With immense success in both retail and industrial divisions in the chocolate industry, Theocom entered the cone manufacturing business under the brand name CHOCOLO. Theocom is a Pvt. Ltd. company specializing in the manufacturing of Sugar Rolled Cone, Wafer Cone primarily used in the ice-cream industry for Automatic Rolled Sugar Cone Production Line.
With immense development and growth over the last 6 years, Theocom has become a well-known manufacturer for sugar rolled and wafer cones. Every cone we manufacture is high in quality, taste and precision. Its perfection rolled into an edible cone!
The batter for all cones is mixed in large vat-like mixers and stored in coolers. Air compressors blow the dry ingredients into the mixers. Separate mixers and coolers are used to combine and store the batter for cake cones and for waffle and sugar cones together. The air compressors that pump in all ingredients are computer-controlled so the recipe for each cone is correct. Computers also control all the other machines in the factory; in the mixing area, they tell the compressors when the coolers are running low on batter, so the next batch is mixed automatically.
As the dry ingredients are blown in, water is added, and the mixers begin to stir the batter. The dry ingredients and water are mixed for nine minutes before the other ingredients are added. The computer signals to a worker when the nine-minute mix is done,... and the worker inspects the partial batter then adds the remaining ingredients by hand. This is one of the few hands-on parts of the process; it is essential to the character and quality of the finished cones. The worker resets the mixer when the ingredients have been added, and the mixer beats the batter for a few minutes at high speed, not only for perfect blending but to add just the right amount of air to the batter. The mixer for the waffle/sugar cone batter is mixed in 56-kg batches. The mixed batter is then pumped to its cooler; the mixer shuts itself off automatically and resets itself for the next batch.
From the coolers, batter is pumped to storage tanks next to the baking ovens. It is then pumped through a pipe. Waffle cone batter is pumped batter flows onto plates much like the bottom plates of waffle irons. The pumping system applies a pre-measured amount of batter to either the mold or the plate. Waffle and sugar cones bake for about 82 seconds, but they take longer to finish because they have to be shaped. The flat, hot, baked circles are rolled into cone shapes by specialized cone-rolling machines in a process that takes about 20 seconds. These cones cannot be handled for packing until they are completely cooled, and they are air-cooled for 2 minutes. Cooling makes the cones firm to hold their shape. Finished cones travel along conveyors to the packing area. Waffle and sugar cones are crisp and delicate, so each one is individually packed in a Styrofoam container with a bottom bowl and a lid (a "clamshell" container). These packages are also boxed. All boxes have been preprinted by an outside printer and box manufacturer. The outer design is not only decorative but carries the nutritional information required by the Indian government for a single-cone serving. Some boxed cones are sent to the dairy-pack industry which fills the cones with chocolate liners and ice cream, freezes their products, and repackages them for individual sale and bulk sale in boxes in grocery stores. Finally, packaged cones are sold in bulk to retail businesses like grocery, chain, convenience, and drug stores. These retailers usually do not fill or modify the cones; they sell the boxed cones directly to the consumer who can make custom desserts and snacks with the cones at home.
Although cone-making is computer-controlled, workers are essential to quality control. The correct addition of ingredients is the most obvious quality control step, but throughout the process specially trained quality control inspectors watch cone making and baking, taste-test cones occasionally, and reject any that are misshapen, broken, or over/under-cooked. Whole cones are also removed from the process and cut and broken apart to check that cones are truly perfect inside and out.