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Mondelez International Reduces Caramel Waste With an Industrial Liquid Filter

Published 06 April 2017 | By Russell Finex

Following the installation of a Self-Cleaning Russell Eco Filter®, Russell Finex have helped Mondelez reduce product waste by 20%


Mondelez International, one of the largest manufacturers in the cookie and biscuit industry, sought to optimize their production process of one of their well-known brands at the Belgian production site. The company's factory in Herentals, Belgium has been in operation since 1960 and produces brands such as Pims, Prince, TUC and Cha-Cha. The Cha-Cha chocolate bar has been around for 50 years and is a thin crunchy wafer covered with caramel and Belgian chocolate. It is one of the most well-known chocolate bars in Belgium.

For many years the company experienced product waste with the manufacturing of this chocolate bar, and wanted to improve production efficiencies. Having already been supplied seven Russell Compact Sieves® for the check screening of flour, the company counted on Russell Finex's expertise to solve this new filtration problem.

The production process begins with baking a thin crispy wafer and coating it with caramel. The wafer is then laid to rest for 24 hours. After this stage, several wafers are pressed together, cut to size and covered with chocolate. When the wafer is covered with caramel, wafer crumbs get into the excess caramel, making it non re-usable. Hence, caramel is wasted at this point of the production process. Alex Pardon, Continuous Improvement Facilitator at Mondelez International, explains: "We sought a solution to recover the wasted caramel in order to reduce the product loss and improve the production process. We required a machine which could filter a high viscosity paste, at a high temperature in order to keep the caramel in liquid form for it to be reclaimed for reuse."

Russell Finex offered to test their industrial liquid filter Self-Cleaning Russell Eco Filter® at the Mondelez site. The results of the tests were very positive with the in-line filter keeping the high viscose caramel in a liquid state by filtering at a temperature of 35°C. In addition, a special taste test found no difference in quality between a bar with or without the reclaimed caramel and as a result Mondelez decided to install one Self-Cleaning Russell Eco Filter®.

The installation of the Self-Cleaning Russell Eco Filter® resulted in a 20% reduction in product loss and improved the waste disposal process. Pardon explains: "Before the filter was installed the product needed to be manually disposed of by employees. This routine has now become unnecessary". The filter also provided further benefits. Due to its unique self-cleaning SpiroKlene™ wiper system and replaceable stainless steel filter element, there is minimal operator involvement and no need to replace filter elements, resulting in substantial cost savings. The unit is also easy to strip down and clean, reducing production downtime

For more information about filtering caramel or on how we can help you with your unique requirements please contact us.