MODULAR SOLUTIONS


From a practical standpoint, Paolo


believes that modular moulding lines translate into shorter delivery times for standard configurations, faster installation on site and smoother start-ups. “Because modules are pre-engineered and factory-tested, commissioning risks are reduced and time-to-production is minimised,” he says. Offering a word of warning, however, Paolo pointed out that modularity should never imply standardisation at the expense of quality. High performance, precision and repeatability should be built into each module and maintained across the entire line. With chocolate manufacturers under


growing pressure to launch new products, limited editions and seasonal items, often in smaller batches and with shorter times-to-market, modular moulding lines should be designed to help absorb the complexity associated with new product introductions. Integrating automated mould change solutions, for example, can help reduce downtime and make frequent format changes more manageable without compromising productivity. Paolo argued that the flexibility


offered by modular systems is especially valuable today in a market where consumer preferences are evolving so rapidly – from chocolate-only products to items incorporating wafers, biscuits, additional ingredients, and a wide variety of shapes and textures. “A modular approach allows manufacturers to adapt their lines by upgrading specific sections rather than replacing the entire system. New technologies can be introduced step-by-step, and free modules can be foreseen in the original layout to accommodate future developments as


A MODULAR APPROACH


ALLOWS MANUFACTURERS TO ADAPT THEIR LINES


BY UPGRADING SPECIFIC SECTIONS RATHER THAN REPLACING THE ENTIRE


SYSTEM. NEW TECHNOLOGIES CAN BE INTRODUCED STEP-BY-STEP


strategic approach to managing change over time.”


Adaptability is key The confectionery market is in a constant state of flux and the adoption of modular production systems can provide a way for manufacturers to remain flexible enough to keep up with these changing demands – from customers, consumers and due to changing legislation. The practical implications of adopting modular production solutions can include reduced start-up times, while the use of standardised modules can also help reduce the traditional cycle of tweak– test–scrap that often accompanies new product introductions or pack format changes, so it can also help reduce waste and ensure more sustainable production. Modular systems can also keep


business needs grow,” he says. “Modular design matters most in areas where change is frequent and value creation is highest. In chocolate moulding lines, for example, this includes depositing technologies, shell-forming solutions and mould handling systems. These are the sections most affected by new product concepts, recipe evolution and production flexibility requirements.” Ultimately, Paolo believes that modularity can transform chocolate moulding lines into living systems that are scalable, adaptable and future- ready. In conclusion, he says: “For confectionery manufacturers looking to balance efficiency, quality and innovation, modular production should not be treated just a technical choice. Instead, it should be considered as a


CAPEX costs down, helping avoid over purchasing equipment for a project that may not happen or may be short-lived . Instead of specifying a single do- everything line at the outset, modular systems allow capacity and capability to be staged – adding modules only when demand or trends justify them. By embracing modular solutions,


confectionery manufacturers will be better placed to respond quickly to emerging market trends and new packaging format requirements. They will also be in a good position to address ongoing regulatory changes and sustainability initiatives. Whether embracing new packaging materials, reducing energy consumption, or enhancing product traceability, modular production lines empower manufacturers to meet changing expectations in a much more effective way.


MARCH 2026 • KENNEDY’S CONFECTION • 23


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