In a chocolate-making facility, uninterrupted flow is everything. A single blockage can halt production and trigger hours of cleanup.
That is what happened at a specialty food plant, where a temperature drop caused chocolate to harden inside the transfer piping. When the flow stopped, operators shut down the equipment, cleared the lines, and restarted the process, only for the problem to return. Each interruption decreased output and disrupted the schedule.
To prevent further losses, the facility turned to MCE to find a way to keep the chocolate moving.
The Problem: Chocolate Flow Disruptions Threaten Production
In a specialty food plant known for its premium confections, operators faced a recurring nightmare. Chocolate was cooling and thickening inside the transfer lines between the mixing tanks and packaging stations. Once the product stopped flowing, pumps strained, valves clogged, and the entire shift ground to a halt.
Each blockage required a complete shutdown and time-consuming cleanup. Technicians had to disassemble sections of piping, flush out hardened chocolate, and restart the system. These interruptions affected the consistency and quality of the final product even after production resumed. Operators noticed color variation and grainy texture in the final product, likely due to uneven tempering. In a business where texture and flavor define brand reputation, those lapses had a real cost.
The cause was simple: a loss of temperature. Chocolate behaves differently at different temperatures, and even small fluctuations can change its viscosity. As the liquid moved through unheated stainless-steel piping, it cooled just enough to thicken and stick to the inner walls. Without consistent temperature control, the product lost its smooth flow.
The facility’s maintenance team had tried temporary fixes, but they never lasted. Insulation alone couldn’t prevent the heat loss, and portable heaters introduced new risks for food and operator safety. They needed a permanent, engineered solution that maintained precise temperature without disrupting their sanitary production environment.
The Solution: Electric Heat Trace System
The plant turned to MCE for help. MCE specializes in engineered process solutions for temperature-sensitive materials and has deep experience supporting sanitary applications across food, biotech, and pharmaceutical industries. MCE recommended an electric heat trace system from Nelson Electric, a trusted name in process temperature maintenance.
After reviewing the plant’s layout, the MCE team identified where the chocolate lost heat between the processing and holding tanks. MCE’s engineers recommended a Nelson Electric heat-trace system, a trusted solution used across the food and industrial markets to maintain process temperatures or prevent freezing.
The design included:
- Self-regulating heating cables that automatically adjust their heat output to the surrounding temperature, preventing overheating or cold spots.
- Temperature controls and thermostats calibrated to maintain the chocolate’s optimal flow range.
- Termination kits and installation components to ensure a safe, reliable setup in a sanitary environment.
Unlike rigid mechanical systems, the electric heat trace installation required no process redesign. The cables wrapped directly onto existing piping, beneath the insulation, delivering even heat along the entire run. MCE engineered the system to maintain temperature consistency through both jacketed and non-jacketed sections of the line.
This approach allowed the plant to maintain the chocolate’s viscosity precisely where it mattered within the transfer piping, without altering the recipe or adding new equipment to the production floor.
The MCE team coordinated the project from design through delivery. MCE supplied detailed installation guidance and technical documentation that showed how each component fit into the system. MCE also verified configuration requirements before shipment to help the plant’s installation crew complete the setup quickly and safely.
The Result: Smooth Flow, Fewer Interruptions
When the system came online, the difference was immediate. Chocolate flowed continuously between tanks without thickening or separation. The heating elements kept the material within its target temperature range, eliminating the frequent stoppages that once plagued production.
As a result, plant downtime dropped significantly. Maintenance crews no longer spent hours clearing clogs or sanitizing lines mid-shift. With fewer interruptions, the packaging line ran more efficiently, resulting in increased throughput. Operators gained confidence that each batch would move cleanly through the system, producing consistent, high-quality chocolate with every run.
Beyond the measurable improvements, the new system also created a safer, more efficient work environment. Crews no longer performed hot-water flushes or used improvised heating tools to clear pipes. The temperature was automated, predictable, and fully contained within the process line.
Plant management also saw a faster-than-expected return on investment. Each prevented shutdown meant saved labor hours and fewer off-spec batches (and waste). For a daily production process, even small performance gains add up to considerable savings over time.
Why It Worked: Technical Knowledge + Practical Execution
What set this project apart was MCE’s ability to combine technical understanding with practical execution. The team analyzed the process, asked detailed application questions, and used their existing knowledge of food-grade heating systems to recommend an approach that met the plant’s performance and regulatory requirements.
MCE’s partnership with Nelson Electric gives them direct access to proven technology and quick product availability.
MCE also understands that many facilities struggle with over-engineered or incomplete systems. In this case, the team bundled all required components into one package – cables, controls, and installation accessories – reducing guesswork and minimizing installation time. The design avoided unnecessary complexity, allowing the plant’s maintenance team to manage the system with minimal training.
And because MCE keeps an inventory of essential Nelson components, we were able to ship parts quickly, preventing extended downtime between the design and installation stages.
Finally, MCE remained involved during commissioning to verify temperature control settings and ensure the system performed as expected. That level of engagement helped the plant avoid the trial-and-error phase that often follows new installations.
Partner with MCE for Reliable Temperature Control
Whether you process food, chemicals, or temperature-sensitive materials, consistent heat can mean the difference between steady output and daily disruptions. MCE helps companies achieve that consistency with complete Nelson Electric heat trace systems, expert guidance, and quick delivery.
If your facility faces challenges maintaining product temperature, MCE can design and deliver a system that keeps your process flowing smoothly. Connect with MCE’s engineering team to learn how a properly designed heat-trace solution can keep your lines running and your production on track.
