As bakeries embrace automation, industry leaders Projective and Schubert are transforming production with cutting-edge systems that cut costs, boost efficiency, and deliver on sustainability. Kiran Grewal reports.
Automation is emerging as the key solution for boosting efficiency, cutting costs, and meeting rising sustainability standards in the bakery industry. As an example, Bonheur ASA, the Norway-based industrial investment giant, has recently announced it has acquired a controlling stake in Projective, a global consulting and engineering firm. As bakeries grapple with growing demands for efficiency, sustainability, and cost-cutting, this partnership stands to make a big impact by unlocking new opportunities in automation, energy efficiency, and streamlined processes. For bakery manufacturers, Projective’s expertise could be the golden ticket to harnessing advanced technologies, saving costs, and meeting evolving standards in production.
Projective’s vision for a modern bakery industry
Since its founding in 2004, Projective has become known for its tailored solutions across industries as diverse as pharmaceuticals, brewing, utilities, and food manufacturing. But its mission isn’t just about technical support—it’s about transforming how companies manage their processes and reach ambitious sustainability goals. CEO Ray Wellham explains: “We assist companies to save energy and water, reduce costs, and improve sustainability in their operations.”
For bakeries, where every kilowatt and drop of water counts, this focus translates into real savings and a leaner, greener production line. By adopting Projective’s innovative solutions, bakeries can integrate automation tools that reduce energy use, manage waste, and cut water consumption, transforming these perennial challenges into streamlined assets.
Automation and cost control
Automation has long been an aspiration for bakeries seeking to keep pace with demand while controlling costs. However, true automation isn’t just about adding machines—it’s about developing interconnected systems that allow for precise control over each aspect of production. That’s where Projective’s expertise in industrial utilities and energy efficiency can help bakeries gain a competitive edge.
Imagine a bakery production line with automated monitoring and adjustment systems that optimise energy use in real-time, ensuring each batch is baked at the perfect temperature while using the minimum energy required. Or a system that tracks water usage across each production stage, saving every possible ounce without sacrificing quality. These are the types of solutions Projective excels at, with years of experience helping companies worldwide.
This high level of process automation means less human intervention, fewer errors, and faster turnaround—crucial for bakeries looking to maximise their throughput and reduce operational downtime. As Lloyd Butterworth, Investment Director at Fred. Olsen Investments AS, puts it: “Projective’s focus on energy consumption, manufacturing carbon intensity, and energy efficiency is of great societal importance.”
Baking a more sustainable future
But there’s more to this story than automation. Bonheur’s investment in Projective comes at a time when sustainability is no longer just a bonus for businesses—it’s a necessity. For bakeries, this means adopting sustainable practices to meet consumer expectations and regulatory demands, from reducing carbon emissions to lowering resource use and waste. With a strong background in utilities management, Projective can help bakeries adopt green technologies that integrate seamlessly with their operations, from energy-efficient ovens to waste management systems designed to minimise environmental impact.
These practices aren’t just good for the planet—they’re cost-effective. As Projective’s CEO Wellham shares, the consulting firm has already “proven [its] track record” in helping companies reduce energy and water usage, leading to lower operational costs alongside improved sustainability. For bakeries, reducing the amount of energy and water used directly correlates with reduced costs, creating an alignment between financial goals and environmental responsibility.
Bonheur’s investment brings fresh energy to Projective’s mission, supporting the firm’s plans to expand its services and support a wider range of industries—bakeries included. The influx of capital will allow Projective to grow its teams and develop new, cutting-edge systems to support automation and sustainability for larger and more varied clients.
This expansion brings clear benefits for bakeries looking to scale up or refine their operations. Projective will not only offer solutions that optimise utilities and processes, but its expanded reach means bakeries can expect more tailored support, including equipment selection advice and utility management consulting specific to their production needs. As Øyvind Engesrønning, CEO of Fred. Olsen Investments AS, said: “We hope to see the company continuing to help existing and new clients in their decarbonisation efforts and reaching their net zero targets.”
