Markus Gebhart, Hans Brunner GmbH - Increased product flexibility through the use of changeable/magnetic moulds

1987- 1992 studies of industrial engineering (FH) at the FH Munich

1992-2006 Fa. Urotech GmbH, medical devices (plastic implants and disposable products for urology), started there as production manager, then managing director.

2006- now company Hans Brunner GmbH, chocolate molds, managing director

Katharina Hilker, Bühler GmbH - New plant concepts based on alternative mould transports

We create unique holographic designs from chocolate, without additives or post-processing, directly from the injection-molded or thermo-formed chocolate plastic molds. Katharina Hilker is a Product Manager for Chocolate Moulding lines at Bühler since 2014. Being passionate about chocolate production and innovation, she took part in Bühler’s Innovation Challenge in 2014 developing ChocoBotic with her team: a chainless moulding line, based on two robots focusing the flexible production of pralines and the Hygienic Design. After three years of R&D, the ChocoBotic was brought to market in 2017. Within an Exposure Program, Katharina harvested her own cocoa to explore the beginning of the cocoa value chain. In 2017, she represented Bühler at the One Young World Summit in Bogota. She holds a B.Sc. in Food Technology, a M.A. in Business Engineering and is a certified Coach.

The presentation:

New plant concepts based on alternative mould transport

New paths require a new way of thinking.  Integrated technology using robotics is paving the way for innovative design to link up with manufacturing processes: lines free of chains and their lubricants, fewer components, and fewer stations – coupled with a more hygienic design, more flexible processes, and multi-use stations. ChocoBotic turns this vision into reality.

The main benefits of alternative mould transport:

Process times and steps are adjustable for each product

The cooler design and the missing chains ease the cleaning

Modular design concept which is easy extendable in the future

Jens Templin, Hildebrand Industry AG - Economical and technical basics for efficient mould cleaning

Jens Templin has been working for Hildebrand Industry since 2011. As manager for the service and technical department Jens Templin has gained extensive experiences in mould washing through working with chocolate manufactures worldwide. From small confectionery producers to global players, Jens Templin knows about the applications and requirements of the demanding customers. Especially the insight in the day-to-day cleaning business enables Jens Templin to analyze processes and to provide advice on the "dos and don'ts" in the challenging field of mould washing.

Sein Vortrag:

The speech gives insight into the mould washing process on two levels. One level is the technical basic to implement a successful! cleaning process with interdisciplinary information around the cleaning process. The second is the economical level. Facts and figures about impacts on cost efficient procurement and operation of cleaning machines will provide useful information to be able to scrutinize the current wash process or to specify upcoming machine enquiries.

Dr. Rudolf Fernengel, 2R Kunststofftechnik GmbH & Co. - Defects and damage analyses on polycarbonate chocolate moulds; interaction with detergents, ingredients and other external factors

Studied mechanical engineering and plastics technology

young technical talent in the Volkswagen plant

Head of plastics technology at BMW

Head of Technology 2R Kunststofftechni (2R = Richard and Rudolf Fernengel)

Ronald Krzywinski, Bi-Ber GmbH & Co. Engineering KG - Adaptive 3D detection by profile scanner with reflex optics (mould break check, dirt, foreign objects)

Ronald Krzywinski received his diploma in electrotechnical engineering from the University of Chemnitz in 1992. His emphases were electrical and mechanical device design and development. 

After some years working experience as a development engineer of cameras for medical diagnosis he founded Bi-Ber in 1997. Since then, Ronald Krzywinski worked as General Manager in his company which is a solution provider for Machine Vision Systems.

The Presentation:

Current 3D mould break inspection systems can inspect fragile ridges for chipping, but not deeper indented areas, such as the cavities on the top side. Not only is it impossible to directly inspect these areas, but laser line data can also inadvertently lead to pseudo pixels, due to especially thin ridges or reflections off ridges and curves, thus producing unreliable results.

Help is at hand with the innovative 3D profile scan process with integrated reflex optics. With this technology, even cavities can be inspected at a high frequency to ensure that the entire mould is free from chipping and foreign bodies. 

