Chocolate cooling tunnel CTA

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Overview
A chocolate cooling tunnel removes heat after depositing or enrobing and discharges set products for demolding, packaging or further processing. Tunnel length and belt speed determine residence time; independently controlled cooling zones set the air temperature the product traverses. Conveyor type and chassis are selected from product format, site geometry and mold footprint.

Cooling duty
Residence time is defined by tunnel length and belt speed (adjustable from the HMI). Sizing is performed for the longest-cycle product considering piece mass, cavity or deposit depth and inlet and zone temperatures (factory nominal zone temperature 7 °C). Refrigeration capacity is selected to maintain zone temperature under product heat load at the required throughput.

Process suitability — immediate exclusions

• Standard range excluded: required tunnel length outside 4–30 m or belt width outside 300–2000 mm — custom engineered configuration required.
• Multi-storey excluded: where simultaneous mold cooling and belt enrobing is needed or enrobing > 50 kg/h — multi-storey cannot operate both processes simultaneously at higher enrobing throughput; specify separate CTA or CTI tunnel.

Three decisions fixed at order

• Product format → conveyor: Enrobed and belt-deposited drops/coins/callets run on a PU belt. Molded chocolates use mold track on CTA PU belt, modular belt on CTI, or elevator (ETCTA/ETCTI). Elevator families are mold-only.
• Site geometry → chassis: Restricted floor length with ceiling clearance → elevator (saves up to 80% horizontal length). Restricted ceiling with floor length available → horizontal CTA or CTI. Partial constraints at artisan scale → multi-storey. Architecture cannot be converted after delivery.
• Scale and mold footprint → family: CTA for 4–12 m (incl. 12 m); CTI above 12 m up to 30 m. Belt width engineered at order and may cross family ranges; for a 1000 mm belt specify at least 14 m tunnel length. ETCTA takes 175×275 mm molds (108 / 144 / 180); ETCTI takes 205×600 mm molds and is sized at order.

Conveyor comparison: PU belt vs mold track vs modular belt
Enrobed products, belt-deposited drops/coins/callets | Polyurethane (PU) belt (standard CTA/CTI) — use mold track (CTA) or modular belt (CTI) when production is molded chocolates.
Molded chocolates, tunnel 4–12 m (CTA) | Mold track on PU belt (option) — CTA limited to 12 m.
Molded chocolates, tunnel >12–30 m (CTI) | Modular belt (option) — CTI preferred for industrial molded lines; modular belt is poor for loose drops/enrobed pieces.

Chassis comparison: horizontal vs elevator vs multi-storey
Horizontal (CTA/CTI) | Long floor footprint | Standard ceiling
Elevator (ETCTA/ETCTI) | Compact (up to ~80% shorter) | Tall ceiling required (vertical stages)
Multi-storey | Intermediate footprint/height | Suitable for artisan mixed operations but bath section limited to ~50 kg/h

Model families and selection rules

• CTA (artisan): length 4–12 m; typical belt width 300–800 mm; PU belt standard; mold track optional; 380 V three-phase. Typical use: workshop and small-production enrobed and belt-deposited lines.
• CTI (industrial): length >12–30 m; typical belt width 600–2000 mm; PU belt standard, modular belt optional; 380 V three-phase. Typical use: high-throughput industrial lines.
• ETCTA (elevator artisan): mold footprint 175×275 mm; 18 vertical stages; capacities 108 / 144 / 180; rod conveyor with rodless pneumatic transfer; compressed air 4–6 bar; total power ≈ 8.5 kW; used where floor length is constrained and ceiling height is available.
• ETCTI (elevator industrial): mold footprint 205×600 mm; vertical stages and capacity sized per project; compressed air 4–6 bar; total power ≈ 10.5 kW typical; used for industrial molded lines with constrained floor length.

Common features (all models)

• AISI 304 stainless steel construction.
• 35 mm CFC-free rubber insulation.
• Cooling zones: CTA 1 standard (2 optional ≥8 m); CTI 2 standard (3 optional); ETCTA/ETCTI always 2 independently controlled zones.
• Factory-set zone temperature normally 7 °C (adjustable from external refrigeration controller).
• Belt speed adjustable from the HMI.
• Mist eliminators for dry air delivery optional.
• Residence time and refrigeration sized at order to the line's longest-cycle product.

Warranty and lead time
1-year warranty against manufacturing and construction defects. Typical lead time 3–4 months from order once length, belt width, mold capacity, conveyor type and refrigeration sizing are confirmed at quotation.

Related equipment (typical upstream / downstream)

• Upstream (molded elevator families): one-shot depositor or semi-automatic molding machine for mold feeding.
• Upstream (PU-belt configurations): chocolate enrober, drop-line depositor or lentil forming machine.
• Downstream: demolding for elevators; bulk collection, packaging or further processing such as panning for PU-belt configurations.

Technical specifications

• Product name: Chocolate Cooling Tunnel
• Available families/models: CTA (artisan), CTI (industrial), ETCTA (elevator artisan), ETCTI (elevator industrial)
• Length ranges: CTA 4–12 m; CTI >12–30 m; elevator vertical stages sized per project
• Belt width (typical): CTA 300–800 mm; CTI 600–2000 mm; custom widths engineered at order
• Conveyor types: PU belt (standard), mold track on PU (CTA option), modular belt (CTI option), rod conveyor with pneumatic transfers (elevators)
• Construction: AISI 304 stainless steel; 35 mm CFC-free rubber insulation
• Cooling zones: CTA 1 standard (2 optional ≥8 m); CTI 2 standard (3 optional); ETCTA/ETCTI 2 zones
• Factory-set zone temp: typically 7 °C, adjustable
• Control: belt speed via HMI; zone temperatures from external refrigeration controller
• Power supply: 380 V three-phase (kW depends on length, belt width and capacity; examples: ETCTA ~8.5 kW, ETCTI ~10.5 kW)
• Compressed air (elevators): 4–6 bar for rodless pneumatic transfers
• Refrigeration: sized to product heat load, throughput, belt width and required residence time
• Optional accessories: mist eliminators, interior lighting, top lids with gas springs for cleaning access
• Warranty: 1 year (manufacturing and construction defects)
• Lead time: typically 3–4 months from order (final sizing and configuration confirmed at quotation)