The most modern cocoa processing plant in Switzerland 🎞️

Automation is crucial since PRONATEC works with a batch separation process for traceability. It was included in the project at an early stage because the entire structure is different from other plants. “The efficiency of the plant at the Swiss site, as well as the uncompromising standard of a 100% organic certification, was a priority for PRONATEC from the very beginning,” says Joachim Essig, Head of Sales Cocoa & Malt at Bühler. “Fully integrated automation, small-scale batch production, batch separation, and full traceability were already important topics in the initial discussions in mid-2018, as were gentle handling of raw materials, food safety, and the highest hygienic design standards.” 

But before PRONATEC decided on the new plant, a thorough decision-making process was carried out. “Because we used to have the beans processed by contractors in Europe, we knew the upstream and downstream costs, but we were not familiar with the processing costs,” says Simon Yersin. “We received excellent and exceptionally quick support from Bühler with necessary analyses and information, which enabled us to calculate and assess the entire business concept. This in turn helped us to decide in favor of the Swiss location.”

“Our experience with the Tornado roaster has been very positive. We appreciate the high flexibility,” says Yannick Rihs, Plant Manager at PRONATEC. “Once it’s set up, the level of reproducibility is very high. The advantage of the Tornado is that each batch can be roasted differently.” Joachim Essig shares Rihs’ enthusiasm about the machine. “The Tornado roaster sets new standards in the cocoa industry. It’s designed for 24-hour operation, including weekends. The Tornado roaster has been on the market for many years. It’s the most frequently installed roaster for cocoa, it’s very flexible and fully automated. A robust device all-around.”

The project was so challenging because it was so out of the ordinary; this is a small plant that must produce at a high level of efficiency and meet all the requirements of strict organic labels, such as batch separation. “PRONATEC has invested a lot of time and energy in preparation right from the start,” says Michael Richard, Project Manager at Bühler. “We did trials in the pilot plant at Bühler. We held workshops to understand the special requirements of an organic plant and incorporate them into the process. This helped us design, install, and commission a complete processing plant in just two years, all in an existing building.” For the project manager of PRONATEC, Michael Grether, who supervised the project from the beginning, the cooperation was also extremely positive: “We certainly challenged Bühler but we were able to find good solutions to all challenges. The commissioning went smoothly and even our most optimistic expectations were met, which allowed us to begin production so early.”

For David Yersin, it was clear from the beginning where and, above all, with whom the plant should be built. “We are a Swiss company that will produce in Switzerland, with a Swiss machine builder on our side. As an innovative market leader, Bühler was the only remaining option for me after a short evaluation phase,” says Yersin with great conviction. Two core elements of the plant, the Tornado cocoa nibs roaster and the Nova mill, are manufactured by Bühler in Appenzell, which is perfectly in line with PRONATEC’s philosophy in terms of quality and having a local partner. 

“As an SME, the plant was a big investment for us,” says David Yersin. “However, we are already noticing that quality and the fact that we produce regionally are becoming more and more important to many of our customers. Thus, it is an investment in the future.”

Since October 2022, PRONATEC’s organic cocoa processing facility has been operating in three shifts. “A large part of the revenue has already been secured,” says Simon Yersin. “We’ve also left a lot of space for future projects, which we hope to fill with more Bühler equipment.”