New production plant

Meeting technological demands with a constructive, environmentally-friendly ethos

Discover the new production plant in Orsenigo
A cutting-edge structure

In planning the various stages for the construction of the new Orsenigo facility, ICAM took its inspiration from two key elements that define production in terms of quality and food safety: functionality and traceability. The primary requirement was to design a fully automated plant, then to ensure this was compatible with guaranteeing complete traceability of each process, from the raw materials to the finished product ready for the shelves.  Hence the request for the implementation of a system able to guarantee complete supervision and management of the entire production cycle and the infrastructures, so as to guarantee 360° control over the integrated process.
This complete control over the production chain, coupled with technological independence, has been adopted by ICAM as the signature features of a production system compliant with the very highest quality standards and careful to make the very most of the typical, genuine original cocoa varieties used.
Thanks to its hands-on experience and presence in the areas where the cocoa is grown, the company is able to offer solid guarantees regarding every aspect of the production chain: the origin of the raw material, the genotypes of the individual cocoa varieties, the particular features of the plantations, as a result of their geographical position, the climate, the morphological characteristics of the soil and the exposure to sunlight, the processing and conservation the beans undergo, right through to the complete recognisability and traceability of the product during the complex processing stages that take place in the Orsenigo plant. It is thus possible, for each product, to produce a map documenting its entire journey, from growing to processing.

The Orsenigo facility is a functional plant able to deal with all stages of the process (from the request for production and the supply of the raw materials through studying the recipe to the scheduling and planning of production), thus guaranteeing complete traceability of both products and raw materials.

The modern plant systems used, the observance of strict regulations governing food safety and hygiene, the care taken to work only with whole, undamaged cocoa beans, the cleaning of the machinery to remove any foreign bodies, and the frequent tests on production play a decisive role in defining the ultimate quality of the cocoa and the chocolate, which thanks to this system are able to maintain their original flavour and characteristics.

Plant area50.000m2

Cocoa beans50.000tonnes/year at full capacity

Production capacity120tonnes/day
Take a look at the technological areas of the plant

Warehouse
Warehouse
Warehouse
Therigorously controlled stocking of the sacks containing cocoa beans of various types and origins allows for complete traceability of the batches of cocoa. Using a pneumatic transport system, the cocoa beans are delicately transferred from the warehouse to the subsequent sterilisation and roasting phases, thus avoiding crushing and therefore micro-contamination of the raw material.
Chocolate production
Chocolate production
Chocolate production

The new production facility, running at full capacity, allows ICAM to process a total of 50,000 tonnes of cocoa beans per year. 2 refining lines, 4 mixers and 8 conching machines form the heart of the company’s production facilities. In order to meet the growing demand for food safety and allergen-free products, ICAM pays especially close attention to “cross contamination”. For this reason, separate, dedicated production lines are used for different types of products: organic, conventional, white chocolate, milk chocolate and dark chocolate. 

Chocolate currently produced

produced chocolate26.000tonnes/year
production staff200on a continuous cycle over three shifts
tablets10.000tonnes/year
Semi-finished products16.000tonnes/year

Trigeneration Plant
Trigeneration Plant
Trigeneration Plant

Trigeneration guarantees exceptional performance for the production of electricity, steam and hot and cold water.

The plant produces

of electrical energy2,4megawatts
of thermal energy1,7megawatts
of refrigeration energy0,7megawatts
energy costs-50%

Roasting plant
Roasting plant
Roasting plant

Before production, the cocoa is sterilised using a dedicated debacterisation unit.

production capacity4tonnes/hour

Presses and pulverisation
Presses and pulverisation
Presses and pulverisation

During the initial stage of production, the cocoa butter is separated from the cocoa powder.

tanks for storing the liquid chocolate 6610 tonnes tanks
for the butter 225 tonnes tanks
for loading the tankers625 tonnes tanks

Quality control and R&D laboratories
Quality control and R&D laboratories
Quality control and R&D laboratories
Quality control extends from the raw materials to the finished product. Sample organoleptic testing is carried out on all the semi-finished products and products destined for the end consumer, so as to guarantee maximum quality and safety.

