Sponsored: Sweet success, powered by data
Credit: Maestrani
For over 170 years, Maestrani Schweizer Schokoladen AG has delighted consumers worldwide with its chocolates. Driven by the joy in progress and its purpose of sharing happiness, Maestrani blends a pioneering spirit with family values and a commitment to “making the world sustainably happier bit by bit.” The company’s data-driven strategy enhances transparency and product quality, already delivering an 18 percent efficiency boost—laying the groundwork for an even sweeter future.
Set in Flawil, Switzerland, Maestrani’s production facility includes the “Chocolarium World of Discovery,” welcoming 230,000 visitors annually to experience how happiness is infused into its chocolate. Behind this immersive experience, over 4,500 tonnes of chocolate are produced each year for flagship brands Minor, Munz, and Maestrani. As a key Swiss chocolate player, Maestrani continually aims higher, leveraging digitalization with Bühler to create a smart chocolate line. This transformation has improved efficiency by 18 percent and revolutionized operations.
“Our history is built on family values, innovation, and continuous improvement,” says Christoph Birchler, CEO of Maestrani. “We see enormous potential in the chocolate market. To consistently offer the high-quality products our consumers love, we need to be faster, more adaptable, and ready for future challenges.”
Embracing digitalisation
Maestrani’s journey toward digitalisation began in 2016. “Our production processes relied heavily on operator experience. We knew our goals but lacked the data to pinpoint inefficiencies,” explains Carsten Engelhardt, Technical Director at Maestrani.
With Bühler, Maestrani installed intelligent sensors to monitor processes in real-time and collect actionable data. This data fed into Bühler Insights, a platform aggregating information from sensors, machine controls, and offline sources. The first step was modernizing control systems for seamless data flow. Bühler Insights replaced guesswork with actionable insights, enhancing efficiency, quality, and flexibility while maintaining craftsmanship.
Unlocking gains
“Once we had the data, we were excited to see what we could do with it,” says Engelhardt. Maestrani and Bühler’s teams analyzed the data and found a key bottleneck in the five-roll mill causing suboptimal grinding. For the first time, Maestrani gained real insights into operations.
Utilizing Bühler Insights, the inefficiency was quantified, and scenarios simulated. “We identified adjustments and made targeted interventions that boosted production efficiency,” says Sudhir Punyamurthula, Data Analyst at Bühler. One key change involved installing a new conveyor belt to empty the mixer faster, optimizing the five-roll mill’s operation.
“By working with data, we moved from relying solely on operator experience to making data-supported decisions that significantly enhanced efficiency,” explains Patrik Keller, head of production & logistics at Maestrani. “Before, we knew things could run more smoothly but couldn’t pinpoint the issues. Bühler Insights helped us visualize inefficiencies, interpret data, and implement precise solutions. Our efficiency improved by nearly 20 percent—truly a game-changer.”
Enabling efficiency
Maestrani sees the smart line as the future of chocolate production. “Our vision for a smart factory combines machine intelligence, personnel, and seamless data flow for production optimisation,” says Engelhardt. The next steps include expanding traceability, optimising conching, and automating mass production with minimal manual intervention.
The smart line also addresses the growing challenge of finding skilled personnel. “Using insights from data to guide operators rather than relying solely on expertise is pivotal,” says Engelhardt. “We need systems that optimise processes and allow teams to focus on higher-value tasks.”
The collaboration with Bühler was key to enabling this transition. Bühler’s digitalisation expertise provided Maestrani with the tools and insights needed to begin its smart factory journey. “When Bühler started exploring digitalisation, Maestrani was an ideal partner due to their proximity and openness to innovation,” says Fabian Dintheer, Digital Program Manager at Bühler. “We tested sensor systems in real production conditions, unlocking greater transparency.”
Data analytics played a crucial role, using advanced simulation models to analyze stoppages, faults, maintenance, downtime, and cleaning times. “Comprehensive data collection enabled thorough analysis,” Dintheer explains.
A partnership for the future
The integration of Bühler Insights has reduced manual interventions, streamlined production, and optimized resources. Operators can now respond instantly to disturbances, reducing downtime and ensuring consistent quality. Maestrani also handles more orders within the same two-shift production, allowing employees to focus on higher-value tasks.
“Our machines now communicate better, preventing disruptions and improving recipes,” says Keller. “This project has driven progress in quality, financial outcomes, and operational capacity.”
While the project has delivered tangible results, the Bühler-Maestrani partnership goes far deeper. “Our collaboration began in 1985 and has evolved into something unique,” says Birchler. “As Bühler’s direct neighbor, we serve as a real-time lab, helping refine their technologies in real production conditions while benefiting from cutting-edge innovations.”
Birchler emphasizes that Maestrani’s digital journey is about working smarter and more sustainably. “This data-driven approach positions us to not only meet current market demands but to adapt and thrive in the future. We may be one of Bühler’s smallest customers, but as neighbors, we’ve become one of their most engaged partners—both geographically and strategically.”
- Read more about Maestrani’s journey here: [Link
