Open Access Article
Yuni Kusumastuti
*ab,
Jordan Maulana Ma'arifb,
Muh. Irsalb,
Dewanti Cahya Widi
bc,
Nur Rofiqoh Eviana Putri
ab,
Mukmin Sapto Pamungkas
ab,
Lusiana Oliviab and
Jonas Kristantoa
aChemical Engineering Department, Faculty of Engineering, Universitas Gadjah Mada, Jalan Grafika 2, Yogyakarta 55284, Indonesia. E-mail: yuni_kusumastuti@ugm.ac.id
bSmart Biomaterial Research Group, Chemical Engineering Department, Faculty of Engineering, Universitas Gadjah Mada, Jalan Grafika 2, Yogyakarta 55284, Indonesia
cAgrotropica Learning Center, Faculty of Agriculture, Universitas Gadjah Mada, Jalan Flora, Yogyakarta 55281, Indonesia
First published on 16th April 2026
The valorization of cacao shells offers high added value because of the rich content of bioactive compounds. This study investigated the application of cacao shell waste as an antibacterial agent through green extraction processes. The extraction was carried out by integrating SAE-DES (sonication-assisted and deep eutectic solvent) with a choline chloride-lactic acid-based solvent. The parameters of extraction, including temperature, solid-to-solvent ratio, and DES concentration, were optimized applying a Box–Behnken design in RSM (response surface methodology). The optimum conditions were found to be 80 °C, a solid-to-solvent ratio of 1
:
10, and a DES concentration of 62.65%, with TPC (total phenolic content) and TFC (total flavonoid content) of 4.94 ± 0.10 g GAE per g sample and 5.97 ± 0.09 g RE per g sample, respectively. Additionally, the mass transfer coefficient (kca) and equilibrium constant (Hs) range from 8.73 × 10−3 to 14.80 × 10−3 min−1 and 0.56 × 10−3 to 41.91 × 10−3 g solid per cm3, respectively. FTIR analysis confirmed the presence of significant functional groups of phenolic compounds in the extract. Furthermore, the extract was effective against Escherichia coli and Staphylococcus aureus.
Cacao shells contain various bioactive compounds, including polyphenols, flavonoids (catechins, quercetin, epicatechins), phenolic acids (gallic acid, coumaric acid, and protocatechuic acid), and lignin derivatives.5,6 These compounds have antioxidant, anti-inflammatory, and antimicrobial activities,7,8 making cacao shells potentially useful in the development of biodegradable packaging materials,9,10 natural food additives,11 and nutraceutical products.12 However, the cacao shells extraction is still a challenge due to their complex lignocellulose structure that inhibits the penetration of solvents and mass transfer. Cacao shells consist of the epithelial layer, mesocarp, and endocarp, which comprise a biopolymer matrix. The composition of the matrix consists of cellulose (44.69%), hemicellulose (11.15%), lignin (34.82%), and pectin (10.10%).13 Therefore, the efficiency and quality of the compounds obtained are extremely dependent on the extraction methods, the solvents, and the operating conditions.
Extraction of phenolic compounds from cacao shells is generally carried out using conventional techniques including maceration and Soxhlet extraction with organic solvents like ethanol and methanol.14 These methods are associated with certain drawbacks, including a lengthy extraction period, excessive use of solvents, as well as health and environmental risks. The harsh conditions of the process can lead to the degradation of sensitive compounds, causing low-yield extracts with reduced biological activity. Moreover, the observed limitations have led to the development of alternative environmentally friendly extraction methods, such as PLE (pressure liquid extraction), SAE (sonicated assisted extraction), SFE (supercritical fluid extraction), EAE (enzyme-assisted Extraction), LGE (liquid gas extraction), and MAE (microwave-assisted extraction).15–17 The alternative techniques have been reported to enhance the extraction efficiency, lower the usage of solvent, and generate better reproducibility.18,19 Among these methods, SAE is among the most efficient because it uses acoustic cavitation to break down the rigid plant cell matrix, thereby increasing solvent penetration and mass transfer.20 However, SAE performance is strongly influenced by the solvent type, so selecting an appropriate solvent system remains a key factor for maximizing bioactive compound yield.
One type of solvent that is increasingly being developed is a DES (deep eutectic solvent), formed by combining HBA (hydrogen bond acceptors) and HBD (hydrogen bond donors). DES offers various advantages, including biodegradability, non-toxicity, and low volatility, making it more environmentally friendly.21–23 In addition, organic acid-based DES have been reported to have intrinsic antimicrobial activity.24 However, its high viscosity often limits mass transfer and extraction kinetics. Combining DES with SAE can overcome these limits by increasing compound diffusion. Nevertheless, the application of SAE–DES combinations to extract bioactive compounds such as TPC (total phenolic content) and TFC (total flavonoid content) from cacao shells remains very limited, offering opportunities for further research in optimizing the efficient, sustainable recovery of high-value compounds. Furthermore, achieving the highest and most optimum levels of these compounds is challenging because parameters like solvent concentration, temperature, and time often have complex interactions. Most previous analysis apply one factor at a time testing, which fails to show how these variables work together to affect the yield. Therefore, response surface methodology (RSM) is required to make a mathematical model that studies these interactions simultaneously to ensure an efficient, resource-saving, and high-quality extraction process.25
The analysis aims to maximize the green extraction of TPC and TFC from cacao shells applying an integrated SAE–DES method. To achieve this, RSM with a BBD (Box–Behnken design) was applied to assess the temperature interactions, solid–solvent ratio, and DES concentration. The obtained extracts were analyzed using the FTIR (Fourier Transform Infrared Spectroscopy), while the antibacterial efficacy was assessed against Escherichia coli and Staphylococcus aureus by the agar well diffusion technique. The findings provide a valuable contribution to the sustainable valorisation of cacao shell waste and the creation of natural antibacterial agents to be used in industries by searching for the best conditions to maximise yield with minimum resources imposed.
