For months, we’ve worked hard on our project at Belcolade, and now the puzzle pieces are finally falling into place.
The machines have been tested in stand-alone mode, interconnected, and we’ve received a solid indication of the capacity. We’re now entering the final stage of our project: hot testing with real chocolate. The project is well on track for its handover to production in September.
From Cold Testing…
Once all machines were perfectly installed, we could begin testing. Were all electrical connections in place? Was each machine functioning as expected?
In the first phase, we tested each machine individually.
Next, we tested the interaction between the various machines. How seamless is the transition between machines from different suppliers? Are the bags sealed properly? Does the system respond correctly when a bag of chocolate drops arrives? We made adjustments where needed to achieve a smooth and streamlined filling process.
…To a Hot Recipe for Success
Only in the final testing phase does real chocolate come into play. During these hot tests, we assess the full process—from liquid chocolate in the tanks to perfectly formed chocolate drops in bags. Needless to say, product quality is the top priority.
Some of the key steps being carefully tested:
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- Double-walled tanks: These use hot water in the outer shell to maintain the chocolate’s temperature and prevent solidification.
- Pumping and sieving system: Chocolate is pumped from the tank through a sieve and metal detector, filtering out oversized particles or contaminants.
- Tempering unit: This machine gives the chocolate the correct crystal structure for a glossy finish and firm setting.
- Depositor: Forms the characteristic chocolate drops.
- Bagging machine: Fills the drops into 5 or 10 kg bags.
- Palletizer: Stacks all bags onto pallets and sends them to the wrapper.
- Conveyors: Bags and pallets are transported between machines via rollers or conveyor belts, with additional manipulations (turning, flattening, metal detection, etc.) along the way.
- Wrapper: The final step, where the pallet is wrapped and made ready for storage and shipment.
The Moment of Truth
With chocolate now being fed into the depositor, we’re running the first full production runs. This allows us to conduct capacity tests across all machines and components. We verify whether everything performs as promised during procurement.
How much chocolate can be processed per hour? At what speed are bags filled? We fine-tune the process and ensure everything is ready for the final production launch.
Spic and span
Of course, we will deliver the packing area and installation in immaculate condition. Cleaning a project during execution happens in phases. We closely monitored the schedule and encouraged all suppliers to complete their work within the agreed timeframe. Since the end of June, the warehouse has officially been classified as a production area—entry is now only allowed with proper sanitation, hairnets, and appropriate clothing.
In the meantime, everything has been meticulously cleaned:
the entire installation inside and out, all piping, walls, floors, and the roof.
A clean environment is crucial for safe food processing.
We’re currently finalizing the hot tests and adding the finishing touches. This ensures a smooth and successful start-up when production officially takes over.
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