How is AI Reshaping Uncertain Chocolate Supply Chains?

The chocolate industry is facing a major supply chain crisis.

Climate change has caused poor cocoa harvests in Ghana and the Ivory Coast, where 60% of the world’s cocoa is grown, leading to price increases of 400% over the past year.

With many processing plants operating at reduced capacity, companies are searching for sustainable alternatives.

NotCo, a food-tech company known for plant-based innovations, believes AI holds the answer.

NotCo's patented AI platform, Giuseppe, has been designed to reimagine food production by analysing the molecular structure of ingredients.

The AI suggests plant-based alternatives that replicate the taste, texture and function of animal products. Now, it has turned its attention to chocolate.

Fernando Machado, Global Chief Marketing Officer at NotCo, explains: “We created this AI platform, which we named Giuseppe after the painter Giuseppe Arcimboldo from the mid-1500s who used to do portraits with fruits and vegetables.

"It's basically creating art with plants.”

By feeding data into Giuseppe, the team developed a cocoa-free chocolate bar that mimics the flavour and melting profile of traditional chocolate.

The formulation blends upcycled ingredients, endemic Chilean cereals, fermented seeds and other sustainable crops. NotCo’s innovation reduces reliance on cocoa, a commodity deeply tied to deforestation, child labour and supply chain instability.

Traditional cocoa farming involves harvesting only the seeds of the cacao plant, leaving the rest of the tree unused. This process drives illegal deforestation, particularly in West Africa, where large areas of rainforest are cleared for plantations.

By replacing cocoa with upcycled ingredients, NotCo reduces environmental harm while creating a stable supply chain for chocolate production.

Rethinking sustainability in the chocolate industry

Since launching in 2015, NotCo has focused on making food production more sustainable.

The company’s plant-based alternatives for dairy and meat use significantly less water and energy compared to traditional methods. For example, its NotMayo product requires 97% less water and produces 26% less CO₂ than conventional mayonnaise.

By applying this approach to chocolate, NotCo is introducing a new model for sustainable supply chains. The company aligns with circular economy principles — minimising waste, reducing deforestation and cutting emissions — while maintaining the indulgent taste that consumers expect.

Fernando explains how the AI-led process works: “The way we do things today, and the reason why I'm saying this today, is that we take an animal-derived product and do a whole analysis on that product — chromatography, physical properties, all sorts of things — to create almost like a DNA or snapshot of what the product is.

“We feed that into Giuseppe, and then Giuseppe proposes four or five recipes that could match that target. Then, the chefs take those recipes, prepare the product, try the product and give feedback to Giuseppe.”

This method has resulted in a chocolate bar that accurately mimics a 50% cocoa content, offering a viable alternative for manufacturers facing cocoa shortages.

The success of this innovation also paves the way for AI-driven alternatives in other confectionery products, such as ice cream, snack bars and powdered chocolate drinks.

Ethical concerns and industry collaboration

NotCo is not the only company working to make chocolate more sustainable.

Tony’s Chocolonely, a brand known for its ethical supply chain practices, has been campaigning against child labour and modern slavery in cocoa farming since 2005. The company ensures that all its cocoa is 100% traceable and pays farmers higher prices to support fair wages and better working conditions.

If cocoa-free chocolate gains wider adoption, companies like Tony’s Chocolonely will need to consider how this shift impacts cocoa farmers. A sudden drop in demand for cocoa could leave farmers without income, raising ethical concerns around job losses in West Africa.

A balanced approach is needed — one that ensures sustainability while supporting the livelihoods of those who depend on cocoa farming. If companies like NotCo and Tony’s Chocolonely work together, they could create a model where AI-driven alternatives complement traditional cocoa production rather than replace it entirely.

As climate change continues to disrupt global supply chains, food innovation will be crucial for long-term stability. AI-powered solutions like Giuseppe offer a glimpse into the future of chocolate — one where sustainability, ethics and technology work together to transform the industry.

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