Chocolate Factory Equipment Maintenance and Worker Safety Tips
Elizabeth Ruiz, Editor, Maintenance World
Posted 2/5/2025
With Valentine’s Day only a week away, MW thought it would be fun to dive into what it takes to properly and safely maintain a chocolate factory. This newsletter will include tips for chocolate factory equipment maintenance and cleaning and safety tips that can be applied across manufacturing industries.Â
Chocolate Factory Equipment Maintenance and Reliability Tips
Equipment reliability practices in chocolate factories are the same practices we are familiar with across the Food and Beverage manufacturing industry, just with some specific equipment. The same principles such as planned maintenance, scheduled cleaning, and keeping equipment at the right temperature.Â
Check out Jim Bourne’s with Hilliard’s Chocolate Systems basic plan on keeping a chocolate operation running smoothly (courtesy RCI blog):
Chocolate Factory Equipment Maintenance
By having the chocolate equipment in good operating condition, it will help avoid possible contamination from the equipment and avoid down time. Talk with the machine manufacturer to discuss maintenance, such as lubrication with a food-grade lubricant, replacement of worn parts and wear items such as belt drives.
Create a chart to detail periodic inspections and repairs to the machinery. When a machine is not operating properly or making a new noise, investigate and repair the problem to avoid down time. Developing problems rarely get better on their own. Since cleaning is a big part of maintenance, do periodic break downs of equipment to inspect, clean and locate any issues.
Chocolate Factory Equipment Cleaning
Scheduling a few minutes each day for daily and periodic cleaning will help equipment run more efficiently and reduce the risk of contaminated product. As a fat-based food, chocolate can be easily compromised by heat, strong odors, allergens and moisture.
Fortunately, chocolate has a very low moisture content and low water activity, so it is less likely to support pathogens on its own. The low moisture also means chocolate equipment does not need a complete breakdown and cleaning daily as other equipment does, such as ice cream equipment.
Cleaning methods for eliminating allergens and pathogens in chocolate equipment can be divided into two categories: dry cleaning and wet cleaning. Dry cleaning does not use water, so cleaning is done by scraping chocolate out, vacuuming out solid chocolate bits and wiping down equipment with alcohol wipes. This method is best for machine parts that can be disassembled.
Larger machines are often cleaned intact by flushing the system with melted cocoa butter to access pipes, pumps and hard-to-reach areas. Wet cleaning involves the use of warm to hot water and liquid sanitizers. The water and sanitizer will introduce moisture, so each component being wet cleaned must be completely dry before reassembly. Be sure to use sanitizers that do not have a strong fragrance, otherwise the fragrance can be picked up by the chocolate.
Wet cleaning pipes, pumps and other restricted areas can also be problematic if moisture is introduced in the cleaning process but not removed. Introducing moisture presents a higher risk of pathogen and mold growth, so it is important that all surfaces that are wet cleaned are completely dry.
Daily Cleaning
At the end of the day, raise the chocolate temperature to break the temper. Run the untempered chocolate through the pumping system and the wire belt, because untempered chocolate is less likely to crystalize overnight. The cooling belts can be cleaned and dried while they are running. Avoid using excessive water and use only damp cleaning cloths, drying afterwards. If the equipment has screens to filter out debris, clean them at least daily.
Drain chocolate from the curtain hopper and wire mesh belt into the tank to prevent the chocolate from setting up and causing problems on start-up. Clean any non-chocolate materials such as nuts, sea salt and toppings from the machine. Also, clean floors and walls around and under the equipment daily.
Periodic Full Cleaning
Periodic full cleanings are a necessity in chocolate factory equipment maintenance. You should assess your own situation and risk to determine how frequently to perform a full cleaning. Are you more likely, in your operation, to introduce moisture, allergens or contaminants to the equipment and the chocolate? The more likely you are to be compromised, the more often you should do a complete breakdown, cleaning and drying.
Be aware that moisture or other contaminants can also be introduced by other means. Excessive moisture from centers or toppings can cause issues. HVAC in the plant can poorly filter dust or dehumidify the air. Clean and check the cooling tunnels and air blowers to eliminate condensation and dust problems.
