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    Scharffen Berger Chocolate Maker (A)

    Uploaded by

    Andy Vibgyor
    Scharffen Berger was a premium chocolate maker founded in 1996 in the US. It was facing high demand and looking to expand capacity. The document describes Scharffen Berger's product lines, pricing, sales figures, and production processes. It details each step in the chocolate making process from bean cleaning and roasting to conching, tempering, molding, and packaging. It also discusses how the company identified and addressed bottlenecks to gradually increase its monthly production capacity from 40,000 kg to meet rising demand.

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    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd

    Scharffen Berger Chocolate Maker (A)

    Uploaded by

    Andy Vibgyor
    625 views8 pages
    Scharffen Berger was a premium chocolate maker founded in 1996 in the US. It was facing high demand and looking to expand capacity. The document describes Scharffen Berger's product lines, pricing, sales figures, and production processes. It details each step in the chocolate making process from bean cleaning and roasting to conching, tempering, molding, and packaging. It also discusses how the company identified and addressed bottlenecks to gradually increase its monthly production capacity from 40,000 kg to meet rising demand.

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    case analysis

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    Scharffen Berger Chocolate maker (A)

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    Scharffen Berger was a premium chocolate maker founded in 1996 in the US. It was facing high demand and looking to expand capacity. The document describes Scharffen Berger's product lines, pricing, sales figures, and production processes. It details each step in the chocolate making process from bean cleaning and roasting to conching, tempering, molding, and packaging. It also discusses how the company identified and addressed bottlenecks to gradually increase its monthly production capacity from 40,000 kg to meet rising demand.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    625 views8 pages

    Scharffen Berger Chocolate Maker (A)

    Uploaded by

    Andy Vibgyor
    Scharffen Berger was a premium chocolate maker founded in 1996 in the US. It was facing high demand and looking to expand capacity. The document describes Scharffen Berger's product lines, pricing, sales figures, and production processes. It details each step in the chocolate making process from bean cleaning and roasting to conching, tempering, molding, and packaging. It also discusses how the company identified and addressed bottlenecks to gradually increase its monthly production capacity from 40,000 kg to meet rising demand.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 8

    Group A3

    Anjali Chandru Anuradha Dhote Oshin Vijaykumar Pankaj Bhati Sarika Chauhan Subharti

    Company overview
    Scharffen Berger was founded in 1996 by Robert

    Steinberg and John Scharffenberger. The chocolate maker in US market competing for $1.2 billion premium quality chocolate segment. Company had 60 employees and operated from a 27,000 sqft facility with 20,000 sqft production area, office space of 5,000 sqft and retail space of 2,000 sqft Facing high market demand which is outstripping production. High growth in demand is expected for its premium chocolate products and hence planning capacity expansion

    Business Overview
    Primary products at Scharffen Berger were
    Unsweetened (99% cacao) , Extra Dark (82% cacao) , Bitter sweet

    (70% cacao), Semi-sweet , Mocha, Mint (all have 62% cacao), Milk Chocolate (41% cacao)
    Others: chocolate sauce, drinking chocolate, cocoa powder and

    chocolate covered figs Pricing


    Retail: $0.50 for 5 gm., $2.00 for 1 ounce, $4.00 for 3 ounce, $10.00

    for 10 ounce. Wholesale: approximately $0.35 per ounce

    Sales
    $0.6 million in 1998, $10 million in 2004, Over $15 million estimated revenues for 2005

    Cleaner (8hrsX7days)
    100 Kg

    96 Kg

    250 Kg

    Bags
    4 Kg Waste

    Roaster and Racks (8hrsX7days)

    250 Kg

    Bins Winnower (8hrsX7days)


    65 Kg Waste 185 Kg

    START

    Bins
    1400 Kg 140 Kg 140 Kg

    Conche (3X8hrsX7days)

    1400 Kg 115 Kg

    115 Kg

    Molder (2X8hrsX7days)

    Temper (2X8hrsX7days)

    Tank Conche (3X8hrsX7days)


    1400 Kg

    Tank

    Mixer (2X8hrsX7days)

    1400 Kg

    Packing Self=35%, Other=65%

    Processes involved:
    Bean Cleaner:
    Cleaning the cacao beans

    Capacity: 200 Kg
    Operated at: 100 kg in 15 min

    Roaster:
    To roast the cacao beans in order to enhance their flavor

    Operation capacity: 250 Kg for 75 min and 15 min to cool off

    Winnower:
    To crack the cacao bean and separate the nib from the shell Capacity: 450 kg Operated for 250 kg of which 185 kg nib recovered

    Processes involved:
    Melangeur:
    Used to ground the nibs; this released the cacao butter and turned

    the dry nibs to chocolate paste


    Batch size: 115 kg Time needed: 75 mins

    Conche:
    For aerating and grinding the cacao granules Batch size: 1400 Kg Average time requirement: 48-72 hours

    For unsweetened chocolate: 40 hours


    For sweetened chocolate: 50 hours

    Processes involved:
    Tempering
    Liquid chocolate is turned to solid state with the desired level of

    stability, smooth feel in the mouth and snap


    Batch: 140 kg per hour

    Molding
    Molding: Solidifying a chocolate Batch size: 140 kg per hours, 20 min to solidify

    Packaging:
    35% of the chocolate was packaged in the factory itself

    65% of produce was sent to third party co-packers

    Increasing capacity
    Capacity of the process is dependent on the bottleneck within

    process flow
    Initial capacity at 40000 Kg/per month, restricted by 48-72

    processing hours taken up by conches


    Introduction of Ball-mill
    Increases capacity by 10%
    Leads to a new bottleneck in the system Melangeur

    Further additions to capacity done by increasing number of shifts

    of different machines and identifying new bottlenecks and adding further shifts or machines accordingly
    Refer Excel sheet

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