Cocoa POD processing

Abstract

A cocoa pod includes a husk and cocoa beans housed within the husk. The cocoa pod is conveyed across a cutting assembly that includes blades. Conveying the cocoa pod across the cutting assembly separates a portion of the husk from a remaining portion of the husk to expose the cocoa beans. The exposed cocoa beans are separated from the remaining portion of the husk. In some cases, a major central axis of the cocoa pod relative to a horizontal plane is maintained at a predetermined non-zero angle as the cocoa pod is conveyed across the cutting assembly. In some cases, the cocoa pod is held in an upright position with a peduncle of the cocoa pod located at the top of the cocoa pod and at a predetermined height as the cocoa pod is conveyed across the cutting assembly.

Description

Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]COCOA POD PROCESSINGCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to U.S. Provisional Application Serial No. 63 / 708,054, filed on October 16, 2024, the contents of which are hereby incorporated by reference in their entirety.TECHNICAL FIELD

[0002] This disclosure relates to cocoa pod processing, e.g., to extract cocoa beans out of cocoa pods.BACKGROUND

[0003] Cocoa beans (also sometimes referred to as cocoa, cacao bean, or cacao) is the dried and fully fermented seed of Theobroma cacao, from which cocoa solids and cocoa butter can be extracted. For example, cocoa beans are the basis of chocolate and can be used to form a variety of chocolate confections (e.g., M&M’s®, Snickers®, etc.).

[0004] Cocoa beans grow within cocoa pods (sometimes referred to as cocoa seed pods) and require extraction from the cocoa pod before the cocoa beans can be processed to produce chocolate. Generally, the interior substances of the cocoa pod is referred to as “meat”, which includes both the cocoa beans, placenta, and a white membrane substance that grows around the cocoa beans.

[0005] Extracting the meat from cocoa pods can be challenging. For example, some conventional processes include the manual use of machetes to chop open the cocoa pods, and the manual extraction of the meat from the cocoa pods.SUMMARY

[0006] This disclosure describes technologies relating to cocoa pod processing systems and methods for separating cocoa beans from cocoa pods. The subject matter described in this disclosure can be implemented in particular implementations, so as to realize one or more of the following advantages. Using the cocoa pod processing systems and methods described can be safer than conventional approaches that rely on machetes or other sharp blades of a user to chop off the ends of the cocoa pod to access the meat of the cocoa pod. The systems and methodsAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] described are safer because they rely on a conveyor-driven system with safety shields / guards where the user does not come into contact with sharp blades (unless the user is servicing the machine). In some examples, all the user needs to do is place the cocoa pods within a conveyance receptacle of the system, press a start button of the system (if applicable), and the system will automatically cut the cocoa pod, extract the meat, and automatically separate and collect the meat for further processing. The cocoa pod processing systems and methods described can process from 2,000 to 4,000 cocoa pods per hour, from 4,000 to 6,000 cocoa pods per hour, from 6,000 to 8,000 cocoa pods per hour, or from 8,000 to 10,000 cocoa pods per hour. This is very fast, as a processing rate of 2,000 to 4,000 cocoa pods per hour translates to roughly one cocoa pod being processed each second. As processing speed increases (for example, faster than 10,000 cocoa pods per hour), the cleanliness of collected cocoa beans may decrease. The cocoa pod processing systems and methods described can be more sanitary than conventional approaches that rely on a user manually scooping out the cocoa beans with their hands or a contaminated instrument (e.g., dirty spoon, etc.). The cocoa pod processing systems and methods described can avoid damaging cocoa beans while extracting the cocoa beans from cocoa pods. The cocoa pod processing systems and methods described are adjustable so that they can accommodate varying sizes and shapes of cocoa pods. In some cases, the cocoa pod processing systems and methods described can extract cocoa beans from cocoa pods in an efficient and clean manner without requiring sorting of cocoa pods prior to being opened / broken. The term “cocoa” has been used throughout this disclosure and refers to both “cocoa” and / or “cacao.” Additionally, while the systems and method described refer to “cocoa pods,” the same and / or similar systems and methods are applicable to non-cocoa pods, such as cocoa clones. For example, the systems and methods described can be used to process other types of organic pods such as a fruit pod or a vegetable pod. Because the systems and methods described can automatically process cocoa beans without requiring user intervention, intensive labor and labor costs can be mitigated and / or eliminated. In some cases, the systems and methods described process cocoa beans in such a way as to avoid removing beans from diseased pods that may be compacted within and / or attached to the husk, thereby reducing the potential of collecting diseased beans. The systems and methods described can be implemented as a centralized system or method. The systems and methods described are versatile in that they may be implemented as a centralized system or method or as an in-field system or method. A centralized system, for example, is one that is located at a central pod processing location that canAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] be on or off farm. For a centralized system, the cocoa pods can be harvested and brought to the centralized system for processing. In such cases, transportation of the cocoa pods to the centralized system may be necessary. An in-field system, for example, is one that is located in the field where the cocoa pods are being harvested so that the cocoa pods can be processed by the in-field system as they are harvested. For in-field systems and methods, the cocoa pods can be processed soon after harvesting without requiring transporting of the cocoa pods over long distances (for example, over a mile). In some cases, in-field systems can be made to be mobile so that they can be moved to different locations where cocoa pods are being harvested.

[0007] The details of one or more implementations of the subject matter of this disclosure are set forth in the accompanying drawings and the description. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.DESCRIPTION OF DRAWINGS

[0008] FIG. 1 is an illustration of the composition of an example cocoa pod showing the meat of the cocoa pod and the husk of the cocoa pod.

[0009] FIG. 2A is a side view of an example cocoa pod processing system for separating cocoa beans from cocoa pods shown in FIG. 1.

[0010] FIG. 2B is a side view of an example conveyor and receptacle of the cocoa pod processing system of FIG. 2A, holding a cocoa pod.

[0011] FIGS. 2C and 2D are side and cross-sectional views of an example cutting assembly of the cocoa processing system of FIG. 2 A, along with the cocoa pod, conveyor, and receptacle of FIG. 2B.

[0012] FIG. 2E is a side view of an example separation assembly of the cocoa pod processing system of FIG. 2A.

[0013] FIG. 3 is a flow chart of an example method for processing cocoa pods.

[0014] FIG. 4A is a side view of a conveyor, receptacles, and cutting arrangement of an example cocoa pod processing system for separating cocoa beans from cocoa pods shown in FIG.1.

[0015] FIG. 4B is a top view of a cocoa pod, conveyor, and receptacles of the cocoa pod processing system of FIG. 4A.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]

[0016] FIG. 4C is a cross-sectional view of a cocoa pod held by a receptacle and being cut by the cutting arrangement of the cocoa pod processing system of FIG. 4A.

[0017] FIG. 4D is a side view of an example separation arrangement of the cocoa processing system of FIG. 4A.

[0018] FIG. 5 is a flow chart of an example method for processing cocoa pods.DETAILED DESCRIPTION

[0019] This disclosure describes cocoa pod processing systems and methods for extracting cocoa beans from cocoa pods.

[0020] FIG. 1 is an illustration of the composition of an example cocoa pod 100. The cocoa pod 100 includes a husk 102. The husk 102 includes an exocarp portion of the cocoa pod 100, a mesocarp portion of the cocoa pod 100, and an endocarp portion of the cocoa pod 100. As shown in FIG. 1, the mesocarp portion spans between the endocarp and the exocarp. In this way, the term “husk” or “outer shell” can refer to any or a combination of the exocarp portion, the mesocarp portion, and the endocarp portion of the cocoa pod 100.

[0021] The cocoa pod 100 also includes an interior 104 that represents a space within the cocoa pod 100 and is defined by the husk 102. The interior 104 contains meat 106 (sometimes referred to as pulp). As shown in FIG. 1, the meat 106 includes both cocoa beans 108 and a substance surrounding the cocoa beans 108. The substance surrounding the cocoa beans 108 can be referred to as “pulp”. In some examples, the substance is a white membrane substance. The membrane substance includes a placenta 107 and a funicle that attaches cocoa beans 108 to the placenta 107. In this way, the meat 106 includes cocoa. The cocoa pod 100 also has two ends 110 that are opposite from each other (one of these ends 110 is hidden from view in FIG. 1).

[0022] While FIG. 1 shows a cocoa pod 100 that is cut in half along a cut line 114, this is merely for illustrative purposes. In most cases, the husk 102 (e.g., the exocarp portion, the endocarp portion, and the mesocarp portion) of the cocoa pod 100 are discarded once the meat 106 (e g., the cocoa beans and the surrounding substance, which includes the placenta 107) has been extracted from the interior 104 of the cocoa pod 100.

[0023] FIG. 2A is a side view of an example cocoa pod processing system 200 for separating cocoa beans 108 from cocoa pods 100. The system 200 includes a moveable conveyor 202 (e g., a conveyor belt or chain). The conveyor 202 includes a conveyance receptacle 204. While only single representation of the receptacle 204 is shown in FIG. 2A, the system 200 canAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] include additional receptacles 204 (e.g., from 20 to 60 or more than 60) that are spaced apart (e.g., equally spaced apart) along the conveyor 202. A user 206 can place a cocoa pod 100 onto the receptacle 204. In at least this way, the methods described involve receiving a cocoa pod 100 in the receptacle 204. The system 200 includes a cutting assembly 210 including blades 212a, 212b. The cutting assembly 210 is configured to cut across a portion of each cocoa pod 100 to separate the husk 102 into separate portions and expose the cocoa beans 108. The cutting assembly 210 is configured to cut the husk 102 of each cocoa pod 100 while avoiding cutting the cocoa beans 108 to minimize damage to the cocoa beans 108 during cocoa pod processing. The system 200 includes a separation assembly 220. The separation assembly 220 is configured to separate the exposed cocoa beans 108 from the husk 102. The system 200 can process cocoa pods 100 to separate cocoa beans 108 from the cocoa pods 100 independent of computer control. For example, operation of the system 200 is not controlled by a computer and does not require sensing equipment to successfully process cocoa pods 100 to extract cocoa beans 108 from the cocoa pods 100.

