BATCH VS CONTINUOUS PRODUCTION


reducing avoidable downtime and waste, while maintaining the same quality and food safety standards across both smaller bespoke runs and larger orders.” A series of small orders can create a


disproportionate amount of administrative and operational work if


they are not


planned effectively. Grouping compatible products, preparing materials in advance and sequencing production to reduce unnecessary cleaning or adjustments can help. Clear communication between sales, product development, procurement and manufacturing is equally important, particularly when customers


request


changes at short notice. Manufacturers also need reliable


information about demand. Better forecasting and production planning can help identify which products justify long runs and which are better suited to smaller, more frequent batches. Where orders are uncertain, the ability to make a measured initial run and scale up once demand becomes clearer can be commercially useful — provided the product and process can be reproduced consistently.


Designing lines for greater adaptability Equipment suppliers are responding to these demands not only by improving changeover times but also by making production systems more adaptable. At interpack 2026, Bühler highlighted


ChocoX, its modular chocolate moulding line, which is designed to manufacture a range of products including solid and filled bars, pralines, one-shot applications and aerated products. According to Bühler, modules can be added or exchanged within 30 minutes, and the automation system detects new line configurations. The company says this approach can reduce time to market for new products by four to five months, cut cleaning time by 70% and reduce downtime during format changes by up to 50%. These are manufacturer-reported


figures rather than universal outcomes, and actual performance will depend on the product mix, line configuration and operating conditions. Nevertheless, the example shows how modularity can make product variation


less dependent on


lengthy mechanical changes. Digital monitoring is another part


of the development. In April 2026, German


confectionery


manufacturer Winkler und Dünnebier Süßwarenmaschinen (WDS) announced


machinery


its All-in-One SmartMould, developed with Swiss technology company CHoNova. The system combines sensors and software to monitor factors including temperature, humidity, vibration and the behaviour of chocolate as it crystallises and releases from the mould. This does not make production planning


less important; it gives manufacturers more information with which to manage it. Consistency remains essential whether a line is producing one million units of a standard product or a smaller quantity of a bespoke recipe. Monitoring process conditions can support that consistency, but it must sit alongside validated procedures,


operator expertise and


appropriate quality controls. The wider direction is towards


systems that can accommodate product changes while retaining repeatability. Faster cleaning, accessible machine components, modular equipment and more precise process control can all contribute. However, the investment case will differ between manufacturers. A high- volume producer with a stable portfolio may gain more from maximising uptime on dedicated lines, while a business with a varied customer base may place greater value on equipment that can be reconfigured efficiently.


Where made-to-order has an advantage For Hames Chocolates, the value of made-to-order production is particularly apparent where customer requirements extend beyond a standard product specification. “Made-to-order production works particularly well for seasonal and limited-edition ranges, private label products, exclusive recipes and more complex or highly decorated confectionery. “It is also useful where customers need


bespoke branding, specific pack formats or smaller order quantities. The main advantage is being able to respond quickly to unexpected orders, trial new ideas and adapt to changing demand, while helping customers avoid excess stock,” says Carol. These applications often involve several


variables at once. A seasonal product may require a particular shape, recipe, decoration and packaging format, all tied to a fixed retail launch date. A private-label range may need to meet a retailer’s precise specification, while a limited edition may be intended to test consumer response before a wider rollout. In such cases, the ability to tailor the


order can be as important as the speed of manufacture. A customer may not need the lowest possible unit cost at the expense of committing to volumes that are difficult to


48 • KENNEDY’S CONFECTION • OCTOBER 2026


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