Reducing Food Processing Labor Costs with Robotics

The robots are coming–and just in time, too! Labor costs across the food processing industry are rising as skilled workers become ever harder to find. It’s not difficult to see why: uncomfortable working conditions, long hours, and repetitive tasks drive high turnover across the industry and make it hard to replace the aging existing workforce.

That’s a challenge for food processors–but also an opportunity. Smart processors are relying increasingly on advanced robotic technologies to do the most repetitive tasks and, in some cases, to take over entire lines. That, in turn, helps companies to reduce their payrolls and reassign existing workers to more fulfilling tasks.

In this article, we take a closer look at the challenge that high labor costs present to the food processing industry and the transformative effect that food-handling robotics from leading suppliers like Grote has on the industry. We’ll also look at some specific ways that robotic systems are having an impact, and illustrate these with real-life case studies.
 

WHY ARE FOOD INDUSTRY LABOR COSTS SO HIGH?

Despite recent inflation, the food processing industry is generally in a good place, with continued strong demand for affordable prepared and packaged products. However, labor costs across the industry have been rising steadily.

There are numerous reasons for this, but the biggest is the difficulty in finding skilled, competent workers to replace those aging out of the labor pool.

Let’s be honest–working conditions in the industry are tough and often include:

• Cold, sterile, and industrial working environments
• Tedious, repetitive tasks over long hours
• Risk of injury, from repetitive strain injuries from repeated movements to long-term back issues from standing for long hours
• Low pay–despite recent improvements, typical wages are still relatively low
• Few opportunities for advancement–high turnover, a transient workforce, and many temporary workers make it hard to work your way up in seniority.

As a result, the food processing industry faces a long-term problem attracting willing, competent laborers. The U.S. Bureau of Labor Statistics projects that employment in the sector will drop 7% between 2023 and 2033, with an additional 155,000 job positions opening up annually across the industry.

That’s a problem, given the growing demand for packaged and prepared foods. For example, the frozen pizza market alone is projected to grow at a compound annual growth rate (CAGR) of 6.9% from 2023 to 2030.

Higher payrolls and unfilled spaces on the line pose a serious threat to food processors’ efficiency and profitability, as well as their ability to keep up with rising demand. That’s driving a new wave of investment in line and process automation, powered in many cases by smart, agile, and flexible robotics solutions.
 

ROBOTICS TO THE RESCUE

Robotics takes automation to the next level, allowing food prep tasks to be carried out with accuracy and precision, time after time.

Combined with 3D vision systems, robots can pick and place irregularly placed or grouped items that would have previously needed human intervention. And more advanced systems are smart enough to perform tasks for two or more applications, bringing unprecedented flexibility to your operations.

Robotics have a measurable impact on food assembly line costs and productivity in at least three areas:

1. Automating Repetitive Tasks

Robotics are well-suited for repetitive, labor-intensive tasks where humans often struggle to maintain speed and consistency during a long shift. This is particularly useful for:

• Applying food to a food base or tray
• Arranging food
• Transferring food
• Placing food in packaging

By automating these common food-handling tasks, food processors can reduce the cost of manual labor while reallocating the available workers to higher-value roles.

2. Increasing Production Speed

Robotic systems deliver consistent, reliable performance without fatigue or distraction, making food assembly line operations easier to manage and integrate.

How fast do they work? Delta robots–systems capable of moving in all three dimensions–can perform up to 100 actions per minute, while 4-axis and 6-axis robots typically operate at around 60 actions per minute.

In reality, it’s the ability of your robot to match its operation to the speed of the rest of your line, rather than raw speed itself, that increases overall efficiencies and savings. For this reason, most Grote robotic line equipment is designed to work at a speed of 60 items per minute, the industry standard for integrated production.

3. Ensuring Precision and Quality

Delta robots equipped with 3D vision systems are capable of handling and placing irregularly shaped objects with consistent precision, while even basic portioning or sauce application systems perform with accuracy, ensuring waste is limited and you are making the best possible use of your ingredients.

Unlike human workers, robotics don’t experience fatigue, distractions, or variations in performance. This results in a more predictable output and less variability in product quality. That’s important for your bottom line and reputation because consumers return to products they trust.

 

 

HOW DO ROBOTICS SAVE LABOR COSTS?

Robotics systems do require a significant up-front investment, so it’s important to understand how they deliver measurable returns to your business, and specifically your payroll.

Here are five ways that increased use of robotics can help reduce labor costs:

1. Lower Employee Turnover Costs

High labor turnover is a challenge for many food processing plants. Departing workers leave a vacuum behind them, and recruiting, onboarding, and training new workers takes time and money, while the productivity of new workers is often lower in their first weeks of work.

How much does employee turnover cost companies? A study by Gallup found that voluntary turnover in the U.S. economy costs employers up to $1 trillion annually. Meanwhile, the Society for Human Resource Management (SHRM) estimates the cost of replacing a single minimum wage worker at $1,500, with some consultancies putting the figure far higher.