[0024] As described previously, the system 200 can include a plurality of receptacles 204 and at any particular moment, more than one conveyance receptacle 204 can empty and open waiting for the user 206 to deposit an additional cocoa pod 100. For example, in some cases, the user 206 can use both hands to load two cocoa pods 100 into two receptacles 204 at the same time. Alternatively, the user 206 can load the cocoa pod 100 onto the receptacle 204 while a second user loads a second cocoa pod 100 into a second receptacle 204. In at least these ways, in some cases, more than one cocoa pod 100 can be loaded into the system 200 simultaneously.

[0025] The conveyor 202 is a continuous member that can translate in a consistent direction (e.g., clockwise as viewed in FIG. 2A). For example, the conveyor 202 moves in a first horizontal direction, rotates around an end roller, moves back in a second, opposite, horizontal direction, rotates around another end roller, and repeats back to moving again in the first horizontal direction.

[0026] The system 200 includes a motor 208 that is coupled (e.g., using rollers, gears, belts, sprockets, etc.) to the conveyor 202 to advance the conveyor 202 in the clockwise direction. In some cases, the motor 208 is an electric motor with a user-adjustable speed control. In some cases, the motor 208 is configured to rotate the conveyor 202 at a rotational rate sufficient for the system 200 to process from 2,000 to 4,000, from 4,000 to 6,000, from 6,000 to 8,000, or from 8,000 to 10,000 cocoa pods 100 per hour. In scenarios where these speeds are used, in some cases, the userAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]206 can be replaced or supplemented with a chute that automatically deposit cocoa pods 100 into respective conveyance receptacles 204 (e.g., using the force of gravity).

[0027] As shown in FIG. 2A, the conveyor 202 conveys (e.g., as driven by the motor 208) the cocoa pod 100 toward one or more processing stations. In this example, the conveyor 202 conveys the cocoa pod 100 toward the cutting assembly 210. In the depicted embodiment, the motor 208 drives the conveyor 202 continuously through the cutting assembly 210. For example, the motor 208 can continuously convey the cocoa pod 100 toward the cutting assembly 210 at a constant velocity.

[0028] The cutting assembly 210 refers to a general portion of the system 200 associated with cutting the cocoa pods 100. Likewise, the separation assembly 220 refers to a general portion of the system 200 associated with separating the cocoa beans 108 from the husk 102.

[0029] The lower portion 102a of the husk 102 separated by the cutting assembly 210 can, for example, be directed to and / or fall into a first receiving section. The upper portion 102b of the husk 102 from which the cocoa beans 108 are extracted can, for example, be directed to and / or fall into the first receiving section after the cocoa beans 108 have been extracted. The cocoa beans 108 that have been extracted from the upper portion 102b of the husk 102 can, for example, be directed to and / or fall into a second receiving section.

[0030] FIG. 2B is a side view of the conveyor 202 and receptacle 204 holding a cocoa pod 100. The conveyor 202 is configured to move in a direction parallel to a horizontal plane (H). The cocoa pod 100 defines a major central axis (L). The receptacle 204 is configured to hold the cocoa pod 100 such that the major central axis (L) of the cocoa pod 100 relative to the horizontal plane (H) is at a predetermined angle (A) of greater than 0°. In some embodiments, the predetermined angle (A) is adjustable. In some embodiments, the predetermined angle (A) is in a range of about 3° to about 17°. The receptacle 204 can be made of stainless steel, such as food-grade stainless steel A304. The receptacle 204 can be made of structural steel, such as structural steel A36. In some embodiments, the receptacle 204 is adjustable. For example, the receptacle 204 can be adjusted to adjust the predetermined angle (A). As another example, the receptacle 204 can be adjusted to hold cocoa pods 100 of varying sizes while maintaining the predetermined angle (A) for each cocoa pod 100. The system 200 can be calibrated to process cocoa pods 100 of any size. In some embodiments, the system 200 is configured to process cocoa pods 100 having lengths greater than 200 millimeters (mm) and outer diameters greater than 40 mm. In some embodiments,Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] the system 200 is configured to process cocoa pods 100 having a dimension (e.g., length) of at least 5 centimeters.

[0031] In this example, the receptacle 204 includes a first rod 204a, a second rod 204b, and wings 204c positioned between the first rod 204a and the second rod 204b. The cocoa pod 100 can be positioned, for example, such that the major central axis (L) of the cocoa pod 100 aligns centrally on the first rod 204a and the second rod 204b. The first and second rods 204a, 204b extend from the conveyor 202 at different heights for holding the cocoa pod 100 at the predetermined angle (A). In this example, the cocoa pod 100 is placed onto the receptacle 204 such that the second rod 204b penetrates into the husk 102 of the cocoa pod 100, which can secure the cocoa pod 100 to the receptacle 204. In some examples, the cocoa pod 100 may be placed onto the receptacle 204 such that the first rod 204a and / or the second rod 204b penetrates into the husk 102. The wings 204c can be spaced apart laterally with respect to the major central axis (L) of the cocoa pod 100 and extend outward to support the generally ellipsoidal shape of the cocoa pod 100. The wings 204c can help to centralize the cocoa pod 100 along the receptacle 204. In this example, the first rod 204a includes a support 204d that further supports the cocoa pod 100. In this example, the cocoa pod 100 is shown with the end of the cocoa pod 100 that includes the peduncle 112 positioned near the first rod 204a, while the opposite end (shown in FIG. 1) of the cocoa pod 100 is positioned near the second rod 204b. In other examples, the end of the cocoa pod 100 including the peduncle 112 can be positioned near the second rod 204b, while the opposite end of the cocoa pod 100 can be positioned near the first rod 204a. The peduncle 112 is the stalk that connects the cocoa pod 100 to a cocoa tree before the cocoa pod 100 is harvested. In some embodiments, the distance B between the first rod 204a and the second rod 204b is adjustable. For example, the distance B between the first rod 204a and the second rod 204b can be adjusted to adjust the predetermined angle (A). As another example, the distance B between the first rod 204a and the second rod 204b can be adjusted to hold cocoa pods 100 of varying sizes while maintaining the predetermined angle (A) for each cocoa pod 100.

[0032] FIGS. 2C and 2D are side and cross-sectional views of an example cutting assembly210 of the system 200, along with the cocoa pod 100, conveyor 202, and receptacle 204. The blades 212a, 212b are positioned on the horizontal plane (H). The blades 212a, 212b are aligned to cut across a portion of the cocoa pod 100, such as the husk 102, as the cocoa pod 100 is moved by the conveyor 202. The blades 212a, 212b cutting across the husk 102 as the cocoa pod 100 isAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] moved by the conveyor 202 causes the husk 102 to separate into separate portions (lower portion 102a and upper portion 102b). As shown in FIG. 2D, the blades 212a, 212b are separated from one another by a distance E. The distance E is sufficiently large such that the blades 212a, 212b avoid contact with the cocoa beans 108 as the cocoa pod 100 is moved by the conveyor 202 across the blades 212a, 212b. In some embodiments, the distance E is in a range of from about 1 centimeter (cm) to about 6 cm. The distance E between the blades 212a, 212b ensures that the cocoa beans 108 do not get damaged by the blades 212a, 212b as the cocoa pod 100 is moved by the conveyor 202 across the blades 212a, 212b. The lateral widths of the first and second rods 204a, 204b of the receptacle 204 are narrower than the distance E between the blades 212a, 212b such that the blades 212a, 212b do not come into contact with the first and second rods 204a, 204b.

[0033] In some embodiments, the height at which the blades 212a, 212b are positioned with respect to the conveyor 202 is adjustable. For example, the height of the blades 212a, 212b with respect to the conveyor 202 can be adjusted to account for differently sized cocoa pods 100. In some embodiments, the height of the blades 212a, 212b with respect to the conveyor 202 is in a range of from about 10 cm to about 18 cm.

[0034] In this example, the cutting assembly 210 includes a centering guide 214 positioned above the blades 212a, 212b with respect to gravity. In some embodiments, the centering guide 214 is biased downward (e.g., by a spring) or sufficiently heavy to apply a small downward force with respect to gravity on top of the cocoa pod 100 as the cocoa pod 100 is moved by the conveyor 202 across the blades 212a, 212b. The centering guide 214 is configured to prevent lateral movement of the cocoa pod 100 in relation to the direction in which the conveyor 202 moves the cocoa pod 100 across the blades 212a, 212b. In this example, the centering guide 214 includes wings 214a, 214b extending outward for conforming to the generally ellipsoidal shape of the cocoa pod 100. In other examples, the centering guide 214 is generally flat. In other examples, the centering guide has a generally hemicylindrical (half a cylinder divided longitudinally) shape. The centering guide 214 of the cutting assembly 210 and the wings 204c of the receptacle 204 can, for example, work together to prevent lateral movement of the cocoa pod 100 in relation to the direction in which the conveyor 202 moves the cocoa pod 100 across the blades 212a, 212b. In some embodiments, the blades 212a, 212b are made of stainless steel or structural steel that has been tempered. Tempering heat treatment of steel can enhance its durability and lifespan.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]

[0035] The first blade 212a can include a downward fold 212a’ positioned at an end of the first blade 212a opposite of the end that first comes into contact with the cocoa pod 100. The second blade 212b can include a downward fold 212b’ positioned at an end of the second blade 212b opposite of the end that first comes into contact with the cocoa pod 100. The downward folds 212a’, 212b’ are configured to facilitate separation of the husk 102 (that has been cut by the blades 212a, 212b) into the separate portions (lower portion 102a and upper portion 102b). For example, the shape of the downward folds 212a’, 212b’ can force the lower portion 102b to diverge from the upper portion 102b in response to conveying the cocoa pod 100 across the downward folds 212a’, 212b’. The downward folds 212a’, 212b’ can be, for example, curved or straight. The lower portion 102a of the husk 102 that has been separated from the upper portion 102b of the husk 102 by the blades 212a, 212b (and downward folds 212a’, 212b’) can fall due to the force of gravity, while the upper portion 102b of the husk 102 remains on top of the blades 212a, 212b. Separation of the lower and upper portions 102a, 102b exposes the meat 106 (including the cocoa beans 108) of the cocoa pod 100. In some cases, the height of the blades 212a, 212b with respect to the conveyor 202 can be sufficiently short such that the peduncle 112 remains a part of the upper portion 102b. The exposed meat 106 can hang from the upper portion 102b. The upper portion 102b including the exposed meat 106 can move from the cutting assembly 210 to the separation assembly 220. The lower portion 102a that has separated and fallen away from the upper portion 102b can be directed to and / or fall into the first receiving section (e.g., a hopper for husk material).

