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Equipment Set Up & Optimisation
Cost Reduction
Bespoke Coaching & Training
Quality Improvement
Recipe Reformulation
Equipment Set Up & Optimisation
Cost Reduction
Bespoke Coaching & Training
Quality Improvement
Recipe Reformulation
ADI Group, Border Biscuits, Brighter Foods (THG), Burtons Biscuits, Cerealto,
Deans of Huntly, Dofreeze LLC, Dream Chocolate USA, East Coast Bakehouse,
EGI Group, Elkes Biscuits, Farmhouse Biscuits, Forsan Foods, Fox’s Biscuits, Halo Foods, Hotel Chocolat, Jaffa Crvenka, Kraft-Heinz, Meadow Foods Inclusions, MinterEllison, National Brands Ltd (AVI), Natra Cacao, Park Cakes, pladis, Premier Foods, Pulsin,
Pure Heavenly Chocolate, Valeo Foods (Valeo Confectionery UK, Balconi (Italy), Schluckwerder (Germany), Carstens Lübecker Marzipan (Germany), IDC Holding (Slovakia)), Wholebake and Zar Group.
Chocolate manufacture, bulk storage, tempering, enrobing, depositing, aerating, cooling, finished product storage and product distribution
Maximising throughput, minimising waste and downtime
Optimising coverage and weight control. Minimising overuse.
First time industrial manufacturing
Equipment specification, installation and commissioning assistance
Process scale up
New product launches and first production support
Best practice line set up for traditional recipes, Free-From recipes and Reduced Sugar recipes
Best practice supercoating and compound coating operation
Best practice use of tempermeters
Plant troubleshooting
New supplier and new ingredient introduction
Cocoa powder, cocoa liquor and cocoa butter production optimisation
Cost saving through formulation, specification and manufacturing savings
Ball mill, refiner conching and 2 stage refining process optimisation to minimise fat requirement
Chocolate overuse? Unscheduled production downtime? Recipes too expensive?
From savings across one material (for example, chocolate!) to savings across your complete ingredients portfolio
Bespoke training built with the needs of your team, your product range and your equipment in mind. In the classroom or on your line.
For first time chocolate users through to experienced teams
Basic, Intermediate and Masterclass level training as 1-2-1s or for groups
Specialist team training and coaching for teams such as plant engineers and
QA/Technical teams
Can be tailored for specific subjects - such as recipe optimisation, legislation etc
Business and Material Strategy Workshops - chocolate strategy building and implementation to drive profit and reduce costs
Coaching on in-house formulation modelling
End 2 end chocolate performance auditing
Bloom Risk Assessment mapping
Diagnosing and preventing chocolate bloom
Minimising fat migration issues and impact on product quality
Optimising coating coverage and surface appearance
Optimising coating rheology - viscosity and yield stress
Investigating and reducing consumer complaints
Building Good Manufacturing Practice documents, specifications and visual standards
Ingredient intake testing and in-process material testing guidance
How to improve and get more value from your Supplier relationships
Reformulating to deliver a claim or cost against a sensory brief
Reformulating to improve heat resistance and Summer running
Reformulating to improve ease of processing, weight control etc
Use of functional emulsifiers - how to use PGPR (E476) effectively and consistently
Cocoa / milk solids optimisation
Sugar reduction, Free From and Vegan formulation
On site visits assessed processing, specification and formulation optimisation to deliver a €1.5M opportunity on a €14M spend
A 2 day end to end survey of their production identified improvements to their existing production line and guidance on selecting and operating new manufacturing equipment
Guidance on the identification of an equipment supplier, specification of equipment and and ancillary equipment capable of meeting the clients expected chocolate needs of 15,000T / year
I developed a new quality assessment tool (with photographic visual standards) which enabled the client to rapidly identify whether product is at risk and what remedial action or subsequent distribution controls needed to be applied
I recommended pilot plant equipment and ways of working including sensory assessment requirements to enable the client to produce their own in house test recipes. Analytical requirements including testing equipment were also agreed
A bespoke 1 day training course was developed to train a team of operators to best store, temper, enrobe, cool and handle finished products through the distribution chain - with the classroom session supported by time on the production line to demo critical WOWs discussed and explored
By running a workshop on collaborative and strategic thinking AND reviewing the recipe in use, we developed a more optimal product AND a robust, future WOW that meant all business teams could influence the recipe being used to ensure it was optimal with respect to cost, claim, ease of handling, line running etc
I conducted a one day visit to review the recipe and site performance, and discussed how to manage suppliers and conduct effective performance reviews
A line visit and audit quickly identified the root cause of the issue - the chooclate recipe - an provided guidance on how to move to a recipe that simplified production. A skills gap analysis was run and training for the Operators in chocolate process control provided over 3 sessions
A specially constructed 1 day training for key personnel gave them the fundamental information and watch outs they needed - this was after a familiarisation discussion with them that allowed me to pitch and tailor the content to their proposed product, equipment and way of working
I provided hands on set-up and processing recommendations to recover their processing capability and control. A series of site visits allowed me to train and coach the team in all aspects of chocolate manufacturing, tempering, depositing and cooling
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