Baked goods are in higher demand than ever, but the rules of the game are changing. From the “free-from” trend and flexible packaging materials to data-driven production, both consumer behaviour and production requirements are evolving. Here’s how you can successfully overcome these challenges.
Convenience and functional snacks on the rise
Purchase decisions are more conscious than ever. Consumers are seeking products that fit a healthy lifestyle: less sugar, more protein and fiber, and “free-from” options – all in convenient, on-the-go formats. Short ingredient lists build trust, while resealable single portions increase usability. The key is to meet different snacking occasions – from indulgent moments to functional energy boosts.
From standard to variety
More flavors, seasonal editions, new recipes – variety sells but increases complexity. Products with “free-from” formulations require gentle handling to minimise breakage. The answer lies in production lines that handle product and format changes with very short setup times – allowing portfolios to expand without cannibalising the standard range.
Boosting efficiency, reducing waste
With rising raw material and energy costs, every percentage point of OEE counts. Gentle product handling, precise linear movements, and the right grippers ensure that delicate goods and chocolate surfaces remain intact. The result: less waste, stable margins – and consistent quality on the shelf.
Rethinking sustainability – focus on materials and sealing technology
The EU Packaging and Packaging Waste Regulation (PPWR) sets clear guidelines for recyclable packaging. Switching from composite materials to mono-materials or paper changes mechanical and thermal properties – and calls for innovative forming and sealing technologies. Flexible, modular systems capable of processing multiple pack styles and sustainable materials on the same line are becoming a key operational lever.
Higher product complexity, stricter hygiene design
As variety grows, so do food safety requirements: allergen management is becoming a permanent priority. Hygienic machine design with smooth surfaces and easily removable components shortens cleaning times, reduces downtime, and simplifies safe changeovers between recipes.
Labor shortages and cost pressure: automate where it matters
Fewer workers, same quality: automation provides relief along the entire line – from product infeed and inline quality checks to primary and secondary packaging. Combined with connected equipment, real-time monitoring and predictive maintenance enable demand-based servicing, fewer unplanned stops, and longer machine lifetimes.
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Media contact
Joseph Clarke
Editor, International Bakery
Tel: +44 (0) 1622 823 920
Email: editor@in-bakery.com
