Rising demand for cocoa processing lines sees Bühler’s Appenzell site expand production

Swiss technology group Bühler has reported an enhanced order uptake for its range of cocoa processing equipment, which has led to an increased rate of activity at its Appenzell production site, writes Neill Barston.

As the company noted at its Networking Days event last week at its global headquarters in Uzwil, there remain notable challenges for the sector in terms of environmental test, as well as operating within uncertain international marketplaces that are affected by geopolitical instability and economic headwinds.

However, the event offered some hope for the future, highlighting the urgent need for collaborative working across industry in order to meet sustainability goals, as much as in needing to meet the rising demand for cocoa-based products, as well as many other food ranges.

Consequently, as the company acknowledged, in light of increasing cocoa prices, the broader sector is increasingly focused  on resilient supply chains, which has required significant investment.

As the business noted, its Appenzell location in Switzerland has found itself especially busy, employing 100 people, along with providing 21 apprenticeship placements for the sector, as demand for engineers and technicians serving this market segment continues to rise.

In terms of the wider picture, the company noted that governments and companies worldwide, especially in cocoa-producing countries, are increasingly relying on local cocoa processing to secure value creation in their countries, reduce transport costs, and strengthen local economic cycles. Notably, as Confectionery Production has previously reported, this has seen the emergence of cocoa production sites being created in core producing nations of Ghana and Ivory Coast within the past few years.

Business expansion
According to Buhler, it is not simply a case of increasing capacity, but also quality and yield – which are significant factors in the global cocoa market in determining higher pay for farmers.

As the Swiss tech company noted, its presence in many producing regions has proved to its advantage, meaning that it has regional support networks that few of its competitors can match at scale.

Furthermore, as the company observed,  cocoa prices have been at record levels for around two years and are likely to remain high in the medium term.

There have been a number of combined factors behind this, as the company noted, this has included  poor harvests caused by extreme weather conditions and crop diseases, as well as an ageing farmer workforce that is increasingly struggling to maintain production levels in the present smallholder-dominated model of cocoa production in West Africa.

Consequently, as the business noted, for these reasons, and in view of the price trend for cocoa, there is a significantly greater incentive to expand processing capacities in the countries where it is grown.

Investors and cocoa processing companies are turning to Bühler not only for state-of-the-art process technology that ensures maximum yield of this expensive commodity with the highest efficiency.

An equally important factor is that Bühler can support its customers locally with the best service and offers customized training and development opportunities for customer technicians at their plants. The combination of these advantages has led to a significant increase in investment in new processing plants over the last few months, which in turn has triggered a wave of orders for Bühler. 

“In challenging times, our customers rely on quality and efficiency, as well as on local support and service. Our commitment to innovation and partnership-based collaboration worldwide gives our customers security and confidence. That’s why Bühler is the obvious choice,” says Stefan Scheiber, CEO of the Bühler Group.
 

Bühler solutions: Local proximity, global expertise
Bühler’s strength lies in combining state-of-the-art cocoa technology with a regional presence on site. This holistic approach goes far beyond machine engineering and the installation of solutions.

Throughout Africa, especially West Africa – the heart of the global cocoa industry – Bühler works directly with its customers, providing on-site support, building long-term relationships, and contributing broad expertise. The Bühler Cocoa Innovation and Competence Center in Abidjan, Ivory Coast, enables customers to develop skills and expertise tailored to their local context. This is complemented by the ongoing support of the Bühler Flavor Creation business unit with its engineering and testing facilities in Uzwil – a unique combination that builds trust and ensures success in the market.

Swiss quality from Appenzell makes the difference
The Bühler production site in Appenzell is playing a central role in this wave of orders for cocoa processing equipment. Appenzell is where engineering, manufacturing technology, and the highest quality standards come together.

All key components for Bühler’s cocoa processing lines have been manufactured in Appenzell for three years. Firmly rooted in Appenzell, Bühler has continuously invested in innovation, training, and the latest manufacturing technology at this site. This has enabled the most sophisticated machines and components from the Swiss foothills of the Alps to find their way into cocoa processing plants around the world. 

As the company added, the Bühler plant in Appenzell manufactures and assembles machines that use infrared technology to pre-treat cocoa beans before they are broken and hulled.

The resulting cocoa nibs are then roasted. The roasters and coolers required for this process are also manufactured in Appenzell. Roasting is an essential step in the process. Not only does it allow the intense flavor and full aroma of the cocoa bean to develop, it also ensures that the beans are efficiently processed into semi-finished products such as cocoa butter and cocoa mass, which are essential for the production of chocolate

Teamwork, the highest quality standards, and a commitment to performance play a decisive role in the manufacture and assembly of cutting-edge technology in the field of cocoa processing. “Working with the team in Appenzell is characterized by a professional and friendly relationship at all levels. Transparency, openness, and a winning spirit are what set the team apart,” says Stefan Kellenberger, Managing Director Chocolate & Coffee at Bühler.

“Challenges and problems are clearly identified so that we can work together to find a solution. The team in Appenzell lives by the motto ‘One team – one Bühler,’” Kellenberger continues.