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Report - Production Planner 2012
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REPORT ON: TRAINING PROGRAM FOR PRODUCTION PLANNER
SUBMITTED TO: OPERATIONS MANAGER
BARRY CALLEBAUT GHANA LIMITED
FREE ZONE ENCLAVE – TEMA
SUBMITTED BY: ADANUTTY TEFE RICHARD
DATED: THIS TUESDAY, DECEMBER 04, 2012

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Objective:- The objective of this program is to develop a familiarization with general operation of
Barry Callebaut Ghana Limited.
Scope:- Explore various levels of production operation from raw materials reception to final
delivery of finished products.
Limitations:- Due to time factor, planned visits to both Maintenance Planner and Automation
Engineer for necessary training could not be achieved. However, schedules with Q/A
was initiated but could not be completed for the same reason as described above
Throughout the program, emphasis was laid on demonstrated understanding of
principles and workings of equipment, and system appreciation without the necessary
technical or theoretical rigour.
The report is therefore cursory and a direct result of Q&A’s without reference to any
technical material(s)/documentation(s) in place. Where applicable, figures and
deductions made should be considered arbitrary as they may not truly reflect the real
physical process thereof.
Overview:- Barry Callebaut Ghana Limited (BCG) is a subsidiary of Barry Callebaut International, with
specialization in Natural Cocoa Liquor and Cocoa Nibs. BCG boasts of two production
lines namely, Barth and Buhler. Since 100 percent of BCG’s final products are directly for
the export market, consistency with product quality and safety is a sine qua non.
Hence, the practice remains that every necessary effort is sacrificed to meet
specifications and deadlines.
Professionalism, team work, passion and integrity become the hallmark in ensuring/
meeting these values at Barry.
1.0 Quality Assurance
1.1 QMS/BRC
To BCG, quality means meeting customer inherent specifications. Safety, on the other hand
refers to producing safe food for human consumption without any associated health
hazards.
Barry no longer operates with the ISO system of quality; instead it runs the BRC (British
Retail Consortium) system.
1.2 GMP
Rules on GMP include, but not limited to:
 Exclusion of jewelry (including engagement rings) from the factory premises.
 Use of pens otherwise single-unit and metal detectable ones are forbidden inside
the factory.
 It is further forbidden to carry cell phones to the production lines.

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1.3 Hygiene
Hygiene rules MUST be adhered to without compromise. There are only two approved
entry points to the production floor. These are equipped with checks and mechanisms to
rid of possible contaminants. The following include some hygiene practices:
 People working in the white zones cannot cross into the red zones unless they
effect a change from white clothing to brown.
 It is forbidden to shake hands in the production area.
 Use of scented body perfumes by production staff is not allowed.
1.4 QA
There are well documented procedures and standards that must be followed when
carrying out tasks. Strict adherence is required for the purpose of control and possible
reviews.
2.0 Bean Reception and Processing
2.1 Dumping
The first stage of the production process begins where raw beans are received and
dumped (25tons per each delivery) into a pit within 45 minutes. These are screw-conveyed
and bucket-elevated through a strainer (to trap strings, etc.), then through a cleaner to rid
of other light materials such as dust and organic debris by aspiration into cyclones. The
bean is then transferred into the appropriate silo (Barth/Buhler), according to the bean
delivery plan.
Observations:-
 Bean sorting documentations inappropriate as figures lack coherence.
 Waste recording not regular.
 Waste figures are not actually weighed but estimated because personnel (through
experience) assume range values.
 Opening under the Barth silo cause spillage of beans.
Recommendation:-
 Bean sorting operatives trained and well supervised.
 Personnel responsible should empty and actually weigh waste from silos at approved
intervals.
 Welding, instead of adhesive glue to seal opening against bean spillage.

