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The Nestlé Cailler chocolate factory

A sweet challenge – optimally mastered

Producing chocolate that satisfies the highest standards over many decades requires robust and high-quality equipment which also meets EHEDG stipulations. The Vitalobe type series from KSB features pumps that are well-equipped to take on any challenge. They fulfil the hygienic requirements, handle the product gently, are robust and so flexible that they can be optimally adjusted to the process conditions – qualities that play an important role for a company with a rich history like Nestlé Cailler.

The project: Robust and reliable hygienic pumps for handling cocoa mass

Having produced chocolate for over 200 years, the company has a wealth of experience in the best way to process raw materials and ingredients. Maison Cailler creates exquisite chocolates made with fresh milk from the region, sustainably sourced cocoa and selected ingredients. Every day, around 300,000 of these sweet temptations are shipped from the factory in Broc. Cailler is one of the few chocolate manufacturers in the world that adds lightly condensed milk instead of milk powder to the cocoa mass. This method gives Cailler chocolate products their unmistakable flavour and unique texture.

However, the presence of outdated equipment with a poor level of reliability in the production process meant that it was time to change pumps.

The customer: The Nestlé Cailler chocolate factory 

Cailler is the oldest active Swiss chocolate brand. Now part of Nestlé, its headquarters are located in Broc, Switzerland. The family-run company in West Switzerland is responsible for the entire production process, from the cocoa bean through to the packaged chocolate creations. The chocolate factory also houses a museum, attracting thousands of visitors every year.

Maison Cailler in Broc attracts thousands of visitors every year

Maison Cailler in Broc attracts thousands of visitors every year

The challenge: Transport of highly viscous, solids-laden foodstuff requiring gentle handling

In terms of production, processing the cocoa mass is anything but simple. In particular the transfer of the cocoa with sweetened condensed milk repeatedly posed new challenges for the chocolate maker. Although the cocoa mass is highly viscous and contains abrasive cocoa particles, it nevertheless needs to be handled gently.

The solution: The Vitalobe rotary lobe pump which is flexible and extremely easy to clean

Having established a good relationship with KSB Switzerland, the company decided to opt for a Vitalobe rotary lobe pump. And following three years of cooperation, the customer has been very satisfied – especially with regard to KSB’s fast response times. An Etanorm pump and a number of valves, including the BOAX® butterfly valve, were already in operation at the Broc factory to the full satisfaction of the customer.

The Vitalobe range comprises rotary lobe pumps for transporting high-viscosity, solids-laden fluids and fluids that require gentle handling – precisely the conditions at the chocolate factory.

The positive displacement pump from KSB can pump fluids with a viscosity of up to 200,000 mPas and also offers reverse mode operation. It can also be configured to suit different requirements by using interchangeable rotary lobes. The rotary lobes are made of stainless steel 1.4404 (AISI 316L) as standard. Alternatively, depending on the size and type of the rotor, other materials are available including a so-called anti-seizure alloy (CY5SnBiM) or a plastic-coated metal variant.

The Vitalobe rotary lobe pump at work

The Vitalobe rotary lobe pump at work

Users hold this flexibility in particularly high regard as the pump can be configured to the process conditions with a high level of precision. As hygiene is critical in the process of producing chocolate, initial validation was required by Cailler – but this posed no problems for KSB thanks to its EHEDG-certified products.

The team first of all opted for a test run with the Vitalobe pump in which the challenges of the viscous chocolate mass were clearly illustrated. Thanks to the flexibility and positive spirit of collaboration, a perfect solution was quickly found by using a rotor in the form of a gear wheel. As well as achieving reliable operation, a further positive result was a decrease in production line stops which reduced the need for manual pump cleaning. And thanks to quick and easy dismantling, this cleaning process does not hold up production at the factory for long. The pump can also be cleaned and sterilised using CIP and SIP processes without leaving any residues.

After the test phase, the pump was put into permanent operation in February 2018. Not only does KSB’s Vitalobe ensure perfectly sterile processes, it is also flexible, robust and reliable and can be cleaned very easily without leaving any residues. As the customer was very impressed by these properties in its daily operations, the chocolate experts have decided to integrate four additional Vitalobe pumps into processes at the Nestlé factory in Broc over the next two years. With Vitalobe now helping to ensure improved reliability and smooth running of processes in the production of the company’s mouth-watering delights, this has been a sweet challenge to master!

