CASE STUDY
Installation of New Chocolate Moulding Circuit
Capacity mapping, Project Management & Project Engineering to scope and install a new chocolate moulding line within Hotel Chocolat’s Hadley Park Facility.
The Challenge
With an aspiration to increase throughput and capacity and improve consistency whilst considering resourcing requirements ongoing at their Hadley Park facility; Hotel Chocolat partnered with Protolan to deliver the installation of a new chocolate moulding circuit.Delivering Success
To support the ongoing capacity of the factory Protolan removed an existing moulding line and relocated equipment to create a new one: Capability included mould warming, decoration, filling, cooling, de-moulding, robotic product pack placement and in-line product wrapping. In conjunction with capability we optimised the line volumetrically by installing a stainless platform enabled the cooling process to be created on a first-floor level. To ensure full automation capability, an optimised mould re-design was implemented, and a new flow wrapper was installed to deliver maximum production flexibility and efficiency.Main challenges
1) Ensuring the robotic “product to pack” process was streamlined because of the range in product size and design. 2) The project took place within a live working environment and it was imperative that there was no disruption to ongoing output Alongside the project a new “future proofed” mould wash facility was created to support site and capacity expansion (included civils alternations as well as construction)Services Employed
Project Management
Project Engineering
Capacity Planning
“Having worked alongside Protolan previously installing a liquids bottling line, we chose James and his team to assist because we knew we could rely on their knowledge and expertise to deliver the right result. The hygiene and changeover process improvement project was delivered professionally and on time. I would not hesitate to recommend Protolan and will definitely use them again in the future should the need occur.”
- Richard Greathead, Chief Executive
Nutrition Group PLC
“The Protolan team have been an important part in the success of our recent, complex projects. They are a dedicated partner who are responsive, client-conscious and own a wealth of food manufacturing knowledge. Protolan’s project team worked closely with our internal team to deliver a multifaceted project, providing innovative solutions to ensure best practice across the factory. They show great diligence and flexibility when faced with project challenges. I look forward to a continued relationship with Richard and his team and would not hesitate to recommend them.”
- Gary McEvoy (General Manager)
Bakkavor Texas
“I have worked with Protolan over numerous years and am more than happy to recommend them to deliver our projects. They understand our business and are skilled in utilising their extensive food manufacturing expertise to support our complex needs. They have the foresight to identify possible issues and give solutions that are effective, offering genuine insight for our business. The Protolan team provide an experienced, knowledgeable and straight-talking resource. It is a pleasure to work with them.”
- Simon Wood (Chief Engineer)
Hotel Chocolat
“Protolan show great understanding of the food industry. They have the leadership, food expertise and project management skills to understand our challenges and familiarise themselves with our business objectives. Their concise communication provided us with a clear view of the issues and challenges of the project, providing us with a tangible project plan and a successful scheme.”
- Sally Mitchell
Saladworks
“Having worked with Protolan on several major projects, I am always impressed by their expertise within the food industry and positive attitude. They fully integrated into our team and that of the wider business, understood our challenges and delivered a tangible plan guided by solid project management and engineering practices. They have been a pleasure to work with and we will continue to work with them on future projects.”
- Jason Kelly (Head of Operations - Core Produce)
Morrisons
"Having worked with Protolan on previous projects, Revolution Foods had no hesitation to engage them to collaborate with us on a new project in challenging times.
Protolan work with us in complete partnership, ensuring they understand the scope of our requirements and the challenges involved. Thorough, responsive, and professional, Protolan ultimately brought our project to a successful conclusion.
I would have no reservation in recommending Protolan."
- Jose Morales Senior
Director of Operations Revolution Foods