Examples of Previous Client challenges
"We want to save costs across our coatings"
"We want to increase our production throughput, but we have persistent quality problems"
"We want to increase our production throughput, but we have persistent quality problems"
On site visits assessed processing, specification and formulation optimisation to deliver a €1.5M opportunity on a €14M spend
"We want to increase our production throughput, but we have persistent quality problems"
"We want to increase our production throughput, but we have persistent quality problems"
"We want to increase our production throughput, but we have persistent quality problems"
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
"We'd like to start manufacturing our own chocolate and coatings in house"
"We want to increase our production throughput, but we have persistent quality problems"
"We want to reduce chocolate bloom and need a way of telling if production is at risk"
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
"We want to reduce chocolate bloom and need a way of telling if production is at risk"
"My entire team need to understand how to process and handle chocolate, not just one or two of them"
"We want to reduce chocolate bloom and need a way of telling if production is at risk"
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
"We want to develop our own chocolate recipes - what kit and supporting equipment do we need?"
"My entire team need to understand how to process and handle chocolate, not just one or two of them"
"My entire team need to understand how to process and handle chocolate, not just one or two of them"
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
"My entire team need to understand how to process and handle chocolate, not just one or two of them"
"My entire team need to understand how to process and handle chocolate, not just one or two of them"
"My entire team need to understand how to process and handle chocolate, not just one or two of them"
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
"How do I stop my manufacturing team arguing with my buying team about the chocolate they source?"
"We haven't changed our chocolate recipe in years - and the supplier isn't providing great service"
"We haven't changed our chocolate recipe in years - and the supplier isn't providing great service"
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
"We haven't changed our chocolate recipe in years - and the supplier isn't providing great service"
"We haven't changed our chocolate recipe in years - and the supplier isn't providing great service"
"We haven't changed our chocolate recipe in years - and the supplier isn't providing great service"
I conducted a one day visit to review the recipe and site performance, and discussed how to manage suppliers and conduct effective performance reviews
"I'm giving away more than 10% of chocolate during enrobing - how can I reduce this?"
"We haven't changed our chocolate recipe in years - and the supplier isn't providing great service"
"We'll be using chocolate for the first time soon and need some fundamental guidance and training"
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
"We'll be using chocolate for the first time soon and need some fundamental guidance and training"
"We'll be using chocolate for the first time soon and need some fundamental guidance and training"
"We'll be using chocolate for the first time soon and need some fundamental guidance and training"
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
"We make specialist "Free From" chocolate bars and are struggling with our manufacturing process"
"We'll be using chocolate for the first time soon and need some fundamental guidance and training"
"We make specialist "Free From" chocolate bars and are struggling with our manufacturing process"
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
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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Need an factory visit to resolve a production or quality issue on your chocolate line?