There are operations that do a full break down quarterly, monthly and even weekly, depending on their own situation. Operations that perform very few full cleanings put themselves at the greatest risk. Following good manufacturing processes will help you protect your customers, your employees and your business.
Curious about the more chocolate-specific equipment?
Read this Introduction to Chocolate Coating Machines from Golden Bake:Â
Chocolate coating machines are essential equipment for any confectionery or chocolate manufacturing business. These machines are responsible for giving that smooth, glossy finish to chocolates, truffles, or even coated nuts. However, like any piece of machinery, they require regular maintenance to keep them running smoothly and to ensure the quality of your final product. In this article, we will discuss the importance of regular maintenance for chocolate coating machines and provide you with some helpful tips to keep them in top-notch condition.
Understanding the Components of a Chocolate Coating Machine
Before diving into maintenance procedures, it’s crucial to understand the various components that make up a chocolate coating machine. These machines consist of a conveyor belt, a chocolate holding tank, a tempering unit, an enrobing chamber, and a cooling tunnel. Each of these components plays a vital role in the coating process and requires specific attention during maintenance.
Cleaning and Sanitizing the Conveyor Belt
The conveyor belt is the heart of the chocolate coating machine, as it carries the chocolates through the coating and cooling processes. Regular cleaning of the conveyor belt is essential to maintain hygiene and prevent cross-contamination. Start by removing any leftover chocolate and debris from the belt. Then, use a food-grade cleaner and warm water to thoroughly clean the surface. Ensure there are no traces of chocolate or cleaning agents left behind before resuming production.
Proper Chocolate Tempering Techniques
Tempering is a crucial step in the chocolate coating process that ensures the chocolate has a smooth, shiny finish and a crisp texture. Improper tempering can lead to uneven coating and poor quality products. To maintain your machine’s performance, it’s important to regularly check and calibrate the temperature control unit. Use an accurate thermometer to verify that the tempering unit is reaching and maintaining the desired temperature range. Make any necessary adjustments to guarantee consistent and reliable tempering.
Chocolate Factory Equipment Maintenance – Chocolate Holding Tank
The chocolate holding tank stores the melted chocolate, keeping it at the correct temperature for the coating process. Regularly inspect the tank for signs of wear or damage, such as rust or leaks. Clean the tank thoroughly after each production run, ensuring that no chocolate residue remains. This prevents cross-contamination between different batches and preserves the quality of your chocolate. Additionally, consider using a food-grade plastic liner inside the tank to further simplify cleaning and reduce the risk of contamination.
Checking and Cleaning the Enrobing Chamber
The enrobing chamber is where the chocolates are fully immersed and coated with the melted chocolate. Over time, excess chocolate can accumulate inside the chamber, leading to uneven coating and impaired functionality. Regularly inspect and clean the enrobing chamber, removing any leftover chocolate or debris. Use warm water and a non-abrasive sponge or cloth to avoid scratching the surface. Ensure that the chamber is completely dry before resuming production to prevent water from affecting the chocolate’s quality or tempering process.
Periodically Lubricating Moving Parts
To keep your chocolate coating machine running smoothly, lubricating the moving parts is essential. Check the manufacturer’s instructions to identify the recommended lubricant for each specific component. Apply a small amount of lubricant to the designated areas, such as the chain or gear drive, to reduce friction and wear. Be cautious not to over-lubricate as excess lubricant can attract dust and debris, causing further damage. Regularly inspect these parts for signs of wear and replace them if necessary.
Maintaining the Cooling Tunnel
Once the chocolates are coated, they pass through the cooling tunnel to solidify the chocolate coating and achieve the desired texture. The cooling tunnel requires regular maintenance to ensure proper function and prevent overheating. Inspect the cooling system, including fans and vents, to ensure they are clean and free from obstruction. Clean the conveyor belt in the cooling tunnel, similar to the cleaning process mentioned earlier. Additionally, verify that the temperature inside the cooling tunnel is consistent and within the recommended range for optimal results.