[0036] FIG. 2E is a side view of an example separation assembly 220 of the system 200. The separation assembly 220 receives the upper portion 102b including the exposed meat 106 from the cutting assembly 210. The separation assembly 220 includes a platform 221 configured to receive the upper portion 102b including the exposed meat 106 from the cutting assembly 210. In some cases, the platform 221 is positioned at a slightly lower height in comparison to the blades 212a, 212b of the cutting assembly 210 with respect to gravity to ensure that the upper portion 102b slides down from the cutting assembly 210 and onto the platform 221. In some cases, the platform 221 is directly attached to the blades 212a, 212b.

[0037] The separation assembly 220 includes a moveable conveyor 222 (e.g., a conveyor belt or chain). The conveyor 222 is a continuous member that can translate in a consistent direction (e.g., counter-clockwise as viewed in FIG. 2E). For example, the conveyor 222 moves in a first horizontal direction, rotates around an end roller, moves back in a second, opposite, horizontalAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] direction, rotates around another end roller, and repeats back to moving again in the first horizontal direction.

[0038] The separation assembly 220 includes a motor 228 that is coupled (e.g., using rollers, gears, belts, sprockets, etc.) to the conveyor 222 to advance the conveyor 222 in the counter-clockwise direction. In some cases, the motor 228 is an electric motor with a user- adjustable speed control. In some cases, the motor 228 is configured to rotate the conveyor 222 at a rotational rate sufficient for the system 200 to process from 2,000 to 4,000, from 4,000 to 6,000, from 6,000 to 8,000, or from 8,000 to 10,000 cocoa pods 100 per hour.

[0039] The conveyor 222 includes a wall 224. While only a couple representations of the wall 224 are shown in FIG. 2E, the separation assembly 220 can include additional walls 224 (e.g., from 20 to 60) that are spaced apart (e.g., equally spaced apart) along the conveyor 222. The wall 224 moves with the conveyor 222 and pushes the upper portion 102b from the cutting assembly 210 to the platform 221 and across the platform 221 in the first horizontal direction. The platform 221 defines a void space that is aligned with the exposed meat 106 such that the exposed meat 106 hangs from the upper portion 102b through the void space as the conveyor 222 and wall 224 pushes the upper portion 102b across the platform 221.

[0040] The separation assembly 220 includes a rotary separator 226 that is configured to rotate in a direction opposite of the direction the conveyor 222 and wall 224 moves the upper portion 102b across the platform 221. In this example, the rotary separator 226 rotates counterclockwise. The rotary separator 226 is positioned below the platform 221 with respect to gravity. The rotary separator 226 is aligned to come into contact with the exposed meat 106 hanging from the upper portion 102b through the void space defined by the platform 221. The rotary separator 226 rotates and separates the exposed meat 106 from the upper portion 102b of the husk 102 in response to contacting the exposed meat 106. In some embodiments, the rotary separator 226 includes a plurality of scrapers that simultaneously rotate to separate the exposed meat 106 from the upper portion 102b of the husk 102. The scrapers of the rotary separator 226 can be, for example, made of steel (such as food-grade stainless steel A304 or structural steel A36) or another material, such as food-grade rubber. In some embodiments, the scrapers of the rotary separator 226 rotate in a direction opposite of the direction of the conveyor 222 (e.g., counter-clockwise). In some embodiments, the scrapers of the rotary separator 226 rotate in the same direction of the conveyor 222 (e.g., clockwise). In some embodiments, the scrapers of the rotary separator 226Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] rotate in varying directions. For example, at least one of the scrapers of the rotary separator 226 can rotate clockwise, while at least one other scraper of the rotary separator 226 rotates counterclockwise. The meat 106 (including the cocoa beans 108) that has been separated from the upper portion 102b by the rotary separator 226 can be directed to and / or fall into the second receiving section (e.g., a hopper for cocoa beans). The upper portion 102b of the husk 102 can be directed to and / or fall into the first receiving section or another receiving section (e.g., a hopper for husk material) after the meat 106 has been separated from the upper portion 102b. In cases where the meat 106 separated from the upper portion 102b by the rotary separator 226 includes material other than the cocoa beans 108 (e.g., pulp, placenta 107, etc.), the meat 106 can be further processed to extract the cocoa beans 108 from the meat 106.

[0041] FIG. 3 is a flow chart of an example method 300 for processing cocoa pods 100. The method 300 can, for example, be performed by the system 200. At block 302, a cocoa pod 100 is conveyed in a direction parallel to a horizontal plane (H) across a cutting assembly 210, thereby separating a portion (such as the lower portion 102a) of the husk 102 from a remaining portion (such as the upper portion 102b) of the husk 102 to expose the cocoa beans 108. As described previously, the cutting assembly 210 includes a first blade 212a and a second blade 212b that are positioned on the horizontal plane (H) and aligned to cut across a portion of the cocoa pod 100 as the cocoa pod 100 is conveyed across the cutting assembly 210 at block 302. An angle of the major central axis (L) of the cocoa pod 100 relative to the horizontal plane (H) is maintained at a predetermined angle (A) of greater than 0° as the cocoa pod 100 is conveyed across the cutting assembly 210 at block 302. In some embodiments, the predetermined angle (A) at block 302 is in a range of about 3° to about 17°. The blades 212a, 212b can be separated from one another by a predetermined distance E that avoids contact of the blades 212a, 212b with the cocoa beans 108 as the cocoa pod 100 is conveyed across the cutting assembly 210 at block 302. The cocoa pod 100 can, for example, be conveyed across the cutting assembly 210 by the conveyor 202 at block 302. After separating the lower portion 102a of the husk 102 from the upper portion 102b of the husk 102 at block 302, the exposed cocoa beans 108 are separated from the upper portion 102b of the husk 102 at block 304.

[0042] Separating the cocoa beans 108 from the upper portion 102b at block 304 can include contacting the cocoa beans 108 with the rotary separator 226 that is rotating. Separating the cocoa beans 108 from the upper portion 102b at block 304 can include conveying the upperAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] portion 102b with the exposed cocoa beans 108 in a first direction (for example, generally the same direction as the cocoa pod 100 was conveyed across the cutting assembly 210 at block 302) toward the rotary separator 226 and rotating the rotary separator 226 in a second direction that is opposite the first direction (for example, in a counter-clockwise direction). In some embodiments, the rotary separator 226 is rotated in the same, first direction in which the upper portion 102b with the exposed cocoa beans 108 is conveyed (for example, in a clockwise direction). In some embodiments, as described previously, the rotary separator 226 includes multiple scrapers that rotate in different directions. For example, at least one of the scrapers of the rotary separator 226 can rotate counter-clockwise, while at least one other scraper of the rotary separator 226 rotates clockwise. The method 300 can include preventing lateral movement (for example, by the centering guide 214) of the cocoa pod 100 in relation to the direction in which the cocoa pod 100 is conveyed across the cutting assembly 210 while the cocoa pod 100 is conveyed across the cutting assembly 210 at block 302. In some embodiments, prior to conveying the cocoa pod 100 across the cutting assembly 210 at block 302, the method 300 includes adjusting the predetermined angle (A) at which the major central axis (L) of the cocoa pod 100 relative to the horizontal plane (H) is to be maintained as the cocoa pod 100 is conveyed across the cutting assembly 210 at block 302. In some embodiments, a height of the blades 212a, 212b is adjusted with respect to the conveyor 202. In some embodiments, the cocoa pod 100 is conveyed across the cutting assembly 210 at a conveyance rate sufficient for processing from 2,000 to 4,000, from 4,000 to 6,000, from 6,000 to 8,000, or from 8,000 to 10,000 cocoa pods 100 per hour. In some embodiments, the method 300 is not implemented by a computer.

[0043] FIGS. 4A and 4B show a side view and a top view, respectively, of a portion of an example cocoa pod processing system 400 for separating cocoa beans 108 from cocoa pods 100. The system 400 includes a movable conveyor 402 (e.g., a conveyor belt or chain). The conveyor 402 includes a conveyance receptacle 404. While a couple representations of the receptacle 404 are shown in FIG. 4A, the system 400 can include additional receptacles 404 (e.g., from 20 to 60) that are spaced apart (e.g., equally spaced apart) along the conveyor 402. The block arrows shown in FIGS. 4A and 4B represent a general direction in which the conveyor 402 conveys the receptacles 404. The receptacle 404 is configured to hold a cocoa pod 100. A user 206 can place a cocoa pod 100 into the receptacle 404. In at least this way, the methods described involve receiving a cocoa pod 100 in the receptacle 404. The system 400 includes a cutting arrangementAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]410 including blades 412a, 412b. The cutting arrangement 410 refers to a general arrangement of components of the system 400 associated with cutting the cocoa pods 100. The cutting arrangement 410 is configured to cut across a portion of each cocoa pod 100 to separate the husk 102 into separator portions and expose the cocoa beans 108. The system 400 can process cocoa pods 100 to separate cocoa beans 108 from the cocoa pods 100 independent of computer control. For example, operation of the system 400 is not controlled by a computer and does not require sensing equipment to successfully process cocoa pods 100 to extract cocoa beans 108 from the cocoa pods 100.

[0044] In this example, the receptacle 404 is configured to hold the cocoa pod 100 in an upright position with the peduncle 112 located at the top of the cocoa pod 100. In some embodiments, the receptacle 404 has a substantially cylindrical shape. In some embodiments, the top end of the receptacle 404 is an open end, which can facilitate ease of cocoa pod 100 input into the receptacle 404. The receptacle 404 can be made of steel, such as food-grade stainless steel A304 or structural steel A36.