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Bean from Silo (130T)
3.0 Bean Processing – Barth and Buhler Lines
3.1 Barth Line
Bean processing using the Barth line follows the skematic:
3.1.1 Magnetic Separator
This separator isolates ferrous materials from the beans by magnetism.
3.1.2 Weighing Scale
The scale measures the quantity of beans processed within a particular duration. This,
however, is mal-functioning presently.
3.1.3 De-stoner
Further cleaning takes place in here where stones, by virtue of their relatively higher
mass fall out into a collection bin against an aspiration; and beans move along an
inclination, up a bucket elevator into the optimizer.
3.1.4 Optimizer
The optimizer, serving both as a pre-warmer and a hopper receives the beans from the
destoner. Beans in the optimizer is pre-warmed by air at about 30-60oC before delivery
into the Infra-red (IR) machine.
Magnetic
Separator
Weighing
Scale
Destoner Optimizer
Infra-red
m/c
Spark
Arrestor
Crusher Winnower

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3.1.5 The IR
Heating supplied by burning liquefied petroleum gas at about 110oC completes the
heating process in the IR. Simultaneously, H2O is sprayed during this heating process to
enable the beans to “pop-out” or become swelled –up. This stage is vital for effective
crushing and the subsequent performance of the winnower. Any flames resulting from
the naked fire introduced in the IR is stopped by the spark arrestor.
3.1.6 Crusher and Winnower
A short cylindrical drum with a conical base makes the crusher cross-section. The
swelled beans are thrown against the walls thus crushing them before entry into the
winnower. The winnower, consisting of five chambers of varying mesh/sieve
dimensions slopes down a gradient. This coupled with a vibrating mechanism and
density cause separation of the shells from the cocoa nibs. The shells are thus aspirated
through channels and collected into cyclones, where the nibs get transferred into
hoppers for roasting.
3.2 Buhler Line
The skematic below describes bean processing on the Buhler line:
3.2.1 MS/WS/DES
These function as in Barth above.
3.2.2 Roaster
The roaster employs countercurrent flow of air at about 142oC in three different
chambers called Zones to effect roasting of beans. It processes beans at a rate of about
4.4ton/hour. The roasting gives peculiar taste and aroma to the beans.
Bean from Silo (150T)
Magnetic
Separator
Weighing
Scale
Destoner Roaster Debacterizer
Crusher Winnower

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3.2.3 Debacterizer
The batch hopper delivers roasted beans at a rate of 100-120kg per cycle into the
reactor. Here, microscopic organisms are killed by introducing steam at high
temperature and pressure (4.0bar) for 4 sec.
3.3 Differences Between Barth and Buhler
Barth Buhler
1. Not a continuous flow process Continuous flow process
2. Nibs are roasted Beans instead of nibs roasted
3. Winnower/Roaster part of red/white zone respectively Winnower at white and roaster
red zone
4. Uses gas as source of heat for roasting Uses steam
5. Various qualities such as 522, 523, 552, 516, 518, etc. can be
roasted
Only 502 and 525 recipes roasted
Observations:-
 Frequent stoppages due to product-build-up alarm on Buhler.
 Lots of overflows from chamber 1 - Barth.
 Faulty weighing scales (Barth and Buhler).
 Barth, unlike Buhler had faulty/ineffective aspiration at destoner, as about 80% beans
instead of stones are collected.
Recommendations:-
 Consider an idle situation where batch hopper (BH) delivers about 45 batches per hour:
(ref. table 1.0).
Table 1.0
Deductions:-
 If roaster throughput is 4.4t/h, then BH’s discharge per cycle ≤ 100kg.
 If therefore product build-up alarm at BH occurs, then roaster throughput ˃˃˃ 4.4t/h; or
chain conveyor speed (flow rate) into BH lacks required synchronization.
 Over- flow needs to be checked – ineffective performance of IR/crusher, say.
BH discharge (kg) Throughput(Mt/h)
100 4.5
110 4.95
120 5.40

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 Restoration of weighing scales for more control.
 Barth destoner aspiration needs fine-tuning.
3.4 Winnower Analysis
The performance of the winnower is assessed by carrying out analyses, namely:
1. Nibs in shells
2. Shells in nibs
Only shells in nibs is considered here:
About 3.0kg of product was sampled from winnower outlet at the red zone. Documented
procedure for analysis was followed and the following results obtained below:
Chamber Nib(g) Shells(g)
1 0.31 0.00
2 15.28 0.84
3 29.47 0.52
4 45.82 0.56
5 6.73 0.47
Total 97.61 2.39
Table 2.0
The result, shells (2.39%) ˂ 3.0% was considered ok.
3.5 Roasting
As stated earlier, Buhler roasts beans and Barth nibs.
3.5.1 Roasting – Buhler
A Buhler -roasted bean produces only one quality as it is continuous. This quality may be
defined to be 502 or 525, depending on the specific customer. You may therefore have a
502 nib/liquor or 525 nib only (525-quality of liquor not available)!
3.5.2 Roasting – Barth
Unlike Buhler, different grades of recipes/qualities are available on the Barth line. Some
of these include: 516, 518,522, 523, G3, CMC, etc. It is mainly here that sterilization of nibs
take place on the Barth line.
Below is table 3.0 showing some roasting details on the Barth line.
Quality Code Max. Ster. Temp. (°C) Water (l) Holding Time (min.)
MED. {
522 125 90/30 10
523 125 90/30 10
524 125 90/30 10
G3 516 123 150/0 5

