NEWS AND BLOG

As a company designing and constructing chocolate manufacturing facilities, we appreciate the process of turning cocoa beans into chocolate bars. This article delves into the technical aspects involved with designing such facilities, to ensure optimal functionality and efficiency of the production system while working with the project team to achieve the project’s budget and schedule.

Conceptual Development. Understanding what products will be made, the packaging formats necessary for each SKU, and the production volumes needed for every SKU and packaging format is the starting point to determine how to design the facility. Our team works side-by-side with our clients to ensure the design of the new chocolate facility remains focused on one thing: achieving the goals of the business.

Flexibility and Scalability. Future growth should always be considered when designing a new chocolate production facility. Austin’s design team is experienced with master planning facilities to help tailor our client’s capital investment to the business’s more immediate needs while designing for cost-effective expandability of the facility for future growth.

Layout and Flow Optimization. One of the primary considerations in designing a chocolate manufacturing facility is the layout and flow of the production process. We value our clients’ input and work closely with them to create a layout that minimizes unnecessary movement of materials and personnel, ensuring smooth transitions from one production stage to the next.

Hygienic Design Principles. Chocolate is commonly used in ready-to-eat products, so ensuring that hygienic design principles are strictly adhered to is requisite. We implement features such as smooth, easy-to-clean surfaces, segregated production zones, appropriate air balancing between quality zones, and efficient drainage systems to prevent cross-contamination and ensure compliance with food safety standards.

Raw Material Reception and Storage. The layout should include designated areas for receiving and storing raw materials, primarily cocoa beans. These areas should be strategically located near the receiving docks for easy unloading and provide sufficient space for storing bulk quantities of beans in a climate-controlled environment.

Processing Area. The processing area is where the cocoa beans are cleaned, roasted, cracked, and winnowed to separate the cocoa nibs from the shells. This area requires specialized equipment such as roasters, crackers, and winnowers arranged sequentially to facilitate the flow of materials from one process to the next while allowing for adequate access to equipment for maintenance and sanitation activities.

Grinding and Refining. After winnowing, the cocoa nibs are ground into a paste known as chocolate liquor, which is then refined to achieve the desired particle size and smoothness. This process typically involves the use of refiners and conches arranged in a continuous flow to ensure consistent quality and flavor development.

Tempering and Molding. Tempering is a critical step in chocolate production that involves heating and cooling the chocolate to stabilize the cocoa butter crystals, ensuring a shiny appearance and crisp snap. The tempered chocolate is then molded into various shapes and sizes. The floor layout should include dedicated tempering machines and molding lines arranged in a sequential order to minimize cross-contamination and maximize throughput.

Packaging and Storage. Once molded, the chocolate products are packaged for distribution. The packaging area should be located near the molding lines and equipped with packaging machines, conveyors, and labeling systems for efficient packaging and labeling of products. Additionally, the facility should include designated storage areas for finished products, packaging materials, and ingredients, with proper inventory management systems in place to track and manage inventory levels.

Quality Control and Testing. Quality control is essential throughout the production process to ensure that the chocolate products meet the desired specifications and standards. The layout should include designated areas for quality control testing, equipped with testing equipment and facilities for sensory evaluation, viscosity measurement, and other quality parameters.

Support Facilities. In addition to the main production areas, the layout should also include support facilities such as offices, employee break rooms, restrooms, equipment and parts washrooms, and maintenance workshops. These facilities are ideally located where they can provide easy access for employees while minimizing disruptions to production operations.

Safety and Ergonomics. Safety is first and foremost in any manufacturing environment. We design facilities with clear sightlines, ergonomic workstations, and safety features such as emergency shut-off systems to protect workers and prevent accidents. The elimination of poor ergonomics is an important consideration during design to understand what safety risks to workers can be eliminated through improved design or automation.

Temperature and Humidity Control. Temperature and humidity control are paramount to maintaining product quality and consistency in chocolate production.. Designing the HVAC system to allow for air movements from high hygienic zones to low hygienic zones is critical while making provisions for high concentrations of heat, moisture, and dust. Spot cooling for operators and dust collection systems are commonly required in chocolate operations.

Equipment Selection and Integration. Selecting the right equipment is crucial for efficient chocolate production. In collaboration with our clients, we are experienced in developing equipment specifications and managing the equipment selection process to ensure the right equipment is selected, including ingredient handling systems through packaging and end-of-line automation. We have well-established relationships with many vendors and regularly work with them, so their equipment is integrated early on during the design process.

Energy Efficiency. Sustainability is a key focus in modern facility design. We incorporate energy-efficient lighting, equipment, and building materials to minimize environmental impact and reduce operational costs.

Regulatory Compliance. Compliance with local building codes, zoning regulations, and food safety standards is non-negotiable. Our team stays up to date with industry regulations to ensure that all aspects of the design meet regulatory requirements.

By carefully planning the layout and flow of the chocolate manufacturing facility, selecting the right equipment and vendors, and effectively incorporating best-in-class standards for hygienic design, safety, and energy efficiency early into design, we can create a facility that maximizes productivity, ensures product quality, and meets the needs of our clients and their customers.

ANTON ROZICH Director of Project Planning Call 440.544.2295 | Email Anton | View Profile