By automating repetitive tasks, processors reduce their reliance on manual labor. This helps save on recruitment and training costs while also minimizing the disruptions caused by a rotating workforce.

2. Fewer Workplace Injuries

Manual labor in food processing is inherently risky. By automating tedious, dangerous, or repetitive tasks, robotics help reduce the chance of slips, falls, and repetitive strain injuries. Automating these tasks reduces the risk of injury, leading to fewer workers’ compensation claims and lower insurance premiums.

3. Decreased Training Expenses

Training new employees takes time, and high turnover means that this process is ongoing. Robotics helps to eliminate the need to constantly train new workers on basic, manual tasks, saving you money and freeing up HR staff for other functions.

4. More Efficient Use of Available Labor

Robotics solutions reduce the number of workers you need and allow the workers you have to move up to less-strenuous supervisory or support roles, boosting their wages while increasing operational efficiency. For example, in many cases, a single operator can supervise multiple robotic systems, drastically reducing the need for manual labor.

5. Less Dependence on Short-Term Workers

The labor shortage has forced many food processors to rely heavily on hiring agencies and short-term contract workers. Acquiring and paying these workers costs more over time than maintaining your workforce. By increasing the use of robotic systems in your operation, you can reduce your reliance on both, resulting in significant cost savings.
 

GROTE ROBOTIC SOLUTIONS IN ACTION

Grote is a world leader in robotics automation for food processing. Let’s look at two case studies involving Grote equipment that demonstrate how robotics can help cut labor costs while enhancing productivity and profitability.

1.Sandwich Producer Automates Their Line with Grote Robotics

A large sandwich and wrap manufacturer in the UK manually assembled, cut, and packaged wraps. Production and quality were inconsistent, and labor was increasingly hard to find and keep. They turned to Grote Company to automate further with robotics and were able to eliminate six operators from their food assembly line.

 

CASE STUDY

The Challenge: Manual wrap assembly, cutting, and packaging Inconsistent production rates and quality Difficulty finding and retaining labor Excessive handling increased food safety risks Line workers working closely together during COVID-19

Solution       Grote implemented a robotics system to pick, align, cut, and organize wraps for       packaging Fit the existing footprint Interfaced with the existing packaging conveyor       The custom configuration included: End effector specific to the operation Infeed and outfeed conveyors Twin lane system with two 3D vision systems Two 4-axis Stäubli HE robots Grote ultrasonic cutter Single HMI (human-machine interface) for operation

Results Increased production capacity to 100 wraps per minute Improved quality to 95% accuracy (+/- 3 mm) Eliminated six operators per shift

Read the full case study here.

2. Martel Foods Automates Sandwich Lidding with Grote Robotics

Martel Foods is a family-owned manufacturer of ready-to-eat products based in Quebec, Canada. Martel uses cutting-edge equipment and technology to produce high-quality perishable products, including packaged sandwiches. Grote’s automation solutions helped them repurpose workers into other roles, and eliminate some personnel.
 

CASE STUDY
The Challenge       Martel Foods: Needed a solution to increase sandwich production and reduce manual labor Faced a shortage of available skilled labor Aimed to free up workers for less mundane tasks       Martel turned to Grote Company for automation help.
The Solution       Grote developed a robotic sandwich “lidding” solution (placing the top piece of bread on a sandwich).       Key equipment components: 3D vision system 4-axis Stäubli HE robot Custom end-of-arm tooling with guarding       Robotics were integrated into Martel’s existing sandwich assembly line using Grote Bread Denester Grote Ultrasonic Sandwich Cutter       Completed installation over one weekend, with machinery operational on Monday.
The Results Martel can now “lid” 52 sandwiches per minute, a nearly 50% increase in production. The equipment replaced one operator per shift. The transition freed up workers to focus on more engaging tasks. The equipment seamlessly integrates with other Grote systems, bridging the gap between full automation and manual labor.
“The new equipment has helped Martel close the gap between full automation and manual labor. It works seamlessly with the rest of the Grote equipment on the line.” - Serge Martel, Owner, Martel Foods

Read the full case study here.
 

GROTE: YOUR ROBOTICS SOLUTIONS PROVIDER

Grote has been pioneering smart automated solutions to food processing challenges for over half a century. Today, we are at the forefront of the adoption of robotic technologies to enhance and integrate processing and to reduce the industry’s dependence on manual labor.

Our robotic solutions allow you to achieve more with fewer people on the shop floor, improving profitability and overall process efficiency. From building sandwiches and wraps to separating pizzas and tortillas, our robotic units are designed to automate some of the most mundane tasks, reducing your labor bill and freeing up your employees for higher-value tasks.

Bring us your labor and automation challenges–we’ll work with you to design, test, and install a robotic solution that will have an immediate impact on your bottom line and deliver measurable value for years to come.

Contact us today to get started, or click below to learn more about our industry-leading food robotics solutions.

 

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