Analytical grade reagents used in this study included ethanol p.a. (C2H6O, Supelco, ≥99.90%), sodium hydroxide p.a. (NaOH, Merck, ≥99.00%), aluminum chloride p.a. (AlCl3, Merck, ≥98.00%), sodium nitrite p.a. (NaNO2, Merck, ≥99.90%), gallic acid p.a. (Merck, 100.00%), rutin p.a. (Merck, ≥96.00%), sodium carbonate p.a. (Na2CO3, Merck, ≥99.90%), Folin–Ciocalteu reagent (Merck), choline chloride (C5H14ClNO, Himedia, ≥99.00%), lignin p.a. (Sigma-Aldrich, 95.00%), cellulose p.a. (Sigma-Aldrich, ≥99.90%), distilled water (aquadest), deionized water (aquabidest), and lactic acid (C3H6O3. Himedia, ≥90.00%).
:
2 molar ratio, following a modified procedure adapted from Xia et al.26 A binary mixture of 100 g was stirred at 250 rpm for 2 h at 80 °C. The process continued until a clear, homogeneous, and uniform, indicating the complete formation of the eutectic phase.
:
10–1
:
45 (w/v), and DES concentrations of 50–100% (v/v). During variation of each parameter, the other variables were kept constant at their default values (80 °C, 1
:
10 (w/v), and 100% (v/v)). Specifically, when temperature was varied, the solid-to-solvent ratio and DES concentration were fixed at 1
:
10 (w/v) and 100% (v/v), respectively. During the extraction, aliquots were collected at fixed time intervals from 5 to 240 minutes for mass transfer analysis. Each sample was subsequently diluted with ethanol before the analysis of TPC.
The mass transfer process was explained theoretically in three consecutive steps: (1) diffusion of phenolic compounds from the inside of the cacao shell matrix to the particle surface, (2) movement of solutes from the surface into the surrounding liquid film, and (3) convective transfer from the boundary layer into the bulk solvent medium. Among the proposed models, the convectively controlled mass transfer mechanism was considered most applicable in this study. This model considers that intra-particle diffusion occurs at a faster rate compared to interfacial transfer, as supported by the relatively small particle size and the rapid attainment of extraction equilibrium (within three hours).
![]() | (1) |
Eqn (1) describes mass transfer based on Fick's law in convection, where NA is the mass transfer rate of bioactive compounds from solids to solvent (g GAE per cm3 min), kca is the volumetric coefficient of mass transfer from solids to solvent (min−1), and
is the concentration of bioactive compounds at equilibrium with bioactive compounds in solids (g GAE per cm3). CAf is the concentration of bioactive compounds in the solvent (g GAE per cm3). The equilibrium equation can be estimated by the formula as follows:
![]() | (2) |
![]() | (3) |
![]() | (4) |
![]() | (5) |
MS is the mass of the extracted cacao shell solid (g solid). In addition the initial and boundary conditions in eqn (4) and (5) are:
| t = 0 × CAf = CAf0 = 0 × XA = XA0 | (6) |
| t = t × CAf = CAf × XA = XA | (7) |
The kca and Hs parameters are evaluated based on the resulting R2 coefficient (eqn (10)), which is desired to be high, close to 1. R2 coefficient was obtained based on the SSE (sum of squared errors) and SST (total sum of squares), following:
![]() | (8) |
![]() | (9) |
![]() | (10) |
| Independent variables | Symbols | Coded levels | ||
|---|---|---|---|---|
| −1 | 0 | 1 | ||
| Temperature (°C) | x1 | 40 | 60 | 80 |
Ratio solid : solvent |
x2 | 1 : 10 |
1 : 25 |
1 : 40 |
| DES concentration (% DES in water) | x3 | 25 | 50 | 75 |
| Run | Variables | Total phenolic content (g GAE/g sample) | Total flavonoid content (g RE/g sample) | ||||
|---|---|---|---|---|---|---|---|
| x1 | x2 | x3 | Actual | Prediction | Actual | Prediction | |
| 1 | 0 | 0 | 0 | 1.70 ± 0.08 | 1.82 | 2.41 ± 0.05 | 2.62 |
| 2 | 0 | 0 | 0 | 1.82 ± 0.04 | 1.82 | 2.65 ± 0.13 | 2.62 |
| 3 | 0 | −1 | −1 | 3.04 ± 0.16 | 3.08 | 3.92 ± 0.29 | 3.81 |
| 4 | −1 | 0 | −1 | 1.01 ± 0.03 | 1.01 | 2.13 ± 0.02 | 2.17 |
| 5 | +1 | +1 | 0 | 1.39 ± 0.02 | 1.42 | 2.08 ± 0.08 | 2.01 |
| 6 | +1 | 0 | +1 | 2.30 ± 0.01 | 2.30 | 2.51 ± 0.17 | 2.60 |
| 7 | −1 | 0 | +1 | 1.14 ± 0.01 | 0.98 | 1.82 ± 0.01 | 2.46 |
| 8 | 0 | 0 | 0 | 1.94 ± 0.09 | 1.82 | 2.79 ± 0.05 | 2.62 |
| 9 | −1 | −1 | 0 | 2.77 ± 0.01 | 2.73 | 4.51 ± 0.02 | 4.59 |
| 10 | 0 | +1 | −1 | 0.98 ± 0.07 | 0.79 | 1.66 ± 0.04 | 1.68 |
| 11 | +1 | −1 | 0 | 4.44 ± 0.08 | 4.25 | 5.52 ± 0.07 | 5.58 |
