CONTINUOUS PROCESSES
functions to be combined flexibly and ensures that adaptations or extensions to a production line is possible at any time. “Another important aspect is flexibility,”
oversee a much larger section of the process that in a batch process. There will also likely be a reduction in handling and logistics labour. In batch production, operators are needed to move product around the factory floor between process steps. Because continuous process lines are physically connected from start to finish, they largely eliminate the need for such movement. “A continuous processing line will always solution to meet high-volume
the best
production needs due to the enhanced volume management,” continues Jarrod. “Continuous processing lines offer more flexibility, with increased automation giving the ability to tailor line speeds to meet requirements. Due to the decreased human interaction, product quality is also often improved because the process is more replicable, ensures continuity and enhances hygiene. Health and safety are also enhanced as there are fewer human interactions with the process.” Going on to explain how confectionery
producers can ensure they are able to balance high speed production with product quality and consistency on continuous process lines, Jarrod says: “Product quality is balanced through greater automation, as individual ingredients can be weighed and sized, ensuring repeatability and minimised waste while increasing throughput. More mechanisation ensured higher uniformity. Different dies and processes can be added flexibly to offer a greater product range while maintaining customer focus. Increased mechanisation reduces the possibility of human error and variation, ensuring uniformity and consistency. “Further, with the ever-increasing use of AI in confectionery processing, more options have become available to optimise and configure continuous processes for a vast array of applications.”
Perfect alignment Also offering advice for anyone tasked with specifying a continuous confectionery processing line, Mark Stepney, Managing Director at Schubert UK, says the key is to look at the overall system. “A continuous line will only deliver its full potential when all process steps are perfectly aligned. This includes a stable product infeed, reproducible processes, and a consistent line logic throughout,” he says. Schubert ensures that even lines
for continuous production, with high throughputs, are based around modular technology which enables individual
74 • KENNEDY’S CONFECTION • APRIL 2026
continues Mark. “Markets are changing rapidly. Formats, products, and packaging styles are becoming more diverse. Therefore, continuous lines need to be designed to enable fast and simple changeovers. This is the only way to minimise downtime and maintain high overall equipment effectiveness in the long term.” Mark argued that high output and
continuous processes go well together, but that they can only ever reach their full potential when combined with a modular and flexible machine architecture. “Continuous production should not be seen as a rigid concept, but as a scalable solution that can adapt to changing requirements and remain economically viable over time,” he says. Mark also pointed out that high processing speeds must not come at the expense of product quality, and he says that this requires precisely coordinated interactions between mechanics, control systems, and image processing. “Integrated inspection is a key element for success,” he says. “Modern vision systems are able to check products and packaging inline helping ensure that only flawless units continue through the process.” Product handling also plays a crucial role,
especially in the confectionery industry where gentle handling of sensitive products is often necessary. This can be achieved through well-designed gripper systems, smooth motion sequences, and a stable process design. “Ultimately, it is about maintaining stable processes,” says Mark. “Only then is it possible to achieve high speeds while ensuring consistent quality.”
End of the line McKinsey & Co has reported that the adoption of AI-powered robotics and predictive maintenance systems has cut downtimes and increased throughput by up to 25% in mid-sized confectionery factories, while real-time production analytics are also helping in the dynamic adjustment of smart factories, resulting in increased output and consistent quality standards. Fast-moving consumer demands and ever
stricter regulations have highlighted the importance of portioning precision and quality control. Ishida can meet this demand with its multi-head weighers which are able to ensure accurate portioning with minimal giveaway and waste at the end of the line. Ishida says that the introduction of self-
learning inspection systems has reduced product defects by 40% in some smart factories. Enabling the scanning of thousands of products per minute, these systems are having a transformative impact on quality control and defect detection on continuous production lines.
A continuous melting machine for chocolate
Premier Forrester believes it created a first in the chocolate manufacturing industry – a continuous chocolate melting machine. Melting chocolate is a challenging
task. The process can be time- consuming and energy inefficient and involves having to buy liquid in bulk or melting chocolate blocks or buttons in a tank. Often, several tanks are needed to process different types of chocolate, which can take up valuable space on the factory floor. The best way to melt chocolate
involves adding small amounts at a time to a melted batch, and this process can consume a great deal of both time and energy. The process can also create a lot of excess waste, as chocolate held for extended periods can go off colour which means it cannot be used and ends up as costly waste. To overcome these traditional challenges, Premier Forrester developed a solution that is able to continuously melt chocolate at a temperature of 45°C, reducing energy consumption and slashing chocolate waste to almost zero because the ‘wetted’ area of the equipment
with less than 500g of product being left at the end of the process. The continuous melting machine
can directly feed a temperer and directly link melting to a line, while topping up from bulk. White chocolate can be conveniently stored in solid form and can be melted instantly without any risk of discolouration
is exceptionally small,
Ishidia’s CCW AS multi-head weighing
solutions, for example, incorporate self- learning capabilities that can proactively optimise machine performance, accuracy and efficiency, while its Sentinel 5.0 production monitoring software enables the transfer of this learning between machines for real-time optimisation of production lines. As factories become smarter, so are
continuous processing lines. The adoption of smart technologies is seeing these once inflexible production lines become more flexible. They are still not the best solution for all confectionery applications but, as technology continues to take strides forwards, it will be interesting to see how their use grows in our industry.
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82 |
Page 83 |
Page 84
