Bühler launches Lucent cocoa nib roaster with 20% lower energy consumption, higher throughput

BELGIUM – Bühler has unveiled Lucent, a next-generation cocoa nib roaster designed to reduce energy consumption while increasing productivity for industrial cocoa processors worldwide.  

The new system uses at least 20% less energy per tonne of cocoa than its predecessor while delivering up to 20% higher throughput within the same production footprint. 

The launch comes as cocoa processors face increasing pressure from volatile cocoa prices, rising energy costs and tighter operating margins. According to Bühler, energy represents between 10% and 20% of total operating expenses in cocoa processing, with roasting remaining the most energy-intensive stage of production. 

Lucent incorporates heat recovery technology, predictive roasting controls and a fully sealed product chamber to improve efficiency, consistency and food safety. The company said the system is now available to industrial cocoa manufacturers globally. 

Bühler explained that its previous Tornado roaster operated as a batch process in which hot air roasted cocoa inside a rotating drum before exhaust air was vented after each cycle, resulting in significant thermal energy losses. Lucent addresses this challenge through an integrated heat exchange system that recovers return air and reduces the load on the gas burner. 

According to the company, the redesigned drum geometry and optimised fill levels lower gas consumption by at least 20% compared with Tornado while increasing throughput by up to 20% without expanding the machine’s physical footprint.  

Bühler also offers an optional hybrid roasting mode that combines convective and conductive heat transfer, delivering energy savings of up to 40% in specific applications. 

The new cocoa roaster also introduces a fully enclosed roasting chamber and an advanced sealing system that keeps the product physically separated from combustion air throughout the roasting process.  

Constructed from stainless steel with an easy-clean finish, the machine includes service openings that provide direct access to critical components, reducing maintenance time and simplifying inspections. 

Bühler added that the redesigned system also minimises yield losses, addressing a limitation in previous-generation roasters where cocoa product could be drawn into the airflow during processing. 

The Lucent roaster features a self-learning control system that continuously monitors roasting parameters and automatically adjusts burner temperature, airflow and process speed. Operators select a roasting profile, after which the algorithm manages the process, with roasting cycles lasting between 40 and 60 minutes depending on the raw material.  

The system also adapts to variations in incoming cocoa to maintain consistent roasting results while reducing dependence on specialist operator expertise. 

Bühler said the development was guided by feedback from industrial cocoa processing customers, with priorities around efficiency, hygiene and operational simplicity shaping the final design. A 

 prototype will be installed at a customer site in Asia during the first quarter of 2027, with further applications for roasting other commodities planned over the following two years. 

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