With the reflex process, the optical path crosses a semipermeable mirror that splits the path into two separate paths. In the camera sight, the paths overlap together again on the inspected object. Given that the second optical path has an auxiliary mirror and gives onto the laser line from the opposite side, alignment, angle, scale and length are identical for both views. 

Dr. Bernhard Grimm, Hans Turck GmbH & Co. KG - The Chocolate Mould 4.0 Identification and mould management at a different level

Bernhard Grimm received his diploma in Physics at the University of Heidelberg in 1988, where he also received his doctoral degree in 1992 for the development of a confocal eye scanner. In the same year he started to work for the Hans Turck GmbH & Co. KG as Product Manager for industrial sensors. In 2005 he moved to Bernstein AG in Porta Westfalica as Marketing Manager. In 2006 he came back to Turck to establish the Vertical Market Management for the Food and Packaging industry. Since 2015 he is responsible for all Vertical Marketing activities as Director Vertical Marketing. In 2016 he also took over the lead of the Business Development Management for Automation Systems. The emphasis of his work is to identify industry trends in Turck’s target industries and to be part of the development and marketing of tailor made products and solutions for these trends. Together with leading suppliers of the chocolate industry he founded in 2009 a working group about track-and-trace of chocolate moulds with RFID. He is co-founder and part of the steering committee of FERA (Association for research and development of robotic and automation solutions), which has a strong focus on the Industrial Internet of Things.


The RFID-Technology for the identification of chocolate moulds is increasingly being used in the chocolate industry. Advantages of this technology include increasing equipment efficiency, improvement of product quality and enhanced food safety. These advantages can only be realized if the RFID technology is supplemented by a suitable controller and database connection as well as the corresponding software. Turck is now presenting a complete system that fulfils the specific requirements of an identification system for food production as well as the interface to machine control, MES or inventory management systems. Even decentralized data processing in Turck’s RFID interface of or a connection to the Turck cloud are easily possible. On request, it allows access to all relevant data at any time and at any place. In the speech the application details, that are important for the chocolate production, are explained as well as the possibilities for evaluation and visualization.

Dr.-Ing. Bernard Rocklage, FOM / iVC - Process optimization through intelligent forms

Dr. Bernard Rocklage received his diploma in mechanical engineering with focus on chemical processes from the University of Bochum. Afterwards he worked for the Institute of Thermo- and Fluid Dynamics with his research focus on modelling and calculating the heat- and flow field of turbulent flows. In 1997 he received his doctor degree in mechanical engineering. Since then he worked for more than 20 years in the chocolate division of Mondelez Int., former Kraft Foods, in various fields covering Quality, Engineering, Business Development, global Technology and European R&D, where he was responsible for the chocolate process developments, process optimizations and process innovations, as well as for the European pilot plant and the implementation of Innovation Management and Lean Six Sigma methods. In 2018 Dr. Bernard Rocklage accepted a university lecture assignment of the FOM University of Economics and Management in Stuttgart for the topics Quality Management, Process Management and Technology Management. In addition to this he works as industrial management consultant for process optimization, Lean Six Sigma, technology and innovation management.


Chocolate molds are one of the most essential elements within the chocolate production as they are the only device in a molding line with direct contact to the chocolate itself. In the last decades molds have been perceived as a necessary utility of a molding line and their design and features barely have been changed. But molds are instrumental for determining the shape and the quality of the product and finally the performance of the production line. With an industry wide transformation towards I4.0 compatible production and the business-driven pressure to optimize line performance while maintaining product and production quality, molds need to be perceived as important and beneficial equipment of the chocolate production. This presentation is about how to lift-up the intelligence of molds by introducing clever features to aim for optimizing chocolate production process lines in various dimensions.

Bernd Plies, Winkler und Dünnebier Süßwarenmaschinen GmbH - Smart Mould Entry into 'Condition Based Monitoring' to increase your plant availability

Bernd Plies studied electrical engineering / electronics at FH Koblenz and gained his first experience in the field of electronics development and automation applications at Elbag GmbH in Weisel.

After a career change (development of electronic test systems), he turned to independence in order to implement not only PC measurement technology but also automation tasks.

In 1995, first projects for the automation of confectionery machines, focusing on servo-drive technology, have been realized.

