Automating Ingredient Handling: Balancing ROI and Future-Proofing Bakery Systems

Successfully implementing an automatic minor ingredient handling system requires careful consideration of existing processes, recipes, and ingredients. The decision to automate isn’t simply about adopting new technology; it’s about strategically balancing capital investment with return on investment (ROI). A well-planned system should not only address current needs but also be adaptable for future expansion.

The ROI of Automation: A Phased Approach

According to Jon Goecker, sales manager, confectionary and snacks at Coperion, “Balancing the level of automation versus capital investment and ROI is part of the conversation with every project.” He notes that there may be a point where automating certain ingredients isn’t financially viable in the short term, but a forward-thinking system design allows for the addition of more automated ingredients as needs evolve.

Common Pitfalls in System Integration

Integrating a new minor ingredient handling system into an existing operation presents several potential challenges. Alessandro Gaudenzi, brand and content manager for Agriflex, highlights common issues including inadequate space planning and workflow integration, software incompatibility with existing production systems, and underestimation of ongoing maintenance and calibration requirements.

Thorough Needs Assessment is Crucial

Gaudenzi recommends a comprehensive needs assessment to ensure the chosen system aligns with the bakery’s specific operations. Selecting a modular system design enhances scalability for future growth. Proper ventilation and dust control are essential for safely handling powdered ingredients.

Prioritizing Automation: Volume and Impact

Not all minor and micro ingredients require automation to realize benefits. Pieter Van Hoecke, business development manager, North America sales, Spiromatic, suggests focusing on ingredients used in large volumes, across multiple recipes, or those where accurate measurement has a significant impact on product quality. By prioritizing these ingredients, bakeries can reduce manual scaling efforts.

Van Hoecke explains, “We analyze the recipes and minor ingredients to determine which minors have a business case and which ones don’t. We typically identify that if you automate just 20% of the minor ingredients — those used the most often — you have automated 80% of the scaling needed.”

Ingredient Characteristics and System Design

The characteristics of the ingredients themselves play a critical role in system design. Ingredients should generally represent a single-digit percentage of the total dough formulation, though this can vary depending on the specific recipe, according to Johnny Quinonez, food systems sales engineer, south central United States, Mexico and Central America, Zeppelin Systems USA.

Challenges with Pneumatic Conveying

When automating micro-ingredient additions, ensuring proper delivery to the processing point is crucial. As stated by an expert, the process design must support handling small quantities, whether in pounds or ounces/grams.

Manual Additions: When to Hold Back

Some ingredients are better suited for manual addition. Large particle sizes in dry ingredients can lead to overshooting or undershooting target weights. Ingredients like brown sugar, tablets, and inclusions such as raisins are often better added manually, as noted by Ken Girts, director of sales and marketing for Fred D. Pfening Co.

Storage Considerations: Temperature and Humidity

Temperature and humidity significantly impact ingredient flow. Van Hoecke emphasizes the importance of storing ingredients according to supplier guidelines, recommending a dry, temperature-controlled environment for sensitive ingredients. Shortening, butters, and inclusions may be more cost-effective to add manually.

Maintaining Flexibility and Future Expansion

While automation offers numerous benefits, preserving some manual flexibility can be advantageous. Gaudenzi suggests leaving ingredients used in quantities of less than 5 grams as manual additions. Dominick Fortuna, president, Volkmann, recommends designing systems with future expansion in mind, allowing for the addition of automation steps later without replacing existing equipment.

The Importance of a Holistic Approach

Successful implementation requires a comprehensive project view, including space requirements and ingredient replenishment planning. Involving both production and maintenance teams early in the planning process is essential, as highlighted by an expert. Selecting the right equipment for each ingredient’s unique properties is also critical.

Precision and Maintenance

Minor ingredient systems require more frequent attention than bulk systems to maintain accuracy. Regular calibration and cleaning of critical components are essential to prevent weight discrepancies, as Girts points out.

Key Benefits of Automation

Automating minor and micro ingredients offers numerous advantages, including improved accuracy, consistency, traceability, food safety, and reduced workload. However, these systems are not one-size-fits-all solutions. A thoughtful approach, considering the bakery’s unique situation and goals, is key to successful implementation.