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Introduction

Helvetas Vietnam, in partnership with AirXCarbon, is pioneering a groundbreaking initiative to transform cocoa husks into bioplastic materials, merging sustainability with innovation. This initiative, part of the EU-funded project "Circular Economy Cocoa: From Bean to Bar" (2022-2026), tackles the critical global challenges of agricultural waste management and plastic pollution. The project aims to improve the efficiency of the cocoa supply chain while promoting a circular economy in Vietnam's agri-food sector.

The objective of this initiative is to create biobased plastic granules from cocoa husk powder, which can be utilized in a wide range of consumer products and packaging. Two bioplastics formulations have been successfully piloted: one based on polypropylene (PP) and the other on polylactic acid (PLA). These materials provide eco-friendly alternatives to traditional plastics, reducing the reliance on petroleum-based resources and offering a sustainable solution for the growing demand for biodegradable packaging.

Double Solutions for Plastic Pollution and Agricultural Waste Management

Plastic pollution is one of the most pressing environmental issues globally, as plastics take centuries to decompose, polluting land and water while posing significant threats to ecosystems and human health. The packaging industry, a major consumer of plastic materials, has come under increasing scrutiny for its environmental impact. The search for sustainable, eco-friendly alternatives to plastic is therefore more urgent than ever, with biodegradable packaging solutions offering promising opportunities to reduce plastic waste and promote circular economy practices.

In Vietnam, cocoa farmers annually generate about 50,000 tons of cocoa husks, most of which remain underutilized. While a small portion is repurposed for compost or animal feed, the majority are discarded, leading to environmental pollution. As cocoa prices rise and cultivation areas expand, the rising need for circular economy solutions to handle the waste from cocoa production has become critical.

The EU-funded Cocoa Project led by Helvetas offers a feasible solution by converting cocoa husks into biodegradable packaging materials. This innovation could reduce both agricultural and plastic waste while creating new economic opportunities for farmers and businesses, providing additional income from a byproduct previously seen as waste. It also marks a step forward in advancing the circular economy in Vietnam, reducing reliance on fossil-based materials, and meeting the growing demand for sustainable consumer products.

Production Process of Bioplastics from Cocoa Husks

Cocoa husks are rich in carbohydrates and lignin, with moderate levels of cellulose and pectin, making them ideal for the production of biodegradable materials. Additionally, the husks contain small amounts of protein and minerals that improve the stability and biodegradability of the bioplastics.

Through a process of test and adjustment, the project team has successfully created two bioplastics: Cocoa-PP (polypropylene-based) and Cocoa-PLA (polylactic acid-based). These materials offer distinct advantages, catering to different market needs. Cocoa PP provides superior rigidity and flexibility, making it ideal for manufacturing durable, reusable products, while Cocoa-PLA is fully biodegradable, making it more suitable for single-use items.

The production process of Cocoa-PP begins by blending pure polypropylene resin with finely milled cocoa husk powder to create bioplastic granules, which are then processed using advanced twin-screw extrusion technology. The process ensures that the cocoa husk powder is prepared to the exact specifications - uniform particle size (<0.07 cm) and low moisture content (<10%) - to create high-quality bioplastics. These granules, which are compatible with injection molding, retain the strength and flexibility of traditional plastics, incorporating up to 51% agricultural waste. This reduces the portion of petroleum-based raw materials and the life of products made from Cocoa-PP is approximately five years.

For Cocoa PLA, the production process involves combining polylactic acid (PLA), a biodegradable polymer, with cocoa husk powder. The resulting mixture is ideal for creating biodegradable single-use products like trays, cups, straws, and utensils. This formulation balances rigidity with biodegradability, offering an innovative solution for sustainable packaging in the food and beverage industry.

Superior Advantages: Why Cocoa-Based Bioplastics Are Better

Mr. Le Thanh, CEO of AirXCarbon, explains “When compared to traditional plastic packaging, both Cocoa-PP and Cocoa-PLA offer significant environmental benefits. Cocoa PP incorporates up to 51% agricultural waste, reducing the reliance on fossil-based raw materials. While conventional plastics can remain in the environment for centuries, Cocoa PLA is fully biodegradable, making it an ideal solution for single-use products”.