[0045] In this example, the receptacle 404 includes an adjustable base 404a. The cocoa pod 100 held within the receptacle 404 rests on top of the adjustable base 404a. The adjustable base 404a is configured to adjust a height at which the cocoa pod 100 is held by the receptacle 404 such that the conveyor 402 is spaced from the peduncle 112 of the cocoa pod 100 by a predetermined distance. In some embodiments, the adjustable base 404a includes a spring 404b that exerts an opposing force against the weight of the cocoa pod 100 for maintaining the peduncle 112 of the cocoa pod 100 is spaced from the conveyor 402 at the predetermined distance. In some embodiments, the predetermined distance is in a range of from about 14 cm to about 28 cm. In this example, the cocoa pod 100 shown on the right is larger and heavier than the cocoa pod 100 shown on the left and because of this, the spring 404b shown on the right is more compressed than the spring 404b shown on the left. Despite the difference in size and weight of the cocoa pods 100, the peduncles 112 of the cocoa pods 100 are at substantially the same height with respect to the conveyor 402 due to the adjustable base 404a. In this example, the receptacle 404 includes a support bracket 404c. The support bracket 404c is coupled to the conveyor 402 for securing the receptacle 404 to the conveyor 402 as the conveyor 402 conveys the receptacle 404 and the cocoa pod 100 being carried by the receptacle 404.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]

[0046] As described previously, the system 400 can include a plurality of receptacles 404 and at any particular moment, more than one conveyance receptacle 404 can empty and open waiting for the user 206 to deposit an additional cocoa pod 100. For example, in some cases, the user 206 can use both hands to load two cocoa pods 100 into two receptacles 404 at the same time. Alternatively, the user 206 can load the cocoa pod 100 onto the receptacle 404 while a second user loads a second cocoa pod 100 into a second receptacle 404. In at least these ways, in some cases, more than one cocoa pod 100 can be loaded into the system 200 simultaneously.

[0047] The conveyor 402 is a continuous member that can translate in a consistent direction (e.g., clockwise as viewed in FIG. 4A). For example, the conveyor 402 moves in a first horizontal direction, rotates around an end roller, moves back in a second, opposite, horizontal direction, rotates around another end roller, and repeats back to moving again in the first horizontal direction.

[0048] The system 400 includes a motor 408 that is coupled (e.g., using rollers, gears, belts, sprockets, etc.) to the conveyor 402 to advance the conveyor 402 in the clockwise direction. In some cases, the motor 408 is an electric motor with a user-adjustable speed control. In some cases, the motor 408 is configured to rotate the conveyor 402 at a rotational rate sufficient for the system 400 to process from 2,000 to 4,000, from 4,000 to 6,000, from 6,000 to 8,000, or from 8,000 to 10,000 cocoa pods 100 per hour. In scenarios where these speeds are used, in some cases, the user 206 can be replaced or supplemented with a chute that automatically deposit cocoa pods 100 into respective conveyance receptacles 404 (e g., using the force of gravity).

[0049] As shown in FIG. 4A, the conveyor 402 conveys (e.g., as driven by the motor 408) the cocoa pod 100 toward one or more processing stations. In this example, the conveyor 402 conveys the cocoa pod 100 toward the cutting arrangement 410. In the depicted embodiment, the motor 408 drives the conveyor 402 continuously through the cutting arrangement 410. For example, the motor 408 can continuously convey the cocoa pod 100 toward the cutting arrangement 410 at a constant velocity. The conveyor 402 conveys the cocoa pod 100 held by the receptacle 404 in a direction parallel to a horizontal plane (H) toward the cutting arrangement 410.

[0050] The blades 412a, 412b are positioned on the horizontal plane (H). The blades 412a, 412b are aligned to cut across a portion of the cocoa pod 100, such as the husk 102, as the cocoa pod 100 is moved by the conveyor 402. The blades 412a, 412b cutting across the husk 102 as the cocoa pod 100 is moved by the conveyor 402 causes the husk 102 to separate into separate portionsAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ](lower portion 102a and upper portion 102b). In some embodiments, the blades 412a, 412b are made of stainless steel or structural steel that has been tempered.

[0051] In some embodiments, the height at which the blades 412a, 412b are positioned with respect to the conveyor 402 is adjustable. For example, the height of the blades 412a, 412b with respect to the conveyor 402 can be adjusted to account for differently shaped cocoa pods 100.

[0052] In this example, the cutting assembly 410 includes a centering guide 414 positioned above the blades 412a, 412b with respect to gravity. In some embodiments, the centering guide 414 is biased downward (e.g., by a spring) or sufficiently heavy to apply a small downward force with respect to gravity on top of the cocoa pod 100 as the cocoa pod 100 is moved by the conveyor 402 across the blades 412a, 412b. The centering guide 414 is configured to prevent lateral movement of the cocoa pod 100 in relation to the direction in which the conveyor 402 moves the cocoa pod 100 across the blades 412a, 412b. The centering guide 414 and the adjustable base 404a can work cooperatively to maintain the peduncles 112 of the cocoa pods 100 at substantially the same height with respect to the conveyor 402 regardless of varying size and weight of the cocoa pods 100. For example, the spring 404b of the adjustable base 404a compresses at least based on the weight of the cocoa pod 100, and the centering guide 414 may apply a downward force on the cocoa pod 100 to maintain the peduncle 112 of the cocoa pod 100 at the predetermined distance with respect to the conveyor 402 in cases where the weight of the cocoa pod 100 insufficiently compresses the spring 404b of the adjustable base 404a.

[0053] The first blade 412a can include a downward fold 412a’ positioned at an end of the first blade 412a opposite of the end that first comes into contact with the cocoa pod 100. The second blade 412b can include a downward fold 412b’ positioned at an end of the second blade 412b opposite of the end that first comes into contact with the cocoa pod 100. The downward folds 412a’, 412b’ are configured to facilitate separation of the husk 102 (that has been cut by the blades 412a, 412b) into the separate portions (lower portion 102a and upper portion 102b). For example, the shape of the downward folds 412a’, 412b’ can force the lower portion 102b to diverge from the upper portion 102b in response to conveying the cocoa pod 100 across the downward folds 412a’, 412b’. The downward folds 412a’, 412b’ can be, for example, curved or straight. The lower portion 102a of the husk 102 is separated from the upper portion 102b of the husk 102 by the blades 412a, 412b (and downward folds 412a’, 412b’), and the upper portion 102b of the husk 102 remains on top of the blades 412a, 412b. Separation of the lower and upper portions 102a,Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]102b exposes the meat 106 (including the cocoa beans 108) of the cocoa pod 100. Tn some cases, the height of the blades 412a, 412b with respect to the conveyor 202 can be sufficiently short such that the peduncle 112 remains a part of the upper portion 102b. The exposed meat 106 can hang from the upper portion 102b. The upper portion 102b including the exposed meat 106 can move from the cutting assembly 410 to a separation arrangement 420. The separation arrangement 420 can include a vacuum system, a blowing system, a mechanical system, or any combinations of these to separate the beans 108 (part of the exposed meat 106) from the upper portion 102b. An example of the separation arrangement 420 including a mechanical system is shown in FIG. 4D and described in more detail later. The lower portion 102a that has separated from the upper portion 102b can be directed to and / or fall into a first receiving section (e.g., a hopper for husk material).

[0054] FIG. 4C is a cross-sectional view of a cocoa pod 100 held by a receptacle 404 and being cut by the cutting arrangement 410 of the system 400. In this example, the blades 412a, 412b are positioned on the horizontal plane above the receptacle 404, such that the blades 412a, 412b avoid contact with the receptacle 404 as the cocoa pod 100 is conveyed across the cutting arrangement 410. As shown in FIG. 4C, the blades 412a, 412b are separated from one another by a distance E. The distance E is sufficiently large such that the blades 412a, 412b avoid contact with the cocoa beans 108 as the cocoa pod 100 is moved by the conveyor 402 across the blades 412a, 412b. In some embodiments, the distance E is in a range of from about 1 cm to about 6 cm. The distance E between the blades 412a, 412b ensures that the cocoa beans 108 do not get damaged by the blades 412a, 412b as the cocoa pod 100 is moved by the conveyor 402 across the blades 412a, 412b.

[0055] In this example, the centering guide 414 includes wings 414a, 414b extending outward for conforming to the generally ellipsoidal shape of the cocoa pod 100. In other examples, the centering guide 414 is generally flat. In other examples, the centering guide has a generally hemicylindrical (half a cylinder divided longitudinally) shape.

[0056] FIG. 4D is a side view of an example separation arrangement 420 of the system 400. The separation arrangement 420 receives the upper portion 102b including the exposed meat 106 from the cutting arrangement 410. The separation arrangement 420 includes a ramp 421 configured to receive the upper portion 102b including the exposed meat 106 from the cutting arrangement 410. In some cases, the ramp 421 is positioned at a slightly lower height inAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] comparison to the blades 412a, 412b of the cutting arrangement 410 with respect to gravity to ensure that the upper portion 102b slides down from the cutting arrangement 410 onto the ramp 421. In some cases, the system 400 includes a mechanism (e.g., a conveyor belt) that pushes the upper portion 102b including the exposed meat 106 from the cutting arrangement 410 onto the ramp 421.

[0057] Similar to the platform 221 of the system 200 described previously, the ramp 421 defines a void space that is aligned with the exposed meat 106 such that the exposed meat 106 hangs from the upper portion 102b through the void space. The ramp 421 is configured to vibrate. Due to the vibration by the ramp 421 and the force of gravity, the upper portion 102b moves down the slope of the ramp 421. The vibration by the ramp 421 causes the cocoa beans 108 to separate from the upper portion 102b. For example, the vibration by the ramp 421 causes the cocoa beans 108 to become loose and separate from the meat 106. The cocoa beans 108 that have separated from the upper portion 102b can be directed to and / or fall into a second receiving section (e.g., a hopper for cocoa beans). In some cases, a remaining portion of the meat 106 (e.g., pulp, placenta 107, etc.) remains attached to the upper portion 102b despite the vibration imparted by the ramp 421. The upper portion 102b of the husk 102 still connected to the remaining portion of the meat 106 can be directed to and / or fall into the first receiving section or another receiving section (e.g., a hopper for husk material) after the cocoa beans 108 have been separated.