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CMC 518 123 90/30 2
CAD 552 125 90/30 2
Table 3.0
3.6 Cooling
Cooling process takes place after roasting. The cooled product is then sent to either nibs
packaging for bagging into sizes including 1300, 1100, 575kg etc.; or the grinding/refining
line for slabs of liquor.
3.7 Grinding and Refining
Where the nibs are meant for liquor instead of nibs bagging, grinding is required. There are
two grinding hoppers (H110 and H111). These serve the grinder with nibs at a rate of about
3.5t/h. The grinder initiates the fineness specification to about 8.0%. Further reduction is
achieved in the three attritors arranged in series, and a vibrating sieve; - this way, a
fineness specification as low as 0.4% can be achieved.
During the grinding and refining process, the liquor is sampled from storage tanks (such as
T11, T12, and T13) for moisture, free fatty acids and fat analyses. Details of how these
analyses are carried out are beyond the scope of this write-up. However, a specification
such as, NCL–2C516–737 interprets thus:
NCL – Natural Cocoa Liquor
2C – Degree of fineness (1.5%)
3C – 0.5 or 0.75% fineness
4C – 0.4% fineness
516 – Quality (G3)
737 – Packaging size (1ton)
Other packaging sizes such as 709/708 for 1.05/0.84ton respectively are also available.
The fat specs are defined per a particular customer. So that NCL-2C516-737 may have a fat
spec of say 54% for customer “A” or 52% for “B”. Where a certain quality (liquor) is out of
specification (OOS) on fat, it is usually dosed with butter (cocoa) until the desired quality is
achieved; hitherto, the said product is “Downgraded”. Downgrading here means that, the
product’s original ID is replaced with a different one and the fat spec also altered
accordingly. As an example, consider a product spec such as:
NCL-2C502-737 (53.5% Fat) may be downgraded to NCL-2C542-737 (52.0% Fat). Thus there is
a reduction to 52.0% fat of 502 quality, to 542 quality with the same 1.5% fineness and 1.0
ton packaging size.

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3.7.1 Liquor Moulding
From T11, T12, or T13 the liquor is transferred into T14 for moulding. Temperature becomes
a critical variable here. Maximum inlet temperature of liquor to T14 is about 45°C. This is
achieved with skids in-between the grinder and the storage tanks; and between the
storage tanks and T14.
In order to prevent melting of the moulded liquor on transit, tempering is done to effect
recrystallization of the liquor. Three heat exchanger zones in the tempering machine
ensure the correct temperatures are met before moulding and subsequent solidification
through about 20-metre length of cooling tunnel. A temper meter is available to test for
idle temper-index in the range of 3.0 – 6.0.
3.8 Product Packaging/Labeling
Packaging sizes such as 1.0ton (30 x 33.33kg), 1.05ton (35 x 30kg) and 0.84ton (28 x 30kg)
are available for liquor; whereas 1.3, 1.1, 0.575, etc. are available for nibs.
Labeling is done for traceability purposes. This includes the lot number, production date,
date of expiry, etc. The table below shows some labels with their respective descriptions:
Lot no. Year Day of Prod. Origin (7) Product Prod. Line Lot qty.
122177101 12 217 BC Ghana Liquor Barth 1st
120437203 12 43 BC Ghana Liquor Buhler 3rd
121207106 12 120 BC Ghana Nib Barth 6th
120057205 12 57 BC Ghana Nib Buhler 5th
Table 4.0
3.9 Critical Control Points
In order to ensure the safety of the final products certain checks and mechanisms have
been identified at specific sections along the length 0f the production lines to address
particular potential threats/hazards to human health. These mechanisms are better called
here Critical Control Points (CCPs). There are about four (4) such points identified during
the entire training programme, and these include:

