Automation Meets Tradition in UK Bakeries: Robots on the Rise

In the United Kingdom, bakeries are increasingly pairing automation with traditional craft. From Glasgow to London, robots and skilled workers are joining forces to bake at scale while keeping flavour and texture intact.

Heritage and high-tech at Tunnock’s near Glasgow

At the Tunnock’s plant just outside Glasgow, caramel moves between floors on a multi‑level production line, filling the air with a sweet aroma. The wafer biscuits are built in five caramel layers, a job overseen by a team of 12 who judge the caramel’s texture by sight and touch.

“We’re producing around 20 tonnes of caramel each day,” says Stuart Louden, the plant’s engineering and transport manager and the fifth generation of the family to work here. He explains that caramel testing is hands-on: operators press the surface to feel its consistency.

After caramel is prepared, a conveyor carries it to the lower floor, where a dedicated team spreads it onto wafers. Spreading caramel is very sticky and precise work, done by people with experienced judgement.

Although much of the factory relies on automation, some steps remain labour-intensive. The spreading lines operate at night, while human workers provide flexibility and save space.

Together, automated equipment and human operators produce about seven million wafer bars and 4.5 million tea cakes each year. The company continues to grow by embracing new technology while protecting its classic recipes.

Automation and the craft of cake decorating

Building on this blend of speed and craft is a new robot arm for cake decoration. Unifiller, a Canadian firm now part of the Coperion group, has developed HIRO to handle toppings, including caramel, using the same piping techniques a pastry chef would use.

“If you can squeeze it through a pastry bag, our equipment can handle it,” says Derek Lanoville, a researcher and development manager at Coperion.

Hygiene is a top concern. The equipment must come apart easily for cleaning, and Swiss robotics company Stäubli supplies a cleanable arm designed for food production.

One challenge is the natural variation in baked goods, such as cakes that vary in size or centring on their base. The system must accommodate these differences rather than rely on exact uniformity, notes Mr. Lanoville.

Human skill remains central in bread production

In northwest London, The Bread Factory bakes for Gail’s and other outlets around the clock. The plant uses about 16 tonnes of flour to produce up to 40,000 loaves each day. Much of the work is automated—mixing dough and dividing it into portions—but shaping and handling dough still depends on experienced bakers who bring a delicate touch.

Experts note that staff provide flexibility—if a recipe is tweaked, people can observe the effects and adjust the process accordingly. “You can automate more, but you still need human oversight to safeguard the process,” says a senior adviser.

Expert perspective on automation in food production

Craig Le Clair, principal analyst at Forrester, argues that the optimal path is a hybrid model. Automation should speed routine tasks while preserving the “soul” of handmade products like decorated cakes.

He adds that transformation should focus on areas that benefit from consistency, speed, and volume, without erasing the human artistry that adds value.

Industry outlook and investment plans

Back in Glasgow, managers are evaluating upgrades to their lines, but investment depends on the broader economy. Cocoa prices have fluctuated in recent years, influencing decisions to postpone large purchases. One firm signals a potential upgrade of around £2.5 million when market conditions improve.

Conclusion

Automation is reshaping UK bakeries, but most producers view it as a partner to human skill rather than a replacement. By combining reliable machinery with expert hands, they aim to boost output while preserving traditional taste and texture.

Short summary

Automation is changing how UK bakeries work, taking on repetitive tasks while allowing skilled bakers to focus on craft. The result is faster production and more consistency without sacrificing flavour. Industry leaders advocate a balanced approach that protects the craft while embracing technology.

Key takeaway: A hybrid approach to automation helps preserve the craft and character of bakery goods while enabling higher production and consistency. See BBC News for more context BBC News.

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