Kit Kat Wafer Bar

Introduction

A Kit Kat bar is one of the oldest and most classic of snack bars. As one of the most widely recognized and enjoyed snacks in the world, this iconic chocolate covered wafer bar has delighted many generations. But have you ever wondered what it actually takes to produce a Kit Kat bar and transport it from production to the dinner plate?

In this blog post, we will be exploring just that, breaking down the entire process of how a Kit Kat wafer bar is created and travels to a dinner plate. We will be discussing everything from the wafer ingredients, to the process of coating, wrapping, and packaging these products, to the different methods and routes for delivering them to retailers for consumption. By charting the complete journey of a Kit Kat bar from factory to dinner plate, this post will provide readers with a more in-depth look at just how these delicious treats make their way from the production line to our shelves and our mouths.

Wafer Production and Coating

At the beginning of the production process, all the raw materials necessary to create a client-specific Kit Kat wafer are measured, mixed, and processed. This includes a combination of alternating layers of wheat flour and sugar dough that are then popped and pressed into thin, crispy wafers.

The wafers are then inspected and any defects are removed, before being passed through a sugar syrup bath and finally onto a baking belt. This baking belt moves the wafers through an oven where they become evenly baked and crispy. As soon as the wafers have been baked, they are immediately cooled and sent to a coating station, to prevent any potential “soggy” wafers.

The wafers then pass through a coating of chocolate, followed by an optional layer of rainbow sprinkles. To achieve an even chocolate layer, the wafers must travel through a series of spouts, where the hot and liquid chocolate will settle and evenly coat the wafers. This chocolate is kept at a specific temperature to ensure that it is still liquid when the wafers enter the spouts, so that it adheres evenly and quickly.

Wrapping and Packaging

Once they have been dipped in chocolate and have had layer of rainbow sprinkles added, the Kit Kat bars are then lined up and wrapped by machines, which can pack dozens or even hundreds of individual wafers into a single package. From here, the wafers are passed through an automated wrapping system that seals and packages them into finished final products, which are ready for delivery.

Delivery

Delivery of these ready packaged Kit Kat bars is an important step in the production process. Depending on the size of the delivery, there are two primary methods for transportation. Smaller deliveries are usually transported by a third-party logistics provider via truck. The temperature inside the truck is generally regulated to keep the chocolate from melting, and regional warehouses usually carry extra boxes of Kit Kat bars in case of emergency needs.

Larger deliveries are usually transported via air freight from a regional warehouse. In these cases, the entire shipment is loaded onto a cargo plane, either in individual bricks or larger pallets. As with the truck freight, the precise temperatures within the cargo plane must be regulated, in order to ensure that the chocolate does not melt before arriving at its destination. Additionally, due to the circumstances of international shipments, certain countries and states may have heavier regulations and other product-specific guidelines that must be met when trading internationally.

Retail Distribution

The final step in the journey of a Kit Kat bar is its distribution to retail outlets. This is typically done through a network of independent wholesalers and distributors, who will carry the product from the warehouse where it is stored to its individual retail stores.

Typically, the outlets receiving the Kit Kat bars will be nationwide, big-box stores and convenience chains, as well as independent convenience stores and gas stations. All of these places will already have the necessary refrigeration and dispense systems in place that will allow them to adequately store and display the product for purchase.

Conclusion

We hope that you now have a better understanding of the entire process of creating and distributing a Kit Kat bar from factory to dinner plate. From the milling of the raw materials to the coating of the wafers, to the packing and delivery systems that safely transport these snacks to retailers, the journey of a Kit Kat bar is a complex and impressive one. It is quite incredible to think that the pleasure of a Kit Kat wafer bar can be traced all the way back to a set of carefully calibrated factory equipment and processes.