 ± 0.041 mg/g) and (−)‐epicatechin (0.165 ± 0.099 mg/g). Furthermore, the impact of concentration (1.5 and 3% of cocoa shell in water), high‐voltage electric discharge (HVED) treatment (40 and 80 Hz), and treatment time (15, 30, and 45 min, respectively) on bioactive compounds content was evaluated. Statistically significant differences between treatment conditions were obtained. Generally, water‐HVED treatment at 40 Hz has lower impact on bioactive components than water, and water‐HVED at 80 Hz, therefore, can have a significant effect on future treatments of materials rich in bioactive compounds.Practical applicationsHVED is an innovative nonthermal processing technique that has mechanical and electrical effect on the product resulting with lower costs and increase of functional properties. This study has shown that HVED causes lower decrease of phenolics and methylxanthines in cocoa shell which can have a significant effect on future treatments of materials rich in bioactive compounds. Because it is not recorded in scientific literature that HVED treatment was used on cocoa shell so far, it will help in future research and applications of cocoa shell in the food industry.

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.

Starch is a very common carbohydrate. Along with its use in the pharmaceutical, textile, and paper industries, starch is widely used in the food industry as well, but native starch has limited use due to its certain properties such as retrogradation, problems related to gelatinization, instability at high temperatures, and acidic conditions. Various modification procedures are used to improve the properties of native starch. Along with consumer demands for healthy, minimally processed, and sensibly priced food products, more attention is being paid to nonthermal food friendly technologies that are environmentally friendly and do not severely affect the product. Cold plasma, ultrasound, high pressure, and pulsed electric field as nonthermal methods have little influence on the most important properties of food and thus have significant potential in this regard, as the food produced by nonthermal methods might be more acceptable to consumers. This paper gives an overview of previously mentioned methods in starch modification. Practical applications The food industry, at a recent time, has shown a great interest in the development of procedures which enable minimal food processing and getting products with better organoleptic and nutritive properties with little energy loss and shorter technological procedure duration. This paper presents some of the current research and results of nonthermal methods application in the food industry, mainly its application in starch modification and influence on certain starch properties.