Thiago Jube is a Process Technology Manager at Barry Callebaut Group, bringing over 15 years of manufacturing, process engineering, and quality management expertise. As a food engineer (UFGo) with an MBA, he has led large-scale projects, optimized production processes and implemented lean manufacturing strategies across global markets. Passionate about innovation and sustainability, Jube integrates cutting-edge technology to enhance efficiency while maintaining the highest quality standards. His leadership in training high-performance teams and collaborating with R&D drives continuous chocolate and cocoa production improvement, ensuring excellence from bean to bar.
Through this article, Jube emphasizes the importance of strong leadership, lean manufacturing and continuous improvement principles to optimize chocolate and cocoa production while balancing efficiency, sustainability and profitability.
Key Leadership Principles to Manage Technical Team
Managing high-performance technical teams in a fast-paced production environment requires a blend of strategic leadership, technical expertise and effective people management. The following leadership principles are essential for success:
1. Lead by Example
• Demonstrate a strong work ethic, commitment to quality and a problem-solving mindset.
• Be hands-on when necessary, but empower the team to take ownership of their work.
2. Clear Communication
• Set well-defined goals, expectations and priorities.
• Foster open dialogue, encourage feedback and actively listen to team members.
3. Continuous Improvement Mindset
• Promote Lean, Six Sigma, and other efficiency-driven methodologies.
• Encourage a culture of innovation where employees feel safe to propose and test new ideas.
4. Data-Driven Decision-Making
• Utilize KPIs, process metrics and real-time data to drive performance.
• Make informed decisions based on facts rather than assumptions.
5. Employee Development & Engagement
• Provide training and mentorship to upskill team members.
• Recognize achievements and foster a sense of purpose within the team.
6. Agility & Adaptability
• Be proactive in identifying risks and adaptable to production demands.
• Encourage a mindset where challenges are seen as opportunities to improve.
7. Cross-Functional Collaboration
• Work closely with R&D, quality, maintenance and supply chain teams to ensure smooth operations.
• Break down silos and promote teamwork across departments.
8. Accountability & Ownership
• Set high standards and hold team members accountable for results.
• Provide support when needed but ensure individuals take responsibility for their tasks.
Maximizing Efficiency with Lean Manufacturing and Continuous Improvement
Applying lean manufacturing and continuous improvement (CI) principles has led to significant efficiency gains and quality improvements in chocolate and cocoa production. Some key process improvements include:
Demonstrate a strong work ethic, commitment to quality and a problemsolving mindset. Be handson, when necessary, but empower the team to take ownership of their work.
1.Yield optimization in cocoa processing
• Issue: Variability in nib roasting and cocoa butter extraction leading to yield losses.
• Solution: Implemented real-time process monitoring and automated control adjustments.
• Impact: Increased cocoa butter yield by three to five percent while maintaining flavor integrity.
2. Reduction of Waste in chocolate conching
• Issue: Excessive energy use and material loss during extended conching times.
• Solution: Applied DOE (Design of Experiments) to optimize conching parameters.
• Impact: Reduced conching time by 20 percent, saving energy and raw material costs.
3. Standardization of Liquor Grinding Process
• Issue: Inconsistent particle size distribution affecting chocolate texture.
• Solution: Implemented SPC (Statistical Process Control) and real-time viscosity adjustments.
• Impact: Improved chocolate texture consistency, reducing rework and waste.
4. SMED (Single-Minute Exchange of Die) for Mold Changes
• Issue: Long downtime due to mold changeovers.
• Solution: Applied SMED methodology, reorganizing tool setups and implementing quick-release mechanisms.
• Impact: Reduced changeover times by 50%, increasing production uptime.
5. Implementation of Autonomous Maintenance
• Issue: Unplanned downtime due to equipment failures.
• Solution: Introduced TPM (Total Productive Maintenance) with operator-led inspections.
• Impact: Reduced unplanned downtime by 30 percent, improving equipment lifespan.
6. Reduction of Overproduction in Bulk Chocolate Production
• Issue: Overproduction leads to excessive storage costs.
• Solution: Implemented kanban and pull systems to align production with actual demand.
• Impact: Reduced finished goods inventory by 15 percent while maintaining delivery timelines.
7. Energy & Water Optimization in Cocoa Processing
• Issue: High energy and water usage in cocoa mass production.
• Solution: Introduced heat recovery systems and optimized cooling water cycles.
• Impact: Achieved a 10 to 15 percent reduction in energy and water consumption per ton of cocoa processed.
Balancing Sustainability with Operational Efficiency and Profitability?
Sustainability is a growing priority in the chocolate industry. Here is how we integrate sustainability with operational efficiency:
• Waste Reduction and Process Optimization: Repurposing cocoa shells for biomass fuel reduces waste and energy costs.
• Energy and Water Efficiency: Upgrading to energy-efficient roasting and heat recovery systems lowers costs.
• Sustainable Sourcing and Supply Chain Optimization: Partnering with certified cocoa programs ensures ethical sourcing.
• Packaging Innovations: Using biodegradable or recyclable materials reduces environmental impact.
• Circular Economy and Byproduct Utilization: Repurposing cocoa husks for animal feed or organic fertilizers creates revenue.
• Smart Automation and Digitalization: Implementing IoT and AI-driven monitoring optimizes resource use.
By integrating sustainability into CI and Lean strategies, we enhance efficiency, reduce costs and maintain long-term profitability.
Key Advice for Aspiring Leaders
1.Master the Fundamentals: Gain expertise in chocolate processing, cocoa chemistry and quality control.
2. Embrace Continuous Improvement and Lean Thinking: Learn Lean, Six Sigma and Kaizen methodologies.
3. Stay Ahead of Industry Trends: Keep up with sustainable sourcing, alternative ingredients and automation.
4. Develop Technical and Leadership Skills: Balance technical expertise with leadership and problem-solving abilities.
5. Focus on Sustainability and Ethical Sourcing: Learn about certified cocoa programs and sustainable practices.
6. Leverage Technology and Automation: Familiarize yourself with Industry 4.0 tools like IoT and AI-driven quality control.
7. Never Stop Learning and Networking: Attend industry conferences, workshops, and professional certifications.
8. Be Adaptable and Innovative: Challenge the status quo and seek ways to improve efficiency, quality, and customer satisfaction.
Professionals can drive innovation and excellence in chocolate and cocoa production by adopting these principles.
