Empowering Small Namkeen Manufacturers for Efficiency, Quality, and Growth
Automation refers to the use of technology to perform tasks that were previously done manually. For smaller namkeen manufacturers, automation can lead to increased efficiency, improved product quality and consistency, and reduced labour costs. Automation can also help smaller manufacturers scale their operations more effectively and compete with larger players in the market.
The Automation:
Some potential automation solutions for smaller namkeen manufacturers that can be implemented by them include:
Automated weighing and mixing systems that can accurately measure and blend ingredients to achieve consistent product quality.
Automated frying systems that can fry namkeen products at a precise temperature and duration, resulting in uniform colour and texture.
Robotic systems that can perform tasks such as packing and labelling, reduce the need for manual labour.
Data analytics and machine learning tools can help manufacturers optimize their processes, predict demand, and improve supply chain management.
Challenges Faced:
When implementing automation solutions, small namkeen manufacturers may face several challenges when implementing automation solutions, including:
Smaller manufacturers may not have the resources to invest in automation solutions due to high initial costs, technical expertise, resistance to change, and integration with existing systems. Implementing automation solutions can be complex and time-consuming.
Overcoming these challenges
Smaller namkeen manufacturers can take several steps to overcome the challenges of automation solutions. These include conducting a cost-benefit analysis, partnering with experts or consultants, providing training and support to employees, and gradually phasing in automation solutions.
Automation can offer significant benefits, but it is important to carefully evaluate the costs and potential challenges and develop a plan to overcome them effectively.
Mithai & Namkeen Times engaged in discussions with industry experts specializing in machine automation for frying lines, seeking their insights to gain a deeper understanding of this emerging trend. The following citation provides their valuable contributions to the topic:
The Ideal Time
We began by asking Kavish Dixit, Application Manager, KIRON SERVEPRENEURS PVT. LTD., when it would be ideal for a small namkeen business to set up automated manufacturing lines.
To this, Kavish responded that India is home to a large number of ethnic Indian sweet and namkeen manufacturers, which cater to the demand for traditional and regional sweets and snacks. These manufacturers operate at various scales, ranging from small family-owned businesses to large industrial enterprises. They have been producing sweets and namkeen for several generations, preserving age-old recipes and techniques while also embracing modern production methods.
“The ideal time for a small namkeen business to set up automated manufacturing lines depends on various factors, such as growth stage, production volume, available capital, and market demand. To determine the right timing, businesses should consider stability and growth, production volume, financial readiness, technology and market trends, scalability and long-term planning, and a cost-benefit analysis. Stability and growth are essential for a small namkeen business to establish stability and experience consistent growth; production volume should be evaluated, financial readiness should be assessed, technology and market trends should be researched, and scalability and long-term planning should be considered”, articulated Kavish.
Turning our attention to Mugdha Gujar, she is an Area Sales Manager at E & S FOOD TECHNOLOGIES PVT. LTD.
Mugdha designates, “As an authorized dealer of Italian encrusting machines, we understand the challenges faced by smaller namkeen manufacturers in the Indian food sector. However, as the industry evolves and consumer demands increase, it is necessary to transition to automatic production lines”.
Narrating further, she went on to add, “Smaller namkeen manufacturers should consider automation when they have consistent demand, increased production volume, labour availability, product quality, market expansion plans, cost-effectiveness, and competitive pressures. Automation can streamline operations, enhance productivity, improve product quality, and position themselves for sustainable growth in the Indian food sector”.
“There are several key factors that indicate the right moment for smaller namkeen manufacturers to start considering automation.
Consistent demand & automation: Consistent demand for namkeen products is a sign that it is time to invest in automatic production lines. Automation can help meet the increased demand efficiently and maintain product consistency. If you are producing a significant volume of namkeen and anticipate this trend to continue or grow, automation can help meet the increased demand efficiently and maintain product consistency.
Labour availability & cost: Automating your manufacturing process may be a cost-effective option when manual labour expenses grow and the availability of competent personnel becomes a problem. You can lessen the effects of manpower shortages, boost productivity, and maybe lower ongoing operating expenses by decreasing the reliance on manual labour.
