Capturing Value in the World's Premier Cocoa Origin
Ivory Coast (Côte d'Ivoire) produces over 45% of the world's raw cocoa bean supply, harvesting more than 2.2 million metric tons annually. Despite producing the finest cocoa crops globally, less than 30% of Ivorian cocoa has historically been processed domestically into high-value semi-finished cocoa derivatives or chocolate.
GY & Sons Holding has constructed a world-class Integrated Cocoa Processing & Industrial Chocolate Manufacturing Plant located adjacent to the deep-water Port of San-Pédro. Sourcing 100% certified, traceable cocoa beans directly from local cocoa farming cooperatives, our facility converts raw beans into premium cocoa liquor, deodorized cocoa butter, alkalized cocoa powder, and high-purity industrial chocolate blocks.
By shifting production from raw bean exports to refined industrial chocolate ingredients, our complex supplies major European bean-to-bar chocolatiers (France, Switzerland, Belgium, Germany) and expanding GCC bakery, confectionery, and dairy manufacturers (UAE, Saudi Arabia), securing substantial foreign exchange revenues for Ivory Coast.
Industrial Couverture Manufacturing
State-of-the-art five-roll refiners and thermal conches producing 50%-75% dark chocolate blocks, milk chocolate couverture, and cocoa drops tailored for industrial bakeries and luxury chocolatiers.
Child-Labor-Free Supply Chain
Direct cooperative sourcing with 100% digital polygon mapping, child labor monitoring systems (CLMRS), and Rainforest Alliance / Fairtrade certifications ensuring full sustainability.
Dual-Axis Global Export Trade
Automated liquid tanker loading and refrigerated container logistics supplying European confectionery hubs and GCC industrial food manufacturers directly from San-Pédro port.
From Ivorian Farms to European & GCC Chocolate Masters
Explore our 4-stage industrial cocoa refining and chocolate manufacturing process.
Sustainable Procurement, Fermentation & Solar Drying
Fresh cocoa pods harvested by partner smallholders are opened within 24 hours. The white-pulped beans undergo controlled 6-day wooden box fermentation, developing rich chocolate flavor precursors. Beans are then solar-dried on raised bamboo tables until moisture reaches precisely 7.5%, followed by digital grading and bean cleaning.
High-Speed Winnowing, Nib Roasting & Liquor Grinding
Cleaned beans are gently pre-heated to crack the outer shell, passing through winnowers that separate light shell fragments from pure cocoa nibs. Nibs enter continuous aroma roasters, developing deep cocoa notes. Roasted nibs are ground through multi-stage pin mills into smooth, liquid cocoa mass (cocoa liquor).
Hydraulic Butter Pressing & Alkalized Powder Milling
Pure cocoa liquor enters high-pressure hydraulic presses operating at 500 bar. Golden, pure cocoa butter is pressed out and deodorized for premium chocolate tempering and cosmetics. The remaining cocoa press-cake is pulverized, alkalized (Dutch process), and air-classified into fine, rich cocoa powder.
Refined Chocolate Conching & Temperature-Controlled Export
Cocoa liquor, pure cocoa butter, sugar, and natural vanilla are blended in industrial conches for up to 24 hours, achieving silky smooth particles under 18 microns. Formulated chocolate is molded into 5kg industrial blocks or liquid-filled into heated ISO tank containers for immediate maritime shipment to European chocolatiers and GCC food manufacturers.
Factory Operations & Chocolate Manufacturing Gallery
From cocoa pod harvesting in Ivorian rainforest plantations to industrial chocolate conching and international shipping.
Advanced Processing & Chocolate Technology
Continuous Nib Roasters
Thermal hot-air roasters with precise PLC temperature profiles ensuring uniform roasting and rich, customized flavor development for European specialty chocolate recipes.
500-Bar Hydraulic Butter Presses
High-yield extraction presses squeezing pure, fragrant cocoa butter from cocoa liquor, generating ultra-low fat cocoa cake for high-solubility cocoa powder production.
Five-Roll Chocolate Refiners
Precision steel rollers grinding chocolate mass to under 18 microns, delivering velvet mouthfeel and optimal melt viscosity for industrial confectionery molding.
Heated ISO Tanker Loading Hub
Direct sanitary liquid chocolate and cocoa butter loading infrastructure pumping warm cocoa butter (45°C) straight into sea-tankers bound for European ports.
Transforming Cocoa Farming Communities & National Economy
Fair-Trade & Premium Farmer Bonuses
GY & Sons pays direct sustainability premiums to over 25,000 cooperative cocoa farmers across San-Pédro and Soubré regions, funding local clean water wells, rural schools, and mobile healthcare clinics.
Child Labor Protection & Traceability
Our digital Supply Chain Traceability System tracks every bag of cocoa from GPS-mapped farm plots to factory gates, ensuring 100% child-labor-free production and deforestation-free compliance.
Industrial Foreign Exchange Multiplier
Converting raw cocoa beans into refined butter, powder, and couverture chocolate increases export revenue by 4x per metric ton, generating over $180M annually in foreign currency returns for Ivory Coast.
Green Energy & Waste Recycling
Cocoa bean shells are converted into organic agricultural fertilizer for cocoa farmers, while factory rooftops feature 3.5 MW solar photovoltaic panels reducing carbon intensity.
Ivory Coast to Europe & GCC Trade Logistics
Dual Export Corridors: EU & GCC Markets
Our San-Pédro facility operates specialized dual export logistics lines catering to distinct global market requirements:
- European Union (France, Belgium, Switzerland, Germany): Bulk shipment of pure deodorized cocoa butter, alkalized powder, and single-origin dark chocolate blocks to premier chocolatiers.
- GCC Countries (UAE, Saudi Arabia, Qatar, Oman): Supply of 100% Halal-certified industrial chocolate couverture, bakery cocoa powders, and gourmet chocolate drops to regional food manufacturers.
San-Pédro Deep-Water Port Terminal
Direct factory pipeline to port container berths Rotterdam / Antwerp / Jebel Ali Ports