Industrial Scale Chocolate Printing, Perfected for Precision and Production

A fully automated 3D printing farm producing thousands of chocolates per day for high-end events.

10,000+ Chocolates Per Day
Dual Printer Setup
Fully Automated Production

Project Overview

Our Industrial Scale Chocolate Print Farm was developed to meet the demand for high-volume, high-quality chocolate shapes designed for exclusive events at major hotel chains. This solution allows for the production of custom chocolate designs, bridging the gap between artisanal chocolatiers and bulk suppliers. Capable of producing thousands of chocolates daily, this fully automated 3D printing system delivers precision, efficiency, and flexibility.

Project Goals:

Mass Production of Customized Chocolates: Capable of printing over 10,000 chocolates per day.
Flexibility in Design and Taste: Enable exclusive shapes and flavors to meet high-end customer demand.
Fully Automated Workflow: Minimize labor while ensuring consistent quality.

Why This Solution?

The client’s vision was to create exclusive, customized chocolate pieces on an industrial scale to serve prestigious hotel chains and event venues. With 3D printing, they can:

Deliver Customization and Exclusivity: Offer unique shapes and flavor combinations that elevate the guest experience.
Improve Production Efficiency: With a fully automated setup, labor is reduced, and the output is consistent.
Enhance Product Quality: With precise temperature control and seamless integration of production stages, the chocolates maintain quality, with no fat blooming or texture issues.

This solution meets the client’s needs to produce high-quality chocolates in large batches with full automation, bridging the gap between artisanal craft and high-volume production.

How We Built the Chocolate Print Farm

After extensive testing and multiple development phases, we created a solution based on our FELIX Pro Desktop platform—modified to operate in tandem with specialized automation features and chocolate-compatible printheads. The project also involved collaboration with other parties, including a material supplier (BC) for chocolate and an automation company for custom software, ensuring that the end product could meet industrial demands.

Features

Dual Printer System: Two independent printers in one large frame, capable of simultaneous printing for increased output.
Automated Print Farm Module: Capable of producing up to 10kg of chocolate per hour.
Precision Temperature Control: Maintains chocolate quality throughout the process, preventing fat bloom.
Cooling Print Area: Holds the printed chocolates at 10°C for 10 minutes to ensure stability.
Advanced Tray System: Vacuum tray fixation with pushers, destackers, and a paternoster system to manage trays and blisters.
Software Integration: Coordinated through a Siemens PLC, Repetier-Server, and custom software for seamless operation.

OEM Partnership: As the OEM partner, we manufacture and assemble the print farms on demand, stock necessary components, and provide support for smooth, continuous operation.

Customization Process

Feasibility Phase

Objective: To confirm the viability of printing chocolate at an industrial scale using 3D printing technology.
Solution: We began with a DIY kit based on the FELIX Tec 4 model, adding a chocolate-compatible printhead and cooling system to ensure quality and speed.
Outcome: Initial tests showed that 3D printing could indeed meet the client’s needs, allowing us to move forward with developing a prototype setup.

2. Prototype Phase

Objective: Scale up the process to handle high-volume production in a larger, automated setup.
Solution: We created a dual-printer frame with two Pro Desktop printers, fully automated to load and unload trays and control temperature. The setup was refined to ensure each printed chocolate cooled properly before advancing to the conveyor.
Outcome: A functional prototype capable of large-scale production, complete with automation and precise temperature control.

3. 0-Series Production

Objective: Gather feedback and refine the design based on real-world use.
Solution: Using input from the client and other end users, we redesigned components for greater durability, ordered new parts, and produced the first 0-series batch.
Outcome: A batch of optimized printers capable of meeting continuous production requirements.

4. Final Product Stage

Objective: Transition to full production for high-volume, industrial-scale chocolate printing.
Solution: The final product integrates all previous improvements, resulting in a fully automated chocolate print farm that meets industrial standards.
Outcome: We now deliver these print farms on demand as an OEM partner, supporting the client’s ongoing production needs.

Client Success & Long-Term Impact

Our Industrial Scale Chocolate Print Farm has enabled our client to produce customized chocolate pieces on an industrial scale with minimal labor and waste. Benefits include:

Efficient Mass Production: Automated setup produces over 10,000 chocolates daily.
High-Quality Control: Precise temperature management ensures consistent quality with no fat blooming.
Flexibility for Customization: Ability to create exclusive designs for events, providing hotels and venues with high-quality, customizable products.

This project illustrates how 3D printing and automation can streamline food production, bridging the gap between artisanal quality and industrial efficiency.

Technical Challenges & Solutions

This project required solving complex hardware and software challenges to achieve the desired automation, temperature control, and integration.

Hardware Challenges:

Dual Printer Integration: Ensuring both printers functioned independently within a single frame.
24/7 Operation: Designing durable components capable of non-stop operation.
Temperature Management: Maintaining chocolate temperature from the tempering unit to the final product to avoid fat blooming.

Software Integration:

Multi-Layer Communication: Achieving smooth coordination between firmware, Repetier-Server, and a Siemens PLC for comprehensive control.
Automation Control: Ensuring that every module in the print farm worked together seamlessly, from loading trays to managing cooling times.

Aftercare & Support

As an OEM partner, we provide ongoing support and stock components to ensure the print farms operate smoothly. Our team remains available for any technical support the client may need as they expand their production capabilities.

See It in Action

Start Your Custom Project

Are you looking for a tailored 3D printing solution to meet your unique needs? Contact us today to discuss your project, and let’s create a high-performance, compliant printing solution together.

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