KSB’s Vitalobe reliably pumps cocoa mass to produce the finest chocolate

KSB’s Vitalobe reliably pumps cocoa mass to produce the finest chocolate

Figures I Data I Facts

Location: Broc, Schwitzerland

Company: Nestlé Cailler chocolate factory

Has been producing gourmet chocolate for over 200 years. Every day, around 300,000 of these sweet temptations are shipped from the factory.

Established: 1819

Plant: Chocolate production

End user: Nestlé Cailler chocolate factory

Pump types 

  • 1 x Vitalobe VLBB 105/0074    
    Flow rate: 0.5 m3/h, head: 13 m
  • 1 x Vitalobe VLBB 105/0074
    Flow rate: 0.5 m3/h, head: 22 m

Products used

Vitalobe

Vitalobe

Sturdy rotary lobe pump in hygienic design, bi-directional operation possible, horizontal or vertical orientation of connections. Hygienic design, excellent CIP/SIP compatibility due to its almost complete lack of dead volume or narrow clearances. All wetted components made of 1.4404/1.4409 (AISI 316L/CF3M) stainless steel; various rotor types, shaft seals and process connections available. Installed as a pump set with gear unit and standardised motor. Vitalobe is EHEDG-certified. The pump elastomers comply with the FDA standards and EN 1935/2004. Accessories include a trolley, a heatable casing or casing cover and a pressure relief arrangement. ATEX-compliant version available.

KSB – endüstri armatürlerinin ve pompalarının dünya lideri üreticisi

KSB, 1871 yılında Frankenthal'da (Almanya) kurulmuştur ve 100 yılı aşkın süredir pompa ve endüstriyel armatürlerin lider üreticilerinden biridir. Dünya çapında 15.500'den fazla çalışanı bulunan KSB; kendine ait satış şirketleri, üretim tesisleri ve servis işletmeleriyle, çeşitli uygulamalar için özel pompalar geliştirir ve üretir.

Uzman pompa üreticisinin ürün yelpazesi; yapı ve endüstri teknolojisi, su taşıma ile atık su temizliği ve elektrik santrali süreçlerinde kullanılır. Yenilikçi araştırma ve geliştirme işlemleriyle KSB, çeşitli müşteri taleplerini karşılayabilmektedir. Saygın pompa üreticisi olarak KSB, uzun yıllara dayanan tecrübelere ve teknik bilgilere sahiptir.

Pompa üreticisi KSB: sisteminiz için en iyi çözüm
KSB'nin endüstriyel pompa ve armatürleri, geniş bir uygulama aralığı için uygundur ve enerji açısından oldukça verimlidir. Yenilikçi teknolojilerle kendilerini kanıtlayan ürünler, uzun yıllardır sistemlere başarılı bir şekilde takılmaktadır (bunların arasında Etanorm su pompası da bulunur). 1,5 milyondan fazla satılmış agregayla Etanorm, dünya çapında en başarılı su pompaları arasında bulunur. KSB'nin Yedek parçalar ve servis performansları, KSB endüstri pompalarının ve endüstri armatürlerinin işletim güvenliğini sağlar. Hidrolik, malzeme teknolojisi ve otomasyon pompa üreticisi KSB'nin teknolojik güçleridir ve yüksek performanslı pompalarının başarı sırrı ise bunlara dayanır.

En başından itibaren yetkili servis
Çok sayıda üretim tesisiyle pompa üreticisi KSB, müşteriye yakınlığı ve birinci sınıf servisi garantileyebiliyor. Kapsamlı tecrübe birikimine sahip sertifikalı uzmanlar mükemmel kalite sağlarlar. KSB Service; pompalarınızın, armatürlerinizin ve tüm sistemlerinizin bulunduğu konumda işletime alınmasını, muayenesini, bakımını ve onarımını üstlenir. KSB ayrıca hızlı yedek parça teslimini de sağlar. Böylece doğrudan pompa üreticinizden en iyi servisi elde etmiş olursunuz.