When Hotel Chocolat set out to create the Velvetiser, they didn’t just want to make another mediocre kitchen gadget – they aimed to redefine the hot chocolate experience.
With its promise of silky, barista-grade beverages, the Velvetiser has become a must-have for chocolate lovers everywhere. But what people might not know is that behind this iconic product lies a remarkable story of innovation and collaboration.
To turn their vision into reality, Hotel Chocolat required a method to create the premium chocolate flakes that define the Velvetiser’s luxurious experience.
Enter Premier Forrester, a company renowned for tackling complex engineering challenges. Together, they crafted a bespoke chocolate production system that not only transformed the Velvetiser’s development but also set new standards in efficiency and scalability.
The Early Hurdles
Creating the perfect chocolate flakes wasn’t as simple as it might sound. Initially, Hotel Chocolat tried flaking large chocolate blocks using an industrial cheese grater.
This hands-on method was time-consuming and could only produce a limited volume, holding back their plans to scale up.
Their next attempt involved an automated vegetable grater, which sped things up but introduced new problems. While automated, the system struggled to keep up with demand and strained production capacity, leaving them in need of a breakthrough.
The turning point came when Hotel Chocolat identified a specialised machine that could produce the desired flakes. However, they still faced a challenge: how to consistently mix and deliver chocolate to the machine at scale, without disrupting other production lines.
The Breakthrough Moment: Premier Forrester’s Expertise
To solve this problem, Premier Forrester brought in their engineering expertise. Mike Gee, their director, looked beyond traditional chocolate-making methods and tapped into technologies used in ice cream and mayonnaise production.
The game-changer was a high-shear vacuum mixer, sourced from Limitech, a leader in precision mixing systems. Unlike conventional systems, this mixer could combine Hotel Chocolat’s proprietary powders and melted chocolate, producing a perfect mixture every time.
But it wasn’t just about mixing; Premier Forrester also designed a fully automated recipe control system to manage multiple chocolate streams. This innovation gave Hotel Chocolat the flexibility and consistency they needed to meet growing demand without sacrificing quality.
A Sweet Success Story
The impact of this collaboration was transformative. The new production system exceeded all expectations, enabling Hotel Chocolat to scale their Velvetiser operation with remarkable efficiency.
Key Results:
- Production Efficiency: Output leapt from a modest 10 kilograms per hour to a 600 kilograms per hour.
- Fast Implementation: The entire system was designed, tested, and installed within just 12 months.
- Streamlined Operations: What once required 5–10 operators could now be managed by a single person, freeing up resources for other areas of the business.
Redefining Hot Chocolate
The Velvetiser is now one of Hotel Chocolat’s most beloved products, but its success isn’t just about innovation in the kitchen – it’s a testament to the power of collaboration and creative problem-solving.
Premier Forrester’s ability to think outside the box, embrace cutting-edge technologies, and tailor solutions to unique challenges played a vital role in the Velvetiser’s rise to fame.
Got a production challenge to solve? Let Premier Forrester help you turn your vision into a success story. Contact us today.
