New production site: technological requirements and environment sustainability

This complete control over the production chain, coupled with technological independence, has been adopted by ICAM as the signature features of a production system compliant with the very highest quality standards and careful to make the very most of the typical, genuine original cocoa varieties used.

New production site: technological requirements and environment sustainability

When designing the construction of the new Orsenigo plant, ICAM was inspired by two strategic nodal elements in chocolate production in terms of quality and food safety: functionality and traceability. The primary need was to design a system for a fully automated chocolate production and, secondly, to match this need with a complete traceability of each process, from raw materials up to the product ready for consumption. Hence the requirement to implement a complete system of supervision and management of the entire production cycle of the cocoa processing and an infrastructure for a 360-degree monitoring of the integrated process.
ICAM has made the complete supervision of the production chain and a technological independence become the distinctive elements of a chocolate production which complies with the highest quality standards, carefully enhancing the original cocoa typicality and authenticity.
Thanks to a direct experience and presence in the areas of cultivation, the company is able to offer solid guarantees concerning every aspect of the cocoa processing industry: the origin of the raw material, the genotypes of each cocoa, the peculiarities of the plantations linked to their geographical location, climate, morphological features of the soil and the sun exposure, the processing and storage procedures to which the beans are subjected, up to the full product detectability and traceability through the complex processing and transformation stages carried out in Orsenigo. It is thus possible to delineate a documented map for each product along the entire cocoa cultivation and processing line.
This is a functional system able to manage all phases – from the production requirement to the supply of raw materials, through studying the recipe, programming and planning production – thus ensuring total traceability of products and raw materials.

The modern plant systems, compliance with strict safety and food hygiene standards, attention to processing intact beans, plant cleaning systems to remove any foreign matter and frequent production testing, are crucial factors in defining the final quality of the cocoa and chocolate which will therefore retain the original flavour and characteristics. 

50 k m2
Plant area
30 k tonnes/year at full capacity
Cocoa beans
120 tonnes/day
Production capacity

The technological areas of the plant

Tri-generator

Tri-generator

Tri-generation ensures an outstanding performance for the production of electricity, steam and cold water.

Electrical energy
2,4 megawatt
Thermal energy
1,7 megawatt
Refrigeration energy
0,7 megawatt
Energy costs
-50%
Roasting

Roasting

Sterilisation of the cocoa takes place before production via a separate sterilisation column.

Production capacity
4 tonnes/hour
Presses and powder processing

Presses and powder processing

Separation between the butter and the cocoa powder occurs during the first stage of production.

For storing the liquid chocolate
36 10 tonnes tanks
For Butter
2 25 tonnes tanks
For loading the tankers
6 25 tonnes tanks
Chocolate production and moulding

Chocolate production and moulding

The new production facility allows ICAM to reach, at full capacity, a total of 22,000 tons per year of processed cocoa beans.
3 refining lines, 4 mixers and 9 basins represent the productive engine of the company.
In order to address the growing request for food safety and allergen-free products, ICAM pays particular attention to cross contamination. This is why dedicated production lines have been implemented: for organic and conventional chocolate, for white, milk, dark and gianduja chocolate.

Produced chocolate
22.000 tonnes/year
Production staff
200 on a continuous cycle over three shifts
Tablets
10.000 tonnes/year
Semi-finished products
10.000 tonnes/year
Warehouse

Warehouse

The rigorous storage of the bags containing cocoa beans of various types and origins allows complete traceability of the cocoa batches. Thanks to a pneumatic transport system, the cocoa beans are gently transferred from the warehouse to the subsequent sterilisation and roasting stages, avoiding any crushing and consequent micro contamination of the raw materia

Quality control, research and development laboratories

Quality control, research and development laboratories

Quality control of the raw materials up to the finished product. Random organoleptic tests are in fact carried out on each semi-finished and final product destined for the end consumer, in order to ensure the highest quality and safety.

Characteristics of excellence

Functionality and tracking are the two nodal elements that qualify the ICAM production in terms of food quality and safety.
It is possible to obtain an extremely pure cocoa paste thanks to the rigorous storage of cocoa beans in the specific warehouse and to the innovative cleaning process that frees them from all contaminants. Moreover, the pneumatic transport system gently moves the clean beans from the warehouse to the subsequent sterilisation and roasting stages, avoiding any crushing and micro contamination of the already sterilised and purified product.

Being able to identify each bag of cocoa beans allows fully tracing all types of processing with detailed information concerning the transformation treatment. These are just some of the productive improvements made possible thanks to the technical innovations and technological support which allow monitoring each single element of a complex and articulated production with the utmost precision.

In order to address the growing request for food safety and allergen-free products, ICAM pays particular attention to cross contamination. Dedicated lines for all the processing steps of the cocoa and chocolate production are in fact envisaged, with dedicated tanks for the different types of cocoa paste. This division is able to avoid any contamination due to potentially allergenic products such as milk or hazelnuts.

The modern plant systems, compliance with strict safety and food hygiene standards, attention to processing intact beans, plant cleaning systems to remove any foreign matter and frequent production testing, are crucial factors in defining the final quality of the cocoa and chocolate which will therefore retain the original flavour and characteristics. 

Food safety, laboratory analyses and organoleptic tests on more than 3000 items in production

Food safety, laboratory analyses and organoleptic tests on more than 3000 items in production

ICAM is able to meet the demands of its customers thanks to its ability to generate a high range of products for professionals, from the small pastry shop to the large industry, to which it offers chocolate shells and semi-finished products such as pastes, powder and butter cocoa. Laboratory tests carried out with extreme accuracy at every production level provide excellent quality and outstanding food safety.

Extreme automation of the production processes and flexibility to satisfy the most demanding customers.

Extreme automation of the production processes and flexibility to satisfy the most demanding customers.

The production facilities enable a variety of tastes and a wide range of recipes: 150 dark chocolate recipes, 100 milk chocolate recipes and around 40 white chocolate recipes. A computerised monitoring system ensures complete control and full traceability and total automation of the entire production.
The drop modeller for the icing is provided with a state-of-the-art pouring system, which allows great flexibility of the size of the chocolate drops and buttons, and a 60-metre cooling tunnel for a gentle and stable tempering of the icing coat.
An in-line packaging and an “online labelling” system with the manufacturer’s specifications complete the productive cycle.