Krongrawa W.Ponphaiboon J.Samran C.Limmatvapirat S.Limmatvapirat C.Mahidol University2026-06-262026-06-262026-12-01Applied Food Research Vol.6 No.2 (2026)https://repository.li.mahidol.ac.th/handle/123456789/117529Cocoa bean shell, a major by-product of cocoa processing, is an underutilized source of phenolic bioactive compounds. However, efficient recovery of these compounds and the influence of upstream processing conditions remain insufficiently explored, particularly in relation to sustainable food applications. This study developed an integrated strategy combining roasting process evaluation with statistical optimization of ultrasound-assisted extraction (UAE) to enhance bioactive compound recovery. The physicochemical properties of cocoa butter obtained under different roasting conditions were evaluated to identify suitable processing parameters. Although low-temperature roasting preserved lipid quality, high-temperature roasting provided higher butter yield and improved processing efficiency and was therefore selected. Key extraction variables were screened using a Plackett–Burman design and optimized using a Box–Behnken design with response surface methodology to maximize extraction yield, antioxidant activity, total phenolic and flavonoid contents, and anti-inflammatory activity. Optimal conditions (50.96% v/v ethanol, 5 min, 47.87°C) yielded 33.34 ± 2.81% extract with strong antioxidant capacity. Enhanced extraction efficiency was attributed to acoustic cavitation, which promotes cell disruption and phenolic release. Safety assessment confirmed compliance with international standards, highlighting the potential of cocoa bean shell extract as a sustainable functional ingredient for food and nutraceutical applications and supporting its valorization within a circular bioeconomy framework.Agricultural and Biological SciencesArticleSCOPUS10.1016/j.afres.2026.1022572-s2.0-10504232594827725022