Premium Chocolatier's

Helping a high-end chocolate brand stop shelling out on waste and increase output

The Challenge

On paper, the line was producing 800,000 artisan chocolates per month .In practice? Steel moulds cracked, jammed, and seized  taking 64,000 units with them. 

Operators were stuck in a loop: scrape, clear, sort.532 hours lost. Quality flagged. Returns increased and buyers signalled 

The product wasn’t the problem. The tooling was.

Our Solution

We replaced the rigid steel tooling with food-grade, high-flex silicone moulds that release perfectly formed shells without force.

The new moulds slashed scrap from 8 % → 3 % (reclaiming 40 000 pcs/month), eliminated manual jam prying, and enabled a rapid clean-in-place cycle, transforming stop-start production into continuous, high-yield throughput.

The Bottom Line

Total Savings: ~£75980

In just one month the TCI Culinary collaboration cut waste from 64 000 to 24 000 units, freeing up 40 000 extra saleable chocolates. Ingredient loss savings of £20 000, combined with a 532 hour reduction in labour (worth about £7 980), and a 120 000-unit boost in output delivering an additional £48 000 profit, generated total direct benefits of £75 980, all with no loss of production volume.