Scharffen Berger Chocolate maker (A) Group A3Anjali
ChandruAnuradha DhoteOshin VijaykumarPankaj BhatiSarika
ChauhanSubharti Company overviewScharffen 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 sqftFacing 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 wereUnsweetened (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 figsPricingRetail: $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 ounceSales$0.6 million in 1998,$10 million in 2004,Over
$15 million estimated revenues for 2005
Cleaner(8hrsX7days)Roaster and Racks(8hrsX7days)
Winnower(8hrsX7days)
PackingSelf=35%, Other=65%Molder(2X8hrsX7days)
Temper(2X8hrsX7days)
Mixer(2X8hrsX7days)
Conche(3X8hrsX7days)
Conche(3X8hrsX7days)
BagsTankBinsBinsTankPROCESS FLOWSTART100 Kg96 KgWasteWaste4
Kg250 Kg185 Kg250 Kg65 Kg115 Kg115 Kg1400 Kg1400 Kg1400 Kg1400
Kg140 Kg140 KgProcesses involved:Bean Cleaner: Cleaning the cacao
beansCapacity: 200 KgOperated at: 100 kg in 15 minRoaster:To roast
the cacao beans in order to enhance their flavorOperation capacity:
250 Kg for 75 min and 15 min to cool offWinnower:To crack the cacao
bean and separate the nib from the shellCapacity: 450 kgOperated
for 250 kg of which 185 kg nib recoveredProcesses
involved:Melangeur:Used to ground the nibs; this released the cacao
butter and turned the dry nibs to chocolate pasteBatch size: 115
kgTime needed: 75 minsConche:For aerating and grinding the cacao
granulesBatch size: 1400 KgAverage time requirement: 48-72 hoursFor
unsweetened chocolate: 40 hoursFor sweetened chocolate: 50
hoursProcesses involved:TemperingLiquid chocolate is turned to
solid state with the desired level of stability, smooth feel in the
mouth and snapBatch: 140 kg per hourMolding Molding: Solidifying a
chocolateBatch size: 140 kg per hours, 20 min to
solidifyPackaging:35% of the chocolate was packaged in the factory
itself65% of produce was sent to third party co-packersIncreasing
capacityCapacity of the process is dependent on the bottleneck
within process flowInitial capacity at 40000 Kg/per month,
restricted by 48-72 processing hours taken up by
conchesIntroduction of Ball-millIncreases capacity by 10%Leads to a
new bottleneck in the system MelangeurFurther additions to capacity
done by increasing number of shifts of different machines and
identifying new bottlenecks and adding further shifts or machines
accordinglyRefer Excel sheet
