DoMiReCo.

Traditionally
the best-in-class
roll-refining and
conching solution.

Innovations for a better world.

DoMiReCo.
Solution for the widest range of products.

DoMiReCo – The key to success.

Flexible, reliable and cost-effective.

For over a century, Bühler has developed unmatched expertise in the production
of chocolate, coating and filling masses. Its DoMiReCo process holds a global market
share of about 75% and is synonymous with accurate dosing, reliable mixing, out-
standing refining and taste development, and adjustment of flow properties with mini-
mum fat content in conching.

1 2 3

Ingredients handling Dosing Mixing

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 DoMiReCo.
Solution for the widest range of products.

How you can benefit from the Bühler DoMiReCo process.

– Uniquely high end product quality with an accurately – High production flexibility thanks to minimal product
defined particle size distribution and optimal flavor profile. cross-contamination and almost no restrictions on the
– Significantly lower cost for raw materials thanks to minimum fat level.
1 to 4% less fat required in comparison to other pro- – Minimized metal contamination (< 1 ppm) for top
cesses to achieve the same flow properties. food safety and no restrictions on the production of
– Consistent end product flow properties batch by batch white masses.
regardless of variations in raw materials characteristics.

4 5 6 7

Pre refining Final refining Conching Chocolate mass handling

3
DoMiReCo.
Solution for the widest range of products.

From cocoa beans to final chocolate products –

Bühler is the leading partner when it comes
to long-term system performance for process-
ing all kind of chocolates, coating and filling
masses.

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 DoMiReCo.
Solution for the widest range of products.

Product changes during processing.

From dry and liquid to pasty, powdery and
back to liquid.

Throughout chocolate mass production, the ingredients undergo physical and

chemical transformations which modify their texture and flavor in a number of ways.
Knowledge of these mechanisms unveils the mystery of developing an end product
of sensational texture and taste.

Ingredients handling. Dust-free dry ingredients reception

in conjunction with gentle and reliable handling and storage of
liquid and dry raw materials.

Dosing. Accurate and repeatable dosing to the mixer and

the conches minimizes waste, reduces production costs, and
ensures consistently high production performance.

Mixing. Shearing and kneading releases fat from milk powder

and provides a homogeneous mass consistency with a mini-
mum fat content.

Pre refining. One-pass refining to calibrate sugar and to

provide perfect and consistently high plasticity for efficient
five-roll refining.

Final refining. Refining (grinding & aromatization of sugar)

to the final desired fineness with an accurately defined particle
size distribution.

Conching. High-intensity shearing and kneading in a thought-

fully defined process cycle releases fat and evaporates
moisture as well as acids, providing the desired flavor profile,
mouth feel and flow properties.

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DoMiReCo.
Solution for the widest range of products.

Ingredients handling.
Streamlines operations and ensures high
production reliability.

A reliable dry and liquid ingredients handling system integrated within the process
significantly reduces operating challenges.

There is a strong technological link between a handling system

on the one hand and the DoMiReCo process on the other.
Bühler goes one unique step further in this respect, saying it
is one single process! Bühler offers you engineering services
enabling you to find the solution best suited to your specific
dry and liquid ingredients handling needs – from reception to
dosing of the ingredients to the DoMiReCo process.

These state-of-the-art solutions include hygienic design, mini-

mized dust emissions, ATEX zoning and certified components,
and critical control points, and this for both dry and liquid in-
gredients handling.
MKSB bag & big-bag receiving unit.
For implementing your fully integrated factory concept, we in- – Ergonomic handling of bags and big-bags thanks
vite you to partner with Bühler and benefit from our vast experi- to outstanding sieving and discharge concept.
ence and expertise in designing ingredients handling solutions. – No access platform required.
– Sieve (6 to 10 mm) to retain strings, lumps,
Dry ingredients handling:
impurities, etc.
– Truck, bag and big-bag receiving units
– Exhaust system to control dust emissions.
– Rotary control sieve
– Pneumatic conveying system, including exhaust systems
– Mechanical conveying system
– Storage silos and day bins
– ATEX prevention (active and passive)

Liquid ingredients handling:

– Truck receiving stations and block melters
– Sieves
– Conveying systems
– Jacketed piping MKZI rotary control sieve.
– Storage tanks and day tanks – Mesh size of 1 to 2 mm to remove lumps and
impurities.
– Throughput capacity up to 15 t/h depending on
type of product and mesh size.
– Extremely fast visual checking of the sieve cage
(CCP - critical control point), thanks to specially
designed bayonet catch.