| 12 | +1 | 0 | −1 | 1.64 ± 0.03 | 1.80 | 2.24 ± 0.04 | 2.29 |
| 13 | 0 | +1 | +1 | 0.97 ± 0.01 | 0.94 | 1.28 ± 0.04 | 1.39 |
| 14 | −1 | +1 | 0 | 0.64 ± 0.03 | 0.83 | 2.79 ± 0.04 | 2.73 |
| 15 | 0 | −1 | +1 | 3.19 ± 0.04 | 0.94 | 4.71 ± 0.21 | 4.69 |
The RSM analyzes the main effects, interactions, and quadratic terms, which were then incorporated into a regression model to derive the predictive equation (eqn (11)).
![]() | (11) |
TPC and TFC were recorded as response variables. Optimization was conducted by applying a desirability function to find extraction that yielded the maximum TPC and TFC. To validate the model's predictive performance, the extraction process was repeated 3× under optimal conditions, and the experimental data were compared with the 95% prediction interval (PI Low and PI High).
The TFC was evaluated according to the aluminum chloride colorimetric assay as stated by Blasa et al. and Rodríguez-Martínez et al.28,29 A 1 mL of each extract was reacted with 0.3 mL of a sodium nitrite solution (5% w/v) and then with 0.3 mL of an aluminum chloride solution (10% w/v). After 3 minutes incubation at room temperature, the absorbance was observed at 510 nm applying a UV-Vis spectrophotometer. Rutin was applied as the reference compound, and the findings were represented as mg of rutin equivalent per g of sample (g RE per sample). All assays were performed in duplicate.
For a liquid sample, such as cacao shell extract, FTIR analysis was carried out using an FTIR spectrometer fitted with an ATR (attenuated total reflectance) accessory. A few drops of the liquid extract were put on the clean surface of the ATR crystal. Measurements were separated by thoroughly drying the ATR crystal using ethanol to avoid sample contamination. The obtained spectra were observed by establishing typical absorption bands of functional groups.
The agar well diffusion technique was applied to obtain antibacterial activity. Initially, 1 mL of the standardized bacteria suspension was uniformly distributed on sterile Petri dishes. Mueller-Hinton Agar (MHA) previously equilibrated at 45 ± 1 °C was poured into each Petri dish at a constant volume (20 mL), ensuring uniform distribution for all the plates. After the agar had solidified, 6 mm diameter wells were carefully made applying a sterile cork borer, each filled with 20 µL of the test solution. Positive and negative controls were 10 mg mL−1 trimethoprim and sterile distilled water, respectively. Subsequently, plates were incubated at 37 °C for exactly 24 hours to achieve equal conditions. Antibacterial activities were obtained by measuring the inhibition zones diameter around the wells. Every assay was conducted 3× to make sure reproducibility.
Antibacterial activity, inhibition zone diameter on E. coli and S. aureus, TPC, and TFC values were statistically analyzed applying Statgraphics Centurion version 18 (Statgraphics Technologies, The Plains, VA, USA). Data were obtained as mean ± SD (standard deviation) of duplicate measurements. In determining significant differences among treatments (p < 0.05), one-way ANOVA followed by Tukey's post hoc test was conducted. Different superscript letters were used to denote statistically significant differences.
This study tested three parameters, namely temperature, solid to solvent ratio, and concentration of DES, with samples collected at specific time intervals. The extraction parameters showed significant impacts on the mass transfer coefficient (kca) and equilibrium constant (Hs) in the extraction of TFC from cacao shell, as shown in Table 3. Theoretically, the temperature rise would increase the mass transfer. However, the opposite was observed in this analysis, as the extract indicated the highest concentration of TFC at 80 °C with a mass transfer coefficient (kca) of 8.88 × 103 min−1 and is smaller than the other two data points. At the same time, the extract showed a high equilibrium constant of 9.33 × 103 g solid per cm3, which increased mass transfer's driving force and produced higher TFC. The huge yield increase of TFC at 80 °C could be attributed to enhanced solute diffusion and plant matrix expansion, increasing the surface area of the solvent penetration.33 This provides higher yields of bioactive extract compared to those obtained at lower temperatures.
