A brief history of some of my Product Developments and Technology Improvement
1996-2002 APT Sauro Int’l
-Installed all machinery; built all the pipelines and other connections
-Redesigned and re-built all the technological lines following my own design
-Started production using an outsourced recipe.
-First chocolate tablet, a plain milk chocolate.
-First recipe designed by me with help from a third party.
-Gold medal received for Milk Chocolate Tablet.
-Developed a truffle chocolate filling using specialized fats.
-Adapted the technological lines to be able to manufacture Truffle filled Chocolate Bars.
-Created the First Chocolate Truffle filling and a milk (white) truffle filling.
-Developed and started to produce a larger selection of truffle filled bars:
-Chocolate Truffle Bars
-Milk Truffle Bars
-Rum Truffle Bar
-Coconut Truffle Bar
-Cappuccino Truffle Bar
-Gold medal received for Chocolate Truffle Bars.
-Started the manufacturing of Hollow Chocolate Novelties for Easter and Christmas.
-Gold medal received for Chocolate Novelties.
-Development of the first Chocolate couverture used for enrobing applications:
-Various types of Enrobed biscuits,
-Enrobed wafers.
-Developed and built a belt depositing system for chocolate chips.
-Developed a Chocolate Couverture recipe (for food services market).
-Designed and implemented a system to manufacture solid inclusion tablets.
-Developed a range of chocolate tablets with inclusions:
-Chocolate tablet with Coffee,
-Chocolate tablet with Peanuts,
-Chocolate tablet with Biscuits,
-Chocolate tablet with Caramel Crunch,
-Chocolate tablet with Hazelnuts,
-Chocolate tablet with Raisins.
-Changed the packing system from paper envelope system to BOPP film and fine cardbooard packaging for the chocolate tablets.
-Developed first Compound Chocolate (for enrobing applications) using specialized CBR’s (Cocoa Butter Replacers).
-Implemented a system to use the same line to manufacture Cocoa Butter based products and CBR based products (not compatible).
-Developed a few different recipes for Ice Cream coatings (Milk and Dark) using various CBS’s and coconut oil.
-Designed a moulding head capable of depositing 3 different flavoured fillings into a single bar.
-Altered the wrapping machines to meke it more flexible being able to pack from smaller size chocolates bars to large tablet sizes..
-Prepared a new production line and the logistic for manufacturing chocolate spreads.
-Developed a range Chocolate spread recipes:
-Smooth Peanut Chocolate spread,
-Crunchy Peanut Chocolate spread,
-Hazelnut Chocolate spread.
-Gold medal received for Chocolate Spreads.
-Developed fruit truffle fillings for a small size chocolate bars:
-Strawberry Truffle chocolate,
-Cherry Truffle chocolate,
-Mint Truffle chocolate,
2005-2007 Becka’s Chocolate
-Developed and implemented the recipe and the manufacturing methods (changing the use of some older machinery) for:
-Hokey Pokey
-Mint Crunch
-Extended the Buster Bars range adding 2 more products:
-Hokey Pokey Bars
-Mint Crunch Bars
-Refreshed the design of the range.
-Extended the Rocky Road range adding 3 more products:
-Hokey Pokey Rocky Road.
-Mint Crunch Rocky Road,
-Coconut Rocky Road.
-Used a very creative way to create a non costly professional packaging variation for testing the market on the new products (without the large initial financial commitment related to packaging).
-Later on, re-vamped the design of this range.
-Developed a new range of products and made the design for the packaging (4 new products). The way the design was made resulted in decreasing the set up cost for printing by about 50% (needing only 8 printing plates instead of 16 for the whole project).
-Developed a few smaller runs products aiming for a dedicated market.
2007-2014 Nyco Chocolates
-Worked on the improvement of manufacturing process for ice cream inclusions. The productivity almost doubled on some of these products, over a period of 2 years due to improvements I have implemented (e.g. automating certain jobs, changing production flow and improving speed by changing existing machinery - i.e. designed and installed of a better index reader to the moulding machine, changing parts of the moulding machine in order to speed up certain steps of the depositing process, troubleshooting certain aspects of the machine that use to create issues on these particular products, building custom designed working stations to help the un-moulding process, sourcing better materials for moulds).
