Maestrani in Flawil using modernised cooling technology

Distinctive flavour profile thanks to process cooling and heating

Those wanting to capture new markets have to continually develop distinctive flavour profiles in order to tickle customers’ taste buds. A new generation of conching machines—the key component of manufacturing chocolate—facilitates the precise control required of the individual steps in the production process. “At Maestrani, we’ve decided to invest in this process technology of the future”, explains technical director Carsten Engelhardt. “This allows us to innovate, improve the quality, and expand production output”, he continues.

More powerful and more efficient

A strategic decision with consequences: Initially, the energy and building services design had to be prepared for this step into the future. Because, alongside the boost in production, the new visitor centre also needs to be supplied with energy, energy requirements are now higher. The new chillers must be capable of producing a wide temperature range of 5 to 70 degrees Celsius. The new generation of conching machines, for example, requires the selective supply of cooling energy at a lower temperature level than the equipment previously in use. The supply of energy should also be made much more efficient.

The key challenges:

• Temperature range of 5 to 70 degrees Celsius

• Precise control of the complex system for supplying specific temperatures

• A smart combination of cooling and heat generation

• Energy-efficient operation

To meet Maestrani’s specific requirements, customised chillers from CTA were installed. In the final stage of construction, it will be possible to install up to eight chillers, each with an output of 220 kilowatts and capable of generating cold or heat as required.

Set on hydrofluroolefin (HFO) refrigerants

In the case of Maestrani, the green HFO refrigerant 1234ze was used, which complies with the Swiss Chemical Risk Reduction Ordinance (ORRChem). In terms of efficiency and functionality, it is the ideal solution. The modular design of the energy supply at Maestrani favoured the HFO refrigerant. Small ammonia-fuelled units would have been too expensive to purchase, and using an ammonia chiller would have proven uneconomical, as it could not have been utilised to capacity from the outset.