| Parameters | Temperature (°C) | ||
|---|---|---|---|
| 40 | 60 | 80 | |
| kca (min−1) | 14.80 × 10−3 | 12.53 × 10−3 | 8.88 × 10−3 |
| Hs (g solid per cm3) | 1.59 × 10−3 | 3.98 × 10−3 | 9.33 × 10−3 |
| R2 | 0.79 | 0.88 | 0.95 |
| Error (%) | 0.10 | 0.29 | 0.64 |
| Parameters | Ratio solid : solvent |
||
|---|---|---|---|
1 : 10 |
1 : 25 |
1 : 40 |
|
| kca (min−1) | 8.73 × 10−3 | 9.89 × 10−3 | 11.16 × 10−3 |
| Hs (g solid per cm3) | 41.91 × 10−3 | 10.79 × 10−3 | 0.56 × 10−3 |
| R2 | 0.95 | 0.91 | 0.89 |
| Error (%) | 9.19 | 1.35 | 0.24 |
| Parameters | DES concentration (%) | ||
|---|---|---|---|
| 50 | 75 | 100 | |
| kca (min−1) | 12.93 × 10−3 | 12.08 × 10−3 | 8.88 × 10−3 |
| Hs (g solid per cm3) | 13.89 × 10−3 | 10.36 × 10−3 | 9.33 × 10−3 |
| R2 | 0.98 | 0.97 | 0.95 |
| Error (%) | 0.54 | 0.42 | 0.64 |
According to the data-fitting shown in Table 3, the solid-to-solvent ratio influences both mass transfer and the equilibrium constant. At a lower ratio, solvent availability is abundant, allowing an increase in the extraction rate. As shown in Table 3, a solid-to-solvent ratio of 1
:
40 produced the highest mass transfer rate constant (11.16 × 10−3 min−1) among the data. However, at a lower ratio, the resulting equilibrium constant (Hs) is smaller than the other data. This is due to the low solid content in the system, which limits the solvent's availability around the solid and results in a lower TFC yield.
In addition to temperature and the solid-to-liquid ratio, the DES concentration also affects the values of kca and Hs. An increase in DES concentration causes an increase in viscosity, which can hinder diffusion and solvent penetration.34 Consequently, the mass transfer rate decreases, as the calculated kca value (8.88 × 10−3 min−1) at a concentration of 100% is lower than the other data. In addition to causing decreased viscosity, a reduction in concentration could lead to high conductivity, which enhances the rate of mass transfer.35,36 Among the tested DES concentration variations, 50% DES showed an optimal balance of physicochemical properties, with high kca (12.93 × 10−3 min−1) and Hs (13.89 × 10−3 g solids per cm3) values. These results suggest that partial hydration of DES is necessary to achieve an effective solvent system that maintains adequate solubility for the extraction of flavonoid compounds.37
Even though Table 3 provides a quantitative overview of mass transfer parameters, a deeper understanding of the extraction dynamics can be gained from the mass transfer profiles shown in Fig. 1. Fig. 1(a) shows the impact of temperature and extraction time on TFC. As shown in the graph, TFC tends to increase with rising temperatures. The TFC values under equilibrium conditions at 80 °C, 60 °C, and 40 °C were 9.33 × 10−3 g solid per cm3, 3.98 × 10−3 g solid per cm3, and 1.59 × 10−3 g solid per cm3, respectively. Based on this finding, the increase in temperature results in a higher equilibrium constant, suggesting that the process is endothermic. A similar trend has also been reported previously on the polyphenols extraction from cacao shell and other plants, where the yield of bioactive extracts increases with increasing temperature and with the use of the sonication method for extraction38,39 Moreover, the impacts of the solid-to-solvent ratio and extraction duration on TFC are illustrated in Fig. 1(b). The highest TFC was obtained at a ratio of 1
:
10 and declined with further reductions in the ratio. The lowest TFC value under equilibrium conditions was obtained at a 1
:
40 ratio, with a value of 0.56 × 10−3 g solid per cm3.
