Premier Forrester helps Greggs cut caramel shortbread chocolate waste by 98%

The Details:

• Client: Greggs

• End product: Caramel Shortbread

• Location: UK-wide

• Principals involved: Trikno, Wolf

H2: The Story

Founded in 1939 in Newcastle upon Tyne, Greggs has grown into one of the UK’s most popular and widespread food retailers. With over 2,600 Greggs stores around the country and more set to open, the demand for affordable baked goods is at an all-time high.

With this success comes an increasing demand for production, especially for customer favourites like their caramel shortbread – praised for its crumbly base, smooth caramel, and rich chocolate topping.

With manual production lines relying heavily on manual labour and lacking efficiency and automation, Greggs sought alternative solutions. It partnered with Premier Forrester – experts in chocolate and confectionary manufacturing solutions - to enhance output, reduce costs, and keep up with the ever-growing demand.

The Challenge: Manual Production Processes

Before Premier Forrester’s intervention, Greggs’ caramel shortbread production relied heavily on manual processes, with much of the chocolate application done by hand.

It involved chocolate being poured onto the cooled caramel, and operators turning and banging the sheets until the chocolate had levelled out. While this was effective in Greggs’ infancy when demand was lower, this time-consuming method became unsustainable as demand surged. It also created a lot of waste.

The main challenges faced were:

• Legacy Equipment: The use of rack ovens meant batch production rather than a continuous line. Rack ovens offer far greater flexibility, so the solution had to work around this method of baking

• Inefficiency: Due to manual processes of hand-placing and hand-levelling chocolate, production times were extended, and the acceptable waste level was high.

• Labour-Intensive: Significant manpower was needed to maintain the production pace, which increased operational costs but put a strain on the workforce.

• Inconsistent Quality: Differences in manual chocolate application led to uneven coverage, impacting the uniformity and finish of the final product.

It was clear that Greggs needed a more efficient, cost-effective, and consistent production process – so they turned to Premier Forrester for an automated solution.

Time for a Change: Premier Forrester’s Solution

Greggs knew that they needed to update their production process but weren’t sure the best way to do so. Initially, they sought a chocolate curtain system to cover the caramel, but Mike Gee of Premier Forrester knew that this method wouldn’t be effective, so instead pitched his own idea.

Drawing on over 25 years of experience and expertise in end-to-end food solutions for chocolate and confectionery, Mike Gee suggested using two innovative technologies to automate production for Greggs’ caramel shortbread:

Trikno TCM Depositor

The use of an advanced depositing machine, such as the Trikno TCM Depositor, guarantees that each shortbread product receives the same, precise amount of chocolate, maintaining consistency across every batch.

Key technical features of the Trikno TCM Depositor include:

• High-Speed Operation: Capable of handling large-scale production, boosting output without compromising quality.

• Precision Nozzles: Designed for accurate and uniform chocolate distribution, reducing waste and ensuring consistency across batches.

• Programmable Controls: Adjustable settings for deposition volume, speed, and patterns facilitate adaptation to different production lines.

• Automated Integration: Integrates with existing production lines seamlessly.

Read more about the benefits of Trikno Chocolate Depositor Machines.

WOLF UF300 Tempering Unit:

State-of-the-art tempering units, such as the WOLF UF300, ensure that all chocolate remains at the perfect temper throughout the production process, preventing blooming.

Key technical features include:

• Integrated Mass Pump: Optional, built-in mass pump ensures a consistent mass flow, leading to uniform temperature control.

• Precise Temperature Control: Continuously monitors and adjusts the chocolate’s temperature to maintain optimal tempering.

• Advanced Cooling and Heating System: Rapidly heats and cools chocolate, maintaining the ideal crystallisation of cocoa butter for a smooth and glossy finish.

• Real-Time Monitoring: Integrated sensors and digital controls provide real-time data on chocolate viscosity and temperature.

• High-Capacity Handling: Designed to temper large volumes of chocolate efficiently, supporting high-throughput production lines.

Read more about WOLF machinery.

Results and Impact

The addition of Trikno’s depositor and WOLF’s tempering unit has had a game-changing impact on Greggs’ production.

Not only have these changes meant customer satisfaction is at an all-time high, but the company has also saved money and freed up valuable labour resources.

• Chocolate waste reduced by 97.5%, streamlining wastage from 60 grams per sheet to just 1.5 grams.

• Production rate doubled, meeting the growing demand.

• Significant cost savings, improving efficiency across the board.

• Scalability, setting the stage for future growth.

Why Choose Premier Forrester?

In the competitive world of chocolate production, Premier Forrester stands out as a trusted partner with over 25 years of industry experience in end-to-end food production and consultancy solutions.

Premier Forrester’s ability to deliver a complete chocolate and confectionery manufacturing solution – combining advanced decorating, tempering, and moulding systems – sets them apart from the competition.

By choosing Premier Forrester, manufacturers gain not just access to cutting-edge equipment, but also comprehensive after-sales support, including installation, operator training, and servicing – helping you to stay ahead of the evolving demands of the confectionery market.

Get in touch today to see how Premier Forrester can meet your chocolate production requirements.