The company builds injection molds from aluminum and then uses them to create polycarbonate molds with multiple cavities that are used to produce all sorts of chocolate treats.
“We use polycarbonate so we run everything low melt and our walls are 1/8 to ¼ inch thick so they are really robust,” he said.
Goddeau added: “With chocolate nothing is standardized. Every mold we make is different, different lengths and different widths. There's somewhere between 150-200 different configurations.”
He said the company is always working on new molds. When the price of chocolate rises, it means that less chocolate will be used, so a different mold is needed.
“[Customers] tell us the target and the cavity size. We know all the densities of all the chocolates and any of the filings so we are able to hit the targets,” he said.
Goddeau said Micelli currently has more than 5,000 chocolate molds in house. They're used by just about every chocolate maker in the U.S. and many others worldwide.
Goddeau said that means Micelli has to keep upgrading its machinery. In the last two years, it has added two Bole EK series injection molding machines as well as eight Haas machining centers.
The company added a 880-ton Bole last year to handle a large project for 110,000 polycarbonate molds that meant using over a half million pounds of low-melt polycarbonate.
Pleased with the simplicity of the Bole toggle design, the company added a 360 ton Bole this year. He said the design meant less flex in the platen and molds, and more material savings.
He said that chocolate molds account for 60 to 70 percent of its business. Micelli also molds point-of-purchase displays, beverage trays for delis, and cosmetics.