Bühler introduced updated solutions in chocolate processing: the Finer S Edition 26 five-roll refiner and the ELK S Edition 26 single-shaft conche. The Edition 26 systems run cleaner, smarter, more efficiently, and with greater transparency, Bühler explains.
“Our roll refiner has helped shape the chocolate industry for more than a century. Achieving fineness down to 12 micrometers – crucial for the target particle-size distribution that delivers mouthfeel and smoothness – remains unique to Bühler’s five-roll refiner. That is why we built the Edition 26 on the strongest possible foundation, adding value where customers feel it most: easier operation, greater reliability, higher energy efficiency, optimized maintenance, and better hygiene,” says Skeljzen Nesimi, Head of Product Management, Chocolate & Flavor Creation, Bühler.
With cocoa price volatility and supply shortages, getting the most out of every cocoa bean is a necessity. Bühler engineers analyzed where performance can be improved and developed digital solutions to help optimize the process: “Our sensor technology monitors the refining process and automatically fine-tunes roll speed, pressure, and temperature – all without manual intervention and independent of operator skills. This real-time optimization ensures consistent fineness, increases throughput, and reduces waste,” says Skeljzen Nesimi. A stable and consistent fineness prevents costly fat overdosing in the conche, saving significant production costs.
“In a 24/7 production environment, even small adjustments matter. Our new energy-efficient IE5 motors cut energy consumption by up to 3%. A more hygienic design strengthens food safety and improves access for cleaning, as well as reducing downtime,” says Skeljzen Nesimi. Uptime is further boosted through simplified maintenance and advanced diagnostics.
Consistent results
Conching gives chocolate manufacturers precise control over flavor development, mouthfeel, and flow behavior. Bühler’s ELK S Edition 26 single-shaft conche creates the desired chocolate flavor while reliably removing unwanted volatiles and moisture. The ELK S Edition 26 focuses on simplified operation, energy efficiency, hygienic design, and improved accessibility.
“We have redesigned multiple components on the machine to make it even easier to operate and maintain. Besides the completely new automation system, we have adapted the machine frame and design for higher hygiene and better maintenance. New IE5 drives and food-grade materials also enable higher efficiency and safer production,” says Skeljzen Nesimi. The technology of conching – featuring specially designed ELK conching tools – remains unchanged, enabling intense shearing and high fat release for a perfect mouthfeel and taste. These tools, combined with the conching control, can reduce energy consumption by up to 30% and increase throughput, the company explains. In addition, fat savings of up to 2% are achievable due to enhanced shearing and improved fat release.
Automation
The full system upgrade was developed around Bühler’s Playone automation system, included as a standard component. The Finer S and ELK S Edition 26 automation systems deliver a wide range of benefits, from improved user-friendliness and advanced automation features to remote monitoring and control.
“Our new automation system, powered by Bühler’s Playone, frees operators to focus on higher-value tasks such as quality control. With its web-based design, it can be accessed via any authorized factory device, such as a tablet, desktop, or smartphone, adding flexibility to the production setup,” says Skeljzen Nesimi.
Photos: Bühler