Food and Beverage Manufacturing Worker Safety Tips
Safety, as always, is one of the most important parts of a properly run manufacturing facility. Each industry presents its own set of hazards and issues to watch out for – Food and Beverage is no different. These tips from Bryan Christiansen, Founder and CEO of Limble CMMS written for Food Industry Executive highlight 5 safety practices that are necessary for a safe working environment in a food manufacturing plant.
Building a safer work environment
Creating a safe working environment in a food manufacturing facility is crucial for both the workers and the company. Not only is it important to prevent accidents and injuries, but it also helps ensure the production standards meet expectations. The following sections cover the five necessities you need to create a safe working environment for the employees in your facility.
Employee training
Errors caused by employees are one of the common problems that cause unsafe work environments for manufacturing facilities. Imagine a forklift being recklessly driven in a facility. It can cause damage to the products it is carrying and the machinery in its vicinity. Hurting other employees with the forklift is also a real possibility. Operators and technicians can cause mistakes that risk other employees and plant assets.
You need to take active measures to train employees in safe practices within the facility. Beyond such general training, each employee should also be given adequate training to perform their tasks in the best possible manner. You should also train them on relevant aspects of OSHA guidelines for their tasks. Motivating employees with the right incentives helps them conduct their tasks diligently, avoiding unintended mishaps. It also helps you retain good employees, reducing the need to train a steady stream of new employees.
Standard operating procedures
Before training employees you need to create standard operating procedures (SOPs) for every task in your facility. The reason many employees make mistakes is that they do not know the correct and safe way to execute tasks. SOPs avoid any confusion employees might have and minimizes the chances of errors. In addition to SOPs, you can create checklists out of them for convenience. Checklists make sure no steps are skipped while performing tasks.
Maintenance
Equipment and machinery that are not maintained well are prone to sudden failures. This poses a danger to the operators working with equipment and production lines. Such instances have to be avoided by all means. You need to have a broad maintenance strategy and a schedule to conduct scheduled maintenance without fail. Without a maintenance schedule, you have to engage in reactive maintenance activities when machines break down. This increases maintenance costs, delays production processes, and makes the work environment unsafe.
Personal protective equipment (PPE)
Adequate personal protective equipment (PPE) is essential for ensuring the safety of employees in a food manufacturing facility. PPE includes items such as gloves, hairnets, safety goggles, face shields, aprons, and shoes, which provide a physical barrier between the employee and any potential hazards in the workplace. These hazards may include chemical spills, splashes of hot liquids, or exposure to harmful bacteria or other microorganisms.
You need to ensure that all employees are provided with the appropriate PPE for their specific job tasks. For example, employees working with chemicals or handling hot liquids may require additional protection, such as chemical-resistant gloves or face shields. Additionally, It’s crucial to make sure that PPE is properly fitted, clean, and in good condition to ensure maximum protection.
Regular inspections of PPE should be conducted to ensure that they are in good condition and replace them as necessary. This will help to reduce the risk of accidents and injuries, and will also help to maintain the quality and safety of the food products being produced.
Plant layout
Machines, assembly lines, and workstations need to be arranged in such a manner that the flow of materials happens fast with limited overheads. The plant layout should not be the cause of disruptions in production.
Suppose an employee has to traverse through a path that has many machines, cables, conduits, etc., in the way. In such a case, there is a high chance of an employee tripping on something and hurting themselves.
Similarly, bad design can cause transportation troubles and low product quality. It can also be a source of contamination in food products. You need to invest in creating an intelligent design for the plant layout – take into account the requirements and intricacies of your plant.
We hope you enjoyed this week’s super sweet newsletter! Let us know if you learned anything new.
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Date & Time: Mar 10, 2025 01:00PM EST – Zoom
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Sources – Chocolate Factory Equipment Maintenance and Worker Safety Tips
1. Pro Tips for Effective Equipment Maintenance and Cleaning. RCI Blog. September 8, 2020. Updated January 21, 2021.
2. How to Keep Your Chocolate Coating Machine Running Smoothly with Regular Maintenance. Golden Bake Blog. February 2, 2024.
3. 5 Necessities for a Safe Working Environment Inside a Food Manufacturing Facility. Bryan Christiansen. Food Industry Executive Blog. January 26, 2023.
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