Scharffen Berger Chocolate maker (A)
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Transcript of Scharffen Berger Chocolate maker (A)
Scharffen Berger Chocolate maker (A)
Group A3
Anjali ChandruAnuradha Dhote
Oshin VijaykumarPankaj 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(8hrsX7day
s)
Roaster and Racks
(8hrsX7days)
Winnower(8hrsX7days)
PackingSelf=35%,
Other=65%
Molder(2X8hrsX7da
ys)
Temper(2X8hrsX7da
ys)
Mixer(2X8hrsX7da
ys)Conche
(3X8hrsX7days)
Conche(3X8hrsX7da
ys)
Bags
Tank
Bins
Bins
Tank
PROCESS FLOW
START
100 Kg
96 Kg
Waste Wast
e
4 Kg
250 Kg
185 Kg
250 Kg
65 Kg
115 Kg115
Kg
1400 Kg
1400 Kg
1400 Kg
1400 Kg
140 Kg
140 Kg
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