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 DoMiReCo.
Solution for the widest range of products.

Dosing and mixing.

Where quality and productivity start.

Accurate dosing of raw materials has a direct impact primarily on the downstream
process as well as on the quality of the end product. Shearing and kneading releases
fat from the milk powder and saves money.

SPAR rotary bin discharger.

The rotary bin discharger is designed for discharging and pro-

portioning bulk raw materials from storage bins and hoppers.
It allows fast and highly accurate dosing of dry ingredients and
minimizes bridging of the raw materials.

Together with the ShearMix™ S, it provides a perfect system

for effective dosing at minimum cost. To further increase dos-
ing accuracy, it can also be used for pre-weighing into inter-
mediate bins. – Uniform bin discharge in coarse and fine dosing
as well as in shut-off mode.
ShearMix™ S single-shaft mixer.
– Proven in various installations worldwide with
The ShearMix™ S is a batch mixing system available in a wide different products.
range of sizes. High energy input minimizes the processing – Can be applied for a wide variety of bulk materials,
time. Its unique helical agitator in combination with a variable- including non-free-flowing ones.
speed drive ensures optimal homogenization. Furthermore, a – ATEX-certified.
consistent mass temperature is achieved at the end of this
process stage. Its design enables a high level of free fat to be
generated by removing immobilized fat from the surface of
various particles such as milk powders. Thanks to its highly
sanitary design, the ShearMix™ S achieves fast and complete
discharge.

The ShearMix™ S provides easy exchangeability of the

Bühler SMC mixer.

– High shearing action, resulting in maximum release

of immobilized fat.
– Excellent mixing and shearing action, resulting in
short mixing times and high throughput rates.
– Accurate input weighing of the ingredients thanks
to built-in high-precision load cells.
– Self-discharge at high capacity and good residual
discharge.

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DoMiReCo.
Solution for the widest range of products.

Two-stage refining.
Consistent particle size at minimized energy
input for a smooth end product.

The Bühler two-stage refining process is the worldwide standard in terms of

quality and efficiency. Thanks to its flexibility, it can handle a wide product variety
while allowing easy and reproducible particle size adjustment.

PreFiner™ S two-roll refiner.

The PreFiner™ S enables a mass fineness between 80 and

250 microns to be achieved across a particle size distribution
range that provides optimal mass consistency and high down-
stream process performance. Beside particle size reduction,
this also allows flavor development by wetting amorphous
sugar in the roll gap.

To satisfy customer-specific production needs, the Bühler

two-roll refiner features variable roll speeds and customized
roll cambers. The downstream conveying screw allows perfect
homogenization of the pre-refined mass.

Finer™ S five-roll refiner. – Optimum fineness and plasticity of all masses.

– Maximum production efficiency.
The Finer™ S is capable of processing a vast range of mass-
– Flexible frequency-controlled drive.
es with different compositions and consistencies, thanks to its
– Very easy cleaning and maintenance.
customized gear ratios and roll cambers. This ensures maxi-
mum specific throughputs across a wide range of particle siz-
es between 12 and 60 microns. A beneficial side-effect is the
wetting of amorphous structures with aromatic components,
which later on will contribute to the overall flavor profile. Top
process reproducibility is ensured by the accurately controlled
roll temperature and precisely applied roll pressure. Online
particle size control (FineSens™) transforms roll refining into a
robust and reliable process requiring minimum human inter-
vention and offering highest possible output.

Thanks to the intuitive operating concept of the two- and five-

roll refiners with their large touchscreen displays, users always – Latest sanitation and safety standards.
have tight control over their production lines. The user-friendly – Maximum flexibility in processing a wide range of
control structure permits quick access to all process-relevant masses.
parameters. – Consistent, reproducible fineness and throughput
characteristics.
– Maximum production efficiency.
– Very easy maintenance and cleaning.

