Stuart Grogan, Operations Director at BCH Ltd, explains how integrated turnkey systems are helping confectionery manufacturers improve flexibility, efficiency and control while preparing production lines for future growth.
BCH has a long history in confectionery manufacturing. Could you introduce the company and give an overview of its offerings to the confectionery industry?
BCH has been supplying machinery to the confectionery and allied sectors since our beginnings in 1835.
Today, BCH is a specialist in the supply of both standalone machines and complete turnkey process solutions for the manufacture of a wide range of confectionery products, including starch gel and liquorice, 100% fruit products, caramels, syrups, jams, fondants, jellies and preserves.
What does a typical BCH turnkey confectionery solution encompass, and what are the benefits of taking an integrated approach?
BCH can provide solutions covering the process from the initial kitchen stages through to forming and cutting, depending on the product and requirements of the customer.
The benefit of this approach is that the different stages of the process can be designed and engineered to work together from the outset. Rather than having individual machines operating independently, the complete system can be considered as one production process. This can reduce operational requirements and simplify the management of the production line, while also helping to deliver greater consistency and repeatability.
Another important benefit is having a single partner responsible for the overall process. BCH can work closely with the customer throughout the development, installation, commissioning and start-up of the system, helping to ensure that the final solution performs as intended. The result is a production system designed around the customer’s end product rather than simply a collection of individual machines.
How important is flexibility when designing turnkey systems, particularly as confectionery manufacturers look to diversify their product ranges?
Flexibility has become increasingly important when companies are making significant investments in new production lines. Manufacturers want confidence that the equipment they invest in today will continue to support their business as their product portfolio develops.
A BCH turnkey solution can provide opportunities to diversify through changes to flavours, colours, shapes, formats and fillings, depending on the process and equipment selected.
Our latest generation confectionery extrusion lines, for example, have been developed with future expansion in mind. This can allow manufacturers to introduce additional products and formats further down the line, including a wider variety of shapes and formats for liquorice products, as well as the capability to produce 100% fruit articles.
This approach means the initial investment can provide a platform for future growth rather than being restricted to a single product.
We work closely with customers to understand not only what they need to produce today, but also where they see their product range developing. This allows us to consider future requirements during the initial design stage, helping to make the overall solution a longer-term investment for the business.
What demands are you experiencing from confectionery producers today, and how can turnkey systems help them respond?
There are several common challenges facing confectionery manufacturers, including the need to develop healthier products, rising and volatile raw material costs and the continuing requirement to improve efficiency.
Flexibility and efficiency are therefore key considerations when customers are investing in new equipment. BCH’s confectionery manufacturing portfolio is designed to support a broad product range while also focusing on efficient start-up and shutdown processes.
We have taken significant steps to reduce the energy requirements of our machines and in some instances, our equipment uses a fraction of the energy compared with alternative options on the market. A turnkey approach allows these requirements to be considered across the complete process, rather than focusing on individual machines.
