Teckru Projects: Systems + Products

The Teckru Projects Division specializes in the design, manufacture and installation of complete machines and installations. Besides new equipment Teckru Projects is also active in the repair, overhaul and modernisation of existing machines and plants. Mostly in the area of processing cocoa beans to cocoa powder and butter, and especially in the area of cocoa butter presses.

Product flow

We offer solutions for the entire product flow:

Cocoa Bean Intake, Cleaning, Crushing and Winnowing
Nib Roasting and Alkalising
Cocoa Liquor Grinding
Cocoa Butter Pressing
Butter Filtering, Deoderising and Blocking
Liquor Sieving and Blocking
Cocoa Powder Milling and Stabilising
Bagging of Cocoa powder and kibbles

In addition we can take care of product storage and conveying, plant design and utilities, as well as operator training.

Cocoa Butter Pressing Highlights

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Cocoa Butter Press T16P-A

As one of the few companies in the world we supply the Cocoa industry with state-of-the-art Cocoa Butter Presses. Presses are used for pressing the butter content out of a batch of cocoa liquor, then discharging cocoa cakes with the desired leftover fat content. The leftover fat content is typically 10 to 12%. The main components can be summarized as follows: On one end we find the cylinder body with the main ram and on the other the counter part with the ejectors. They are connected with two long tie rods. In between we find sliding pots and counter-pots. the pots contain the product, and the counter-pots hold the filters which are pressed against the product.

Our horizontal press consists of 16 pots for optimal pressing speeds and allowing for efficient seperation of the butter content. It incorporates the latest insights in both cocoa processing and machine production. All components of the press have been designed and produced to high standards, providing smooth operation and reliability for decades to come. The press is equipped with all necessary safety devices.
All auxiliary equipment and tools required for operating the press can be supplied directly by Teckru Projects. Our team can handle any aspect of the installation work of presses and the auxiliary equipment.

Specifications:
Type of press	T16P-A
Number of pots	16
Inner diameter of pots	450 mm
Filling batch weight	200 kg
Tie-Rod Type	Fixed head
Default Working pressure	550 bar
Product pressure	980 bar
Weight of press	33.000 kg
Length of press	7 meters

This press can be delivered with:

Hydraulic Unit TP-T1
Liquor Pre-Heating System
Cake breaker + hood
Cake conveyor
Liquor filling pump
Operator Tools
Foldable Transparent Hood
Butter collecting Channel+Box
Steel Support Bases/Pedestals
Electrical control (Siemens PLC)

Hydraulic Unit TP-T1

Our hydraulic unit is designed exclusively for the powering of cocoa butter presses. We offer different configurations suitable for the different brands and types of presses: High capacity 14 and 16 Pots presses as well as CM, Vitali, Nagema/Heidenauer and Bauermeister presses. We use our custom manifold design to keep the system compact and safe. General features are:

Modern design with variable oil flow
Nominal Pressures 550 bar, max 700 bar
Energy efficient
Single pump and a minimal amount of valves
Maintenance-friendly
Available in several capacities

Cocoa Cake Breaker

The Teckru Projects Cake breaker is a straightforward system to break the cocoa cakes in smaller cake kibbles. The resulting cake kibbles are of more practical size, suitable for conveyor screws or blower/suction transport. For this reason the machine is best placed early in the process, near the cocoa butter press. Also available is a casing that fits between the breaker and the end of a cake conveyor.

Cake Conveyor

Placed under the Cocoa Butter Press, the cocoa cakes fall in this Cake conveyor. The conveyor is actived at a preset interval, it then moves the cakes towards its open end. After leaving the conveyor the cocoa cake can be further processed by a cake breaker etc.
Teckru Projects can offer either a slide conveyor (shown) or a shaker conveyor. Both conveyor types have been developed over an already proven design, featuring increased durability.

Liquor Pre-Heating System

This system prepares the cocoa liquor prior to pressing. It is suitable for many different types of cocoa presses. Steam is used to raise the temperature of the liquor, an agitator ensures simultaneous mixing and homogenising. Features are:

Very efficient high speed mixing and homogenising
Optional water dosing system
Optional feed pump on plateau
Maintenance-friendly

Cocoa Liquor Feed Pump

Besides specially selected third party pumps, Teckru Projects can also offer its own design of liqour pump. This pump has been developed specifically for cocoa liquor: Excelling in wear-resistance and reliability. But even in the case of wear, this pump can easily be opened up for maintenance.
We offer the pump with different drive configurations. Equipped with a large direct drive it is the best choice for filling cocoa butter presses.