Outstanding characteristics

Functionality and traceability are the two key elements that make ICAM products so reliable in terms of quality and food safety.
An exceptionally pure cocoa paste can be obtained thanks to the rigorously controlled stocking of the coca beans in the dedicated warehouse and the innovative cleaning process able to remove any contaminants from them. In addition, the pneumatic transport system delicately transfers the cleaned beans from the warehouse on to the subsequent sterilisation and roasting phases, thus avoiding crushing and any micro-contamination of the debacterised, sterilised product.

Each individual sack of cocoa beans is unequivocally identified, making it possible to accurately trace every type of processing it undergoes, providing detailed information on the process carried out. These are just some of the improvements to production made possible thanks to the technical innovations and technological support that allow for extremely precise monitoring of every single element in the complex production process.

In order to meet the growing demand for food safety and allergen-free products, ICAM pays particularly close attention to cross contamination, providing dedicated lines fed by tanks reserved for the various different types of cocoa paste. This separation prevents any kind of contamination caused by products containing potential allergens such as milk or hazelnuts.

The modern plant systems used, the observance of strict regulations governing food safety and hygiene, the care taken to work only with whole, undamaged cocoa beans and the scrupulous cleaning of the production machinery all play a decisive role in defining the ultimate quality of the cocoa and the chocolate, which thanks to this system are able to maintain their original flavour and characteristics.

Chocolate produced26.000tonnes/year

Tablets10.000tonnes/year

Semifinished products16.000tonnes/year
  • COCOA GRAIN PROCESSING

    Minimum environmental impact and maximum energy efficiency, for creating extra-sophisticated recipes.

    The ultra-modern cocoa roasting plant is equipped with a postcombustor for the total elimination of any odour emissions and to prevent the release of remaining volatile aromas into the atmosphere, which is of particular benefit to the local community. The specific plant, like the rest of the facility, is served by a trigeneration plant, which, by exploiting the energy of the fuel to the maximum, is able to cut the amount of methane used to feed the production system, thus reducing the environmental impact.

  • COCOA POWDER AND BUTTER PRODUCTION

    Food safety, laboratory analyses and organoleptic testing applied to the 300 + articles in production.

    ICAM is able to meet the requests of customers thanks to its ability to develop a wide range of products both for the end consumer and for small-scale confectionery operators or major industrial concerns.

  • CHOCOLATE PRODUCTION

    Production process fully traced throughout. Over 300 recipes created using cocoa beans from the finest plantations in the world.

    The chocolate production capacity stands at 120 tonnes/day, divided up into over 300 recipes. In order to meet the growing demand for food safety and allergen-free products, ICAM pays especially close attention to cross contamination. The rigorous separation of the production eliminates the risk of any kind of contamination due to potential allergens such as milk or hazelnuts.

  • CHOCOLATE MOULDING

    Extremely high level of automation and flexibility in production processes, to keep even the most demanding customers happy.

    ICAM produces a wide range of articles, such as tablets, pralines and chocolates, in classic flavours such as milk, dark, white and gianduja, as well as with a broad variety of inclusions such as hazelnuts, almonds, raisins and cereals. The production plants allow for a variety of flavours to be produced, as well as a wide selection of recipes: 150 with dark chocolate, 100 with milk chocolate and about 40 with white chocolate.
    The production, divided into 5 moulding lines, guarantees ICAM an indisputable competitive edge. The company’s main strength is the large variety of formats and weights produced, from bars to snack on up to 1 kg blocks. Recipes with inclusions are produced in such a way as to safeguard consumers from allergens, thanks to the rigorous separation of plants, tanks and pipes, governed by certified cleaning and sterilisation processes.

ICAM S.p.A. - Copyright 2018 - Icam
Icam spa, società per azioni – capitale sociale € 12.932.500,00 i.v registro imprese di Lecco n. 00205080138 – rea 58425 – c.f.-p.iva 00205080138 – sede: via Pescatori, 53 – 23900 Lecco – Italy
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