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Brett Beardsell consulting
Brett Beardsell consulting
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Example Services - fully Tailored to Your neeDS

Coaching, Training and People Development

Call Out Support, Chocolate Production and Processing Optimisation

Call Out Support, Chocolate Production and Processing Optimisation

Individual or team coaching


Remote or on-site coaching


Classroom or on-the-line coaching


1-2-1 or groups


Specialist Chocolate Training and Workshops


Business and Material Strategy Workshops


Interim team coaching and leadership


Basic, Intermediate or Masterclass levels available


contact me

Call Out Support, Chocolate Production and Processing Optimisation

Call Out Support, Chocolate Production and Processing Optimisation

Call Out Support, Chocolate Production and Processing Optimisation

Call outs and emergency visits


Cocoa processing optimisation (bean processing, roasting, nib milling, cocoa powder production, cocoa butter production)


Chocolate manufacturing (Refinery) optimisation


Chocolate processing optimisation (tempering, enrobing, moulding, depositing, cooling) 


Plant recommendation and commissioning support 


Export production risk assessments and optimisation


Hot weather risk assessments and optimisation  


Specialist bloom and fat migration investigations


Trial support (new ingredient/new recipe/new supplier change)


Product quality troubleshooting including bloom investigations


Short term staffing support

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Cost Saving - Cost Avoidance - Supply Chain Value Improvement

Call Out Support, Chocolate Production and Processing Optimisation

An End to End Chocolate Business “Health Check” and Optimisation Plan

Recipe cost saving programs


Process improvements to enable new recipe implementation


Value improvement programs


SKU rationalisation


Business continuity project management (eg. currency or geo-political sourcing risk mitigation)


Supply failure incident management and futureproofing


Supplier performance improvement


Supplier partner development


New supplier and new ingredient introduction

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An End to End Chocolate Business “Health Check” and Optimisation Plan

Chocolate R&D, Chocolate Handling Expertise including Bloom Investigations

An End to End Chocolate Business “Health Check” and Optimisation Plan

Identifies and improves points of weakness in terms of productivity, business continuity and quality


Increases overall efficiency and profitability.

https://brettbeardsellconsulting.co.uk/blog/f/e2e-chocolate-business-review---save-money-reduce-risk?blogcategory=Services+Offered


Typical scope :


Recipe spec and design

Procurement processes

Supply and delivery

On site material storage

Use and application - tempering, enrobing, moulding, depositing, cooling

Finished product handling 

Warehousing and distribution

Skills gaps and training needs

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Chocolate R&D, Chocolate Handling Expertise including Bloom Investigations

Chocolate R&D, Chocolate Handling Expertise including Bloom Investigations

Chocolate R&D, Chocolate Handling Expertise including Bloom Investigations

New chocolate recipe development from concept to launch


Nutritional improvement project management (dairy free, sugar reduction, saturated fat reduction, calorie reduction etc)


Technical roadmap and platform development 


Development of Regionally and Globally compliant chocolate recipes 


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Chocolate Excellence Program

Chocolate R&D, Chocolate Handling Expertise including Bloom Investigations

Chocolate R&D, Chocolate Handling Expertise including Bloom Investigations

Continuous Chocolate Improvement through Ongoing Line Support and Coaching


A support program designed to step-change the performance of your people and processes


It considers your people, product, procedures, equipment and materials


The requirement for change is identified, enabled, managed and supported

Contact me

EXAMPLES OF HIGH IMPACT chocolate problems solved ...

  • Set up McVitie’s Hot Weather procedures and Chocolate GMP system, delivering warm weather and then AYR bloom complaint reduction. YOY continuous improvement delivered an estimated 90% reduction in manufacturing linked bloom issues across 7 UK manufacturing sites 


  • Delivered McVitie’s chocolate processing and distribution chain handling training from c1996-2018 


  • Responsible for the Milk and Dark chocolate recipe creation, development, and cost optimisation – and commissioning and continuous technical support to 5 x Half Coated Digestive lines (Branded and Retailer Own Label) within McVitie’s UK 


  • Combined project delivery of 15% line capacity increase, all year-round warm weather running enablement and c€2M savings delivery(+ €0.9M further IDed) for a European cake manufacturer through formulation, specification and operational improvement • 


  • New tempering and enrobing line specification and commissioning, with operator training and coaching - for UK’s largest private label cake, cereal bar and biscuit manufacturers 


  • Premium UK cereal bar manufacturer – 90% reduction in downtime through line operation set up an operator coaching (ongoing) 


  • Ongoing Chocolate Excellence Program delivery across 2 UK and EU Manufacturers – process and procedural optimisation, team development, and coaching   


  • Coating manufacturing and enrobing/filled biscuit optimisation for RSA client – 60% improvement in line downtime (set-up, changeovers, stoppages) and new product launches enabled  


  • Multi line optimisation and recipe change support of UK’s #1 Mini Roll manufacturer


  • Technical support, line setup and team coaching for new chocolate business launch for KSA client – NSV c£3M equivalent in first year of launch  


  •  Acquisition and new business integration support for EU biscuit and cake manufacturing group – identifying c €1.5M simplification and cost saving opportunities through recipe, supplier change and line running optimisation across new Italian and Slovakian sites 


  • Bloom issue resolution for a leading Belgian Praline manufacturer – through process improvement and coaching. Estimated annual benefit €1.75M 


  • New Jaffa line tempering, enrobing and cooling equipment specification and commissioning support across 2 Balkan manufacturers (ongoing) – estimated combined NSV £50M 


  • Downtime and operational improvement support for UK’s #1 Jaffa manufacturer – 8 days running without stoppages extended to desired 13 days running period   


  • E2E assessment and change support of leading EU coated confectionery manufacturer identified and delivered c€1.1M of benefits across enrobing, moulding and one-shot depositing lines     

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