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 DoMiReCo.
Solution for the widest range of products.

Our customer service portfolio.

Continuous upgrading of your installed equipment

throughout its lifecycle and permanent training of
your operators.

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DoMiReCo.
Solution for the widest range of products.

Conching.
The ultimate way to indulge consumers, create
differentiation, and increase productivity.

Bühler is the undisputed leader in the field of conching. This perfected process
transforms the mass into an end product with accurately defined flow characteristics
and sensory properties.

Throughout the conching process, the mass undergoes several

well-defined phases: drying (moisture reduction, removal of vol-
atile substances), deagglomeration (shearing, kneading), flavor
redistribution (from cocoa and milk particles to sugar surfaces),
flavor development (through application of specific temperature
profile), and liquification (adjustment of flow properties).

FRISSE™-ELK S single-shaft conche.

This single-shaft conche is an attractively priced solution

ensuring high efficiency and flexibility. A specially designed
conching tool ensures ideal aeration and pronounced
– Short conching cycles and lower fat consumption in
shearing against the vessel wall.
comparison to other conches.
Removal of moisture and undesirable volatile substances – Software system which allows automatic control of
can be achieved by cascade louver positioning or forced all the process steps.
ventilation. – Minimized maintenance, resulting in high machine
uptime.
FRISSE™-DÜC S triple-shaft conche. – High energy efficiency thanks to direct drive.

The triple-shaft conche Frisse™-DÜC S reduces conching

times thanks to the application of extremely high shear forces.
It enables a top end product quality to be achieved within min-
imum time in terms of texture, melting characteristics, flavor,
and flow properties. The special kneading and shearing char-
acteristics of the DÜC S ensure efficient texture modification
from the dry / liquid input product to the liquid end product.
The conching process can be carried out in different ways to
suit the specific application, thanks to the machine’s combina-
tion of process control, product aeration, accurate tempera-
ture control, energy input and direction of rotation of the con-
ching shafts.
– Shortest conching cycles at lowest possible fat
utilization thanks to overlapping shearing.
– Latest sanitation and safety standards.
– Reduced machine footprint thanks to new drive
configuration.
– Improved vessel design for less product residues.

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 DoMiReCo.
Solution for the widest range of products.

The conching process is key to producing

high-quality chocolates and coatings.

This crucial process step develops the chocolate

flavor – for example a caramel taste at elevated
temperatures or a natural, milky taste at lower
ones – and generates the unique taste by removing
undesirable volatile substances and moisture.

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DoMiReCo.
Solution for the widest range of products.

Conveying. Rework processing.

Moving pasty or Reblend rework with
powdery products. the regular product.

Modularity and hygiene are prerequisites Whatever final or intermediary products

for a high-quality process. Bühler belt you want to feed back into your process,
conveyors gently convey product from A Bühler can offer you a flexible method
to B without changing its properties. of rework processing.

ChocoBelt™ S Steel. VersiMix™.

Bühler ChocoBelt™ S Steel belt conveyors are applied in the One of the most versatile technologies is the twin-shaft
chocolate industry as well as in other food processing and the VersiMix for size reduction, mixing and homogenizing in any
pharmaceutical industries. In general, they are used where rework application. It can be applied for precrushing, lique-
reliable conveying of pasty, granular or powdered products is fying and mixing rework.
required.
UniMill™.
The design of ChocoBelt™ S Steel conveyors is based on
Another efficient technology is the UniMill hammer mill. It grinds
Bühler’s vast experience in plant design and construction in
materials to a fineness of 80 microns, as well as homogenizing
conjunction with its profound product expertise. The minimized
and liquefying them in a single step.
product residues on the belt and at transfer points satisfy the
most demanding sanitation requirements while ensuring high
efficiency.

– Modular design allows individual conveying systems

to be tailored to the specific requirements and space
conditions.
– Conveying systems may have lengths up to
60 meters. VersiMix™.

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 DoMiReCo.
Solution for the widest range of products.

We proudly confirm – 75% of all chocolates

consumed worldwide are produced by the
DoMiReCo process of Bühler.

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DoMiReCo.
Solution for the widest range of products.

Line automation system.

Choose the most suitable system from a
wide range of integrated designs.