[0058] The separation arrangement 420 can include a motor 428 that is coupled to the ramp 421 . The motor 428 can be configured to vibrate the ramp 421 to move the upper portion 102b across the ramp 421 and separate cocoa beans 108 from the upper portion 102b. In some cases, the motor 428 is an electric motor with a user-adjustable speed control. The motor 428 can, for example, vibrate the ramp 421 in directions perpendicular to the slope of the ramp 421. As another example, the motor 428 can vibrate the ramp 421 in upward and downward directions with respect to gravity.

[0059] FIG. 5 is a flow chart of an example method 500 for processing cocoa pods 100. The method 500 can, for example, be performed by the system 400. At block 502, a cocoa pod 100 is conveyed in a direction parallel to a horizontal plane (H) across a cutting arrangement 410, thereby separating a portion (such as the lower portion 102a) of the husk 102 from a remaining portion (such as the upper portion 102b) of the husk 102 to expose the cocoa beans 108. As described previously, the cutting arrangement 410 includes a first blade 412a and a second bladeAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]412b that are positioned on the horizontal plane (H) and aligned to cut across a portion of the cocoa pod 100 as the cocoa pod 100 is conveyed across the cutting arrangement at block 502. The cocoa pod 100 is held in an upright position with the peduncle 112 located at the top of the cocoa pod 100 and at a predetermined height from the horizontal plane (H) while the cocoa pod 100 is conveyed across the cutting arrangement 410 at block 502. The blades 412a, 412b can be separated from one another by a predetermined distance E that avoids contact of the blades 412a, 412b with the cocoa beans 108 as the cocoa pod 100 is conveyed across the cutting arrangement 410 at block 502. The cocoa pod 100 can, for example, be conveyed across the cutting arrangement 410 by the conveyor 402 at block 502. After separating the lower portion 102a of the husk 102 from the upper portion 102b of the husk 102 at block 502, the exposed cocoa beans 108 are separated from the upper portion 102b of the husk 102 at block 504.

[0060] Separating the cocoa beans 108 from the upper portion 102b at block 504 can include vibrating the upper portion 102b of the husk 102, thereby loosening and releasing the cocoa beans 108 from the upper portion 102b. The upper portion 102b can be vibrated, for example, by the motor 428 coupled to the ramp 421. Vibrating the upper portion 102b can loosen and release the cocoa beans 108 from a remaining portion of the meat 106 (e.g., pulp, placenta 107, etc.) while the remaining portion of the meat 106 remains connected to the upper portion 102b. The method 500 can include receiving the cocoa pod 100 in the receptacle 404 including the adjustable base 404a. Conveying the cocoa pod 100 across the cutting arrangement 410 at block 502 can include conveying the receptacle 404 across the cutting arrangement 410 with the cocoa pod 100 disposed at least partially within the receptacle 404 and supported by the adjustable base 404a. The cocoa pod 100 can be held in the upright position with the peduncle 112 at the predetermined height from the horizontal plane (H) (or from the conveyor 402, which is parallel to the horizontal plane (H)) by the spring 404b as the cocoa pod 100 is conveyed across the cutting arrangement 410 at block 502. The method 500 can include preventing lateral movement (for example, by the centering guide 414) of the cocoa pod 100 in relation to the direction in which the cocoa pod 100 is conveyed across the cutting arrangement 410 while the cocoa pod 100 is conveyed across the cutting arrangement 410 at block 502. In some embodiments, a height of the blades 412a, 412b is adjusted with respect to the conveyor 402. In some embodiments, the cocoa pod 100 is conveyed across the cutting arrangement 410 at a conveyance rate sufficient for processing from 2,000 to 4,000, from 4,000 to 6,000, from 6,000 to 8,000, or from 8,000 to 10,000 cocoa pods 100 per hour. InAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] some embodiments, the method 500 is not implemented by a computer.

[0061] EXAMPLES

[0062] Experiments were conducted to verify performance of the cocoa pod processing system in terms of processing speed and cocoa beans collection yield. The experiments were conducted on CCN51 cocoa pods without sorting and harvested the day before the experiments were conducted. On Day 1, the cocoa pods were harvested and placed in crates, with 20 pods per crate and 25 crates per pallet. Extremely diseased pods were removed. The cocoa pods were then re-counted, and the total weight of the cocoa pods was measured. On Day 2, the cocoa pod processing system was charged at a rate of 3,800 cocoa pods per hour. Two operators fed the cocoa pods to the cocoa pod processing system. Downstream, two operators collected beans from husk pieces that were not separated by the cocoa pod processing system. One operator moved crates and pallets. One operator supervised the process and collected data. After processing was completed, the cocoa beans collected by the cocoa pod processing system were weighed, and the cocoa beans collected by the two operators by hand were weighed. The processing time for the cocoa pod processing system to process the cocoa pods was recorded. The processing speed was calculated by dividing the total number of cocoa pods processed by the processing time. For example, for 452 cocoa pods processed in 8 minutes, the processing speed was 56.5 cocoa pods per minute (3,390 cocoa pods per hour). The collection yield was calculated by dividing the weight of cocoa beans collected by the cocoa pod processing system by the total sum of the weight of cocoa beans collected by the cocoa pod processing system combined with the weight of cocoa beans collected by the two operators by hand. For example, for 70 kilograms of cocoa beans collected by the cocoa pod processing system and 30 kilograms of cocoa beans collected by hand, the collection yield was 70%.

[0063] Tables 1, 2, and 3 provide results of various experiments. Table 3 provides impurity and damage data for the experiments conducted on October 17, 2024 and January 23, 2025. The impurity percentages shown in Table 3 are the percentage of cocoa beans collected that exhibited impurities. The damage percentages shown in Table 3 are the percentage of cocoa beans collected that were damaged.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]Table 1: Week 1 trials for verifying processing speed and cocoa beans collection yieldTable 2: Week 2 trials for verifying processing speed and cocoa beans collection yieldAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]Table 3: Various trials for verifying processing speed and cocoa beans collection yield, including impurity and damage data

[0064] The experiments demonstrate that the cocoa pod processing system was able to consistently process cocoa pods at rates greater than 3,000 cocoa pods per hour and was limited by the speed at which operators could manually feed the cocoa pod processing system. The cocoa pod processing system achieved an average collection yield from 87% to 91%, particularly when the cocoa pods had dimensions greater than 12 centimeters in length and 8 centimeters in diameter.

[0065] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a subcombination.

[0066] As used in this disclosure, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B .” In addition, it is to be understood that the phraseology orAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / t ] terminology employed in this disclosure, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

[0067] As used in this disclosure, the term “about” or “approximately” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range.

[0068] As used in this disclosure, the term “substantially” refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.

[0069] Values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “0.1% to about 5%” or “0.1% to 5%” should be interpreted to include about 0.1% to about 5%, as well as the individual values (for example, 1%, 2%, 3%, and 4%) and the sub-ranges (for example, 0. 1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “X, Y, or Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

[0070] Particular implementations of the subject matter have been described. Other implementations, alterations, and permutations of the described implementations are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results. In certain circumstances, multitasking or parallel processing (or a combination of multitasking and parallel processing) may be advantageous and performed as deemed appropriate.

[0071] Moreover, the separation or integration of various system modules and components in the previously described implementations should not be understood as requiring such separation or integration in all implementations, and it should be understood that the described componentsAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] and systems can generally be integrated together or packaged into multiple products.

[0072] Accordingly, the previously described example implementations do not define or constrain the present disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of the present disclosure.EMBODIMENTS

[0073] In a first example implementation (or aspect), a cocoa pod processing system comprises: a conveyor configured to move in a direction parallel to a horizontal plane, the conveyor comprising a receptacle configured to hold a cocoa pod, the cocoa pod comprising a husk and cocoa beans housed within the husk, and the cocoa pod defining a major central axis, wherein the receptacle is configured to hold the cocoa pod such that the major central axis of the cocoa pod relative to the horizontal plane is at a predetermined angle of greater than 0°; a cutting assembly comprising a first blade and a second blade positioned on the horizontal plane and aligned to cut across a portion of the cocoa pod as the cocoa pod is moved by the conveyor, wherein the cutting assembly is configured to separate a portion of the husk from a remaining portion of the husk to expose the cocoa beans; and a separation assembly configured to move the remaining portion of the husk with the exposed cocoa beans and separate the exposed cocoa beans from the remaining portion of the husk.

[0074] In a second example implementation (or aspect) combinable with the first example implementation (or aspect), the cocoa pod comprises a peduncle, and the receptacle is configured to hold the cocoa pod with the peduncle pointing in a second direction generally opposite of the direction in which the conveyor moves.

[0075] In a third example implementation (or aspect) combinable with the second example implementation (or aspect), the cocoa beans are connected to a placenta of the cocoa pod, and the cutting assembly is configured to separate the portion of the husk from the remaining portion of the husk to expose the cocoa beans connected to the placenta.

[0076] In a fourth example implementation (or aspect) combinable with the third example implementation (or aspect), the separation assembly is configured to separate the exposed cocoa beans connected to the placenta from the remaining portion of the husk.

[0077] In a fifth example implementation (or aspect) combinable with the fourth example implementation (or aspect), the conveyor is a first conveyor, and the separation assemblyAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] comprises a second conveyor configured to move the remaining portion of the husk with the exposed cocoa beans in the direction parallel to the horizontal plane.

[0078] In a sixth example implementation (or aspect) combinable with the fifth example implementation (or aspect), the separation assembly comprises a rotary separator configured to rotate in a second, opposite direction of the direction of the remaining portion of the husk with the exposed cocoa beans moved by the second conveyor, wherein the rotary separator is positioned to make contact with the exposed cocoa beans and configured to separate the exposed cocoa beans from the remaining portion of the husk in response to contacting the exposed cocoa beans.

[0079] In a seventh example implementation (or aspect) combinable with the sixth example implementation (or aspect), the rotary separator comprises scrapers.

