When we were approached to support a chocolate factory capacity expansion, the objective was clear: increase production output while improving process efficiency and control.
Rather than simply adding another production line, the project focused on redesigning the upstream chocolate handling system to eliminate manual processes and create a scalable, automated solution.
From initial design through to installation and commissioning, the project delivered a fully integrated chocolate processing and distribution system built for long-term growth.
The Brief: Increase Production Capacity Without Increasing Complexity
The requirement was to introduce a second production line while ensuring the existing chocolate processing system could support higher demand.
The key challenge was upstream. Chocolate and ingredients were being moved manually, leading to inefficiencies, delays, and increased reliance on operators.
Without intervention, adding another line would have doubled these inefficiencies.
The brief was to design an automated chocolate handling and distribution system that improved process flow, reduced manual handling, and enabled consistent, scalable production.
The Solution: Fully Integrated Chocolate Processing and Automation System
We designed and installed a fully automated chocolate handling system, integrating storage, melting, routing, and delivery into a single controlled process.
This included:
- 5 x 1500kg jacketed stainless steel holding tanks with agitation
- A cocoa butter melting system with integrated temperature control and transfer
- An automated valve routing system for directing product across the process
- Pumping and filtration systems for controlled and clean transfer
- Jacketed pipework for temperature-controlled process and product flow
- A multi-point draw station with controlled access to different chocolate types
- Integration with existing factory systems with minimal disruption
- A Siemens S7-1500 PLC and HMI control system for full automation and visibility
This integrated food processing automation system allows full control over chocolate movement throughout the factory, improving consistency and traceability.
Installation was carefully phased to allow ongoing production, ensuring minimal downtime during integration with the live manufacturing environment.
The result: Increased capacity with improved efficiency and control
The factory can now support increased production demand without increasing manual workload.
The automated chocolate handling system ensures chocolate is delivered where and when it is needed, removing reliance on operator movement.
Key benefits include:
- Increased production capacity
- Reduced manual handling and labour dependency
- Improved process consistency and control
- Greater flexibility for multiple recipes and product types
- A scalable system designed for future expansion
By focusing on upstream chocolate processing and automation, the project not only enabled capacity expansion but also improved overall factory efficiency and day-to-day operations.
