The newly opened Ficosota factory near Shumen will produce 230 million wafers under the My Motto brand every year
230 000 000
waffles annual capacity
Modern industrial design, where cool concrete, metal and glass are softened by the abundance of greenery and natural light, creating the feeling of a modern office of an international company. Only the coconut aroma, mixed with that of cocoa and coffee, reminds us that we are actually in a factory. Here, in the brand-new industrial factory of "Ficosota" in Shumen, the company produces the My Motto wafers.
The most surprising wafer on the market - with a square shape, instead of the traditional rectangle and overflowing with cream - is now produced in a factory, designed specifically for the product. This new factory occupies an area of more than 8400 square meters and is located next to the production site of other Ficosota Food products. The My Motto factory has a capacity to produce 230 million wafers a year, thus fulfilling orders destined for 40 countries on 6 continents.
area of the new factory
8400 sq. m.
Modern Technology and Master Technologists in One
The construction and equipment of the new Ficosota factory was entrusted to global industry leaders, guaranteeing high-tech solutions and world-class quality. The My Motto wafer factory is distinguished from other similar facilities by the fully automated production processes which comply with the highest standards - from transport and dosing of wafer flour to final product packaging.
The production line is fully automated and highly efficient, and its operation requires just 10 people. With the support of a leading industry subcontractor, Ficosota also acquired a specially designed hall for storing flour in 25-ton silos. The loading and dosing of 90% of the raw ingredients used for the preparation of wafer sheets and creams are fully automated, and the remaining 10% are strictly controlled by the master technologists of My Motto.
The wafer sheets production line is one of the factory’s technological marvels. It includes 120 individual bakery presses, which guarantees the "crunchiness", and 60 ready-made wafer sheets come out the production line every minute. This is an exceptional oven for crispy and delicious cocoa wafer sheets.
And this is just the beginning – the work of the oven is controlled by several indicators, monitoring whether the sheets are intact and perfectly shaped and weighed. No compromises are allowed here, because even if a tiny corner is broken, the whole wafer sheet is to be automatically removed.
Rigorous input control is fundamental to the success of this exclusive product. According to production manager Emil Petrov, each of the raw ingredients used in the wafer recipe must meet a number of stringent requirements. Even the smallest deviation leads to discarding. "We require our suppliers to hold a number of certificates, the benchmark in our industry, and this is only the first step. Before we sign a contract with a supplier, it is our common practice to visit their factory in person and get acquainted with the production process of the incoming raw materials. Our objective is to be 100% sure of the safety and quality of raw materials before we get them on site,” explains Petrov, adding that you cannot have a perfect product if the raw ingredients used are not produced in exemplary fashion.
Numerous robotised control points are set along the production line, monitoring the basic quality parameters of each wafer. They do not, and cannot, allow any deviation from the parameters set in the programs. In addition to the robots, experienced specialists monitor the entire production process - from the raw ingredients all the way through to the packaging - in a way that the quality and the robustness of flavor of the final product is ensured.
Control at All Levels – Input, Production and Output
Low Cost Savings
High Cost Savings
Low Cost Savings
High Cost Savings
Low Cost Savings
High Cost Savings
Ficosota explains that their main motivation in embarking on this investment venture is the huge potential they see in the development of the product, and in particular, the market for non-coated wafers.
Over the last three years, the company has achieved significant growth in the sales of My Motto products abroad, and in some markets, such as Romania and Ukraine, it is one of the fastest growing products in Ficosota's portfolio. The company believes that when it comes to dealing in a mature category such as this of wafer products, the only way to add value for both the consumer and retailers is to produce a distinctive product that surpasses expectations and defies category clichés.
"That's why our wafer is square instead of the traditional rectangular one; there are two wafers in one package instead of one and a creamy product (80% cream, 20% wafer)" – this is how Rumen Petkov - Global Marketing Director of Ficosota Food synthesizes the recipe for My Motto’s success.
The packaging process is also fully automated, starting with the arrangement of the individual wafers in pairs, through the folding, gluing, and filling of transport boxes, and the arrangement of the pallets with ready to transport goods.
The most impressive robot in the factory – or simply C-3PO, as it is called by the factory employees, inspired by its relative from Star Wars - participates in this final production stage. It receives signals from the production lines when the required number of packages is prepared. It lays line after line, occasionally picking up and placing a sheet of paper between the lines for extra stability. In addition to its speed, the robot possesses real finesse. After raising pallets to a height of 2.40 meters, it adjusts them carefully, packs them and sends them off for transportation to one of the 40 countries where My Motto wafers are sold.
The Secret of the Taste is Hidden in the Cream
All products used in the recipe for waffles meet a number of requirements and even the smallest deviations are not used in production
What distinguishes the new My Motto waffle factory from similar productions is the fully automated and efficient production processes by all standards - from the transport and dosing of the wafer flour to the final packaged product.
The wafer sheet production line is one of the technological marvels in the plant. There are 120 separate bakery presses in it, which guarantee the "crunchiness". This is a kind of oven for delicious cocoa crusts, which works at a speed rate of 60 ready-made waffle sheets per minute.
The ratio of cream to waffle sheet is 80% to 20% in favor of aerated cream, which puts the product at the forefront of the market in terms of the amount of cream, witch it is the bearer of true taste.
The packaging process is also fully automated, starting from the assembly of the pairs of individual wafers, through the folding, gluing and filling of the transport boxes and the arrangement of the pallet with finished products.
My Motto is an unusual wafer that surprises us with a palm oil free recipe containing plenty of cream, aerated to a light and delicate texture for better taste.
Only natural raw ingredients from leading manufacturers are used, such as specially selected hazelnut paste and high-quality cocoa. Artificial colors are taboo, and traditional palm oil has been replaced with coconut oil.
The cream is always prepared in accordance to the original recipe for My Motto, and then tempered and aerated to become fluffy, light and gentle on the palate. This unique technology ensures the feeling of melting in the mouth and an explosion of flavours. The cream to shell ratio is 80% to 20% in favor of the cream. This ensures the product’s leading position on the market in terms of the amount of cream in a wafer and brings the specific taste that the consumer is looking for - Cocoa, Hazelnut, Tiramisu or Vanilla. The secret to the incredible taste lies in the cream.
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