[0080] In an eighth example implementation (or aspect) combinable with the seventh example implementation (or aspect), the scrapers are made of food-grade stainless steel.

[0081] In a ninth example implementation (or aspect) combinable with the seventh example implementation (or aspect), the scrapers are made of food-grade rubber.

[0082] In a tenth example implementation (or aspect) combinable with any of the first through ninth example implementations (or aspects), the first blade and the second blade are separated from one another by a distance that avoids contact of the first blade and the second blade with the cocoa beans.

[0083] In an eleventh example implementation (or aspect) combinable with any of the first through tenth example implementations (or aspects), at least one of the first blade or the second blade comprises a downward fold.

[0084] In a twelfth example implementation (or aspect) combinable with any of the first through eleventh example implementations (or aspects), the predetermined angle is in a range of about 3° to about 17°.

[0085] In a thirteenth example implementation (or aspect) combinable with any of the first through twelfth example implementations (or aspects), the cutting assembly comprises a centering guide configured to prevent lateral movement of the cocoa pod in relation to the direction in which the conveyor moves.

[0086] In a fourteenth example implementation (or aspect) combinable with any of the first through thirteenth example implementations (or aspects), the receptacle is made of food-grade stainless steel.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]

[0087] In a fifteenth example implementation (or aspect) combinable with any of the first through thirteenth example implementations (or aspects), the receptacle is made of structural steel.

[0088] In a sixteenth example implementation (or aspect) combinable with any of the first through fifteenth example implementations (or aspects), the first blade and the second blade are made of stainless steel that has been tempered.

[0089] In a seventeenth example implementation (or aspect) combinable with any of the first through fifteenth example implementations (or aspects), the first blade and the second blade are made of structural steel that has been tempered.

[0090] In an eighteenth example implementation (or aspect) combinable with any of the first through seventeenth example implementations (or aspects), the system comprises a hopper configured to receive the portion of the husk separated by the cutting assembly and the remaining portion of the husk after the cocoa beans have been separated from the remaining portion of the husk.

[0091] In a nineteenth example implementation (or aspect) combinable with any of the first through eighteenth example implementations (or aspects), the receptacle is adjustable for adjusting the predetermined angle or for holding a second cocoa pod of different size.

[0092] In a twentieth example implementation (or aspect) combinable with any of the first through nineteenth example implementations (or aspects), the first blade and the second blade are adjustable for adjusting a height of the first blade and the second blade with respect to the conveyor.

[0093] In a 21stexample implementation (or aspect) combinable with any of the first through twentieth example implementations (or aspects), the system comprises a motor configured to rotate the conveyor at a rotational rate sufficient for the cocoa pod processing system to process from 6,000 to 8,000 cocoa pods per hour.

[0094] In a 22ndexample implementation (or aspect) combinable with any of the first through 21stexample implementations (or aspects), the system comprises a motor configured to rotate the conveyor at a rotation rate sufficient for the cocoa pod processing system to process more than 400 cocoa pods per hour.

[0095] In a 23rdexample implementation (or aspect) combinable with any of the first through 22ndexample implementations (or aspects), the cocoa pod processing system is not computer controlled.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]

[0096] In a 24thexample implementation (or aspect), a cocoa pod processing system comprises: a conveyor configured to move in a direction parallel to a horizontal plane, the conveyor comprising a receptacle configured to hold a cocoa pod, the cocoa pod comprising a husk, cocoa beans housed within the husk, and a peduncle, the receptacle configured to hold the cocoa pod in an upright position with the peduncle located at the top of the cocoa pod, the receptacle comprising an adjustable base configured to adjust a height at which the cocoa pod is held by the receptacle such that the conveyor is spaced from the peduncle of the cocoa pod by a predetermined distance; a cutting arrangement comprising a first blade and a second blade positioned on the horizontal plane to cut across a portion of the cocoa pod moved by the conveyor, the cutting arrangement configured to separate a portion of the husk from a remaining portion of the husk to expose the cocoa beans; and a separating arrangement configured to separate the exposed cocoa beans from the remaining portion of the husk.

[0097] In a 25thexample implementation (or aspect) combinable with the 24thexample implementation (or aspect), the cocoa beans are connected to a placenta of the cocoa pod, and the cutting arrangement is configured to separate the portion of the husk from the remaining portion of the husk to expose the cocoa beans connected to the placenta.

[0098] In a 26thexample implementation (or aspect) combinable with the 25thexample implementation (or aspect), the separation arrangement is configured to separate the exposed cocoa beans connected to the placenta from the remaining portion of the husk.

[0099] In a 27thexample implementation (or aspect) combinable with the 26thexample implementation (or aspect), the separating arrangement comprises a ramp configured to receive the remaining portion of the husk with the exposed cocoa beans, wherein the ramp defines a void space that allows the exposed cocoa beans to hang from the remaining portion of the husk.

[0100] In a 28thexample implementation (or aspect) combinable with the 27thexample implementation (or aspect), the ramp is configured to vibrate to move the remaining portion of the husk along a slope of the ramp and separate the exposed cocoa beans from the remaining portion of the husk.

[0101] In a 29thexample implementation (or aspect) combinable with the 28thexample implementation (or aspect), the separating arrangement comprises a motor coupled to the ramp and configured to vibrate the ramp to move the remaining portion of the husk along a slope of the ramp and separate the exposed cocoa beans from the remaining portion of the husk.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]

[0102] In a 30thexample implementation (or aspect) combinable with any of the 24ththrough 29thexample implementations (or aspects), the cocoa pod comprises a placenta housed within and connected to the husk and attached to the cocoa beans, wherein the ramp is configured to vibrate to separate the exposed cocoa beans from the placenta while the placenta remains connected to the remaining portion of the husk.

[0103] In a 31stexample implementation (or aspect) combinable with any of the 24ththrough 30thexample implementations (or aspects), the first blade and the second blade are separated from one another by a distance that avoids contact of the first blade and the second blade with the cocoa beans.

[0104] In a 32ndexample implementation (or aspect) combinable with any of the 24ththrough 31stexample implementations (or aspects), at least one of the first blade or the second blade comprises downward fold configured to separate the portion of the husk from the remaining portion of the husk to expose the cocoa beans.

[0105] In a 33rdexample implementation (or aspect) combinable with any of the 24ththrough 32ndexample implementations (or aspects), the adjustable base comprises a spring.

[0106] In a 34thexample implementation (or aspect) combinable with any of the 24ththrough 33rdexample implementations (or aspects), the receptacle has a substantially cylindrical shape.

[0107] In a 35thexample implementation (or aspect) combinable with any of the 24ththrough 34thexample implementations (or aspects), the cutting arrangement comprises a centering guide is positioned and configured to prevent lateral movement of the cocoa pod in relation to the direction in which the conveyor moves.

[0108] In a 36thexample implementation (or aspect) combinable with any the 35thexample implementation (or aspect), the centering guide is positioned and configured to apply a downward force on the cocoa pod as the cocoa pod is conveyed by the conveyor to maintain the peduncle of the cocoa pod at the predetermined distance from the conveyor.

[0109] In a 37thexample implementation (or aspect) combinable with any of the 24ththrough 36thexample implementations (or aspects), the receptacle is made of food-grade stainless steel.

[0110] In a 38thexample implementation (or aspect) combinable with any of the 24ththrough 36thexample implementations (or aspects), the receptacle is made of structural steel.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]

[0111] In a 39thexample implementation (or aspect) combinable with any of the 24ththrough 38thexample implementations (or aspects), the first blade and the second blade are made of stainless steel that has been tempered.

[0112] In a 40thexample implementation (or aspect) combinable with any of the 24ththrough 38thexample implementations (or aspects), the first blade and the second blade are made of structural steel.

[0113] In a 41stexample implementation (or aspect) combinable with any of the 24ththrough 40thexample implementations (or aspects), the separation arrangement comprises a hopper configured to receive the cocoa beans that have been separated from the remaining portion of the husk.

[0114] In a 42ndexample implementation (or aspect) combinable with any of the 24ththrough 41stexample implementations (or aspects), the first blade and the second blade are adjustable for adjusting a height of the first blade and the second blade with respect to the conveyor.

[0115] In a 43rdexample implementation (or aspect) combinable with any of the 24ththrough 42ndexample implementations (or aspects), the system comprises a conveyor motor configured to rotate the conveyor at a rotational rate sufficient for the cocoa pod processing system to process from 6,000 to 8,000 cocoa pods per hour.

[0116] In a 44thexample implementation (or aspect) combinable with any of the 24ththrough 42ndexample implementations (or aspects), the system comprises a conveyor motor configured to rotate the conveyor at a rotational rate sufficient for the cocoa pod processing system to process more than 400 cocoa pods per hour.

[0117] In a 45thexample implementation (or aspect) combinable with any of the 24ththrough 44thexample implementations (or aspects), the first blade and the second blade are positioned on the horizontal plane above the receptacle, such that the first blade and the second blade avoid contact with the receptacle as the conveyor moves the cocoa pod across the cutting arrangement.

[0118] In a 46thexample implementation (or aspect) combinable with any of the 24ththrough 45thexample implementations (or aspects), the cocoa pod processing system is not computer controlled.

[0119] In a 47thexample implementation (or aspect), a method comprises: conveying aAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] cocoa pod, comprising a husk and cocoa beans housed within the husk, in a direction parallel to a horizontal plane across a cutting assembly comprising a first blade and a second blade positioned on the horizontal plane and aligned to cut across a portion of the cocoa pod as the cocoa pod is conveyed across the cutting assembly, thereby separating a portion of the husk from a remaining portion of the husk to expose the cocoa beans, wherein the cocoa pod defines a major central axis, wherein an angle of the major central axis of the cocoa pod relative to the horizontal plane is maintained at a predetermined angle of greater than 0° as the cocoa pod is conveyed across the cutting assembly; and after separating the portion of the husk from the remaining portion of the husk, separating the exposed cocoa beans from the remaining portion of the husk.

