Chocolate Batch Manufacturing

Despite fluctuations in ingredient prices, varying consumer tastes, and economic uncertainty, chocolate-based products remain a constant favorite for sweet tooths around the world. With so many external factors putting pressure on the industry, chocolate manufacturers realize that delivering a consistently pure and tasty product is what consumers are really looking for.

The Solution

For Archer Daniels Midland (ADM) Cocoa, supplying and satisfying some of the most demanding and sophisticated customer bases in the world led the company to demand more out of its process control capabilities. In order to meet these various demands, ADM Cocoa opted to build a state-of-the-art cocoa processing plant in Pennsylvania, and needed the help of the NovaTech D/3 Distributed Control System (DCS) to accomplish the task of delivering world-class cocoa products to its customers.

With a the goal of delivering on corporate profitability benchmarks and providing high-quality products, the plant needed the ability to quickly changeover between products and adapt to product recipe changes—all while maintaining compliance with the demanding standards of the FDA, EPA, and other regulatory agencies.

By integrating FlexBatch with the D/3 system, ADM Cocoa gained several advantages. Instead of relying on programmers to build out product recipes and make changes every time they are necessary, FlexBatch empowers the production staff to easily create, modify, and experiment with recipe changes. In addition, NovaTech and ADM engineers collaborated on the design of the automation schema and constructed small, modular programs to accomplish the basic phase logic for each unit of operation. This decreased the complexity of programming, and increased the plant’s ability to easily produce thousands of unique and specialized products using the same basic raw materials.

The combination of the D/3, FlexBatch, and ADM Cocoa and NovaTech engineering delivered highly flexible, dependable, and efficient plant operations and exceptional product consistency and quality for ADM and its demanding clientele.

Related Processes & Experience

Dust Collection, Bean Unloading/Cleaning/Silo/Storage, Breaking and Winnowing (Destoner/Micronizers/Winnowers/Nib Silos), Roasting and Grinding (Roaster/Stone Mills/Ball Mills), Liquor Screening/Storage/Standardization/Melting, Special Liquor Melting, Fat Melting, Butter Melting, Sugar Unloading, Lauric Storage, Non-Lauric Storage, Lecithin, Butter Load In/Out, Liquor Load In/Out, Chocolate Line (Dry Ingredients/Liquor Pre-Batch & Batch Tanks/Butter Batch Tanks/Kneader Mixer/2-Roll/5-Rolls/Conches/Chocolate Storage/Butter Dosing/Chocolate Rework), Black Cake, Powder Packaging, POTASH, Utilities

Related Solutions

Distributed process control, Operator training simulators, Recipe driven state based control, S88 Batch Management and control, S106 Procedural automation and control, Electronic batch reporting, ISA 18.2 Alarm Management, Data historian, Trend visualization, Process analytics, Process simulation, Asset management, Control Loop performance monitoring and optimization, Energy and asset management, Overall Equipment Effectiveness (OEE) Analytics, Regulatory compliance and validation, System hardware and custom I/O cabinet design, Product Lifecycle Services

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