Choco Matic

Ahmad Dardook; Sayed Qutob

Choco Matic

dc.contributor.author	Ahmad Dardook
dc.contributor.author	Sayed Qutob
dc.date.accessioned	2026-10-29T07:00:34Z
dc.date.issued	2026-06-14
dc.description	--
dc.description.abstract	The rising demand for high-quality, customized chocolate bars has driven the need for small- scale, automated production solutions. This project presents the design and implementation of a chocolate bar production line that incorporates a fully automated chocolate tempering machine and a topping system for nuts and raisins. The system integrates three microcontrollers an Arduino Mega 2560 for production line control, an ESP32 for managing the tempering machine and wireless app connectivity, and an Arduino Uno for monitoring filling levels and driving additional LCD displays. Key features include a PT100 temperature sensor for precise heating, a 1950W heating element controlled via SSR, ultrasonic sensors for topping level monitoring, and mode-selection keypads for both chocolate type and topping. Chocolate dispensing and topping systems are actuated using NEMA23 stepper motors, while a windshield-wiper motor drives the conveyor belt. Additionally, real-time feedback is provided through LCD displays, and the entire system can be operated manually or remotely via a mobile application. Thermal behavior and energy usage were modeled using fundamental heat transfer formulas, ensuring reliable tempering with realistic time estimates. The project aims to deliver a scalable, energy-efficient, and user- friendly solution suitable for artisan or semi-industrial chocolate production environments.
dc.description.sponsorship	--
dc.description.statementofresponsibility	In small-scale chocolate manufacturing, one of the most significant challenges lies in maintaining consistent product quality while minimizing manual labor and production time. Traditional chocolate tempering processes are labor-intensive and require precise temperature control to avoid bloom, grainy texture, or poor molding. Likewise, topping customization (such as adding nuts or raisins) often relies on manual intervention, limiting production speed and scalability. Furthermore, there is a lack of affordable, compact, and modular systems that can manage both chocolate tempering and bar assembly including molding, filling, topping, and vibration for customized chocolate products. Existing solutions are either too costly for small producers or too simplified to ensure precision and consistency. In many student or prototype-level projects, the integration of hardware components such as high-power heating elements, industrial sensors, and motor drivers is rarely explored in a production context with real chocolate behavior. Thus, there exists a gap between theoretical automation solutions and real-world food-safe systems. This project aims to address these challenges by designing and implementing a fully automated chocolate bar production line with a real-time monitored tempering system, topping dispensers, and wireless control via a mobile application offering a scalable and modular solution for educational, or semi-industrial environments.
dc.description.tableofcontents	The primary goal of this project is to design and implement an automated chocolate bar production line with integrated tempering and topping systems. The system is built to ensure precise temperature control, consistent bar quality, and efficient topping customization. The detailed objectives are: ➢ Automate the chocolate tempering process using real-time temperature monitoring (via PT100 sensor and MAX31865 module) and a 1950W heating element controlled through an SSR and ESP32. ➢ Provide support for three chocolate types milk, dark, and white each with its unique tempering profile. ➢ Enable topping customization by allowing users to select between raisins or/and nuts or no topping via a dedicated keypad. ➢ Control the mold-filling process using a stepper-controlled stainless-steel pipe and IR sensors to detect mold positioning. ➢ Ensure proper mixing and setting by integrating a vibration motor for uniform chocolate distribution in the mold. ➢ Drive the production line using a windshield-wiper motor controlled by a BTS7960 motor driver for cost-effective and reliable belt movement. ➢ Monitor the filling levels of toppings and chocolate containers using ultrasonic sensors and display them in real time on dedicated LCDs. ➢ Integrate user interaction through keypads, a 20x4 LCD for system status, and remote operation through a mobile app via Wi-Fi (ESP32). ➢ Use modular microcontroller architecture, employing Arduino Mega for the main line, Arduino Uno for filler monitoring, and ESP32 for the tempering control and network interface. ➢ Implement heat transfer calculations to estimate heating time and ensure energy efficiency.
dc.format.medium	Hardware
dc.identifier.citation	--
dc.identifier.other	12112172
dc.identifier.uri	https://hdl.handle.net/20.500.11888/21502
dc.language.iso	en
dc.publisher	Dr. Mahmoud Assad
dc.relation.ispartofseries	--; --
dc.subject.classification	Industry
dc.supervisor	Dr. Mahmoud Assad
dc.title	Choco Matic
dc.title.alternative	--
dc.type	Graduation Project
person.telephone	972598686625