Product quality & consistency: Automation can improve product quality and uniformity, especially when it comes to meeting regulatory standards and customer expectations. It is especially important when it comes to meeting regulatory standards and customer expectations.
Scale & market expansion: Automation of production lines can help expand market reach and introduce new products, as it allows for faster production rates and increased capacity, allowing for a larger customer base and more efficient product diversification.
Cost-effectiveness & ROI: Assessing the financial viability of automation is essential. Consider the upfront investment and evaluate the potential return on investment (ROI) by estimating cost savings, increased productivity, reduced waste, and improved product quality. Automation can lead to long-term cost savings and increased profitability.
Competitor analysis: Analyse competitors in the namkeen industry to determine if they are adopting automation and gaining a competitive edge. Staying ahead of the competition and embracing technological advancements can help maintain market position and stay relevant in the industry.
“The decision to implement automatic production lines should be made after careful analysis and planning. Seek expert advice from authorized dealers like us who specialize in providing solutions for the food industry to evaluate your specific requirements, recommend suitable machinery, and provide ongoing support to ensure a smooth transition to automated production”, concluded Mughda.
Sequentially, we spoke to Raman Dhoot, Director of SM FOOD, on the same query.
Raman Dhoot provided a to-the-point reply. According to him, when a small-industry namkeen maker reaches a daily production level of 2000 kg per day, it becomes increasingly beneficial to consider automating or semi-automating the manufacturing process. Automation can significantly improve production efficiency and output, ensure consistent product quality, reduce cost savings, scale up production, and improve food safety and hygiene”.
“It can also reduce the need for manual labour, reduce ingredient wastage, improve portion control, and optimize energy usage. However, it is important to consider the specific requirements, budget, and feasibility of automation for a very small namkeen manufacturer before making an informed decision about their needs and goals”, voiced Raman.
The entry-level capacity for automation
Depending on the particular needs and production demands of the company, the entry-level automation capability for small namkeen manufacturers might change. It’s vital to keep in mind that each snack manufacturer will have different requirements depending on things like the sort of snacks being made, manufacturing volume, available space, and financial limitations.
According to Kavish, “If we divide them into 4 categories according to their production capacity, the results will look essentially like what is described below:
Categories A, B, and C include manufacturers that produce 400+ tons, 200+ tons, and 100+ tons of capacity per month, respectively. And they have all incorporated basic to full-fledged automation in their production lines, and they are eager to implement any new technology that comes their way.
Now there is 4th category of manufacturers who are very low in capacity, have a small targeted market, and are family-owned with small conventional production facilities. The majority of such producers are worried about automation costs, losing their old traditional method of producing, which will ruin the taste of their produce, space for big equipment, skilled workers to run the machine, or confusion about where and how to implement automation. Such producers should make investments in automation in such a way that it does not make a big change in their existing processes. For example, a peeler, a slicer, a dough mixer, small intermediate conveyors between two processes, a manual packaging machine, etc. After getting experience handling small application-specific equipment, they should invest in more complex and critical machines like blanchers, fryers, and automated packaging solutions. Finally, they should invest in either a semi-automated line or a fully automated line. The goal of implementation of automation in any process is to achieve speed, scale, consistent quality, and hygiene, along with reduction of wastage, energy (heat or electricity), and labour,” Kavish concluded his words.
Mugdha’s input goes as follows: “For manufacturers with a basic production requirement of 60 kg/hr, we offer entry-level capacity encrusting machines that are specifically designed to meet their production needs efficiently.
“Our entry-level capacity encrusting machines are designed to provide optimal performance while maintaining affordability for small-scale manufacturers. These machines are equipped with advanced technology and features that ensure precise and consistent product output while also being user-friendly and easy to operate”.
Speaking about the benefits of automation, Raman Dhoot stated, “Implementing automation in small manufacturing businesses can bring several benefits, including increased productivity, improved efficiency, and cost savings. If a small manufacturer is producing 3 tons per day or 300 kilograms per hour, it may be a suitable time to consider automation.
