Global cocoa processing on the rise: Bühler and Appenzell at the center of a new wave

Technology company Bühler is currently experiencing a welcome countertrend to the otherwise tense situation in the industry, particularly at its production site in Appenzell. In view of rising global cocoa prices and the increasing focus on resilient supply chains, the cocoa industry is embarking on a remarkable new wave of investment. Governments and companies worldwide, especially in cocoa-producing countries, are increasingly relying on local cocoa processing to secure value creation in their countries, reduce transport costs, and strengthen local economic cycles. They are investing strategically – not only in capacity, but also in quality and yield. In this rapidly changing environment, Bühler has consolidated its reputation as a trusted partner for efficient, sustainable, and future-proof solutions in cocoa processing. A key advantage of Bühler is its strong presence in cocoa-growing regions, which means that the systems can be maintained on site by service specialists.

Overcoming challenges: adding value at the point of origin

Cocoa prices have been at record levels for around two years and are likely to remain high in the medium term. This is due to poor harvests caused by extreme weather conditions and disease outbreaks in key producing countries. Added to this is the structural constraint that cocoa trees only grow in certain climate zones and take up to five years to bear fruit. For these reasons, and in view of the price trend for cocoa, there is a significantly greater incentive to expand processing capacities in the countries where it is grown. Investors and cocoa processing companies are turning to Bühler not only for state-of-the-art process technology that ensures maximum yield of this expensive commodity with the highest efficiency. An equally important factor is that Bühler can support its customers locally with the best service and offers customized training and development opportunities for customer technicians at their plants. The combination of these advantages has led to a significant increase in investment in new processing plants over the last few months, which in turn has triggered a wave of orders for Bühler. "In challenging times, our customers rely on quality and efficiency, as well as on local support and service. Our commitment to innovation and partnership-based collaboration worldwide gives our customers security and confidence. That's why Bühler is the obvious choice," says Stefan Scheiber, CEO of the Bühler Group.

Bühler solutions: Local proximity, global expertise

Bühler's strength lies in combining state-of-the-art cocoa technology with a regional presence on site. This holistic approach goes far beyond machine engineering and the installation of solutions. Throughout Africa, especially West Africa – the heart of the global cocoa industry – Bühler works directly with its customers, providing on-site support, building long-term relationships, and contributing broad expertise. The Bühler Cocoa Innovation and Competence Center in Abidjan, Ivory Coast, enables customers to develop skills and expertise tailored to their local context. This is complemented by the ongoing support of the Bühler Flavor Creation business unit with its engineering and testing facilities in Uzwil – a unique combination that builds trust and ensures success in the market.

Swiss quality from Appenzell makes the difference

The Bühler production site in Appenzell is playing a central role in this wave of orders for cocoa processing equipment. Appenzell is where engineering, manufacturing technology, and the highest quality standards come together. All key components for Bühler's cocoa processing lines have been manufactured in Appenzell for three years. Firmly rooted in Appenzell, Bühler has continuously invested in innovation, training, and the latest manufacturing technology at this site. This has enabled the most sophisticated machines and components from the Swiss foothills of the Alps to find their way into cocoa processing plants around the world.

The Bühler plant in Appenzell manufactures and assembles machines that use infrared technology to pre-treat cocoa beans before they are broken and hulled. The resulting cocoa nibs are then roasted. The roasters and coolers required for this process are also manufactured in Appenzell. Roasting is an essential step in the process. Not only does it allow the intense flavor and full aroma of the cocoa bean to develop, it also ensures that the beans are efficiently processed into semi-finished products such as cocoa butter and cocoa mass, which are essential for the production of chocolate. Teamwork, the highest quality standards, and a commitment to performance play a decisive role in the manufacture and assembly of cutting-edge technology in the field of cocoa processing. “Working with the team in Appenzell is characterized by a professional and friendly relationship at all levels. Transparency, openness, and a winning spirit are what set the team apart,” says Stefan Kellenberger, Managing Director Chocolate & Coffee at Bühler. “Challenges and problems are clearly identified so that we can work together to find a solution. The team in Appenzell lives by the motto ‘One team – one Bühler,’” Kellenberger continues.

Investing in the future: training the next generation

Appenzell is more than just a production site – it is where the future of the industry is being shaped. The Appenzell Bühler team comprises around 100 employees, most of whom come from the region. The focus is on plant and equipment engineering, polymechanics, assembly, and automation. Vocational training is very important at Bühler: 21 young men and women are currently being trained at the Appenzell plant. Bühler's strong training program provides young people with advanced technical skills while promoting social skills and creativity. Participation and success in national and international championships underscore the company's strong commitment to supporting and challenging the next generation. Once again, this year, four apprentices from Bühler Appenzell qualified for SwissSkills in September. Alina Friedrich and Lukas Fritsche will compete in the plant and equipment engineering EFZ profession, while Nicola Fässler and Loris Muff will give their best in the welding discipline.

Bringing value creation back home

Bühler's solutions for cocoa processing set global standards. In Uganda, for example, the country's first industrial cocoa processing plant is being built in partnership with Bühler. A trading company is being transformed into a fully-fledged cocoa processor with a tailor-made solution – a family business that focuses on long-term partnerships and local value creation and will produce cocoa mass, butter, and powder directly on site in the future.

Another example is a leading chocolate manufacturer in Greece, which has modernized and consolidated its production with Bühler. By integrating cocoa processing on site, the customer now controls the entire value chain – from bean to chocolate bar – and benefits from increased product quality and efficiency thanks to Bühler's modernization expertise. With Bühler's customized solution, the customer can deliver unique end products and thus differentiate itself.

A reliable partner in challenging times

While global demand for local cocoa processing is growing, Bühler's solutions – with Swiss know-how and expertise from Appenzell – enable customers to efficiently manufacture high-quality products. In a market characterized by volatility and often uncertainty, Bühler is establishing itself as a reliable partner for customers around the world.