Just a decade ago, only large companies could afford robots, but businesses of all sizes are investing in robotics to address the challenges of finding qualified workers.

“The need to place human workers in roles with more added value, combined with the repetitive nature of certain tasks and the safety concerns that come along with many tasks in the bakery, has led a much larger cross-section of bakeries to automate,” observed Felix Pang, robotic solutions specialist, ABI Ltd. “This shift to automation has helped these bakeries prevent injuries and improve overall efficiency on the production line.”

More recently, the need for higher capacity on the production lines, specifically for buns, is driving robotics in bakeries, noted Ken Mentch, automation sales manager, Middleby Bakery. That’s because larger volume lines require larger pans, which are difficult for bakers to handle by hand and are, at times, too large for conventional stackers and unstackers.

Five years ago, the return on investment (ROI) for robotic systems was five-plus years to break even, but it’s under two to three years now, making automation more viable for mid-sized bakeries. Hunter Schultheis, North Central sales manager, BluePrint Automation, attributed this quicker ROI to declining equipment costs, rising labor costs and greater efficiency gains.

“Modern robotics are faster and more accurate, minimizing rework and product waste,” he said.

Bakeries can also factor in lower worker compensation costs caused by reduced lifting and repetitive strain injuries while eliminating difficult or undesirable tasks that may encourage employee retention

Stephane Vieira, bakery systems sales, Niverplast, advanced robotics systems often include predictive maintenance features that minimize downtime and ensure smoother operations.

“Robots can handle hazardous tasks, reducing the risk of workplace injuries and helping businesses comply with safety regulations,” he added.

From a global perspective, the perspective on robotics in the United States often seems misplaced, noted Marcus Kurle, cofounder of AAA20 Group. The debate over ROI and short-term budget strategies leave US manufacturing behind Japan, Germany or even China in terms of robotics density per 100,000 employees.

He said RaaS and other creative financing can sidestep hefty upfront costs. They’re also more affordable than regular payroll expenses and can be implemented swiftly.

“It’s time to move past endless deliberations and embrace practical solutions that can drive immediate improvements,” Kurle stated.

The bottom line is that workforce challenges aren’t going away anytime soon while bakeries and snack producers face greater pressure from retailers and consumers to reduce their costs in an inflationary environment.

That’s especially true for mid-sized bakeries and snack producers.

“They realize that automation is no longer optional. It’s essential to stay competitive,” said John Weddleton, automation product manager, Harpak-Ulma. “With the older, more traditional workforce retiring and manual tasks becoming harder to staff, adopting robotics has become a necessity for staying relevant in the market. Additionally, robots are no longer seen as intimidating. They’ve been simplified, made more user-friendly, and most suppliers offer comprehensive training programs. This makes them much more approachable for bakers who may not have a background in robotics.”

This article is an excerpt from the April 2025 issue of Baking & Snack. To read the entire feature on Robotics, click here.