Automation can significantly increase production output by reducing manual labour and streamlining processes, leading to higher production rates and overall productivity. Automated processes ensure greater consistency in product quality.
Automated machinery often performs tasks faster and with greater precision compared to manual labour.
“Automation requires an initial investment, but it can lead to long-term cost savings and scalability for future growth. It is important to conduct a cost-benefit analysis and assess the specific requirements of the manufacturing process before pursuing automation. Consult with experts or industry associations to ensure the right solution,” Raman added.
The initial hiccups
Mugdha replied, “Small manufacturers should be prepared for the initial hiccups of transitioning to an automatic production line, and by being proactive and addressing these challenges, they can ensure a smoother transition. Here are some common initial hiccups and how to prepare for them:
Upfront investment: Small manufacturers should carefully assess their financial capabilities and create a budget for the transition to an automatic production line. They may need to explore financing options or seek assistance from banks or government schemes.
Workforce adjustment: Manufacturers should communicate openly and transparently with their workforce to explain the reasons behind the transition and address job security concerns. They should also provide training programs to help employees acquire new skills that align with the automated production process.
Training & skill development: Manufacturers should invest in training their employees on how to operate, maintain, and troubleshoot automated production lines. They should also engage with the equipment supplier or authorized dealer to provide comprehensive training sessions to ensure a smooth learning curve.
Process optimization: Automation offers opportunities for process optimization and efficiency improvements, but it is essential to analyse and optimize the existing production process before implementing it. Identify bottlenecks, streamline workflows, and standardize procedures to maximize the benefits of automation. Engage with experts or consultants to ensure a seamless integration.
System integration & compatibility: Manufacturers should work closely with the equipment supplier or authorized dealer to ensure seamless integration and data exchange between different systems, such as inventory management and quality control. It is important to assess the compatibility of the new automation equipment with existing infrastructure and software.
Maintenance & support: Manufacturers should establish a maintenance schedule and train employees to handle routine maintenance tasks. It is advisable to have a service agreement with the equipment supplier or authorized dealer to ensure timely support in case of technical issues.
Monitoring & quality control: Automation requires robust monitoring and quality control systems to ensure consistent product quality. Sensors, cameras, and other monitoring devices should be used to track production parameters and conduct regular quality checks. Establish protocols for quality control and mechanisms for continuous improvement.
Small manufacturers can navigate the transition to an automatic production line more effectively by anticipating and preparing in advance. Seeking guidance from experienced equipment suppliers or authorized dealers can provide valuable insights and support. With proper planning and preparation, the journey towards automation can lead to increased efficiency, improved product quality, and sustainable growth.
“Some of the difficulties in satisfying the requirements include the need for fundamental equipment operating expertise, the building of a basic laboratory for the setup, and sufficient infrastructure for supply and uninterrupted energy, water, and air venting. In order to overcome these challenges, rigorous planning, professional teamwork, and resource allocation are required. It’s crucial to carry out a complete analysis of the production process, determine whether automation is feasible, and create a comprehensive implementation strategy that takes equipment expertise, laboratory setup, infrastructure needs, and supply chain issues into account”, Raman concluded.
Summing up
Automation in frying lines can provide various benefits and considerations for small-scale producers. Automation may help to optimise the frying process by eliminating human error and increasing production speed, as well as handling repeated jobs with accuracy and consistency, ensuring constant product quality.
It can save personnel expenses, reduce ingredient waste, and reduce energy use. Automation systems may be customised to meet the needs of small-scale producers and readily scaled up or down to meet production demands.
However, there are several significant factors to consider.
Automation necessitates a considerable initial investment in equipment, software, and training. Automation systems may require specialised knowledge and abilities, and automation technology is continually improving.
To remain competitive, small-scale producers must keep up with the newest innovations and be prepared to change their systems on a regular basis.
Finding the correct mix between automation and manual operations is critical to keeping their goods’ distinctive features.