In 1998 Bernd Plies moved to Winkler and Dünnebier Süßwarenmaschinen GmbH in Rengsdorf, where he became head of electrical and automation technology department in 2000 and has since then been a member of the WDS competence and strategy team.


Usually, the production of confectionery products is done on moulding plants, where the pro-duction moulds are transported via chain drives to the different workstations. Moulds used in chocolate plants are thermally and mechanically stressed during this production process. While the first solutions for product protection already exist due to sensor-related 'measurement forms', WDS has developed a product, in which the 'intelligent' mould (the so-called WDS Smart Mould) has been upgraded to an integral part of monitoring the production plant. For this purpose, the mould communicates with the base station and the plant control via wireless data transmission, thus allowing a position-accurate, expressive real-time analyzes. With this procedure, not only the production mould but also the production plant is monitored so it is possible to react early to modifications.

This lecture will explain both, the technical background, such as the WLAN-independent wireless data transmission up to practical application. A live demonstration of the mould at the WDS ConfecEco, here in  ZDS production, rounds off the presentation.

Veronica Savu, Morphotonix S.à.r.l. - Small dimensions for big effects: added value through holographic effects on moulded chocolate

Veronica Savu graduated from Caltech in 2000 and earned her PhD in Physics from Yale University (US). In 2007 she moved to Switzerland to pursue postdoctoral research in nanotechnology at EPFL, culminating with a 5 year individual grant from SNF. Over the last four years, Veronica has concentrated her work on business development, sales and marketing for her high-tech start-up Morphotonix, which supports brands with product-embedded distinction and security. She has gained great visibility in the past 3 years for Morphotonix after being selected in the Swiss National Start-up Team for the US and China, while working on business strategy and development with executive MBA teams from IMD Business School, Lausanne. Morphotonix' clients span from Japan to  the US, in industries where brand differentiation and product authentication require additive-free solutions and distinctive quality hallmarks. 


Morphotonix has experience in designing complex holographic patterns and logos based on controlled surface roughness, and uses its proprietary and patented technology platform to integrate them into molds used for chocolate molding. The chocolate replicates the specific mold roughness, controlled with nano-scale precision, which splits natural light into a rainbow. From providing distinction to amazing children, holographic chocolate features Swiss quality and high-tech innovation.    

Markus Gebhart, Hans Brunner GmbH - Erhöhung der Produktflexibillität durch Wechselformen

1987- 1992 Studium zum Diplom Wirtschaftsingenieur (FH) an der FH München

1992-2006 Fa. Urotech GmbH, Medizinprodukte ( Kunststoffimplantate und Einmalprodukte für die Urologie), dort begonnen als Produktionsleiter, danach Geschäftsführer.

2006- jetzt Fa. Hans Brunner GmbH, Schokoladenformen, Geschäftsführer

Burkard van Soest, CTO - d3 technology GmbH - 3D printing: the key to effective development and small series production

Burkhart-Oliver van Soest received his diploma in physics from TU Clausthal.sice then he worked in the R&D lab of "Deutsche Babcok AG", in the UMTS Lab of Mobilcom , and build up his own IT company for 14 years until the sale in 2016. since 2016 he is founder and CEO of d3-technology GmbH, a company related to the "3D" field : 3D Scan , 3D Print ,3D CAD and 3D Vision. The main goal of the company in that area 3D printing is to develop and setup new materials for engineering pupose and dental industry. 


The lecture will cover a complete production flow example of a moulding form  from CAD Design (with or without 3D scan of already existing samples ), minimal modeling and adaptation for the 3D printing process, and the 3D printing process itself . 

Martin Zirbs, Zirbs Kunststoffverarbeitung-Verpackung e Kfr. - Individualisierungskonzepte für Kleinserien

1989-1991 Erfahrung auf dem Gebiet der Qualitätssicherung und Fertigungsüberwachung in der Serienproduktion von Ausstattungskomponenten bei der Firma Stabilus in Koblenz / 1992-1995 kaufmännische Sachbearbeiterin für Angebots- und Auftragsabwicklung bei der Firma Heinlein Stahlhandel in Kulmbach / 1995-heute Erich Zirbs Kunststoffverarbeitung / Gründung der Zirbs Kunststoffverarbeitung-Verpackungen e.Kfr. Zusammen mit meiner Frau Heike Zirbs / 2003 Entwicklung einer Entwicklungsabteilung mit 3D CAD / CAM Technologie erste Aufgaben im Bereich personalisierter Schokoladenformen / 2005 Erweiterung der Entwicklungsabteilung in eine Formenbauabteilung / 2015 erste Aufgaben im Bereich Thermoformen in Verbindung mit Transferdruck auf Schokolade

