Belcolade is the Belgian chocolate brand of the Puratos Group. Since 1988, Belcolade has been delighting the chocolate industry in a positive way by creating innovative flavors and sustainable chocolate solutions at its factory in Erembodegem (Belgium). To package this delicious chocolate safely and with high quality, Belcolade relies on our expertise.
We were previously part of the project team for the development of several production lines for liquid chocolate. After that, we were responsible for the installation of all new utilities and for transforming the existing factory into a CO₂-neutral production site. Currently, we are fully engaged in building an automatic filling line in the packaging hall.
From liquid to Automatically Packed
The goal of the new filling line? To package the chocolate quickly, accurately, and hygienically. It all starts with liquid chocolate and ends with convenient boxes and bags, collected on pallets — soon to be done fully automatically.
A challenge our team is more than happy to take on. The warehouse building was already there; the key was to utilize it as efficiently as possible. In total, six of our colleagues are working to manage this project from start to finish.
Solid and food-safe installation
With a limited footprint and thoughtful design, the available space is used optimally in every dimension. We are currently building multiple levels where, in the next phase, the filling and packaging machines will be installed.
To support the heavy loads of the machines, steel structures are being placed within the existing building. Each structure is calculated to bear its specific load. The constructions are finished with steel plates topped with an epoxy cast floor.
This cast floor is wear-resistant and eliminates joints or seams where dirt or dust could accumulate. It contributes to the high hygiene standards required for this project. After all, the packaging hall must comply with GMP standards, which dictate that the production facility must be clean and hygienic. The cast floors, rounded corners, and many suspended structures are therefore not random choices — they are all part of the hygienic design.
150 meters of Automation
- From liquid to Drops or grains
The filling line will operate fully automatically. Liquid chocolate is pumped from a tank to the depositor. The depositor dispenses the chocolate into various shapes — either drops (discs) or grains (small pellets). The chocolate pieces fall onto a cooling belt to harden. Once firm enough, they move on toward the bagging machines.
- Drops or grains in Bags
In these machines, the drops or grains are collected until the correct weight is reached. The weighing hopper opens, and the product falls into the bag. The bag seams are sealed, and the bag undergoes several automatic quality checks.
- Transport-Ready pallets
Everything in order? Then the bags are labeled and sent on. Small bags are first packed in pairs into folding boxes, while larger bags are stacked directly onto pallets. Each full pallet descends to the ground floor and is wrapped in film — fully ready for transport!
Mission: High-Performance Warehouse
After the current civil construction phase, the machines will be installed. In our next update, we’ll take you through the installation of all automated devices. This will be followed by a thorough testing phase.
Would you like to optimize or further automate your production line? Don’t hesitate to contact us. We’d be happy to explore the possibilities with you!