Press operator Tools

Being in close contact with cocoa producers world wide, we are well aware of the daily activities in the press rooms. To aid the operators and maintenace crews, we can offer several tools to make their work easier and faster.

Filter plate Screen tool (displayed)
Brace for the mounting of press plates
Clamp for the fixing of press plates

Powder Milling and Stabilising Highlights

photo: no.1

TCM classifier mill installation

Replacing the classic pin mill, the Classifier Mill already makes a strong presence in the cocoa industry. It combines milling and classifying in one machine, and is able to consistently reach the powder fineness that the industry demands. ( 99.5% < 75 µm ).
Air flow is an essential part of the Classifier mill, which is generated by a blower. To seperate the fine product from the air flow we use a filter vessel. The air flow is cooled with a heat exchanger/chiller combination, which greatly improves the cocoa product behaviour.

Teckru Projects can supply the cocoa industry with several sizes of TCM mills. We have the know-how and experience to succesfully integrate the TCM system in new or existing cocoa factories.

More information on this system can be found in our TCM brochure:
Teckru Classifier Mills Brochure (PDF - 290KB)

Left an image of a complete TCM-1000 powder milling system. This particular installation is supplied directly with hot pressed cocoa cake. The product ends up bagged and ready, at the right consistency and colour. Additional cooling screws for cooling the product have been integrated.

Cocoa Powder Screener

Although our clasiffier mill has integral screening functionality, it still advisable to process the cocoa powder with a dedicated screener. We can supply cyclone powder screeners that handle this task with great accuracy and reliability. Any impurities are automatically removed from the product flow.

Available in stainless steel
Fully enclosed system
Maintenance-friendly design

Powder Stabilising System

Based the latest insights in the handling of cocoa powder, Teckru can supply a very efficient stabilising system. Adding our powder stabilising unit to the TCM mill completes the system, in which the powder production process is fully enclosed. Kibbled cake from the presses can be packed as stabilized powder in just a few hours. Since powder is at the endpoint of the cocoa factory product flow, it is of crucial importance to attain the desired fineness, consistency and colour. Teckru's complete system will ensure that cocoa powder can be bagged and traded for its full potential.

Other Highlights

Cocoa Bean Impact Crusher

An improved Cocoa bean crusher. Used right before the winnowing process to crush the Bean (still with shell) into smaller Cocoa Nibs.

Wear resistant parts, in several classes
Maintenance-friendly design

Cocoa Liquor Screener Station

A station that can contain up to four cyclone liquid screeners, used for sieving cocoa liquor after fine grinding. It comes with output+reject buffers and pumps. The two lower screeners are normally placed in series after the upper screener. The station uses minimal floor space, still all systems are easy to access for maintenance and cleaning.

Butter / Liquor Coolers

The cocoa butter coming from the butter presses and filter are usually packed in lined carton boxes. Teckru's cooling/tempering units will do this job with great care, accuracy and efficiency. Resulting in a product that quickly solidifies once inside the cartons. The whole process can be fully automated, further decreasing operating and maintenance costs.
Teckru can supply either complete tempering lines or individual machines. When desired, similar tempering systems can also be offered for the handling of cocoa liquor.

These coolers can be delivered with:

Frame for up to 4 coolers
1st stage Heat exchanger for Cocoa Liquor
Filling nozzle with control system (Pneumatics and PLC)
Conveyors, box-closer, box-printer, palletizer
Utilities for cooling and heating water.

Cocoa Liquor Transport pump

Besides specially selected third party pumps, Teckru Projects can also offer its own design of liqour pump. This pump has been developed specifically for cocoa liquor: Excelling in wear-resistance and reliability. But even in the case of wear, this pump can easily be opened up for maintenance.
We offer the pump with different drive configurations. Equipped with a medium speed drive it is the best choice for the transport of coarse and fine cocoa liquor throughout the factory

Cocoa Butter Filter System

For continuous filtration of pressed liquid butter. It consists of a vessel containing specially designed filter candles and utilities. The Filter material has been selected specifically for the processing of cocoa butter. The system features a cleaning facility that can be started when desired, to bring the filter back to optimal production condition without opening the vessel.