Customer Case: Automated Transformation of Artisan Baking

Client Background

Our client is a family-owned Australian company specializing in traditional holiday baked goods. Known for its handmade gingerbread and honey bread, their products are sold in major Australian supermarket chains and local boutique retailers.

Challenges

With market demand growing annually, the existing manual production model could no longer meet production capacity and standardization requirements.

• Production relies heavily on skilled labor, limiting capacity during peak holiday orders.
• Hand-made shaping and baking lead to variations in product size, weight, and color, impacting the brand's premium positioning.
• Existing equipment was unable to handle the highly sticky nature of gingerbread dough, resulting in low production efficiency.
• The client sought to maintain the traditional recipe and flavor while achieving scalable production.

Solution

We customized a fully automated biscuit production line, including:

• High-viscosity dough extruder: Optimized extrusion pressure and die design for the characteristics of gingerbread, ensuring uniform and crumb-free shaping.
• Intelligent baking tunnel oven: Equipped with a multi-temperature zone precision control system and visual inspection to ensure consistent color.
• Automated packaging module: Supports rapid packaging of various product formats, reducing manual contact. The entire line features an integrated PLC control system, allowing parameters (such as thickness and baking time) to be adjusted via the touchscreen, flexibly adapting to different product recipes.

Results

1. Production capacity increased to 400 kg of finished product per hour, a 320% increase in efficiency compared to the original manual process.
2. Product weight variation was kept within ±2%, and color consistency achieved a 98% customer satisfaction rate.
3. Reliance on skilled labor was reduced, reducing production staff requirements by 70%.
4. The customer successfully preserved the flavor of their traditional recipe and entered the international market with standardized products.

Customer Testimonials

"After transitioning to automation, we finally achieved a balance between flavor and scalability. The new production line perfectly replicates the texture of handmade products, and is even more stable—this is truly 'using technology to preserve tradition.'"