[0120] In a 48thexample implementation (or aspect) combinable with the 47thexample implementation (or aspect), the cocoa pod comprises a peduncle, and the peduncle points in a second direction generally opposite of the direction in which the cocoa pod is conveyed.

[0121] In a 49thexample implementation (or aspect) combinable with the 48thexample implementation (or aspect), the cocoa beans are connected to a placenta of the cocoa pod, and the portion of the husk is separated from the remaining portion of the husk to expose the cocoa beans connected to the placenta.

[0122] In a 50thexample implementation (or aspect) combinable with the 49thexample implementation (or aspect), separating the exposed cocoa beans from the remaining portion of the husk comprises separating the exposed cocoa beans connected to the placenta from the remaining portion of the husk.

[0123] In a 51stexample implementation (or aspect) combinable with any of the 47ththrough 50thexample implementations (or aspects), conveying the cocoa pod across the cutting assembly is performed by a conveyor.

[0124] In a 52ndexample implementation (or aspect) combinable with any of the 47ththrough 51stexample implementations (or aspects), the method comprises preventing lateral movement of the cocoa pod in relation to the direction in which the cocoa pod is conveyed across the cutting assembly.

[0125] In a 53rdexample implementation (or aspect) combinable with any of the 47ththrough 52ndexample implementations (or aspects), separating the exposed cocoa beans from the remaining portion of the husk comprises contacting the exposed cocoa beans with a rotary separator that is rotating.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]

[0126] In a 54thexample implementation (or aspect) combinable with any of the 47ththrough 53rdexample implementations (or aspects), the rotary separator comprises a plurality of scrapers.

[0127] In a 55thexample implementation (or aspect) combinable with the 54thexample implementation (or aspect), the plurality of scrapers is rotated in a second direction opposite of the direction in which the cocoa pod is conveyed.

[0128] In a 56thexample implementation (or aspect) combinable with the 54thexample implementation (or aspect), the plurality of scrapers is rotated in the direction in which the cocoa pod is conveyed.

[0129] In a 57thexample implementation (or aspect) combinable with the 54thexample implementation (or aspect), a first portion of the plurality of scrapers is rotated in the direction in which the cocoa pod is conveyed, and a second portion of the plurality of scrapers is rotated in a second direction opposite of the direction in which the cocoa pod is conveyed.

[0130] In a 58thexample implementation (or aspect) combinable with the 54thexample implementation (or aspect), separating the exposed cocoa beans from the remaining portion of the husk comprises: conveying the remaining portion of the husk with the exposed cocoa beans in a first direction toward the rotary separator; and rotating the rotary separator in a second direction opposite the first direction.

[0131] In a 59thexample implementation (or aspect) combinable with any of the 47ththrough 58thexample implementations (or aspects), the first blade and the second blade are separated from one another by a predetermined distance that avoids contact of the first blade and the second blade with the cocoa beans as the cocoa pod is conveyed across the cutting assembly.

[0132] In a 60thexample implementation (or aspect) combinable with any of the 47ththrough 59thexample implementations (or aspects), at least one of the first blade or the second blade comprises a downward fold, wherein conveying the cocoa pod across the cutting assembly comprises conveying the cocoa pod across the downward fold, forcing the portion of the husk to diverge from the remaining portion of the husk.

[0133] In a 61stexample implementation (or aspect) combinable with any of the 47ththrough 60thexample implementations (or aspects), the predetermined angle is in a range of about 3° to about 17°.

[0134] In a 62ndexample implementation (or aspect) combinable with any of the 47thAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] through 61stexample implementations (or aspects), the method comprises, prior to conveying the cocoa pod across the cutting assembly, adjusting the predetermined angle at which the major central axis of the cocoa pod relative to the horizontal plane is to be maintained as the cocoa pod is conveyed across the cutting assembly.

[0135] In a 63rdexample implementation (or aspect) combinable with any of the 51stthrough 62ndexample implementations (or aspects), the method comprises adjusting a height of the first blade and the second blade with respect to the conveyor.

[0136] In a 64thexample implementation (or aspect) combinable with any of the 47ththrough 63rdexample implementations (or aspects), the cocoa pod is conveyed across the cutting assembly at a conveyance rate sufficient for processing from 6,000 to 8,000 cocoa pods per hour.

[0137] In a 65thexample implementation (or aspect) combinable with any of the 47ththrough 64thexample implementations (or aspects), the cocoa pod is conveyed across the cutting assembly at a conveyance rate sufficient for processing more than 400 cocoa pods per hour.

[0138] In a 66thexample implementation (or aspect) combinable with any of the 47ththrough 65thexample implementations (or aspects), the method is not computer-implemented.

[0139] In a 67thexample implementation (or aspect), a method comprises: conveying a cocoa pod, comprising a husk, cocoa beans housed within the husk, and a peduncle, in a direction parallel to a horizontal plane across a cutting arrangement comprising a first blade and a second blade positioned on the horizontal plane and aligned to cut across a portion of the cocoa pod as the cocoa pod is conveyed across the cutting arrangement, thereby separating a portion of the husk from a remaining portion of the husk to expose the cocoa beans, wherein the cocoa pod is held in an upright position with the peduncle located at the top of the cocoa pod and at a predetermined height from the horizontal plane while the cocoa pod is conveyed across the cutting arrangement; and after separating the portion of the husk from the remaining portion of the husk, separating the exposed cocoa beans from the remaining portion of the husk.

[0140] In a 68thexample implementation (or aspect) combinable with the 67thexample implementation (or aspect), conveying the cocoa pod across the cutting arrangement is performed by a conveyor.

[0141] In a 69thexample implementation (or aspect) combinable with the 67thor 68thexample implementation (or aspect), the method comprises receiving the cocoa pod in a receptacle comprising an adjustable base, wherein conveying the cocoa pod across the cutting arrangementAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] comprises conveying the receptacle across the cutting arrangement with the cocoa pod disposed at least partially within the receptacle and supported by the adjustable base.

[0142] In a 70thexample implementation (or aspect) combinable with the 69thexample implementation (or aspect), the receptacle has a substantially cylindrical shape, and the adjustable base comprises a spring, wherein the cocoa pod is held in the upright position with the peduncle at the predetermined height from the horizontal plane by the spring as the cocoa pod is conveyed across the cutting arrangement.

[0143] In a 71stexample implementation (or aspect) combinable with any of the 69ththrough 70thexample implementations (or aspects), the first and second blades are positioned on the horizontal plane above the receptacle, such that the first and second blades avoid contact with the receptacle as the cocoa pod is conveyed across the cutting arrangement.

[0144] In a 72ndexample implementation (or aspect) combinable with any of the 67ththrough 71stexample implementations (or aspects), the method comprises preventing lateral movement of the cocoa pod in relation to the direction in which the cocoa pod is conveyed across the cutting arrangement.

[0145] In a 73rdexample implementation (or aspect) combinable with any of the 67ththrough 72ndexample implementation (or aspect), separating the exposed cocoa beans from the remaining portion of the husk comprises vibrating the remaining portion of the husk, thereby loosening and releasing the cocoa beans from the remaining portion of the husk.

[0146] In a 74thexample implementation (or aspect) combinable with the 73rdexample implementation (or aspect), the cocoa pod comprises a placenta housed within and connected to the husk and attached to the cocoa beans, wherein vibrating the remaining portion of the husk loosens and releases the cocoa beans from the placenta while the placenta remains connected to the remaining portion of the husk.

[0147] In a 75thexample implementation (or aspect) combinable with any of the 67ththrough 74thexample implementations (or aspects), the first blade and the second blade are separated from one another by a predetermined distance that avoids contact of the first blade and the second blade with the cocoa beans as the cocoa pod is conveyed across the cutting arrangement.

[0148] In a 76thexample implementation (or aspect) combinable with any of the 67ththrough 75thexample implementations (or aspects), at least one of the first blade or the second blade comprises a downward fold, wherein conveying the cocoa pod across the cuttingAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] arrangement comprises conveying the cocoa pod to the downward fold, forcing the portion of the husk to diverge from the remaining portion of the husk.

[0149] In a 77thexample implementation (or aspect) combinable with any of the 68ththrough 76thexample implementations (or aspects), the method comprises adjusting a height of the first blade and the second blade with respect to the conveyor.

[0150] In a 78thexample implementation (or aspect) combinable with any of the 67ththrough 77thexample implementations (or aspects), the cocoa pod is conveyed across the cutting assembly at a conveyance rate sufficient for processing from 6,000 to 8,000 cocoa pods per hour.

[0151] In a 79thexample implementation (or aspect) combinable with any of the 67ththrough 77thexample implementations (or aspects), the cocoa pod is conveyed across the cutting assembly at a conveyance rate sufficient for processing more than 400 cocoa pods per hour.

[0152] In an 80thexample implementation (or aspect) combinable with any of the 67ththrough 79thexample implementations (or aspects), the method is not computer-implemented.

[0153] In an 81stexample implementation (or aspect), a cocoa pod processing system comprising: a conveyor configured to move in a first direction, the conveyor comprising a receptacle configured to hold a cocoa pod, the cocoa pod comprising a husk and cocoa beans, wherein the receptacle is configured to hold the cocoa pod such that a major central axis defined by the cocoa pod relative to the first direction is at a predetermined angle of greater than 0°; and a cutting assembly comprising one or more blades positioned to cut across a portion of the cocoa pod moved by the conveyor, wherein the cutting assembly is configured to separate a portion of the husk and expose the cocoa beans.

[0154] In an 82ndexample implementation (or aspect), a cocoa pod processing system comprising: a conveyor configured to move in a first direction parallel to a horizontal plane, the conveyor comprising a receptacle configured to hold a cocoa pod, the cocoa pod comprising a husk, cocoa beans housed within the husk, the receptacle configured to hold the cocoa pod in an upright position, wherein the receptacle comprising an adjustable base configured to adjust a height at which the cocoa pod is held by the receptacle such that the conveyor is spaced from a top portion of the cocoa pod by a predetermined distance; and a cutting arrangement comprising one or more blades positioned to cut a portion of the cocoa pod moved by the conveyor, the cutting arrangement configured to separate a portion of the husk and to expose the cocoa beans.