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a) Roaster Trend/Debacterization
A graph of temperature (ordinate) against time (abscissae) during the roasting process
must follow a particular trend. Any deviations from this curve may result in a
quarantined FP. As mentioned earlier, debacterization uses steam at high temperature
and pressure to kill all microscopic organisms that have the potential of endangering
human health.
b) Particle Detector
There are particle detectors in the twin hoppers at nibs packaging. Foreign materials
are therefore identified and isolated before bagging the nibs.
c) Vibrating Sieve
A vibrating sieve placed just after the attritors allow only the passage of refined liquor.
All other materials that may constitute foreign bodies are eliminated or sieved out as
residue.
d) Magnetic Port 16
This is situated between T14 and tempering machine. Ferrous materials are isolated by
magnetism.
3.10 Warehouse
Cocoa bean is the main raw material for BC Ghana. The warehousing of this is contracted to
an external agency called Sitos Ghana Limited. Packaging materials and finished products
are however stored in-house. The materials are issued to production when required using a
requisition note. There were few instances observed however when production operatives
issued some packaging materials to themselves in the absence of the stores keeper.
Whereas this may be convenient, the principle of monitoring /control is sacrificed. The
likely result would be reconciliation difficulties that may be suffered especially at the close
of the month. That the said materials will be covered later with a requisition by the
Production Planner leaves much to be desired because of possible forgetfulness.
Recommendations:-
 At least the presence of the stores keeper (or representative) should be available when
issuing such stock from warehouse (WRH).

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 Requisition should be made in advance before effecting delivery to production.
 Both Planner and Stores keeper (or their reps.) must verify and reconcile quantities
requested and delivered.
 Perhaps, in the future, a more effective and efficient production records and stock
control management tool such as the HANSA WORLD could be installed to completely
eliminate the existing clerical and rigorous excel computations both by the Planner and
the Stores keeper(and , if required, extended to FP handling, supply chain, logistics,
accounts/finance, etc.).
4.0Measurement
The operation of BC Ghana largely rests on automation. As the result, correct
functioning/performance of plant and equipment is always ensured when the reliability of
process trendsas translated by measuring /monitoring devices is appreciably good enough.
Unfortunately, some of these equipment are either not working at all or lacks the proper
calibration. For example, the WS on both lines had been identified to be dysfunctional. The
second is the silo level sensors for both Barth and Buhler. In fact, getting accurate and
reliable figures for stock reconciliation purposes largely depend on some of these. Below is
an alternative method for determining silo level readings for both silos:
4.1 The Silo Meter
The objective here is to offer a more accurate and reliable measurement of beans in
the silo, as errors due to inaccuracies may be costly when incurred.
Principle
A laser distance measuring tool or electronic tape measure utilizes a laser to
accurately measure the distance from one point to another. The laser is simply
pointed at the object you want to measure the distance to, and the laser measuring
device will display the distance accurately and quickly.
The silo level is a function of height, so that provided this height is accurately known,
there is no ambiguity about the result of its level. Errors from current method of
estimation are avoided, and the true states of processes are computed.
In fact, a laser measuring device such as Fluke 411D (with 100ft. accuracy) is only a
little over USD 100. The height of the Buhler Silo above the three pyramidal chambers
is less than 38ft. A 100ft accuracy or a little less will therefore be worth considering.

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PROCEDURE
1. Direct beam perpendicularly to base of silo at point A (i.e. bean top level).
2. Check and record reading (d1).
3. Direct beam perpendicularly to base of silo at point B (i.e. bean bottom level).
4. Check and record reading (d2).
5. Count and record number of visible graduations from point X to point A.
6. Compute silo reading using template below (ref. excel 1.0)
Assumptions:
1. Level is always above point B.
2. Bean slope profile is linear.
3. Five marks for Barth Silo along 100t volume from point B.
4. Ten marks for Buhler Silo along 126t volume from point B.
5. The six tons (6t) volume at the top ignored for consistency.
Limitations:
1. d2-d1 ≤ 1.85 - distance b/n successive marks (Barth).
2. d2-d1 ≤ 0.87 - distance b/n successive marks (Buhler).

