CHOCOLATE MOULDING HOME OF


in a single stroke. Combining servo and one-shot technologies along with the advances in computer programming power creates the ability to manufacture chocolates with even higher centre-to-shell ratio.” Moulding equipment manufacturers have also had to evolve


their offerings to fit ever more crowded production floors which demand equipment with a smaller footprint. Egan Food Technologies, for example, has recently introduced a fully- automated chocolate moulding line that offers all of the features just mentioned by John, in a compact 9m space. Chilled stamping is another recent technology advance – it


allows chocolate shells to be filled with ingredients that cannot be deposited using the one-shot method – such as wafers or large inclusions or chocolates with more viscous centres and higher heat profiles. “With labour becoming scarce and production costs at an all- time high, more confectionery manufacturers are now looking to automate their processes in a bid to reduce their reliance on manual labour and to allow them to better manage costs. This is another reason for the growing interest in automated solutions which allows for production with less staff,” adds John. With ingredient prices also increasing, chocolate manufacturers are having to get more creative with their cost reduction methods. “Product centres generally carry a lower cost than the chocolate shells,” John explains. “So, manufacturers are increasing the centre ratios of their filled chocolates where they can. In some cases, they are moving to shell forming methods for the highest possible ratios. This of course means that accuracy is becoming increasingly important when producing moulded chocolates with product inclusions – both from a cost control standpoint and for accurate nutrition statements,” concludes John.


Modular is popular Carsten Butz, Technical Director at Winkler und Dünnebier Süsswarenmaschinen GmbH (WDS) also highlighted to me that chocolate moulding technology has changed significantly in recent years, becoming more flexible while continuing to put an emphasis on hygiene. “Today’s moulding plants need to be flexible, with fast changeover times between batches,” he says. “The shorter production line downtimes that come from being able to quickly clean equipment between batches can help achieve higher Overall Equipment Effectiveness (OEE). In addition, new and innovative drive concepts are now allowing for more modular moulding lines, with shorter on- site assembly times, leading to much faster start of production for new lines. In 2019, WDS presented a new production line for chocolate products designed for medium to high-capacity use. Important elements of this – in line with customer demands – included a modular design with a decentralised control unit to give the flexibility to expand the line with minimum effort to enable it to be adapted to meet potential future requirements. “The line is also completely paint-free and offers easy accessibility for cleaning which contributes to the high hygienic requirements demanded in this sector,” explains Carsten.


“Demands for flexibility in moulding processes has increased rapidly,” continues Carsten. “The competitive nature of the confectionery sector requires continuous product innovation to stay ahead of the competition. For


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Kennedy’s Confection October 2022 25


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