Bühler presents new editions of two icons in chocolate mass processing

Bühler introduces  the next evolution of two of its most trusted solutions in chocolate mass processing: the Finer S Edition 26 five-roll refiner and the ELK S Edition 26 single-shaft conche. While the two core process steps in high-quality chocolate mass processing – refining and conching – remain as robust and reliable as ever, the Edition 26 systems run cleaner, smarter, more efficiently, and with greater transparency. With its new Edition 26, Bühler is equipping its customers for future requirements and reinforcing its leading position in the chocolate industry.

Through its proven technologies, Bühler has won long-standing trust and recognition from customers across the global chocolate industry. For decades, its DoMiReCo process – dosing, mixing, refining, and conching – has set the benchmark. At the heart of this process are refining and conching, the two steps that largely define final product quality. Fineness, taste and aroma, flow behavior, and raw material efficiency are all shaped here. With Edition 26, Bühler is helping customers address industry challenges and turn them into business opportunities.

Fine-tuned down to the last detail

“Our roll refiner has helped shape the chocolate industry for more than a century. Achieving fineness down to 12 micrometers – crucial for the target particle-size distribution that delivers mouthfeel and smoothness – remains unique to Bühler’s five-roll refiner. That is why we built the Edition 26 on the strongest possible foundation, adding value where customers feel it most: easier operation, greater reliability, higher energy efficiency, optimized maintenance, and better hygiene,” says Skeljzen Nesimi, Head of Product Management, Chocolate & Flavor Creation, Bühler. 

With cocoa price volatility and supply shortages, getting the most out of every cocoa bean is not just a slogan – it is a direct lever on profitability. Working closely with customers, Bühler engineers took a whole-process view to pinpoint where performance can be improved. To deliver gains, such as greater reliability, higher energy efficiency, and optimized maintenance, Bühler harnesses the full potential of digital solutions. “Our sensor technology monitors the refining process and automatically fine-tunes roll speed, pressure, and temperature – all without manual intervention and independent of operator skills. This real-time optimization ensures consistent fineness, increases throughput, and reduces waste,” says Skeljzen Nesimi. A stable and consistent fineness prevents costly fat overdosing in the conche, saving significant production costs.
 
“In a 24/7 production environment, even small adjustments matter. Our new energy-efficient IE5 motors cut energy consumption by up to 3%. A more hygienic design strengthens food safety and improves access for cleaning, as well as reducing downtime,” says Skeljzen Nesimi. Uptime is further boosted through simplified maintenance and advanced diagnostics.   

Consistent, repeatable results

Conching gives chocolate manufacturers precise control over flavor development, mouthfeel, and flow behavior. Bühler’s ELK S Edition 26 single-shaft conche creates the desired chocolate flavor while reliably removing unwanted volatiles and moisture, delivering consistent, repeatable results. The ELK S Edition 26 focuses on simplified operation, energy efficiency, hygienic design, and improved accessibility. 

“We have redesigned multiple components on the machine, to make it even easier to operate and maintain. Besides the completely new automation system, we have adapted the machine frame and design for higher hygiene and better maintenance. New IE5 drives and food-grade materials also enable higher efficiency and safer production,” says Skeljzen Nesimi. The proven technology of conching – featuring specially designed ELK conching tools – remains unchanged, enabling intense shearing and high fat release for a perfect mouthfeel and taste. These tools, combined with the conching control, can reduce energy consumption by up to 30% and increase throughput without compromising taste and quality. In addition, fat savings of up to 2% are achievable due to enhanced shearing and improved fat release. 

A new era of automation

The full system upgrade was developed around Bühler’s Playone automation system, included as a standard component. The Finer S and ELK S Edition 26 automation systems deliver a wide range of benefits, from improved user-friendliness and advanced automation features to remote monitoring and control. 

“Our new automation system, powered by Bühler’s Playone, frees operators to focus on higher-value tasks such as quality control. With its web-based design, it can be accessed via any authorized factory device, such as tablet, desktop, or smartphone, adding flexibility to the production setup,” says Skeljzen Nesimi. With such a high level of digitalization and automation features, customers benefit from simpler operation, faster onboarding, and higher process transparency .

Excellence from bean to bar

Going beyond chocolate mass processing, Bühler supports customers across the entire value chain – from cocoa processing to final product moulding – delivering equipment, complete plants, and deep process expertise. Through its global network of research and training centers, customers can develop recipes, test technologies, and validate processes under real production conditions.