-Developed a base recipe (and adapted existing machinery in order to manufacture it on-site) for a range of fondant based and pectin based flavoured confectionery fillings. By choosing to manufacture this product on-site versus outsourcing it, it allowed us to reduce the cost by about 50% allowing in the same time to easily extend the range:
- KiwiCrème,
- Butterscotch Crème (containing alcohol),
- Lemon Crème,
- Strawberry Crème,
- Raspberry Crème,
- Orange Crème,
- Mint Crème,
- Coffee Crème,
- Manuka Crème,
- Green Tea & Manuka Honey Crème,
- Cinammon & Manuka Honey Crème,
- Lemon and Manuka Honey Crème.
- Developed a ‘liquid hot chocolate’ for professional use in coffee shops, designed to melt instantly under steaming – no extra stirring needed.
-Developed a chocolate spoon with a flavoured soft center tip designed to flavour hot beverages (e.g. coffee or milk).
-Developed and built a few prototype devices as part of a manufacturing process for manufacturing spec based chocolate chips, and installed them on a production line (the prototypes components were build on ultra low budgets and the line is fully operational and was used in full large scale, producing so far a few tones of product, until final devices were manufactured).
-Developed a Heat Resistant Compound chocolate for the military able to take high heat without melting (Concept can be implemented into chocolate as well, however the blooming issue may remain because of the cocoa butter particularities, even if melting point is improved).
-Worked on developing a flexible system for a full colour digital printing on chocolate (project abandoned due to other systems becoming available before my research was finalized).
-Developed a ‘no sugar / no artificial sweeteners’ chocolate (very low GI, no soy, no dairy) using raw liquid natural sweeteners, and adapted the technology to manufacture it on smaller scale production.
-Worked on a few ‘no sugar / no artificial sweeteners’ hydro-colloid based soft confectionery centers.
-Developed a range of ‘no sugar’ cereal bars, and developed the afferent manufacturing process.
-Developed a Manuka Honey protein bar.
-Developed the manufacturing process for a nut paste bar based on customer specifications.
-Developed a series of chocolate flavoured bake stable chocolate batons for baking industry (secured a contract with one of Fonterra’s companies manufacturing a product for McDonalds Australia using our chocolate).
-Worked with Tip Top (another Fonterra’s companies) to develop a soft chocolate chip for ice cream (the challenge being product stability during transport storage and usage as usage had to be done at room temperature where the chocolate chip would melt; found an innovative solution developing an encapsulation process for the soft chocolate chip). Project abandoned by Tip Top due to inadequate volume requirements for feasibility.
-Worked on developing a new high alcohol level confectionery filling suitable for depositor systems - not using the classic sugar syrup process.
-Developed a heat resistant chocolate chip for a high water activity environment (intended to be added to hot custard). Project abandoned by the customer (Fonterra).
-Developed a high antioxidant level and low GI chocolate bar using "exotic" fruit powders and syrups.
-Developed a high antioxidant level, Low GI, Low fat, chocolate spread.
-Sourced new ingredients and adapted the manufacturing process and the recipes for a range of fruit base fillings using a ‘pectin confectionery base’ and fruit concentrates aiming for further cost savings (by choosing this way of manufacturing for these centers we ended up saving further 40-50% of some of these ingredients)
- Blackcurrant,
- Feijoa,
- Passionfruit,
- Mango,
- Strawberry,
- Raspberry,
- Blackcurrant,
- Blueberry,
- Lime,
-Boysenberry
-Kiwifruit
-Ginger
-Worked on a dairy free ice cream manufacturing line implementation and developed a Risk Management program for this line.
-Developed a new concept in honey presentation and packaging that can be best described as “sliced honey”.
-Worked on a challenging project for one of the top 500 fast growing NZ companies involving unconventional use of surfactants and emulsifiers solutions based on advanced Hydrophilic / Lipophilic Balance System theory.Used pharmaceutical research in taste physiology and psychology of taste to mask very unpleasant tasting ingredients into food creating marketable chocolate products.
-Currently working on developing a very non conventional hard jube ice cream inclusion and using confectionery as functional food.
2014- Present (part time)
Built an new factory that is contract manufacturing products for New Zealand and overseas customers
- In about 2 years we've upgraded the old manual line to a new fully automated line. I have negotiated all the technical aspects of the line with the manufacturer, done the preliminary trials overseas with the manufacturer and commissioned the line here in New Zealand.
- Redeveloped about 5 products to suit the production lines and created about 6 new products.
- Developed and implemented the manufacturing process for the new products on the original manual line and again for the fully automated line at a later stage.
