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Scharffen Berger was founded in 1996 by Robert
Steinberg and John Scharffenberger.
The chocolate maker in US market competing for$1.2 billion premium quality chocolate segment.
Company had 60 employees and operated from a27,000 sqft facility with 20,000 sqft productionarea, office space of 5,000 sqft and retail space of2,000 sqft.
Company Overview
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Primary products
Unsweetened (99% cacao) , Extra Dark (82% cacao) ,
Bitter sweet (70% cacao), Semi-sweet , Mocha,Mint (all have 62% cacao), Milk Chocolate (41%cacao) .
Other products: chocolate sauce, drinking chocolate,cocoa powder and chocolate covered figs.
Business Overview
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5 Retail stores
Over 4000 retail outlets
Website
Sales Channels
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Production Flow
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Step 1: BEAN CLEANER
Carefully selected beans putinto the cleaner, withmachine capacity of 200 kg
cleaned in 15 minutes.
192 kg clean beans recovered.
Production Process
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Step 2: ROASTER
German Roasting machineused to enhance the flavour,with each kind of beanroasted separately.
Works with machine capacityof 250 kg per 75 minutes.
Cooled for another 15minutes.
Production Process
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Step 3: WINNOWER
Cacao beans cracked toseparate chocolate nibsfrom the shells.
Machine capacity 450 kgper hour.
Out of a batch size of 250kg, 185 nibs arerecovered.
Production Process
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Step 4: MALANGEUR (mixer)
Grind the nibs to releasecoco butter and chocolatepaste.
Machine capacity 115kg per
75 minutes. Time of completion based
on look, feel and taste.
Production Process
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Step 5: CONCHE (2 nos)
Refine, mix and aerate thechocolate.
Machine capacity 1400kg.
Time needed: 48 to 72 hrsincluding size reduction ofparticles.
Production Process
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Step 6: TEMPERING &MOULDING
Liquid chocolate turned tosolid state.
Machine capacity 140kg perhour.
Tempered chocolatemoulded into bars.
Machine capacity 140kg perhour.
Production Process
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Step 7: PACKAGING
35% of Berger’s mouldedchocolate packed infactory.
65% to third party co-packers, to reduce cost.
Production Process
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Cleaner Roaster Winno-
wer
Malan
-geur
Conche
(2 nos)
Temperin
-g
Mouldin-
gCapacity(kg)
200 250 450 115 1400 200 140
Batch Size(kg)
100 250 250 115 1400 140 140
Recovery(kg) 96 250 185 115 1400 140 140
Time ofoperation(hrs)
8 8 8 16 24 16 16
Cycle Time(min) 15 75 15 75 4320 60 60
Output perminute(kg)
6.4 3.33 12.33 1.53 0.32 2.33 2.33
Output perday (kg)
3072 1598.4 5918.4 1468.8 460.8 2236.8 2236.8
(a) Analysis: Before ball-mill
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(b) Analysis: After ball-millCleaner Roaster Winno-
werMalan-geur
Conche(2 nos)
Temperin-g
Mouldin-g
Capacity(kg)
200 250 450 115 1400 200 140
Batch Size(kg)
100 250 250 115 1400 140 140
Recovery(kg)
96 250 185 115 1400 140 140
Time ofoperation(hrs)
8 8 8 16 24 16 16
Cycle Time
(min)
15 75 15 75 900 60 60
Output perminute(kg)
6.4 3.33 12.33 1.53 1.56 2.33 2.33
Output per
day (kg)
3072 1598.4 5918.4 1468.8 2240 2236.8 2236.8
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In the current situation conches are the clear
bottleneck.
After addition of ball mill the output per kg from theconches will increase by 386%, however Melangeur
has now become the bottleneck, giving minimumoutput per kg.
Conclusion