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9.25 11.5
Barth Buhler
130.00 150.00
Height (above "B") m
Top Level (d1)
Bottom Level (d2)
No. of Strands (n)
Silo Level (Mt)
Excel 1.0
4.2 The Rework Tank Problem
On September 10, 2012 Master Kodwo Apaa Bentil (Acting Production Planner) found out
that the liquor for rework had all been melted over the weekend. He had no records of the
weight of the slabs. He must get the weight to complete a weekly report. The problem was
to determine the weight of the melted liquor in the tank given that the tank was originally
empty. Luckily enough, a Supervisor who ordered the said melting took records of the
weights. Thanks Kodwo can breathe a sigh of relief. If, however, things had failed…,
consider an analytic solution of the problem below:
Aq = ∫ √(𝑟2
−
𝑥
0
𝑥2
)𝑑𝑥
If 𝑥 = 𝑟 sin 𝜑; 𝑑𝑥 = 𝑟 cos 𝜑 𝑑𝜑
=
𝑟2
2
∫(1 + cos2 𝜑) 𝑑𝜑 =
𝑟2
2
| 𝜑 + sin 𝜑 cos 𝜑|, within appropriate limits.
From the geometry of the figure, sin 𝜑 =
𝑥
𝑟
; cos 𝜑 =
1
𝑟
√(𝑟2 − 𝑥2
); and 𝑥 = √(2𝑟𝑑 − 𝑑2
)
If the level (d) of liquor is determined by direct
measurement, the volume (Vs) of shaded region is
defined for the horizontal cylindrical tank of radius (r)
and length (l).
Now, the shaded area (As) = 2Aqs
Aqs = shaded area in 1st quad.
If Aq = area KLNM, then,

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» Aq =
𝑟2
2
⃓ sin−1 𝑥
𝑟
+
𝑥
𝑟2 √(𝑟2
− 𝑥2
)⃓- within appropriate limits.
=
𝑟2
2
[sin−1
(𝑝/𝑟) +
𝑝
𝑟2 (𝑟 − 𝑑)], for 𝑝 = √(2𝑟𝑑 − 𝑑2)
Aqs =
𝑟2
2
[sin−1
(𝑝/𝑟) +
𝑝
𝑟2 (𝑟 − 𝑑)] − 𝑝(𝑟 − 𝑑)
Required volume (Vs) therefore becomes,
Vs = 𝑟2
𝑙 [sin−1
(
𝑝
𝑟
) −
𝑝
𝑟2 (𝑟 − 𝑑)]
For 𝑟 = 0.75m and 𝑙 = 3.0m, Vs becomes:
Vs = 1.767145868[sin−1
𝑘 −
𝑘
𝑟
(0.75 − 𝑑)] ; for k = p/r
Now, the spread sheet below (rework calculator) returns the weight of liquor by just a single data
entry of the measured level (d), in metres. Simulation was done for three (3) different times when
melting was completed in the rework tank to determine the liquor constant (𝒍 𝒄) at 75.4°C.
lc(kgm-3) 1044.7500 sample 1 sample 2 sample 3
d(m) 0.10 g 157.5900 156.4300 156.1000
p 0.37 ml 150.0000 150.0000 150.0000
k 0.50 kg 0.1576 0.1564 0.1561
π 3.14 m3 0.0002 0.0002 0.0002
weight (kg) 5380.102 lc(kgm-3) 1050.6000 1042.8667 1040.6667
SIMULATION
PROCEDURE
1. Clean and sanitize graduated measuring rule (rod).
2. Insert rod vertically into tank, making sure part of the rod gets inside liquor.
3. Note and mark level (m) of rod against neck of tank as shown below.
4. Remove rod and note level (n) of liquor up the length of the rod.
5. Clean and replace rod in position.
6. Compute the difference (d) = m – n (in meters).
7. Substitute “d” into excel sheet above to compute weight (kg) of liquor in tank.

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APPRECIATION
I know I have acted more often as a child as I constantly asked what, why and how. I may be a bit
irritating but your patience had sustained my zeal to get answers. I humbly want to use this
opportunity therefore to thank sincerely you all who have in diverse ways contributed to the
success of my training. May the Supreme Being reward the sacrifices you have made in my
favour.
It remains my earnest hope to add to what you have heartedly given me, so our collective efforts
would bring to bear the realization of the enterprise objectives of Barry-Callebaut Ghana to the
fullest, and the whole BC – Group at large.
End

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