The baking and snack manufacturing industry is experiencing a profound digital transformation, fueled by automation and artificial intelligence (AI). Confronted with ongoing labor shortages, escalating costs and heightened consumer demands for quality, food manufacturers are embracing advanced technologies to maintain their competitive edge. Far from merely adapting to survive, this shift is about redefining the benchmarks for productivity, consistency and innovation across the sector.
In this blog, two experienced automation and controls leaders in our Food & Beverage Group, Sanjay Jasoliya and Scott Hungerford, share how automation and AI are transforming baking and snack manufacturing operations. Sanjay leads the instrumentation and controls engineering team, specializing in batch and continuous process controls, packaging automation and functional safety. Scott focuses on advanced control and virtualization technologies, drawing from his background in manufacturing systems integration and plant optimization.
What automation technologies currently have the most impact on the manufacturing industry? And how would a manufacturing owner decide where to start?
Sanjay Jasoliya: Over the last few years, AI-driven automation, robotics and smart data analytics have emerged as essential tools in the manufacturing industry. These technologies are streamlining everything from ingredient measurement and mixing to packaging and quality control. They allow owners to maintain consistent outputs while adapting quickly to shifts in consumer demand.
Notably, automation can now be integrated throughout the production process, from raw material receiving and ingredient batching to packaging, palletizing and warehousing. These systems speed up operations and increase throughput. Both automation and AI also contribute to product consistency, minimizing human error while increasing safety. These technologies redirect workers to higher-value roles and more ergonomic-friendly tasks that enhance overall job satisfaction and retention. There are also premium manufacturing execution systems (MES) that are supported by AI-powered analytics, providing granular, real-time tracking of ingredients and finished goods to secure traceability and compliance with stringent regulatory standards.
Scott Hungerford: Not sure where to start? Owners should begin by asking the following questions:
- What problems are we trying to solve?
- Do we have validated, good data and systems to support these advanced technologies?
- Is our team ready for this change?
- Which outcomes do we want to measure?
A clear business case is critical, and a great place to start is typically an area with high potential for return on investment. Think of areas where improvements can yield both operational efficiency and product consistency. Packaging line automation, energy-efficient ovens or dryers, or predictive maintenance on mixers are examples of use cases that drive business benefit in various ways.
When launching digital transformation, getting started can be a challenge. So, owners should look for partners who can help them adopt technologies right from the get-go. For example, we support our clients’ processes by helping them define their goals and objectives early and aligning on them. Here are the three key pillars we start with for smooth tech integration:
- Design proactive infrastructure.
- Embed cybersecurity with zero-trust protocols and anomaly detection.
- Implement iterative validation, using digital twins.
How do you anticipate the industry will integrate these tools, and what kind of impact do you expect this adoption to have?
SH: We expect adoption to continue, especially as technologies become more accessible and cost-effective. The impact will equate to higher productivity, more consistent product quality and the ability to innovate faster.
The integration of real-time factory-floor data enables comprehensive analytics on production performance, product quality and production rates. The real value lies in turning this data into actionable intelligence for operators. Effective SCADA and MES applications aggregate, sort, store and contextualize process data, presenting it through intuitive graphical interfaces tailored for all levels of the manufacturing organization. This empowers teams to make smarter, faster decisions, ultimately driving better outcomes for our clients.
What AI capabilities can manufacturing operations take advantage of right now?
SJ: Right now, AI is being used for predictive maintenance, like spotting equipment issues before they cause downtime, real-time quality control with vision system and even on-the-fly recipe adjustment using properties of the raw ingredients. AI can also forecast demand, optimize supply chains, and automate documentation and compliance. It is also being used in what we call “proof of concept,” where it is applied to address specific client challenges and achieve desirable outcomes like consistent baking results by monitoring and adjusting temperature or speed based on the color of dough.
How can owners optimize their automation tools to adopt more efficient processes for their manufacturing operations?
SJ: Optimization begins with identifying repetitive, high-impact tasks that can be automated for improved results. Owners should integrate real-time data collection, apply lean manufacturing principles, and continuously monitor and refine their processes. Additionally, reviewing performance data and bringing frontline staff into the process regularly helps automation deliver peak results and efficiencies.
In practice, this means using these technologies for live monitoring of key production metrics like temperature and humidity. This capability allows consistent product quality and enables rapid response to any deviations. Additionally, automated storage and retrieval systems (AS/RS) as well as advanced robotics technologies drive precision in batching, extrusion and packaging, enhancing throughput and consistency.
The combination of AI, automation and integrated data management systems is creating new standards for efficiency in the baking and snack manufacturing sector, and beyond. As these tools and technologies become more accessible, the industry can expect to see even greater advancements in safety, reliability and overall production performance.