![]() | ||
| Fig. 1 TPC in SAE-DES under varying conditions: (a) extraction temperature, (b) solid-to-solvent ratio, and (c) DES concentration. Values represent mean ± S.D. (n = 2). | ||
The DES concentration parameter at various times also affects the TFC results, as shown in Fig. 1(c). Based on the graph, an increase in DES concentration in a decrease in TFC. The optimum condition occurs at a DES concentration of 50% with an equilibrium yield of 13.89 × 10−3 g RE per cm3. This value is higher than the yields at 75% and 100% solvent concentrations, with TFC yields of 10.36 × 10−3 and 9.33 × 10−3 g RE per cm3, respectively. This decrease is influenced by the solvent's physicochemical characteristics, with higher DES concentration leading to increased viscosity. Under these conditions, solvent penetration and mass transfer within the cacao shell matrix can be hindered.40
| Source | Total phenolic content (RGE) | Total flavonoid content (RE) | ||||||
|---|---|---|---|---|---|---|---|---|
| SS | MS | F-Value | p-Value | SS | MS | F-Value | p-Value | |
| a SS: sum of squares; MS: mean square. | ||||||||
| Model | 15.13 | 1.68 | 34.97 | 0.001 | 20.67 | 2.30 | 66.83 | 0.000 |
| Linear | ||||||||
| x1 | 2.22 | 2.22 | 46.21 | 0.001 | 0.00 | 0.00 | 0.02 | 0.906 |
| x2 | 11.18 | 11.18 | 232.61 | 0.000 | 14.72 | 14.72 | 428.28 | 0.000 |
| x3 | 0.10 | 0.10 | 2.18 | 0.200 | 0.04 | 0.04 | 1.24 | 0.316 |
![]() |
||||||||
| Quadratic | ||||||||
| x12 | 0.00 | 0.00 | 0.02 | 0.891 | 0.18 | 0.18 | 5.38 | 0.068 |
| x22 | 0.95 | 0.95 | 19.77 | 0.007 | 2.89 | 2.89 | 84.03 | 0.000 |
| x32 | 0.29 | 0.29 | 6.02 | 0.058 | 1.37 | 1.37 | 40.00 | 0.001 |
![]() |
||||||||
| Interaction | ||||||||
| x1 | 0.21 | 0.21 | 4.42 | 0.089 | 0.73 | 0.73 | 21.25 | 0.006 |
| x2 | 0.07 | 0.07 | 1.47 | 0.279 | 0.08 | 0.08 | 2.41 | 0.181 |
| x3 | 0.01 | 0.00 | 0.12 | 0.740 | 0.34 | 0.34 | 10.02 | 0.025 |
![]() |
||||||||
| Fit statistic | ||||||||
| Lack of fit | 0.21 | 0.07 | 4.78 | 0.178 | 0.09 | 0.03 | 0.83 | 0.588 |
| R2 | 0.9844 | 0.9918 | ||||||
| Adj. R2 | 0.9562 | 0.9769 | ||||||
Statistical optimization of the operating conditions in SAE using DES for the recovery of TPC and TFC was performed with the RSM. Several parameters were optimized, including temperature, solid and solvent ratio, and DES concentration. The effect of each parameter was further examined using main effect graphs, as presented in Fig. S2. These graphs show the variations between independent (temperature, solid/solvent ratio, and DES concentration) and dependent variables (TPC and TFC). Additionally, the importance and directionality of individual factors and factor interactions on TPC and TFC, as determined by multivariate analysis (standardized Pareto charts, Fig. S3) is shown. Based on the results, significant interaction effects further confirm the complex interdependency of the extraction variables.
As shown in Fig. 2, three-dimensional graphs were provided to visually identify the interaction of each parameter on the responses obtained. A regression model was constructed using coded variables, which contained linear, interaction, and quadratic terms to comprehensively describe the multifactorial correlation between process parameters and response variables. These models explained the temperature impacts, solvent-to-sample ratio, and DES concentration on yields of TPC and TFC. The addition of interaction and curvature terms increased the model's capacity to accurately represent real experimental behavior, thereby improving the predictive power for process optimization. The final regression equations in terms of code variables are shown below.
| TPC = 1.64 + 0.0372x1 − 0.1403x2 + 0.0360x3 − 0.000041x12 + 0.002255x22 − 0.000448x32 − 0.000769x1x2 + 0.000266x1x3 − 0.000103 x2x3 | (12) |
| TFC = 2.81 − 0.0176x1 − 0.1624x2 + 0.1374x3 + 0.000560x12 + 0.003931x22 − 0.000976x32 − 0.001424x1x2 − 0.000288x1x3 − 0.000782x2x3 | (13) |
![]() | ||
| Fig. 2 Response surface 3D depicting the impacts of SAE-DES factors on TPC (a) and TFC (b) levels in the extract of cacao shells. | ||
The response surface plots obtained from this study were optimal at the corners of the design space instead of the center point. According to the graph in Fig. 2(a), the phenolic yield was found to be continuously increased with rising temperature and decreasing the solid-to-solvent ratio. This is a mixed impact of enhanced mass transfer as well as delignification reactions during sonication and DES treatment. At high temperature, molecular diffusion coefficient increases, thereby reducing mass transfer resistance through plant cell walls. Simultaneously, DES, composed of choline chloride and lactic acid, plays a role in disrupting the lignin structure through hydrogen bonding and mild acid hydrolysis, leading to partial delignification.41 This can enhance porosity and weaken the cellulose-lignin matrix, thus increasing solvent access to intracellular phenolic compounds. The findings indicate a significant difference compared with a previous study that used the RSM optimization method with sonication and ethanol as the solvent.42 In that study, the maximum TPC obtained was only 0.26 g GAE per sample, whereas in this study it reached 4.44 g GAE per sample. This considerable difference is thought to be due to ethanol's limited ability to disrupt the lignocellulosic matrix, particularly lignin, in cacao shell, leading to suboptimal release of phenolic compounds. In addition, at a low solvent-to-solute ratio, solvent dissolution and transport are more efficient. This condition can reduce the concentration gradient and prevent local saturation.43 To strengthen the results of this analysis, TGA (thermogravimetric analysis) and SEM (scanning electron microscopy) were carried out.
