Five ways robotics tech is revolutionising confectionery
Automated robotics technology can lower costs, speed up production, optimise safety processes and increase consumer engagement. It’s why global confectionery players and SME factories are investing in intelligent robotics machinery at an increasing pace. Indeed, a 2023 report by the International Federation of Robotics predicted the robotics industry to grow by 7% in 2024 with the associated revenue projected to reach $42.8bn.
By 2025, the number of robots employed by EU food companies with 10,000 or more employees is expected to rise to an average of 110 from the 75 seen in 2020, according to Dutch bank ING research.
Industrial and service costs are a hurdle
Under ISO 8373:2012, the International Standards Organization (ISO) defines a robot as an actuated mechanism with a degree of autonomy that moves within its environment to perform intended tasks. It sounds simple, but this innovative technology doesn’t come cheap.
High costs remain a core challenge for manufacturers hoping to implement robotic automation, according to a 2022 report by insights company McKinsey with more than a third (36%) of food and beverage manufacturers saying the high costs of implementing robotics holding them back. Nonetheless, the report also found that automated systems will account for 25% of industrial firms’ capital spending until 2027.
Here are five ways investment in robotics could transform confectionery production.
1. An extra pair of eyes to confirm safety
Safety and quality are critical within confectionery factories. Bolstering production processes with robotic automation can provide extra assurance before finished products go on sale.
Vision-guided robotics are therefore set to be significant in robotics automation, reaching a predicted $20.1bn by 2030 compared to its $6.12bn figure in 2021, research by NextMSC reveals. This represents a growth of 12.7% between 2024 and 2030.
This advancing field of robotics uses 2D or 3D cameras to capture images, which enables robots to perform tasks with greater precision. It plays a crucial role in automated ingredient handling, ensuring accurate measurement, dispensing, and minimising errors in candy formulations.
This method has already been employed by fine chocolate brand, Zotter, to boost its production systems’ precision, innovation and quality.
In addition to improving precision, robots equipped with vision systems can enhance product quality by detecting and removing defective confectionery during production, along with increasing safety and efficiency by lowering the need for human intervention in production processes.
2. Optimise production speeds
Manufacturers can implement high-speed robotic production lines to expedite candy creation. These robotic systems are designed to enhance the efficiency of the entire production process, including its shaping, moulding, coating and packaging stages. Many confectionery manufacturers are already using this technology:
- Hershey announced its adoption of robotics to revolutionise its chocolate bar production lines in 2023. Tailored for the company’s dark, extra creamy cookies and cream bar flavours, its advanced technology lines will replace the connected units typical in traditional processing lines to minimise changeover and cleaning time between the chocolate giant’s production runs.
- Nestlé’s Brazilian plants have implemented a robotic palletising cell to improve pallet loading productivity by 53%, while lowering maintenance costs.
- To help overcome struggling sales during the pandemic, Hotel Chocolat adopted automation to handle a larger portion of their confectionery production, including peanut butter, jelly treats and dark chocolate batons.
- Mars collaborated with Accenture in 2022 to modernise its global manufacturing operations. As part of its vision of the ‘Factory of the Future’, Mars will incorporate next-generation robotics to improve efficiency and sustainability, along with collaborative robotics, where robots and human operators work together.
3. Prioritising packaging productivity
Pick-and-place machinery sees robotic arms delicately handle candies, ensuring accurate placement into packaging materials. The tech proves an important addition to the packaging process as consumer needs evolve, product life cycles shorten and labour scarcity increases. It provides manufacturers with more flexibility and minimises the risk of damage.
Omron teamed up with contract manufacturer Vetipak to streamline its packaging capabilities by using pick-and-place robotics.
Nutresa México also leverages robotics in their packaging lines for Muibon and Cremino chocolate bars. The company has collaborated with packaging machinery company Cama to help increase productivity and lower the strain on the workforce at the end of the lines, particularly during the labour-intensive packaging process.
4. Creative robotic applications, in-store and online
Robotics also extends beyond the factory itself and into the design of future factories and marketing strategies. Mars brought its ‘Smiley’ robot into physical stores to boost consumers’ shopping experience. Using robotics tech, ‘Smiley’ was introduced to deliver and display products to shoppers to increase touchpoint opportunities beyond shelves and checkouts.
Similarly, during Halloween in 2020, Hershey used robotics as part of its marketing strategies to create Reese’s Trick or Treat door. Designed to engage with younger generations, the door dispensed king-size Reese’s peanut butter cups.
Clean technology
Hygiene and cleanliness are also paramount considerations when deploying robots in confectionery production. A collaborative study by the European Hygienic Engineering & Design Group, ECOLAB, and Stäubli Robotics found that Delta configuration robots, a common type used in food manufacturing, were identified as having the highest potential for contamination. The study’s recommendations included covering these robots and engaging in a cobot – human and robot – collaborative environment to prevent contamination and meet stringent hygiene standards.
Confectionery companies are also focusing on customising their products and operations using robotics. Zotter aims to create personalised pralines tailored to individual customer preferences, including specific dietary requirements, using robotics. Meanwhile, Bühler has introduced the ChocoBotic, a small batch moulding line that utilises smart technology to optimise chocolate production in small spaces to fit with producers’ requirements.
5. Improving sustainability efforts
Utilising robotics-driven sustainability initiatives can optimise how confectionery companies use resources. Robotics has a role in minimising waste, lowering energy consumption, and improving overall production sustainability within candy manufacturing.
Record-high cocoa prices is an ongoing issue within confectionery. Amid the cocoa crisis, eliminating or reducing the prevalence of pests or diseases is even more crucial. Black Pod Disease poses a considerable threat to cocoa plantations and can lead to crop losses for farmers. Laser robots that can detect and remove black pod disease fungi can provide a solution. These robots could also assist in labour-intensive tasks such as tree pruning, cocoa pod harvesting, bean cracking, and drying, making cocoa farming more appealing to new farmers entering the industry.
