For an industrial chocolate manufacturer in Auckland, Dutch Automation & Technologies was engaged to bring a mechanically refurbished MacIntyre 5T refiner conche back into full production.

The machine was sourced second-hand and mechanically overhauled by a third party. The original control system was no longer usable. Dutch Automation & Technologies delivered a complete new Siemens-based automation platform, from control cabinet design through to commissioning and process optimisation.

Scope of Work

We delivered a full electrical and automation rebuild:

Design and build of a new Siemens-based control cabinet
PLC software development (TIA Portal environment)
HMI development for full operator control
Integration of drives, motors, and process instrumentation
Electrical installation and field wiring
Commissioning of refining and conching process
Control System Architecture (Siemens)

The system was engineered around a robust Siemens platform, ensuring reliability, scalability, and serviceability.

PLC & Software Structure

Modular PLC program separating:
Refining phase
Conching phase
Utility systems
Step-based sequencing for controlled operation
Manual / Auto modes for flexibility
Structured alarm handling with clear diagnostics

HMI

Process overview with live feedback
Dedicated control for refining and conching stages
Operator-adjustable parameters (time, speed, temperature)
Fault indication with actionable messages
Drives & Mechanical Control

The conching process is driven by controlled mechanical energy. The system includes:

110 kW main motor for conching operation
Variable speed control for stable energy input
Controlled ramp-up/down to prevent mechanical stress
Load-aware operation to maintain process consistency
Temperature Control (Dual Loop)

Accurate temperature control is critical in both refining and conching.

We implemented two independent PID control loops:

Water temperature control
Regulates the thermal medium
Ensures stable heat transfer
Product temperature control
Direct feedback from the chocolate mass
Fine-tuned to maintain optimal process conditions

This dual-loop approach ensures consistent product quality and prevents overheating or instability.

Mechanical Automation

To support both refining and conching functionality, the system includes:

Automatic tightening and loosening of internal blades
Controlled via PLC sequences
Ensures correct pressure during refining
Enables transition to conching mode

This functionality is critical to switch between process phases safely and consistently.

Challenges & Engineering Approach

Refurbished refiner conches typically come without reliable electrical data and with unknown mechanical tolerances.

Our approach:

Reverse-engineer the machine’s functional behaviour
Develop a clean Siemens-based control philosophy from scratch
Integrate mechanical functionality into structured automation
Ensure full transparency for operators and maintenance teams
Result

The MacIntyre 5T refiner conche is now operating on a modern Siemens control platform, delivering:

Stable and repeatable refining and conching performance
Precise temperature control via dual PID loops
Controlled mechanical operation with reduced wear
Full operator control and visibility
What This Means for Our Clients

This project demonstrates how Dutch Automation & Technologies converts refurbished machinery into high-performance production assets:

Siemens-based control upgrades for legacy systems
Full integration of mechanical and process functionality
Practical, robust automation built for real-world operation
Systems that operators understand and engineers can maintain

Whether it’s a refiner conche, a production line, or standalone equipment — we design, build, and commission systems that perform.