Optimization was carried out to maximize TPC and TFC yields while still considering feasibility and operational efficiency. In this optimization, three parameters were tested: temperature at approximately 40 °C and 80 °C, solid-to-solvent ratio of 1
:
10 to 1
:
40, and DES concentration of 25–75%. Optimization conducted applying the desirability function approach with two responses, TPC and TFC, which were assigned to the highest importance level (+++++). The optimum conditions were obtained at 80 °C, a solid-to-solvent ratio of 1
:
10, and a DES concentration of 62.65%. Under these conditions, the model predicted an overall desirability value of 0.982, showing a good balance between the two target responses. A desirability value close to 1 signifies a high level of prediction accuracy. In this study, the slightly lower desirability value reflects a compromise between optimal conditions for maximizing TPC and TFC, in which higher DES concentrations tend to enhance TPC extraction. In contrast, slightly lower concentrations are more suitable for maximizing TFC.
To validate the optimization results, calculations were performed under the optimum conditions three times. The comparison between experimental results and predictions is presented in Table 5. The average TPC and TFC values were 4.94 ± 0.10 g GAE per g sample and 5.97 ± 0.09 g RE per g sample, respectively. These values are very close to the predicted model values (4.32 and 5.46, respectively) and fall within the 95% PI (prediction interval), thus confirming the reliability and accuracy of the obtained regression model.
| Analysis | Predicted mean | Predicted median | Std Dev | n | 95% PI low | Data mean | 95% PI high |
|---|---|---|---|---|---|---|---|
| TPC | 4.32 | 4.32 | 0.22 | 3 | 3.71 | 4.94 | 4.94 |
| TFC | 5.46 | 5.46 | 0.19 | 3 | 4.94 | 5.97 | 5.98 |
![]() | ||
| Fig. 3 Fourier transform infrared (FTIR) spectra of cacao shell residues under varying extraction temperature (a) and time (b). | ||
Meanwhile, –CH stretching vibrations at 2920–2850 cm−1 were observed in the FTIR results of all samples. This indicates the presence of aliphatic chains, methyl groups, and methylene groups, which are commonly found in lignin, lipids, or waxy components. This suggests a moderate decrease in peak intensity with increasing extraction temperature and duration. The weakening of –CH groups, especially at 360 minutes, indicates partial solubility or disruption of aliphatic groups due to prolonged sonication. Additionally, the spectral feature in the 1740–1600 cm−1 range indicates the absorption of carbonyl and aromatic compounds.46 The observed C
O stretching band at 1738–1732 cm−1 is correlated with esterified phenolic compounds or lignin derivatives. The data show a decrease in intensity and a slight shift toward lower wavenumbers after extraction, especially at 80 °C and longer extraction times. Similarly, the aromatic C
C stretching band (1647–1613 cm−1) shows a slight shift in position and a decrease in intensity. This indicates successful extraction of the flavonoid backbone and aromatic-rich compounds.48 However, some of these bands are still detected even after 360 minutes of extraction. This suggests the presence of lignin structures that resist complete dissolution, as explained by Giummarella and Lawoko (2017).49
In the fingerprint region (1400–1000 cm−1), pronounced reductions in C–O and C–O–C stretching bands characteristic of polysaccharides and phenolic ethers were observed, reflecting the removal of soluble carbohydrates and ether-linked phenolics.50,51 The emergence of new bands in post-extraction residues and attenuation of signals below 1000 cm−1 further indicate structural rearrangement and degradation of the cacao shell matrix. This is likely due to structural disintegration and progressive damage to the cacao shell matrix. In addition to the spectrum of the extraction residue, Fig. 3 also shows reference spectra of pure lignin and cellulose. All residue spectrum shows a higher similarity to cellulose than to lignin. This indicates that during the extraction process, some lignin compounds and phenolic compounds tend to dissolve and migrate from the solid phase into the solvent, leaving behind a solid fraction richer in cellulose. In general, these FTIR results confirm that increasing the extraction temperature and time plays a role in enhancing the release of bioactive compounds, particularly those derived from phenolic and lignin components, while the more resistant lignocellulosic structures, especially cellulose, remain in the solid residue.
The DES spectrum from Fig. 4 shows characteristic absorptions of the hydrogen bond-contributing component (donor), lactic acid, and the hydrogen bond-accepting component (acceptor), choline chloride, with broadening and merging of the –OH and –NH stretching bands (∼3296 cm−1). This indicates strong hydrogen bonding interactions. Upon the addition of the cacao shell extract, the –OH band becomes more intense. This condition indicates the presence of phytoconstituents rich in hydroxyl groups that have been successfully extracted from the matrix. Several previous studies have also identified the flavonoid phytoconstituent quercetin in cacao shell.52,53 The quercetin structure contains a significant number of hydroxyl groups at positions C-3, C-5, C-7, C-3′, and C-4′, which correlates directly with the increase in the –OH peak in the extract spectrum.54 In addition to the hydroxyl group, new peaks at 1731 cm−1 and 1646 cm−1 in the extract–DES mixture are related to C
O stretching and aromatic C
C vibrations, indicating the presence of carbonyl- and aromatic-rich compounds, which is consistent with the vibrational modes reported for quercetin. Previous studies conducted using Raman spectroscopy support the presence of several bioactive compounds, one of which is a flavonoid such as quercetin.45 Although these spectral characteristics are very similar to those of quercetin, the overlap of vibrational bands in the FTIR spectrum suggests the possible presence of other structurally related polyphenolic or aromatic compounds, such as other flavonoids, in the extract.