For bakery manufacturers, this means that Projective’s expanded team can bring fresh insights and support to improve process efficiencies and reach sustainability targets, which could be a game-changer in a sector looking to innovate.
The Bonheur-Projective partnership arrives at a pivotal moment for the bakery industry. With automation and energy efficiency quickly shifting from “nice-to-haves” to essentials, bakeries have the opportunity to adopt forward-thinking, cost-saving practices that meet both consumer and regulatory demands.
In short, Projective’s solutions offer bakeries a recipe for success in a world where efficiency, automation, and sustainability rule. For those ready to embrace the future, Projective’s expertise could be just the ingredient needed to rise to the occasion.
Boosting efficiency
German biscuit maker Bahlsen has teamed up with packaging specialists at Schubert to introduce a cutting-edge, eco-friendly packaging system for its popular PiCK UP! biscuit bars. The new line reflects a growing trend in bakery manufacturing: using automation to streamline production, lower costs, and enhance sustainability.
For years, Bahlsen has delighted snack lovers with PiCK UP!, the beloved chocolate-filled biscuit bar. Now, with a strong focus on sustainability, Bahlsen has replaced its former plastic-heavy flowpacks with folding cartons made of cardboard, a change that is set to eliminate 112 tonnes of plastic annually. Schubert, Bahlsen’s long-time partner in packaging innovation, designed a custom automated line that meets stringent environmental goals without compromising production speed or quality. Bahlsen’s Project Manager Ulrike Arnold shares her excitement: “The design of the line was tricky, with many columns and low ceilings restricting the space, and yet the result is a line that meets Bahlsen’s highest requirements.”
Bahlsen’s goal was to cut down on plastic, and Schubert responded by integrating thinner films for the inner flowpacks, further reducing material waste. This streamlined system, tailored to Bahlsen’s spatial constraints, is a testament to automation’s transformative role in the bakery industry.
The heart of this upgrade is Schubert’s fully automated, flexible bar packers, which now handle every step in the packaging process: erecting, filling, and sealing the cartons with robotic precision. The line incorporates Schubert’s Transmodul transport robot, ensuring gentle handling to protect the delicate biscuits while increasing overall line efficiency. With each step seamlessly automated, Bahlsen is not only able to meet sustainability goals but also optimise cost-effectiveness.
With a processing rate of up to 850 biscuit bars per minute, the new system is not only efficient but adaptable. Robots handle the bars with such precision that the cartons are designed to be as compact as possible, eliminating excess space and reducing shipping volume. Additionally, the system’s versatility allows Bahlsen to package its treats in up to eight different configurations, a flexibility that’s invaluable in a competitive market.
Cost savings and flexibility
For Bahlsen, the packaging overhaul is both a strategic and sustainable choice. The reduction in packaging material has led to significant cost savings, and the use of automated robots reduces human intervention, minimising errors and downtime. The automation also enables faster setup for format changes, which can be completed in just 20 minutes—ideal for meeting varied product demands.
This innovative line doesn’t just cut costs and support the environment; it also enhances product consistency and improves turnaround times, essential in today’s fast-paced marketplace. Schubert’s robots work in sync to streamline packaging without sacrificing product integrity, a must in the delicate world of bakery goods.
From Bonheur’s investment in Projective to Bahlsen’s partnership with Schubert, bakery manufacturers are reimagining what it means to be efficient, cost-effective, and environmentally conscious. These partnerships and technological advancements underscore an exciting shift: one where cutting-edge automation, energy-efficient systems, and smart packaging solutions drive growth while addressing the critical need for sustainability.
For bakeries around the world, these developments signal a turning point. By leveraging the expertise of firms like Projective and Schubert, manufacturers are not only meeting rising consumer and regulatory expectations but also positioning themselves as industry leaders ready to thrive in a future where every kilowatt, drop of water, and gram of plastic matters. The message is clear: with the right blend of technology, sustainability, and strategy, bakeries have all the ingredients they need to rise to new challenges and serve up a future that’s as sustainable as it is sweet.
Editorial contact:
Editor: Kiran Grewal kgrewal@kennedys.co.uk