- Prepared all documentation required for for legal compliance and conducted necessary audits for it.
-Installed all machinery; built all the pipelines and other connections
-Redesigned and re-built all the technological lines following my own design
-Started production using an outsourced recipe.
-First chocolate tablet, a plain milk chocolate.
-First recipe designed by me with help from a third party.
-Gold medal received for Milk Chocolate Tablet.
-Developed a truffle chocolate filling using specialized fats.
-Adapted the technological lines to be able to manufacture Truffle filled Chocolate Bars.
-Created the First Chocolate Truffle filling and a milk (white) truffle filling.
-Developed and started to produce a larger selection of truffle filled bars:
-Chocolate Truffle Bars
-Milk Truffle Bars
-Rum Truffle Bar
-Coconut Truffle Bar
-Cappuccino Truffle Bar
-Gold medal received for Chocolate Truffle Bars.
-Started the manufacturing of Hollow Chocolate Novelties for Easter and Christmas.
-Gold medal received for Chocolate Novelties.
-Development of the first Chocolate couverture used for enrobing applications:
-Various types of Enrobed biscuits,
-Enrobed wafers.
-Developed and built a belt depositing system for chocolate chips.
-Developed a Chocolate Couverture recipe (for food services market).
-Designed and implemented a system to manufacture solid inclusion tablets.
-Developed a range of chocolate tablets with inclusions:
-Chocolate tablet with Coffee,
-Chocolate tablet with Peanuts,
-Chocolate tablet with Biscuits,
-Chocolate tablet with Caramel Crunch,
-Chocolate tablet with Hazelnuts,
-Chocolate tablet with Raisins.
-Changed the packing system from paper envelope system to BOPP film and fine cardbooard packaging for the chocolate tablets.
-Developed first Compound Chocolate (for enrobing applications) using specialized CBR’s (Cocoa Butter Replacers).
-Implemented a system to use the same line to manufacture Cocoa Butter based products and CBR based products (not compatible).
-Developed a few different recipes for Ice Cream coatings (Milk and Dark) using various CBS’s and coconut oil.
-Designed a moulding head capable of depositing 3 different flavoured fillings into a single bar.
-Altered the wrapping machines to meke it more flexible being able to pack from smaller size chocolates bars to large tablet sizes..
-Prepared a new production line and the logistic for manufacturing chocolate spreads.
-Developed a range Chocolate spread recipes:
-Smooth Peanut Chocolate spread,
-Crunchy Peanut Chocolate spread,
-Hazelnut Chocolate spread.
-Gold medal received for Chocolate Spreads.
-Developed fruit truffle fillings for a small size chocolate bars:
-Strawberry Truffle chocolate,
-Cherry Truffle chocolate,
-Mint Truffle chocolate,
2005-2007 Becka’s Chocolate
-Developed and implemented the recipe and the manufacturing methods (changing the use of some older machinery) for:
-Hokey Pokey
-Mint Crunch
-Extended the Buster Bars range adding 2 more products:
-Hokey Pokey Bars
-Mint Crunch Bars
-Refreshed the design of the range.
-Extended the Rocky Road range adding 3 more products:
-Hokey Pokey Rocky Road.
-Mint Crunch Rocky Road,
-Coconut Rocky Road.
-Used a very creative way to create a non costly professional packaging variation for testing the market on the new products (without the large initial financial commitment related to packaging).
-Later on, re-vamped the design of this range.
-Developed a new range of products and made the design for the packaging (4 new products). The way the design was made resulted in decreasing the set up cost for printing by about 50% (needing only 8 printing plates instead of 16 for the whole project).
-Developed a few smaller runs products aiming for a dedicated market.
2007-2014 Nyco Chocolates
-Worked on the improvement of manufacturing process for ice cream inclusions. The productivity almost doubled on some of these products, over a period of 2 years due to improvements I have implemented (e.g. automating certain jobs, changing production flow and improving speed by changing existing machinery - i.e. designed and installed of a better index reader to the moulding machine, changing parts of the moulding machine in order to speed up certain steps of the depositing process, troubleshooting certain aspects of the machine that use to create issues on these particular products, building custom designed working stations to help the un-moulding process, sourcing better materials for moulds).