![]() | ||
Fig. 4 FTIR spectra of individual components (choline chloride and lactic acid), the synthesized deep eutectic solvent (DES; ChCl : LA), and the cacao shell extract obtained using the DES. | ||
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| Fig. 5 Thermogravimetric analysis (TGA) curves of cacao shells and DES residues obtained from extractions at 40 °C and 80 °C. | ||
In the second stage of degradation (200 to 350 °C), large amounts of mass loss are associated with the depolymerization and volatilization of hemicellulose (220–315 °C) and cellulose (300–400 °C).56 The untreated cacao shells had a wider shoulder of degradation, implying a more disorganized structure of the structure. Meanwhile, the SAE – DES desiccated residues, particularly the extracts at 80 °C, had a thinner and tighter degradation profile, suggesting simplification of the structure. The lower maximum decomposition temperature of the 80 °C residue indicates lower thermal stability due to increased removal of thermally stable components, including lignin and condensed phenolics.57
At the final degradation stage at temperatures above 350 °C, thermal degradation is related to the slow carbonization process of lignin and other resistant aromatic structures. Lignin has a large range of degradation (150–900 °C) due to its complex and cross-linked structure. In Fig. 5, the residual mass of SAE-DES 80 °C residue sample is less compared to others. This indicates that the sample had more delignification than the SAE-DES 40 °C residue and the untreated sample. This pattern positively correlates with the increased TPC recorded in the corresponding extracts, indicating the efficient dissolution of lignin-derived phenolic groups at high temperatures of extraction. Overall, the results of TGA analysis show the structural changes in cacao shell biomass due to SAE-DES extraction. This thermal behavior shows that high extraction temperatures favor the release of phenolic and lignin constituents, thereby leaving residues with greater susceptibility to thermal degradation.
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| Fig. 6 SEM analysis of structural alterations in extraction residues under the influence of (a) temperature (40 and 80 °C) and (b) extraction duration (90 and 360 min). | ||
In Fig. 6(a), that after the extraction process at high temperature (80 °C), a significant morphological difference is evident. Larger pores and cavities are observed in the cell wall structure compared to extraction at 40 °C, which reveals relatively minor cavities. This increase in porosity is attributed to delignification during the DES process at high temperatures. This result is confirmed by thermogravimetric analysis (TGA), which shows significant lignin degradation.60 The delignification process causes the breakage of lignin-carbohydrate complexes, thereby weakening the cell wall structure and allowing the solvent to penetrate.61 As a result, larger pores are formed, which enhance mass transfer by increasing solvent accessibility and diffusion pathways. In this case, the phenolic compounds are facilitated in their mass transfer from the solid matrix into the solvent. SEM results also indicate that the delignification process continues to occur at the maximum tested temperature. This finding aligns with TGA results, which show that lignin degradation continues at temperatures above 80 °C. The continuous degradation is attributed to high temperature, which will increase the delignification process and contact between the solvent and the matrix. This interaction was projected to improve the extraction efficiency more than was recorded in this study.
The combined use of DES and cavitation caused by SAE is significant in the destabilization of cell walls. Specifically, sonication causes microbubbles due to speedy shifts in pressure between compression and expansion phases. These bubbles burst release mechanical shear forces with the ability to rupture plant tissues. The process is referred to as cavitation, which enables the operation of DES in infiltrating plant tissues and solubilizing lignin. The dissolution of lignin takes place depending on the dipole–dipole interaction and the hydrogen bonding.62 The two effects are combined to dissolve bioactive compounds of cell wall components and lignin.
The residues of the cacao shells were extracted after 90 and 360 minutes, with the difference shown in Fig. 6(b). The extraction process using the longer SAE-DES method showed SEM results, where fiber breakage and tissue collapse were observed. These modifications indicated gradual disintegration of cell walls, which correlated with the process of delignification. This promotes an increased mass transfer and greater release of intracellular compounds. This finding is supported by kinetic and diffusion analysis in related studies, which reported higher Biot numbers and effective diffusivity coefficients in DES-based systems. Research conducted by Lee et al.63 demonstrated an accelerated mass transfer process of phenolic compounds from biomass to solvent, attributed to the turbulence induced by sonication and the strong solubilizing power of DES.
