Created with Sketch.
The Austin Company
  • Contact Us
  • Austin Consulting
  • Spanish
  • Why Austin
    • Leadership Team
    • Austin Past and Present
    • Safety
    • Results, Not Excuses
    • Project Gallery
  • Markets
    • Aerospace and Defense
    • Food and Beverage
    • Pharmaceutical and Biotech
    • Automotive
    • Industrial Manufacturing
    • Process Industries
    • Utility Plant Support
    • Commercial
  • Services
    • Design and Engineering
    • Construction
    • Facility Maintenance
    • Location Consulting
    • Planning
    • Development and Financing
  • Subcontractors
  • Careers
  • News & Blog
  • Why Austin
    • Leadership
    • Austin Past and Present
    • Safety
    • Results, Not Excuses
    • Project Gallery
  • Markets
    • Aerospace and Defense
    • Food and Beverage
    • Pharmaceutical and Biotech
    • Automotive
    • Industrial Manufacturing
    • Process Industries
    • Utility Plant Support
    • Commercial
  • Services
    • Design and Engineering
    • Construction
    • Facility Maintenance
    • Location Consulting
    • Planning
    • Development and Financing
  • Subcontractors
  • Careers
  • News & Blog
  • Contact Us
  • Austin Consulting
Home > Automation Considerations for the Baking & Snack Industry
NEWS & BLOG

October 19, 2021 posted in Baking Industry, Design and Engineering, Planning

Automation Considerations for the Baking & Snack Industry

Photo of David Watson

Dave Watson

Food, Bakery and Snacks Engineering SME

Call 440.544.2600 Email Dave View Profile

Automation has made steady progress into many phases of industrial baking, from ingredient handling to packaging to palletizing and warehouse operations. Advances in robotics and digital technology make automation a viable solution for many baking and snack producers, and the ROI can be attractive.

ARE YOU READY?

It is essential to evaluate if your organization is prepared to transition into automation. This step requires a certain level of technical sophistication from both maintenance and operations organizations. Because it can be challenging to transition from manual operations to a highly automated facility It is essential to evaluate your organization’s preparedness.

BABY STEPS

A good place to start the automation journey is in the packaging area.  It is not uncommon for smaller bakers to manually pack finished products into corrugated cases, plastic trays, or baskets. Depending on the line speed, this often involves two to three people. Automation can often reduce the number of people performing these tasks while providing a safer working environment.

For the most part, large bakers were able to begin the automation journey many years ago and are now comfortable with the technology. They also have been able to hire or develop the talent to maintain these systems. However, while large bakers may be more comfortable with automation and robotic technology, no one is fully automated yet.  The vision of a “lights out bakery” is still years away.

TALENT

Transitioning to automation requires hiring and developing solid technical talent. Bakeries must have the ability to operate, clean, and maintain these automated systems. This includes staff who know how to work with programmable controls, computers, and robotic systems and diagnose mechanical problems. It is vital to building an in-house technical team that can speed up today’s ever-changing technology.

FOOTPRINT

On average, automation in the packaging area requires 10 – 15% more space than a manual operation, depending on the application. For example, if you are loading finished products into trays or boxes, the products coming down the conveyor may require three or four people to pick and place the product into the tray or box. This takes a relatively small footprint. However, if you are going to automate this process, you need to lane, align, and feed it into a robotic cell. This requires more space. Some bakeries do not have the footprint to fully automate areas like packaging but can still benefit from other upgrades in technology. For example, bread or roll basket loading can often fit into an existing footprint.

ENERGY

Most automated systems require compressed air and electrical power. While some facilities may experience a slight uptick in energy costs, the cost savings due to reduced labor safety off-sets this occurrence.  Typically, people doing these manual tasks are subjected to repetitive motion, bending, twisting, lifting, and reaching. These constant movements strain workers’ bodies, often leading to injuries to muscles, nerves, ligaments, and tendons.  Automation eliminates these factors and provides a safer work environment for employees.

LABOR REDUCTION

One of the most compelling reasons for implementing automation is the challenge of labor force. For most bakeries, labor costs represent the most significant expense and hardest cost to manage or reduce. Even highly skilled operators can’t match the repeatable accuracy of automation. Some automated systems can also perform multiple operations, eliminating the time required to move materials from one work center to another. 

Today’s labor market is probably one of the most challenging markets bakers have seen in many years.  Hiring and retaining employees has been a significant challenge for most bakers.  Many bakeries are moving to automation due to the inability to retain employees for highly repetitive positions.

PAY-BACK

The return on investment for automation depends on several factors, including each bakery’s financial guidelines for capital investment payback. However, a rule of thumb would be two to three year payback. When calculating your savings from automation, you need to include direct labor savings, improved uptime, quicker changeovers, and reduced workers’ comp costs. 

There is a significant up-front investment required in automation. Ideally, to prepare for a clean installation and startup at the bakery, technical staff should be hired in advance.  This allows them to be a part of the steep learning curve that comes with this new technology. Key maintenance and operations representatives should attend FATs (factory acceptance tests) and participate in installing the equipment.

MAINTAINING TIGHT SPECIFICATIONS

One of the biggest eye-openers when automating is the need to maintain tight specifications on your product. Most products can vary in size throughout the day. Typically, when manually placing the product into a basket, bag, or box, you can squeeze it and get it in there. With automation, there is usually not a lot of room for adjustment. This places pressure on the operators at the front end of the process to ensure the finished product is within specifications.

