The Solution

RMR Process partnered with Barbell Foods to design and implement a comprehensive manufacturing solution that would transform their production capabilities. The project involved:

  • Facility Design & Expansion: Upgrading from their 80-square metre kitchen to a purpose-built 450-square metre factory in Canberra's Hume suburb

  • Process Automation: Implementing automated steak cutting and processing equipment to replace manual operations

  • Production Optimisation: Designing efficient workflow systems for hanging, drying, and packaging processes

  • Quality Assurance Systems: Ensuring organic certification compliance and food safety standards throughout the automated processes

  • Scalable Infrastructure: Creating a facility capable of supporting national distribution growth

Case Study:

Barbell Foods

The Challenge

Barbell Foods, founded by four young entrepreneurs from Canberra, faced significant production bottlenecks as demand for their organic biltong products rapidly outgrew their capabilities. Operating from an 80-square metre commercial kitchen, the team was manually cutting, hanging, and packing steaks—a labour-intensive process that limited their ability to scale. With growing market demand and distribution opportunities emerging across Australia, they needed to transition from manual production to automated manufacturing while maintaining their premium organic standards and product quality.

The Results

The transformation delivered exceptional outcomes for Barbell Foods:

  • Production Capacity: Increased from small-batch kitchen production to large-scale factory output capable of supporting national distribution

  • Operational Efficiency: Eliminated manual steak cutting through robotic automation, significantly reducing labour costs and improving consistency

  • Market Expansion: Enabled nationwide distribution capabilities, moving beyond local Canberra markets

  • Quality Consistency: Maintained premium organic standards while achieving consistent product quality at scale

  • Business Growth: Positioned the company as a leader in the Australian organic meat snack market

Key Takeaway

"Strategic investment in automated food processing technology can transform artisanal food businesses into scalable manufacturing operations without compromising product quality or organic integrity."

"From the guilt-free desktop snack for the white collar professional, to the savoury lunchbox snack for the kids, you don't necessarily need to be a fitness fanatic for our biltong to benefit you." - Tom Hutchison, Co-founder, Barbell Foods