[0155] In an 83rdexample implementation (or aspect), a method comprising: conveying aAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] cocoa pod, comprising a husk and cocoa beans, in a first direction across a cutting assembly comprising one or more blades aligned to horizontally cut across a portion of the cocoa pod as the cocoa pod is conveyed, thereby separating a portion of the husk and to expose the cocoa beans, wherein the cocoa pod defines a major central axis, wherein an angle of the major central axis of the cocoa pod is positioned relative to the first direction is maintained at a predetermined angle of greater than 0°.

[0156] In an 84thexample implementation (or aspect), a method comprising: conveying a cocoa pod, comprising a husk and cocoa beans, in a first direction parallel across a cutting arrangement comprising one or more blades positioned in the first direction, wherein the cutting arrangement is aligned to cut across a portion of the cocoa pod as the cocoa pod is conveyed, thereby separating a portion of the husk and expose the cocoa beans, wherein the cocoa pod is held in an upright position such that a top of the cocoa pod is at a predetermined height from the horizontal plane while the cocoa pod is conveyed across the cutting arrangement.

Claims

Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]CLAIMSWHAT IS CLAIMED IS:

1. A cocoa pod processing system comprising: a conveyor configured to move in a direction generally parallel to a horizontal plane, the conveyor comprising a receptacle configured to hold a cocoa pod, the cocoa pod comprising a husk and cocoa beans, wherein the receptacle is configured to hold the cocoa pod such that a major central axis defined by the cocoa pod relative to the horizontal plane is at a predetermined angle of greater than 0°; a cutting assembly comprising a first blade and a second blade positioned on the horizontal plane and aligned to cut across a portion of the cocoa pod as the cocoa pod is moved by the conveyor, wherein the cutting assembly is configured to separate a portion of the husk from a remaining portion of the husk to expose the cocoa beans; and a separation assembly configured to move the remaining portion of the husk with the exposed cocoa beans and separate the exposed cocoa beans from the remaining portion of the husk.

2. The cocoa pod processing system of claim 1, wherein: the cocoa pod comprises a peduncle; the receptacle is configured to hold the cocoa pod with the peduncle pointing in a second direction generally opposite of the direction in which the conveyor moves; the cocoa beans are connected to a placenta of the cocoa pod; and the cutting assembly is configured to separate the portion of the husk from the remaining portion of the husk to expose the cocoa beans connected to the placenta.

3. The cocoa pod processing system of claim 2, wherein the conveyor is a first conveyor, and the separation assembly comprises a second conveyor configured to move the remaining portion of the husk with the exposed cocoa beans in the direction parallel to the horizontal plane.

4. The cocoa pod processing system of claim 3, wherein the separation assembly is configured to separate the exposed cocoa beans connected to the placenta from the remaining portion of the husk, the separation assembly comprises a rotary separator configured to rotate in a second,Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] opposite direction of the direction of the remaining portion of the husk with the exposed cocoa beans moved by the second conveyor, wherein the rotary separator is positioned to make contact with the exposed cocoa beans and configured to separate the exposed cocoa beans from the remaining portion of the husk in response to contacting the exposed cocoa beans.

5. The cocoa pod processing system of any of claims 1-4, wherein the first blade and the second blade are separated from one another by a distance that avoids contact of the first blade and the second blade with the cocoa beans.

6. The cocoa pod processing system of claim 1, wherein: the receptacle is adjustable for adjusting the predetermined angle or for holding a second cocoa pod of different size; and the first blade and the second blade are adjustable for adjusting a height of the first blade and the second blade with respect to the conveyor.

7. The cocoa pod processing system of claim 1, comprising a motor configured to rotate the conveyor at a rotation rate sufficient for the cocoa pod processing system to process more than 400 cocoa pods per hour.

8. A cocoa pod processing system comprising: a conveyor configured to move in a direction parallel to a horizontal plane, the conveyor comprising a receptacle configured to hold a cocoa pod, the cocoa pod comprising a husk, cocoa beans housed within the husk, and a peduncle, the receptacle configured to hold the cocoa pod in an upright position with the peduncle located at the top of the cocoa pod, the receptacle comprising an adjustable base configured to adjust a height at which the cocoa pod is held by the receptacle such that the conveyor is spaced from the peduncle of the cocoa pod by a predetermined distance; a cutting arrangement comprising a first blade and a second blade positioned on the horizontal plane to cut across a portion of the cocoa pod moved by the conveyor, the cutting arrangement configured to separate a portion of the husk from a remaining portion of the husk to expose the cocoa beans; andAttorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ] a separating arrangement configured to separate the exposed cocoa beans from the remaining portion of the husk.

9. The cocoa pod processing system of claim 8, wherein the separating arrangement comprises a ramp configured to receive the remaining portion of the husk with the exposed cocoa beans, wherein the ramp defines a void space that allows the exposed cocoa beans to hang from the remaining portion of the husk, wherein the ramp is configured to vibrate to move the remaining portion of the husk along a slope of the ramp and separate the exposed cocoa beans from the remaining portion of the husk.

10. The cocoa pod processing system of claim 9, wherein the separating arrangement comprises a motor coupled to the ramp and configured to vibrate the ramp to move the remaining portion of the husk along a slope of the ramp and separate the exposed cocoa beans from the remaining portion of the husk, the cocoa pod comprises a placenta housed within and connected to the husk and attached to the cocoa beans, and the ramp is configured to vibrate to separate the exposed cocoa beans from the placenta while the placenta remains connected to the remaining portion of the husk.

11. The cocoa pod processing system of any of claims 8-10, wherein at least one of the first blade or the second blade comprises downward fold configured to separate the portion of the husk from the remaining portion of the husk to expose the cocoa beans, and the first blade and the second blade are positioned on the horizontal plane above the receptacle, such that the first blade and the second blade avoid contact with the receptacle as the conveyor moves the cocoa pod across the cutting arrangement.

12. The cocoa pod processing system of any of claims 8-10, comprising a centering guide positioned and configured to apply a downward force on the cocoa pod as the cocoa pod is conveyed by the conveyor to maintain the peduncle of the cocoa pod at the predetermined distance from the conveyor, and the first blade and the second blade are adjustable for adjusting a height of the first blade and the second blade with respect to the conveyor.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]13. The cocoa pod processing system of any of claims 8-10, comprising a conveyor motor configured to rotate the conveyor at a rotational rate sufficient for the cocoa pod processing system to process from 6,000 to 8,000 cocoa pods per hour.

14. A method comprising: conveying a cocoa pod, comprising a husk and cocoa beans housed within the husk, in a direction parallel to a horizontal plane across a cutting assembly comprising a first blade and a second blade positioned on the horizontal plane and aligned to cut across a portion of the cocoa pod as the cocoa pod is conveyed across the cutting assembly, thereby separating a portion of the husk from a remaining portion of the husk to expose the cocoa beans, wherein the cocoa pod defines a major central axis, wherein an angle of the major central axis of the cocoa pod relative to the horizontal plane is maintained at a predetermined angle of greater than 0° as the cocoa pod is conveyed across the cutting assembly; and after separating the portion of the husk from the remaining portion of the husk, separating the exposed cocoa beans from the remaining portion of the husk.

15. The method of claim 14, comprising preventing lateral movement of the cocoa pod in relation to the direction in which the cocoa pod is conveyed across the cutting assembly.

16. The method of claim 14 or 1 , wherein separating the exposed cocoa beans from the remaining portion of the husk comprises contacting the exposed cocoa beans with a rotary separator that is rotating, the rotary separator comprises a plurality of scrapers, the plurality of scrapers is rotated in a second direction opposite of the direction in which the cocoa pod is conveyed, and the first blade and the second blade are separated from one another by a predetermined distance that avoids contact of the first blade and the second blade with the cocoa beans as the cocoa pod is conveyed across the cutting assembly.

17. The method of claim 14 or 15, wherein the cocoa pod is conveyed across the cutting assembly at a conveyance rate sufficient for processing more than 400 cocoa pods per hour, and the method is not computer-implemented.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]18. A method comprising: conveying a cocoa pod, comprising a husk, cocoa beans housed within the husk, and a peduncle, in a direction parallel to a horizontal plane across a cutting arrangement comprising a first blade and a second blade positioned on the horizontal plane and aligned to cut across a portion of the cocoa pod as the cocoa pod is conveyed across the cutting arrangement, thereby separating a portion of the husk from a remaining portion of the husk to expose the cocoa beans, wherein the cocoa pod is held in an upright position with the peduncle located at the top of the cocoa pod and at a predetermined height from the horizontal plane while the cocoa pod is conveyed across the cutting arrangement; and after separating the portion of the husk from the remaining portion of the husk, separating the exposed cocoa beans from the remaining portion of the husk.

19. The method of claim 18, comprising receiving the cocoa pod in a receptacle comprising an adjustable base, wherein conveying the cocoa pod across the cutting arrangement comprises conveying the receptacle across the cutting arrangement with the cocoa pod disposed at least partially within the receptacle and supported by the adjustable base, the adjustable base comprises a spring, and the cocoa pod is held in the upright position with the peduncle at the predetermined height from the horizontal plane by the spring as the cocoa pod is conveyed across the cutting arrangement.

20. The method of claim 18 or 19, wherein the first and second blades are positioned on the horizontal plane above the receptacle, such that the first and second blades avoid contact with the receptacle as the cocoa pod is conveyed across the cutting arrangement, and the first blade and the second blade are separated from one another by a predetermined distance that avoids contact of the first blade and the second blade with the cocoa beans as the cocoa pod is conveyed across the cutting arrangement.

21. The method of claim 18 or 19, wherein separating the exposed cocoa beans from the remaining portion of the husk comprises vibrating the remaining portion of the husk, thereby loosening and releasing the cocoa beans from the remaining portion of the husk.Attorney Docket No. 21175-0049W01 / [MARS / P / 387042 / US / WO / 1 ]22. The method of claim 18 or 19, wherein the cocoa pod is conveyed across the cutting arrangement at a conveyance rate sufficient for processing from 6,000 to 8,000 cocoa pods per hour, and the method is not computer-implemented.

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