Barry Callebaut is the world’s leading manufacturer of high-quality cocoa, chocolate and confectionery products. In the factory based in Lebbeke-Wieze (Belgium) the transfer of raw materials is controlled by METTLER TOLEDO weigh modules, platforms and indicators. The solution assures fast and precise weighing of critical components plus easy data integration, which are both vital for an efficient production process.
The plant in Lebbeke-Wieze produces an annual output of more than 250,000 tons of confectionery. At the very beginning of the chocolate manufacturing procedure, during cocoa processing, production is focused on mixing, batching and filling operations with a high throughput and a high degree of automation. At this stage METTLER TOLEDO can be relied upon for fast and accurate measurements.
Raw material batching and chocolate tempering
Batching the exact amount of raw materials is a key factor when producing high quality chocolate. Upon recommendation from METTLER TOLEDO Belgium, Barry Callebaut chose FlexMount® weigh modules and specific process terminals to weigh batching and tempering tanks as well as mixing stations. This solution assures fast and precise weighing of critical components plus easy data integration, which are both vital for an efficient production process.
Simple data integration
Weighing results are transmitted from process terminals via PROFIBUS® DP into Barry Callebaut’s automation system. The PTPN terminals ensure trouble-free connection with 20 updates per second.
Barry Callebaut’s benefits
Due to the simple yet highly effective mounting accessories and the Plug and Play connection, the weighing modules and terminals were easy to install. In contrast to other level sensors, load cells are not affected by dust, foam and solids which do not distribute evenly in tanks. This ensures accurate and repeatable measurements without coming into direct contact with the substance. Technical Manager, Bart Goetmaeckers, explains why he has chosen METTLER TOLEDO weighing equipment: “This solution speeds up the batching process and increases the level of precision and consistency during material transfer. The high quality of the weighing module ensures minimum maintenance costs and maximum availability, which in turn increases productivity.”
Net content control for chocolate bars, chocolate chips and chocolate mousse
Controlling the filling or package weight pays off in two ways. Firstly it ensures full compliance with national and international net content legislation regarding underfilling and secondly it assures minimum overfill. At the molding station for 5 kg chocolate bars, the chocolate mousse filling station and the chocolate chip packaging line, METTLER TOLEDO systems control the filling level and contribute toward cost reductions.
Bart Goetmaeckers concludes: "We are extremely satisfied with the quality of the equipment and the service provided by METTLER TOLEDO. They support us with their expertise in weighing technology and tailored service, helping us to ensure high availability, quality and compliance with regulations."