Customized automation solutions enable you to achieve high productivity and uptime
without compromising on end product quality. Bühler systems provide high reliability
as well as full connectivity, information security and process transparency.

Flexible Automation Solutions. Bühler understands your Quality Assurance and Food Safety. Obtain the key bench-
needs. Together with our specialists, we will find the solution marking characteristics and the safety know-how from Bühler.
perfectly tailored to your requirements.
Information Security and Process Transparency.
Higher Productivity and Uptime. Let the system support Data saving, retraceability of production and analysis of the
your operations and thus increase your efficiency. root causes of trouble provide the process reliability you need.

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 DoMiReCo.
Solution for the widest range of products.

Scale-down to MicroFactory™.
Use the market leader’s compact solution
to produce your own chocolate mass.

Are you a chocolatier who wants to enter the next level of product innovation
and independency? Are you already producing chocolate masses and do you want
to install a separate line for the production of specialties?

DoMiReCo in small means MicroFactory™ –

produce your chocolate of consistently high quality
at a daily capacity of 200...1,600 kg.

The characteristic of MicroFactory™. Benefits.

– Constant particle size at high level of reproducibility. – Inspires product development by shaping flavor and taste
– Grinding under semi-liquid condition using roller refiner. to any direction.
– Intensive conching process / high energy input. – Tailors flow properties to ensure performance of downstream
process steps.
– Reliable and flexible in respect to capacities.

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DoMiReCo.
Solution for the widest range of products.

Digital Services.
Self-optimizing chocolate lines – the future
in chocolate mass production.

The increasing availability of sensor and actuator systems and rapidly advancing
networking technologies make it possible! We are starting to develop the next pro-
cess generation, which propels quality and throughput to the next level.

Top performance. 24/7 optimal processing conditions for Choose your digital services.
consistently high throughput and process efficiency. – Capacity Boost
– Total Particle Size Control
Consistent quality. Less rework and quality control efforts – Plasticity Control
thanks to the most reliable and accurate control system. – Autonomous Refining

Information availability. Smarter and faster decision-making

thanks to KPI dashboards available anytime anywhere.

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DoMiReCo.
Solution for the widest range of products.

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DoMiReCo.
Solution for the widest range of products.

From small to big, from single machine to full scope.

Partner with Bühler according your needs.

Bühler’s production solutions deliver success in the chocolate industry – from single
machines right through to entire production lines and fully integrated factory concepts.
As the leading technology supplier to chocolate manufacturers, we support you as a
partner wherever, whenever and for whatever purpose in your projects and throughout
the lifecycle of your production facility. Our decades-long undisputed market leadership
sustainably proves us as your most capable and most economical long-term partner.

Consulting & process development Services – Deliverables – Process equipment

Project execution throughout the choose your level or Automation system
Life cycle management lifecycle. delivery scope. Mechanical auxiliary equipment
Retrofitting & modernization Electrical auxiliary equipment

Bühler's
service & solution
portfolio.

Components Laboratory equipment

Single machines Solutions – Capacities – From 400 kg/day
Production lines what suits you today find the right scale up to 6 tons/hour
Entire factories and tomorrow. for your needs. One-shift or 24/7 operation

Reliability as a fact and shown in figures –

our installed base proves a partnership based on best value for money.

> 1,000 > 900 > 2,500 > 500 > 1,100
Chocolate mixers Two-roll refiners Five-roll refiners Single-shaft conches Triple-shaft conches

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 DoMiReCo.
Solution for the widest range of products.

Application Centers & process expertise.

Innovate your products and recipes with Bühler.

Differentiation is the main criterion for your success. Bühler provides outstanding pro-
cess technologies to master your product innovations. Feel our passion for chocolate
in one of our Application Centers worldwide.

Bühler Application Centers for chocolate,

coating and filling masses production.

– Uzwil, Switzerland
– Wuxi, China
– Jakarta, Indonesia

19
 Switzerland
CH-9240 Uzwil
Bühler AG

F + 41 71 955 35 82
T + 41 71 955 11 11

www.buhlergroup.com
[email protected]
CF_4420.15.01.EN|04.17

Bühler retains ownership of the copyright and all other rights in

the content of the brochure. Subject to change without notice.