Mr. Nguyen Dinh Tuan, Manager of the Circular Economy Cocoa Project, adds: “What sets these bioplastics apart from others is that cocoa husk powder lowers production costs while adding value by repurposing agricultural byproducts. This makes the materials not only eco-friendly but also competitively priced.”

Mr. Thanh further highlights that rigorous testing has been conducted to ensure that both Cocoa-PP and Cocoa-PLA meet industry standards for tensile strength, moisture content, and biodegradability. The production process is also highly efficient, with trial results showing a yield of 95%-97% from raw materials, indicating strong potential for large-scale production.

From an economic standpoint, both bioplastics are financially viable. Cocoa PP is cost-effective and ideal for reusable products, while Cocoa PLA, although more expensive, caters to the growing premium demand for biodegradable materials.

Production costs for a Cocoa PP cup are approximately 1 USD (25,000 VND), with a lifespan of five years, offering excellent value for consumers. These materials present promising opportunities for scalability and sustainable market growth.

Real-World Applications and Future Prospects

This initiative implies an extension beyond material innovation. By utilizing cocoa husks, an abundant agricultural byproduct, the project exemplifies the principles of the circular economy, turning waste into a valuable resource. The process minimizes the environmental footprint by reducing reliance on fossil fuels and providing scalable solutions for industries seeking sustainable alternatives.

Helvetas and AirXCarbon are currently exploring partnerships with companies like Trọng Đức Cocoa and Marou Chocolate JSC to test these bioplastics in real-world applications. These companies plan to produce insulated cups for beverages and coasters, a practical demonstration of how the materials can be integrated into the market.

The Project has also successfully developed biodegradable pallets from cocoa shells as alternatives to traditional wooden pallets, helping combat deforestation. Introduced at a workshop on March 6, 2025 by Helvetas Vietnam and AirXCarbon, the bio-based pallets generated significant interest from partner cocoa companies and cooperatives. Previously, the project successfully developed paper from cocoa bean husks, now used by Marou Company for chocolate wrappers.

Towards A Sustainable Future

The collaboration between Helvetas Vietnam and AirXCarbon represents a significant leap forward in sustainable packaging innovation. By transforming cocoa husks—an underutilized agricultural byproduct—into high-performance bioplastics, this project addresses critical issues of waste management and plastic pollution. It not only boosts the sustainability of the cocoa supply chain but also establishes Vietnam as a leader in circular economy practices. With its scalability and environmental benefits, this initiative offers a model for global adoption, turning waste into opportunity and setting a new standard for sustainable development in the packaging industry.

MORE INFORMATION

About Helvetas and the EU-Cocoa Project

Helvetas Vietnam, active in Vietnam since 1995, is part of Helvetas Swiss Intercooperation, a leading development organization from Switzerland with over 65 years of global experience and operations in 39 countries. It works across various sectors, including Agriculture, Forestry, Biodiversity Conservation, Eco-tourism, and Rural Economic Development. Helvetas Vietnam currently focuses on 3 key topics including advancing sustainable and inclusive economic development, climate change adaptation, and vocational skills enhancement.

Under the SWITCH-Asia program of the European Union, Helvetas is implementing the project “Circular Economy Cocoa: From Bean to Bar.” The project aims to develop circular economy solutions in cocoa and other agri-food sectors, leading to equitable economic growth decoupled from harmful environmental impacts. The project is being implemented over four years (2022-2026) in 6-7 key cacao-growing provinces in the Central Highlands and Mekong Delta regions of Vietnam with the total budget of about 2 million euro.

About AirXCarbon

AirXCarbon is a leading consultancy in Vietnam in the bioplastics industry, famous for the world's first carbon-free biomaterial made from coffee grounds. With a strong commitment to environmental protection, the company specializes in producing bio-based composites and NetZero Pallets — biodegradable, carbon-negative alternatives to traditional wooden and plastic pallets. Using recycled carbohydrates derived from various by-products such as coffee grounds, coconut shells, rice husks, and bamboo, AirXCarbon's innovations reduce carbon emissions, combat deforestation, and minimize plastic pollution, contributing to a circular economy.

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