The Strategic Approach to Food Processing Automation

Effective process automation in food manufacturing requires more than simply installing equipment—it demands a strategic approach that aligns technology implementation with specific business objectives. Our engineering consultancy team develops automation strategies that focus on:

• Targeted Problem Solving - Addressing specific operational challenges

• ROI-Driven Implementation - Ensuring clear financial benefits

• Scalable Solutions - Technologies that grow with your business

• Operational Integration - Systems that enhance rather than complicate workflows

• Staff Capability Alignment - Automation matched to workforce skills and capacity

This strategic approach ensures that your food processing automation investments deliver meaningful operational improvements rather than creating costly complexity.

Automation Strategy Development: The Foundation of Success

Successful automation begins with thorough evaluation of current operations and clear definition of improvement objectives. Our automation strategy development process includes:

1. Current State Analysis - Detailed analysis of existing processes and pain points

2. Opportunity Identification - Systematic evaluation of potential automation targets

3. Technology Assessment - Evaluation of available solutions against specific requirements

4. Implementation Roadmapping - Development of phased automation strategies

5. ROI Modelling - Detailed projection of costs, benefits, and payback periods

This structured approach ensures that your food processing automation strategy addresses the right challenges with appropriate technologies and realistic expectations.

Case Study: Strategic Automation Planning

A New Zealand baby food company was wanting to increase production volumes and reduce labour costs in their process and packaging operation. Our automation strategy team:

1. Conducted comprehensive process analysis to identify key variability sources

2. Evaluated multiple automation options against specific operational requirements

3. Developed phased implementation plan that prioritised highest-impact areas

4. Created ROI projections for each implementation phase

5. Designed staff transition plan to redeploy labour to higher-value activities

The resulting automation strategy resulted in doubling throughput capacity without increasing labour costs and significant quality improvement through targeted technology implementation, with complete project payback achieved within 14 months.

Control Systems Integration: The Automated Heartbeat of the Food Factory

Effective food processing automation requires seamless integration between diverse equipment and systems. Our control systems integration services include:

• Control Strategy Development - Creating logical frameworks for system interaction

• PLC Programming - Implementing robust control logic for consistent operation

• HMI Design - Developing intuitive operator interfaces for effective monitoring

• Data Collection Systems - Implementing appropriate production metrics tracking

• Remote Access Solutions - Creating secure methods for system monitoring and support

Our food process engineering expertise ensures that control systems are designed specifically for food manufacturing requirements, with appropriate consideration for cleaning processes, product changeovers, and regulatory compliance.

Integration Excellence Approach

Many food manufacturers struggle with "islands of automation"—disconnected systems that create inefficiencies and data gaps. Our integration excellence methodology addresses this challenge through:

1. System Architecture Design - Creating unified frameworks for equipment communication

2. Protocol Selection - Identifying appropriate standards for system interaction

3. Legacy System Integration - Developing interfaces for existing equipment

4. Centralised Control Implementation - Creating single-point operation capabilities

5. Standardisation Planning - Establishing consistent approaches for future automation

This comprehensive approach ensures that your food processing automation systems work together as a cohesive whole rather than as disconnected components.

Production Line Automation: Enhancing Core Operations

Automating core production processes requires careful selection of technologies that deliver appropriate capabilities without unnecessary complexity. Our production line automation services include:

• Process Analysis - Detailed evaluation of production requirements and constraints

• Technology Matching - Identification of appropriate automation solutions

• Equipment Specification - Development of detailed technical requirements

• Vendor Selection Support - Assistance with technology provider evaluation

• Implementation Management - Oversight of equipment installation and commissioning

Our food industry projects experience ensures that production automation technologies align with your specific manufacturing requirements and operational realities.

Case Study: Production Transformation

An Australian ready meal manufacturer needed to increase throughput while improving portion consistency and minimising “giveaway”. Our production line automation team:

1. Analysed existing manual portioning process to identify variability sources

2. Evaluated multiple automated portioning technologies against product requirements

3. Developed custom integration plan for selected equipment

4. Implemented phased transition that maintained production throughout

5. Created comprehensive operator training program for new technology

The resulting automation solution significantly increased throughput while reducing portion weight variation, improving both productivity and product cost control.