-Developed a base recipe (and adapted existing machinery in order to manufacture it on-site) for a range of fondant based and pectin based flavoured confectionery fillings. By choosing to manufacture this product on-site versus outsourcing it, it allowed us to reduce the cost by about 50% allowing in the same time to easily extend the range:
- KiwiCrème,
- Butterscotch Crème (containing alcohol),
- Lemon Crème,
- Strawberry Crème,
- Raspberry Crème,
- Orange Crème,
- Mint Crème,
- Coffee Crème,
- Manuka Crème,
- Green Tea & Manuka Honey Crème,
- Cinammon & Manuka Honey Crème,
- Lemon and Manuka Honey Crème.
- Developed a ‘liquid hot chocolate’ for professional use in coffee shops, designed to melt instantly under steaming – no extra stirring needed.
-Developed a chocolate spoon with a flavoured soft center tip designed to flavour hot beverages (e.g. coffee or milk).
-Developed and built a few prototype devices as part of a manufacturing process for manufacturing spec based chocolate chips, and installed them on a production line (the prototypes components were build on ultra low budgets and the line is fully operational and was used in full large scale, producing so far a few tones of product, until final devices were manufactured).
-Developed a Heat Resistant Compound chocolate for the military able to take high heat without melting (Concept can be implemented into chocolate as well, however the blooming issue may remain because of the cocoa butter particularities, even if melting point is improved).
-Worked on developing a flexible system for a full colour digital printing on chocolate (project abandoned due to other systems becoming available before my research was finalized).
-Developed a ‘no sugar / no artificial sweeteners’ chocolate (very low GI, no soy, no dairy) using raw liquid natural sweeteners, and adapted the technology to manufacture it on smaller scale production.
-Worked on a few ‘no sugar / no artificial sweeteners’ hydro-colloid based soft confectionery centers.
-Developed a range of ‘no sugar’ cereal bars, and developed the afferent manufacturing process.
-Developed a Manuka Honey protein bar.
-Developed the manufacturing process for a nut paste bar based on customer specifications.
-Developed a series of chocolate flavoured bake stable chocolate batons for baking industry (secured a contract with one of Fonterra’s companies manufacturing a product for McDonalds Australia using our chocolate).
-Worked with Tip Top (another Fonterra’s companies) to develop a soft chocolate chip for ice cream (the challenge being product stability during transport storage and usage as usage had to be done at room temperature where the chocolate chip would melt; found an innovative solution developing an encapsulation process for the soft chocolate chip). Project abandoned by Tip Top due to inadequate volume requirements for feasibility.
-Worked on developing a new high alcohol level confectionery filling suitable for depositor systems - not using the classic sugar syrup process.
-Developed a heat resistant chocolate chip for a high water activity environment (intended to be added to hot custard). Project abandoned by the customer (Fonterra).
-Developed a high antioxidant level and low GI chocolate bar using "exotic" fruit powders and syrups.
-Developed a high antioxidant level, Low GI, Low fat, chocolate spread.
-Sourced new ingredients and adapted the manufacturing process and the recipes for a range of fruit base fillings using a ‘pectin confectionery base’ and fruit concentrates aiming for further cost savings (by choosing this way of manufacturing for these centers we ended up saving further 40-50% of some of these ingredients)
- Blackcurrant,
- Feijoa,
- Passionfruit,
- Mango,
- Strawberry,
- Raspberry,
- Blackcurrant,
- Blueberry,
- Lime,
-Boysenberry
-Kiwifruit
-Ginger
-Worked on a dairy free ice cream manufacturing line implementation and developed a Risk Management program for this line.
-Developed a new concept in honey presentation and packaging that can be best described as “sliced honey”.
-Worked on a challenging project for one of the top 500 fast growing NZ companies involving unconventional use of surfactants and emulsifiers solutions based on advanced Hydrophilic / Lipophilic Balance System theory.Used pharmaceutical research in taste physiology and psychology of taste to mask very unpleasant tasting ingredients into food creating marketable chocolate products.
-Currently working on developing a very non conventional hard jube ice cream inclusion and using confectionery as functional food.
2014- Present (part time)
Built an new factory that is contract manufacturing products for New Zealand and overseas customers
- In about 2 years we've upgraded the old manual line to a new fully automated line. I have negotiated all the technical aspects of the line with the manufacturer, done the preliminary trials overseas with the manufacturer and commissioned the line here in New Zealand.
- Redeveloped about 5 products to suit the production lines and created about 6 new products.
- Developed and implemented the manufacturing process for the new products on the original manual line and again for the fully automated line at a later stage.
- Prepared all documentation required for for legal compliance and conducted necessary audits for it.