| Code | Temperature (°C) | Extraction time (min) | TPC (g GAE per g sample) | TFC (g RE per g sample) | Inhibition zone (mm) |
|---|---|---|---|---|---|
| a Average ± SD; n = 3; GAE = gallic acid equivalent; RE = rutin equivalent. | |||||
| DES-1 | 80 | 90 | 0.24 ± 0.00 | 0.07 ± 0.01 | 27.67 ± 2.08b |
| DES-2 | 80 | 150 | 0.49 ± 0.00 | 0.16 ± 0.00 | 30.33 ± 1.04 ab |
| DES-3 | 80 | 180 | 0.65 ± 0.00 | 0.11 ± 0.00 | 33.33 ± 0.21 ab |
| DES-4 | 80 | 360 | 1.35 ± 0.01 | 0.15 ± 0.02 | 27.33 ± 0.58b |
DES (ChCl : LA) |
24.33 ± 2.03a | ||||
| Positive control | 39.67 ± 3.95b | ||||
The highest antibacterial activity was observed in the extract, with an inhibition zone diameter of 33.33 ± 0.21 mm, which was statistically equivalent to that of the positive control (39.67 ± 3.95 mm, p > 0.05). This result was obtained from a sample with an extraction time of 180 minutes. The potent inhibition of E. coli by this cacao shell extract can be attributed to multiple synergistic antimicrobial mechanisms produced by the phenolic compounds, flavonoids, and organic acids present in the extract.
There are four possibilities in this process. First, these bioactive compounds inhibit bacteria's efflux pumps, thereby averting the release of toxic substances and enhancing intracellular amassing of antibacterial agents. Second, the flavonoids also interact with bacterial ribosomes, restraining the production of proteins and interfering with important metabolic processes. Third, polyphenols prevent the activity of DNA gyrase, entangling the DNA and interfering with the replication process. Fourth, amphiphilic phenolic compounds and organic acids have the capacity to destabilize the bacteria cell membrane, causing leakage of the cytoplasm and loss of cell viability.64,65
According to the data presented in Table 6, the inhibition zone diameter dropped in the sample with the extraction time of 360 minutes, despite higher TPC. The reduction is due to thermal degradation of thermostable antibacterial agents, such as quercetin, catechins, and other flavonoids, or structural changes that decrease bioavailability and membrane permeability.66
DES solvent (ChCl
:
LA) alone also showed relatively high antibacterial activity (24.33 ± 2.03 mm). This finding supports previous studies stating that NaDES (natural deep eutectic solvents) containing organic acids have intrinsic antimicrobial properties due to their low pH (1.28 ± 0.25) and their ability to denature proteins in microbial cell membranes.67 Another study reported an inhibition zone of 5.26 ± 0.71 mm for extracts obtained from conventional ethanol extraction of cacao shell against E. coli.65 Interestingly, the inhibition zone produced by extraction using the SAE-DES method can generate a larger inhibition zone. This confirms the synergistic effect between choline chloride and lactic acid when combined with ultrasonication, thereby significantly increasing the yield of phenolic compounds.
The antibacterial properties of the extract were also tested on S. aureus, as shown in Table 7. Analysis of the optimal cacao shell extract resulted in 28.83 ± 0.76 mm inhibition zone. This value is larger than that of trimethoprim (positive control), which has an inhibition zone of 22.67 ± 0.29 mm (p < 0.05). This confirms that cacao shell extract obtained using SAE-DES exhibits strong bactericidal efficacy. According to a study reported by Álvarez-Martínez et al.,68 plant extracts rich in polyphenols show greater inhibitory activity against Gram-positive bacteria. This occurs because the thick but porous peptidoglycan layer allows the penetration of small antimicrobial molecules, unlike the outer lipopolysaccharide layer in Gram-negative bacteria, which acts as a barrier.
| Bacteria | Inhibition zone (mm) S. aureus |
|---|---|
| Trimethoprim (positive control) | 22.67 ± 0.29b |
| Optimum extract DES | 28.83 ± 0.76a |
DES (ChCl : LA) |
21.17 ± 5.75b |
| Distilled water (negative control) | 0.00 ± 0.00c |
However, in this study, the cacao shell extract showed higher activity against E. coli than against S. aureus, contrary to previous studies. This unusual result is because of the unique phenolic and flavonoid profile of cacao shell. The content of low-molecular-weight hydrophilic phenolic compounds and abundant organic acids is suspected to penetrate the porin channels of Gram-negative bacteria, thereby disrupting the integrity of their cytoplasmic membrane.69 Additionally, extraction using the DES method enables the increased recovery of small and polar bioactive compounds by modifying their ionization state. This can increase the permeability of the compound to pass through the outer membrane of Gram-negative bacteria. The synergistic interaction between the acidic DES environment (pH 1.28) and polyphenol compounds can also further weaken the E. coli cell wall through a combination of acid stress and oxidative damage, which explains the remarkable inhibitory activity observed.70
:
LA) in extracting bioactive compounds from cacao shell waste. Temperature, solids-to-solvent ratio, and DES concentration can significantly impact the concentration of bioactive compounds extracted, as determined by TPC and TFC analyses. The process registered mass transfer coefficient (kca) and equilibrium constant (Hs) ranges of 8.73 × 10−3 to 14.80 × 10−3 min−1 and 0.56 × 10−3 to 41.91 × 10−3 g solid per cm3, respectively. The results of RSM optimization with BBD indicated that the optimal operating conditions were 80 °C, a solids-to-solvent ratio of 1
:
10, and a DES concentration of 62.65%, yielding extracts with the highest content of bioactive compounds. FTIR spectral analysis confirmed the existence of bioactive compounds, which showed potential as antibacterial agents through E. coli. and S. aureus growth inhibition.
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