Smart Renewing of a High-Speed Chocolate Molding, Cooling & Wrapping Line
Challenge
A leading confectionery producer was facing increasing operational risks caused by an obsolete control and motion architecture across its chocolate molding, cooling and wrapping line.
The existing hardware had reached End-of-Life, making spare parts increasingly difficult to source and exposing production to prolonged unplanned downtime.
At the same time, limited synchronization between molding, cooling and wrapping processes was affecting line stability. Variations in speed, temperature control and product transfer increased the risk of bottlenecks, micro-stoppages and chocolate scrap.
IEMA US Intervention
- Machine Upgrade: complete retrofit of the legacy motion control system with high-precision servo drives to improve speed control and synchronization.
- System Renewing: replacement of outdated PLC logic with a modern, high-speed processing architecture capable of coordinating molding, cooling and downstream packaging operations.
- Wrapper Integration: synchronization of wrapping machines with upstream production stages to ensure continuous product flow and reduce accumulation, jams and micro-stoppages.
- HMI Evolution: implementation of a 15” stainless steel touchscreen HMI designed for food-grade environments, with real-time visualization of process parameters and tempering curves.
- Data Integration: implementation of MQTT communication protocols for production batch monitoring and remote data availability.
The Results
- 12,8% increase in production speed through optimized motion profiles and improved line synchronization.
- Reduced chocolate scrap through more precise thermal and motion control.
- Smoother product flow from molding to wrapping, reducing bottlenecks and micro-stoppages.
- Predictive maintenance capabilities for earlier identification of potential failures.
- Updated food safety and electrical documentation compliance.
From Molding to Wrapping: One Integrated Production Flow
Modernizing a chocolate production line is not only about replacing obsolete hardware.
It means creating a fully synchronized production ecosystem, where molding, cooling, accumulation and wrapping work together as one integrated process.
Turn legacy equipment into a high-performance production asset.
Contact IEMA US for a technical system evaluation.
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Download our PDF brochure to discover:
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The real advantages of revamping and renewing
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Real-world case studies
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Technologies used and results achieved
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