Bühler launches cocoa roaster that cuts energy use and increases output

SWITZERLAND – Bühler has introduced Lucent, a new industrial cocoa nib roaster that cuts energy use by at least 20% per tonne of cocoa while increasing throughput by up to 20% within the same machine footprint.

The Swiss technology company developed Lucent to help cocoa processors manage high cocoa prices, rising energy costs, and tighter operating margins. Roasting remains the most energy intensive stage in cocoa processing and accounts for a large share of energy costs across production.

Lucent recovers heat that previous systems released during roasting. Its heat exchange system uses return air to reduce the load on the gas burner, while a redesigned drum and improved fill levels lower gas use and increase output without requiring extra factory space. Bühler also offers a hybrid roasting option that combines convective and conductive heat transfer and can reduce energy use by up to 40% in some applications.

“Roasting is where flavor is created. It is one of the steps our customers care about most, and it has historically been the step where the most energy is wasted. Lucent enhances flavor control while reducing energy use,” said Isabelle Kirckof, Product Manager Market Segment Cocoa & Malt at Bühler.

The new roaster also places food safety at the center of its design. A fully enclosed roasting chamber and sealing system keep the product separate from combustion air throughout the roasting process. Stainless steel construction, easy access service openings, and a design that reduces product loss also support cleaning and maintenance.

“Food safety standards in the cocoa and chocolate industry are tightening, and our customers need equipment that meets those standards structurally, not through process workarounds,” said Joachim Essig, Head of Sales Cocoa & Malt at Bühler.

Lucent uses a self-learning control system that monitors roasting conditions and automatically adjusts burner temperature, airflow, and process speed. Operators only need to select the roasting profile before the system manages the process.

“Roasting has always been as much about expertise as technology. Lucent combines both by embedding process knowledge into the machine, making repeatable flavor profiles and consistent roast levels easier to achieve,” Kirckof said.

Bühler developed Lucent using customer feedback and will install the first prototype at a customer site in Asia during the first quarter of 2027. The company manufactures the equipment at its Appenzell facility in Switzerland.

The launch follows Bühler’s recent integration of UK based engineering company Endeco, a move that expands its presence in the UK and Ireland by combining Bühler’s processing technologies with Endeco’s engineering, project management, and installation experience.

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