Double-Layer Moulding Line

Equipped with state-of-the-art cooling systems and sensors that continuously maintain constant humidity and temperature, this line was designed with quality, high capacity and energy efficiency as top priorities. Shaping chocolate is the most critical production step in the chocolate industry. To achieve the desired shape, liquid chocolate must be poured into moulds and then cooled with great precision.

Process steps: liquid chocolate is poured into the moulds, spread evenly by vibration, and then enters the cooling tunnel, which contains six separate cooling zones. Chocolate exiting the tunnel proceeds to the mould-twisting unit for demoulding, where it is released from the moulds by vacuum suction cups mounted on two precision-positioning, servo-controlled robotic arms. This release step offers three options, selectable from the operator panel: direct transfer onto a polyurethane belt, layer-by-layer placement into a separator, or automatic placement onto plates via a plate-feeding machine.

Moulds leaving the system empty are reheated to the chocolate filling temperature before returning to the filling stage; nuts or similar inclusions can be added to the chocolate at this point if desired.

Designed as a double-layer system, COOLTERM — unlike conventional tunnels — delivers cold air simultaneously to both the top and bottom of the chocolate. The airflow never makes direct contact with the chocolate surface. Integrated air dryers keep the chocolate’s moisture level constant and prevent microbial spoilage.