Blueprint (Design of Factory) of

Cadbury Plant
We take Mondelez International Cadbury Plant at Sri City. Andhra Pradesh largest Asia-
Pacific manufacturing facility.

Cadbury Plant in Sri City, Andhra Pradesh

Inside Mondelez’s best performing Indian Factory, half of the staff are women

PROCESS DESIGN

The process followed at Cadbury India is categorized under line flow. The company can
come under make to order because it produces goods, which have a day-to-day basis
demand. So, it comes under make to stock and maintains some amount of inventory but not
a larger amount because its goods are perishable and have a certain expiry date.

Cadbury has a product portfolio, which includes chocolates, beverages, biscuits, candies
and gums. Its major production of chocolates undergoes a long process, which starts with
the cocoa bean. It is the heart of the sweetest delicacy in the world, which is actually bitter.
During the 18th Century, people only used to eat the sweetish flesh of the cocoa fruit. It has
also been used as a form of currency. There are two basic types of cocoa named Criollo and
Forastero cocoas. The seeds of the Criollo cocoa are of finer quality and are thus used in
high quality chocolates whereas 90% of the world crop accounts for Forastero cocoa.

The basic process of chocolate making at Cadbury India: -

1. Harvesting:
 Firstly, the cocoa beans after harvesting, is treated to prevent the beans from rotting.
The fruit is opened at fermentation sites or at any of the collecting points.

2. Fermentation:

The technique for the fermentation process depends on region to region and is thus
decisive regarding the production of high-quality raw cocoa.

3. Drying:

The cocoa beans are still not dry enough and contain about 60% water in them. In
order to soak this water, the beans are spread out on the ground or on mats under
the sun.

4. Cleaning:

After the beans are dry enough, they are thoroughly cleaned through sieves and also
by brushing Further, with the help of powerful vacuum equipment, the last vestiges of
wood, sand and the finest due is extracted.

5. Roasting:

This entire process is carried out automatically during which the temperature
reaches 130°C in the 10 feet high furnaces. The roasting process is performed to
develop the aroma.

6. Crushing and shelling:

With help of the crushing machine, the roasted beans are broken into medium sized
pieces.

7. Blending:

In order to process special recipes, the crushed beans are weighed and blended.
This is a secret of every chocolate factory that how the different types of cocoa are
mixed and in particularly what ratio.

8. Grinding:

Grinding is basically done to develop the cocoa paste. The crushed cocoa beans are
brought onto rollers where they are processed into a fine paste. This paste is a
resultant of the heat generated and the friction which causes the cocoa butter in the
beans to melt giving out the liquid mixture. The production process at this point is
divided into two ways which meet soon after they are done with their respective
paths. One way, a part of the cocoa paste is taken to large presses in order to extract
the cocoa butter while the other way, the other part of the paste is blended and
refined during which some butter is added to the mixture.

9. Cocoa butter:
 Cocoa butter is an essential ingredient for chocolates because it is not only a part of
every recipe but it also gives chocolates its fine structure beautiful shine and delicate,
gorgeous glaze.

10. Cocoa powder:

After the butter is extracted from the paste through large presses, cocoa cakes are
left which contain about 10-20% proportion of fat which further depends on the
intensity of compression. These cakes are mashed again and properly sifted in
several stages which results into cocoa powder. A dark and very strong aromatic
powder which can be used for preparation of excellent and delicious drinks known as
cocoa. The four basic ingredients for making chocolate are cocoa paste, cocoa
butter, sugar and milk. Using these ingredients and blending them according to the
recipe to be prepared, three types of chocolate can be obtained which form the basis
of ever product assortment.
These are: -

 Kneading

 Rolling

 Conching

Manufacturing Process
The above is the entire manufacturing process followed at Cadbury India for its various
differentiated chocolates. It shows the in-house activities of Cadbury till the dispatch.

Plant Layout

Plant layout refers to arrangement of physical facilities like machines, equipment’s, tool etc.
in such a way that to have quickest flow of raw material at the lowest possible cost and with
the least amount in processing of the product.

Cadbury follow combination layout, combination of line layout and process layout. Till time
the chocolate mass is made company follow line layout.

Step 1: First Cocoa beans are transferred to roasting and winnowing machines.

Step 2: transferred to grinding machine.

Step 3: blending of cocoa liquor takes place.

Now the process layout starts where different types of chocolate is made according to their
distinct flavor and variation.

Different add on materials are mixed with final liquid chocolate to give variation. For
example:

rice crackles are added to liquid chocolate to manufacture dairy milk crackle.