From complex tank planning to data-driven efficiency at Barry Callebaut

About Barry Callebaut

The Barry Callebaut Group produces high-quality chocolate and cocoa products and is the global market leader in its sector. The company operates in 138 countries and employs more than 13,000 people, with 66 production facilities and 26 Chocolate Academies.

The factory in Wieze, Belgium, is the largest chocolate factory in the world. Every day, the site produces around 1,000 tonnes of liquid chocolate, representing a value of over four million euros per day. From this facility, Barry Callebaut supplies international brands such as Mondelez, Nestlé, Hershey, Unilever and Tony’s Chocolonely.

The challenge

In 2022, Barry Callebaut was confronted with a salmonella contamination in a batch of lecithin from a supplier. As lecithin is used in all chocolate recipes, the company decided, as a precaution, to temporarily shut down the factory in Wieze.

After the restart, quality procedures were significantly tightened. Each delivery of liquid chocolate had to undergo a testing procedure before being sent to customers. The testing time is approximately 24 hours.

For deliveries to more distant markets, this is not an issue. Transport times there often take several days.

For customers in the Benelux, where transport times are often only a few hours, this created a complex planning challenge.

Chocolate therefore had to be temporarily stored while awaiting test results.

Storage in tanks was limited by available capacity. Letting trucks wait on-site was an expensive alternative. During peak periods, up to 60 trailers would be parked in a waiting zone, representing a cost of up to €60,000 per day.

“We could not justify these costs to the senior leadership team. We needed to find a way to structurally solve this challenge while at the same time reducing costs.”

Sumit Gupta, Supply Chain Planning Manager, Barry Callebaut

The solution

Barry Callebaut worked together with supply chain architects from valueXstream to develop a data-driven solution.

The goal was to optimally combine tank capacity and transport flows during the waiting time for test results.

Based on operational data, valueXstream designed a blueprint for the most cost-efficient way to temporarily store chocolate in tanks or trucks.

By combining partial loads and making smarter use of tank capacity, waiting costs could be significantly reduced.

ValueXstream then developed a planning tool that automates the process.

The tool provides operators with clear instructions on:

• where chocolate should be temporarily stored
• when it can be released for transport
• how transports can be optimally combined

This way, all teams work with one central plan for tank capacity and deliveries.

Changes at customer level are also immediately processed, so operators always work with the most up-to-date information.

“Operators now work with the most up-to-date information. This makes the tool reliable and very user-friendly.”
Sumit Gupta

Fast implementation

In this project, valueXstream applied a pragmatic and flexible approach. The solution was developed based on existing operational data and in close collaboration with the teams in Wieze.

Within three months, the planning tool was fully implemented.

As a result, Barry Callebaut was able to quickly respond to stricter quality procedures without disrupting daily production and deliveries.

The result

By optimising tank capacity and transport planning, Barry Callebaut was able to drastically reduce waiting costs.

The costs related to waiting for test results decreased by more than 60 percent.

In addition, the planning tool brought more structure and transparency to daily operations.

Operators no longer need to make complex decisions based solely on their experience. Instead, they follow a clear process based on data and optimisation.

Collaboration between different teams also became easier, as everyone works with the same planning.

“We now have full visibility of the planning of our tank capacity. Our employees know exactly what they need to do and when.”
Sumit Gupta

Key benefits

Optimised planning of tank capacity
The planning tool provides clear guidelines for the storage and release of liquid chocolate.

Factory processes aligned with business objectives
Waiting time for quality control is efficiently integrated into operational planning.

Cost savings of more than 60 percent
Through optimisation and automation of the planning process, waiting costs are drastically reduced.

Fewer human errors
The tool automates complex planning decisions and increases the reliability of the process.