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A man picks a cocoa plant from a tree.

Indonesian cocoa production embraces Internet of Things

To drive national cacao industry forward, Indonesia is combining on the ground teaching and training with artificial intelligence (AI), big data and digital process automation. The goal is a globally competitive chocolate production.

image of cocoa powder

Indonesia is one of the world's largest cocoa producers, ranking third after the Côte d'Ivoire and Ghana. The island nation’s diverse climate and soil yield high-quality cacao varieties with unique, rich flavors. Though brimming with potential, the industry suffers from lack of technology and infrastructure, low productivity, quality issues and limited access to high-quality markets with stable prices.

Cocoa Teaching and Learning Industry (CTLI) is a state-sponsored enterprise run by the Universitas Gadjah Mada (UGM) in Batang, Java. Its aim is to drive the Indonesian cocoa industry forward by "providing farmers with training and access to technology, developing a better and more stable network, and establishing certification and quality standards that align with international markets," explains Nur Muhib, General Manager at UGM CTLI.

Digital transformation is a must for an export-oriented company like us.
Nur Muhib, General Manager at Gadjah Mada University, Cocoa Teaching and Learning and Industry (CTLI)

The key to competitive cocoa: digital transformation

CTLI currently produces 50 tons of cocoa annually, half of its total capacity. To ensure that more raw materials meet manufacturer standards, it ushered in digital solutions. "Digital transformation is a must for an export-oriented company like us," continues Nur Muhib.

Automation technology is ubiquitous throughout CTLI. Critical motors are equipped with Simatic CSM2000 vibration sensors and analyzed with Siemens Condition Monitoring System (CMS) X-Tools. Simatic Siwarex weighing system simplifies the cocoa butter filling process.

The wirelessly integrated Simatic PCS 7 allows maintenance engineers to monitor motors and pumps remotely via Simatic tablets and commercial smartphones. Simatic Scalance S firewall protects the network against outside intrusions.

"By utilizing IIoT, we can oversee and control the factory in real-time from anywhere at any time,” says Nur Muhib.

A man presses a button on the screen of a tablet.

AI and the Golden Batch

A man wearing a hard hat uses a tablet to check a control cabinet.

The factory is additionally equipped with the AI-enabled Siemens Process Monitoring Analytics (PMA) software. Using sensor readings from the roasting machine, it can learn and teach itself how to produce the Golden Batch – where the roasting process is completed in the fastest time, in the most-energy efficient manner, and to the highest quality.

By ensuring quality processes and quality results, we can bring the 'bean to bar' concept to life.
Dr. Hargo Utomo, Director of Business Development and Incubation, Gadjah Mada University

Big data brings “bean-to-bar” notion to life

CTLI relies on the Industrial IoT application suite Insights Hub to monitor its plantations. It is currently developing an app to predict the quality of cacao yields based on weather conditions. Big data will play a key role in further optimizing chocolate production. "We will further analyze all historical data stored in the data center," says Dr. Hargo Utomo, Director of Business Development and Incubation at Gadjah Mada University.

Indonesia is also looking to increase overall demand for organic and sustainable cocoa products and to develop derivatives with high added value, such as chocolate, chocolate drinks, and cosmetics made from cocoa. Dr. Hargo Utomo concludes, “By ensuring quality processes and quality results, we can bring the 'bean-to-bar' concept to life."


April 2023

Contact:
Astri Ekaputri
Danu Setyo Nugroho