Der Vortrag:

-Kurze Vorstellung

-Kurze Einführung in den Bereich Thermoformung als Grundlage und zum besseren Verständnis der Einsatzmöglichkeiten (Positiv- und Negativformung, Formkontakt und Formkontaktflächen usw.)

-Abbildungsmöglichkeiten mit Gravuren (2D), Erweiterte Gravuren ("2 1 / 2D"), Relief (3D)

-Arten und Herstellungsverfahren von Transferdrucken (Digital und Siebdruck)

-Möglichkeiten des Drucktransfers (einfacher Transfer mit Flachfolien, Formengebundener Transfer, Transfer mit bedruckten Formteilen)

-Möglichkeit zur Diskusion

Dr. Knut Fanke & Dr. Dana Middendorf, DIL-Deutsches Institut für Lebensmitteltechnik e.V. - How does mold surface affect the chocolate gloss - An update from the corresponding research project

Dana Middendorf
studied food chemistry at Technical University of Braunschweig and graduated in 2009 as diploma food chemist and in 2010 as state-certified food chemist. Since then, she is working in the department of food structure and functionality at the German Institute of Food Technologies (OIL). In 2015, she received her Ph.D. in food chemistry from TU Braunschweig. As research scientist at OIL, her main research topics are characterization of surfaces and interfaces as well as surface active substances with respect to chocolate, emulsifiers and ice cream.

Knut Franke
studied food engineering at Technical University of Dresden and received his Ph.D. in food engineering there in 1989. From 1993 to 1995 he worked as a project engineer in the company 'Tscheunschner & Bindler' with the focus on development of measuring equipment for chocolate properties. Since 1995 he is with the German Institute of Food Technology (OIL) where he is responsible for reserach in confectionery technology, fats, egg products, and others. From 2008 to 2015 he was the head of the research unit 'food robotics'.


The gloss of chocolate surfaces is substantially determined by the surface structure of the mould in the micro- and submicrometer scale. Especially, the micro- and submicro surface interactions of the mold and the chocolate produced with this mold are of interest. In addition to the micro-roughness, also surface polarities and local adhesion forces are important. These properties can be determined in high resolution by atomic force microscopy (AFM), both on mold as well as on chocolate surfaces. In this presentation, methodical possibilities for characterizing surfaces by AFM are explained and correlated to local differences in gloss properties. Furthermore, local properties of the mold and resulting molded chocolate surfaces are presented and discussed. Special attention is given to the correlation between macroscopic gloss properties and the results of microstructural characterization. 

Isabell Rothkopf, Fraunhofer Institut für Verfahrenstechnik und Verpackung - Contribution of molding technique and adjusted cooling tunnel parameter to improve fat bloom stability of filled chocolates

lsabell Rothkopf received her diploma in process engineering from the Karlsruhe Institute of Technology; her emphases were Food Process Engineering and Biomolecular Separation Engineering. Afterward, she started her Ph.D thesis about the interaction of fat crystallization and migration in filled dark chocolates in 2013 at the Fraunhofer Institute for Process engineering and Packaging. In 2017 she became the researcher in charge for chocolate technology. Besides, I sa bell Rothkopf is the scientific advisor of the work group "chocolate technology" of the Industry Association for Food Technology and Packaging (IVLV,.. lndustrievereinigung fOr Lebensmitteltechnologie und Verpackung e. V.).

The presentation:

Cocoa butter crystallization properties are important for manufacturing of high quality chocolate products. Therefore, characteristics for good·and poor crystallization have to be found and measurement needs to be standardized. Currently, a lot of different measuring instruments are used and even for established devices such as NMR or DSC, standardized methods are missing. The idea is to compare different instruments and methods and find benchmarks for good and poor crystallization properties. A supplementary target is to facilitate the comparability of quality control at incoming goods department and specifications given by the supplier.

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