KEEPING UP WITH THE MARKET

Wherever you are considering automation, it is valuable to keep up to speed with current technology, what other bakers are doing, and the next best steps for your unique product and facility. When considering equipment suppliers, be sure to enter partnerships with companies that can support you through the training and maintenance journey. Make sure you understand all the needs and be able to communicate them clearly to vendors. Clear expectations should be established during the negotiating process.  It is crucial that everyone understands these expectations for line efficiency, throughouts, and changeovers.   

The best-in-class approach is to hire technical folks early in the project to work closely with vendors and benefit from first-hand equipment training. In addition, technical staff can benefit from being a part of the acquisition and installation process.

PHASED APPROACH

A phased approach to automation is usually the best course of action. There is considerable risk associated with drastic changes to operations. Phasing allows you to spread the risk out over time. We recommend a two- or three-phase investment. This prevents staff from being overtaxed while gaining experience with the technology. As comfort levels increase with the additional automation, you can move to the next phase, building on all that has been learned.

Any approach should consider the impact the change will have on your ability to get the product to the market. For example, maintaining product specs, equipment, and training can take time to get right, slowing down production.

While phasing plans vary, typically phases are implemented about a year apart. Timing considerations include any challenges encountered with the first phase, staffing requirements, and equipment lead times.

CRITICAL QUESTIONS

  • What products is your bakery running?
  • What are the speeds you are running?
  • How many changeovers do you have each day?
  • What are the specifications of the product?
  • What is the bakery’s available footprint?
  • Are you comfortable with robotics?
  • Should a non-robotic solution for automation be considered?

The early stages of automation planning often lead to more questions than answers. But, partnering with experienced bakery designers, engineers, constructors, and vendors, means you won’t be going it alone. Meeting the challenges of today’s food and snack industry requires out-of-the-box thinking. However, with a well-thought-out, phased approach, the automation game can be won.  

Looking for an expert?

To connect with one of our knowledgeable team members for a media opportunity, please contact Leslie Panfil via phone or email. We look forward to sharing our expertise!

440.544.2255 | info@theaustin.com

MORE NEWS FROM THE AUSTIN

The Heart of the Matter

March 13, 2023 by Sean Barr, PMP

Winter Construction Safety Guide

March 9, 2023 by Charlie Engel

Two Books and a Podcast that Inspires Service, Leadership, and Purpose.

March 8, 2023 by Mike Pierce
Austin®
Transparency in Coverage Privacy Policy Employee Resources
  • Connect with The Austin Company on LinkedIn
  • Follow The Austin Company on Facebook
  • Follow The Austin Company on Twitter
  • Subscribe to The Austin Company's YouTube Channel
Manage Cookie Consent
To provide the best experiences, we use technologies like cookies to store and/or access device information. Consenting to these technologies will allow us to process data such as browsing behavior or unique IDs on this site. Not consenting or withdrawing consent, may adversely affect certain features and functions.
Functional Always active
The technical storage or access is strictly necessary for the legitimate purpose of enabling the use of a specific service explicitly requested by the subscriber or user, or for the sole purpose of carrying out the transmission of a communication over an electronic communications network.
Preferences
The technical storage or access is necessary for the legitimate purpose of storing preferences that are not requested by the subscriber or user.
Statistics
The technical storage or access that is used exclusively for statistical purposes. The technical storage or access that is used exclusively for anonymous statistical purposes. Without a subpoena, voluntary compliance on the part of your Internet Service Provider, or additional records from a third party, information stored or retrieved for this purpose alone cannot usually be used to identify you.
Marketing
The technical storage or access is required to create user profiles to send advertising, or to track the user on a website or across several websites for similar marketing purposes.
Manage options Manage services Manage vendors Read more about these purposes
View preferences
{title} {title} {title}
Manage Cookie Consent


This website stores cookies on your computer. These cookies are used to collect information about how you interact with our website and allow us to remember you. We use this information in order to improve and customize your browsing experience and for analytics and metrics about our visitors both on this website and other media. To find out more about the cookies we use, see our Privacy Policy.

If you decline, your information won’t be tracked when you visit this website. A single cookie will be used in your browser to remember your preference not to be tracked.


We use cookies on our website to give you the most relevant experience by remembering your preferences and repeat visits. By clicking “ACCEPT”, you consent to the use of all cookies. For more information, please visit our Privacy Policy.
Functional Always active
The technical storage or access is strictly necessary for the legitimate purpose of enabling the use of a specific service explicitly requested by the subscriber or user, or for the sole purpose of carrying out the transmission of a communication over an electronic communications network.
Preferences
The technical storage or access is necessary for the legitimate purpose of storing preferences that are not requested by the subscriber or user.
Statistics
The technical storage or access that is used exclusively for statistical purposes. The technical storage or access that is used exclusively for anonymous statistical purposes. Without a subpoena, voluntary compliance on the part of your Internet Service Provider, or additional records from a third party, information stored or retrieved for this purpose alone cannot usually be used to identify you.
Marketing
The technical storage or access is required to create user profiles to send advertising, or to track the user on a website or across several websites for similar marketing purposes.
Manage options Manage services Manage vendors Read more about these purposes
View preferences
{title} {title} {title}