Cluster Production
Premier Forrester are experts in efficient, flexible cluster production and manufacturing.
Clusters are bite-sized pieces of confectionery made by binding nuts, cereals, or dried fruit with chocolate, compound coating, or sugar syrups.
Change the inclusions or adjust the portion size and you can create a different product without rebuilding the entire line.
Our expert team at Premier Forrester will help you achieve that with precision and control when reviewing your cluster production lines and machinery. We work directly with our Principals to select and commission the right equipment for your cluster products, then install and integrate it into your line.
Cluster production process
Cluster production can be a straightforward sequence; but every stage — from ingredient preparation to cooling — must be carefully controlled to keep shape, gloss, and weight consistent.
A typical cluster production line includes:
- Ingredient preparation. Nuts can be roasted, chopped, or screened. Dried fruit is portioned and sometimes pre-dried to manage stickiness.
- Coating. Mix-ins are combined with chocolate, compound, or syrup at controlled temperatures to achieve the right viscosity.
- Forming. Free-dressing depositors drop portions directly onto a belt, or moulds can be used when tighter weight control is needed.
- Cooling. A cooling tunnel stabilises the texture and gloss before inspection and packaging.
Each step can be scaled or adapted to suit different recipes and volumes, which makes the right choice of machinery critical.
Machinery for cluster production
Cluster production - need to know
For manufacturers, the challenge comes with achieving even distribution of inclusions, avoiding syrup crystallisation, and preventing poor cooling that slows production.
- Likely bottlenecks. Feeding and distribution of inclusions can slow production if not well controlled, leading to weight drift or rejects.
- Product variations. Nut, cereal, and fruit mixes behave differently in viscosity, flow, and cooling, so machinery settings must adapt.
- Batch size effects. Small SKUs run best with flexible free-dressing; higher volumes push toward continuous feeding and automated pack-off.
- Hygiene and changeovers. Frequent recipe shifts and allergen handling (nuts, dairy, fruit) require quick, validated cleaning access.
- Sustainability levers. Precise dosing reduces waste, while controlled cooling and tempering minimise energy use and rework.
By combining leading equipment into a single, reliable line, we help manufacturers boost throughput, stabilise quality, and keep costs under control.
Talk to Premier Forrester about cluster production
Whether you are building a new cluster line, optimising weight control, or expanding into new blends of fruit, nuts, and cereals, we can design a system that balances flexibility with output.
Contact us, and we will map your process, specify the right machinery, and integrate it into a line that runs steadily, day after day.