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Design, Test, Revolutionize: Prototype by Servi Doryl

For over 50 years, Servi Doryl has stood out as a leader in innovative design and manufacturing of cheese molds. Our success largely relies on our commitment to innovation, where prototyping plays a central role.

A prototype is an initial representation of a cheese mold or associated equipment, designed to test and validate various aspects of its construction. At the heart of our prototyping process, our design team collaborates closely with our clients to understand their specific needs.

This article explores the importance of prototyping to ensure that the products we develop precisely meet the needs and constraints of our clients, the cheesemakers.

Different Types of Prototypes

Prototype for soft cheese: Rapid Prototyping

The prototype dedicated to soft cheeses ensures homogeneous draining, thus guaranteeing optimal consistency and surface condition of the cheese. This stage is crucial for obtaining a final product of quality, both in terms of taste and visual appeal for end consumers.

For these prototypes, we explore additive manufacturing impressions. Additive manufacturing, also known as 3D printing, revolutionizes the creation of three-dimensional objects.

3D Ripening mats

These 3D prototypes are made from photosensitive resins that are not suitable for food contact. The material they are composed of being quite fragile, these prototypes should be handled with care.

In terms of washing, we recommend hand washing at low temperature for these 3D prototypes. In our prototyping process, we do not limit ourselves to cheese molds.

We also have the ability to design prototypes for a diversified range of products, including items such as draining mats. This versatile approach allows us to explore new possibilities and meet the varied needs of our clients.

Nicolas and Carlos – Engineering office

Prototype for pressed cheese: Molded Prototype

The prototype for pressed cheeses validates uniform pressing allowing the crust to close properly. Leveraging our expertise, we work closely with our clients to select the most suitable patterns and micro-perforations for each type of cheese. These choices have a direct impact on the texture and flavor of the final product.

This prototype also verifies the compatibility between the mold and the cheesemaker’s mechanization line. Indeed, prototypes validate the final dimensions by passing under molders, presses, decapping, cleaning, and then storage.

Unlike prototypes for soft cheeses, these prototypes are made from polypropylene (PP), which will also be the same material used for the production series. The assembly method also differs from mass production. Thus, these prototypes can be screwed and not polyfused.

These prototypes, once the tests are done, should be removed from the production line (risk of foreign body due to screws).

They should be washed following the washing recommendations recommended by Servi Doryl. These are the same as for pressed cheese molds already in service.

Jerome & Christophe – Production workshop

Testing Phase:

The testing protocol is prepared jointly between the project team of our client (frequently composed of the production manager, the quality department, as well as the research and development department of cheesemaking) and the technical-commercial team of Servi Doryl.

The prototype testing phase goes beyond simple evaluation in cheesemaking. Indeed, it is essential to test prototypes under conditions as close as possible to their final use. This approach ensures a realistic evaluation of the cheese mold’s performance and allows for identifying any necessary adjustments to optimize its effectiveness. That’s why our collaborators prefer to visit cheesemakers during these testing phases. For example, for a test on soft cheeses, here are some elements that are monitored:

  • Serum drainage
  • Curd temperature at molding and unmolding
  • Curd pH at molding and unmolding
  • Cheese weight at molding, unmolding, and before packaging

Laser marking

To facilitate their identification, we have made our prototypes easily identifiable. Indeed, thanks to our laser marking, we have the possibility to affix distinctive marks on each prototype, thus ensuring their traceability and follow-up throughout the manufacturing process.

Contractual Terms:

Our prototypes can be loaned, rented, or purchased according to the specific needs of our clients. For loaned and rented prototypes, it is imperative to return them to Servi Doryl after the testing phase. The practice of lending or renting allows access to quality prototypes for the greatest number of people. This fits into one of our 3 values ​​which is Corporate Social Responsibility (CSR).

Case Study: Richemont

In 2022, the CFR Brioude cheese dairy, affiliated with the Richemont group, welcomed two blue square molds and followers for a testing phase. Testing of the blue moulds on their production line began in September 2022 and continued for 1 year.

Regular visual checks of the equipment were carried out to assess the behaviour of the blue plastic over time. The objective was to ensure that these molds fully met the expectations of cheesemaker clients. Points of vigilance included sticking, any color changes due to material use, potential wear of the plastic material, and cheesemaking results. To date, the quality of the molds remains unchanged, and the CFR Brioude cheese dairy is fully satisfied with the products.

At Servi Doryl, we are proud of our craftsmanship, which allows us to design and manufacture tailor-made prototypes for our clients.

Going through Servi Doryl also guarantees personalized support during which our team brings its expertise to define the testing protocol, analyze the results, and choose the best solution for each cheese dairy.

Our commitment is to continue innovating and strengthening our relationships with our clients worldwide because their satisfaction is our main goal.