From Manual to Fully Automated: Slice & Apply Solutions

In food processing, efficiency and consistency are key to maintaining product quality, meeting production demands, and ensuring profitability. Over time, the industry has transitioned from manual food preparation to fully automated systems that enhance speed, accuracy, and hygiene. One such transformation has occurred in the slice and apply process, particularly in sandwich, pizza, and ready-to-eat food production.

Understanding the different levels of slice and apply automation can help food processors determine where they stand and whether further automation makes sense for their operation. Below, we outline the four main methods of slice and apply in food processing and the benefits of each.

1. Manual Slicing & Application

At its most basic level, the slice and apply process is entirely manual. Workers use knives or hand-operated slicers to cut meats, cheeses, and other ingredients before manually placing them onto products like sandwiches, baked goods, and prepared foods.

Pros:

• Low initial investment
• Flexibility to accommodate varied product types
• Suitable for small-scale operations

Cons:

• High labor costs and potential risks
• Inconsistent slice thickness and placement
• Slower production speeds
• Increased risk of contamination

For small, specialty food manufacturers or those with highly customized products, manual slice and apply may still be a viable approach. However, as production volumes increase, the limitations of this method become more apparent.

2. Tabletop Slicer with Manual Application

The next step in the evolution is implementing a tabletop slicer to bulk slice ingredients while still manually applying them to products.

Pros:

• Faster slicing than manual methods
• More consistent slice thickness
• Still relatively low-cost compared to fully automated solutions

Cons:

• The labor-intensive application process remains
• Potential for bottlenecks in production and quality assurance due to manual placement
• Continued risk of food safety issues from human handling and slicer sanitation practices

This level of automation can be a great stepping stone for mid-sized food processors looking to improve efficiency without fully committing to an automated line.

3. Automated Slicer with a Separate Application System

At this stage of automation, food processors integrate an automated food slicer to handle slicing while using a separate application system (such as conveyance solutions or robotic material handling) to apply sliced ingredients onto the product. This eliminates manual slicing and significantly reduces the need for human labor in the application process.

Pros:

• High-speed, consistent slicing with minimal labor
• Reduced human handling improves food safety
• Greater efficiency compared to manual placement
• It can accommodate a variety of setups
• Fully automated systems are available for some applications

Cons:

• Slicing and application systems must be integrated
• A larger footprint is needed for multiple solutions
• Much higher price point, depending on the solutions chosen

This setup is ideal for food processors who want to automate slicing and application to improve efficiency and have extensive footprint and budget–perhaps for a new line or plant install–or a “canned” application with a fully integrated system available.

4. Fully Automated Slice & Apply Machine

At the highest level of efficiency, food processors implement a slice-and-apply slicer. This single machine integrates slicing and ingredient application into a seamless process, maximizing efficiency, accuracy, and hygiene.

Pros:

• High-speed production with minimal labor
• Precise and consistent targeting and placement of sliced ingredients
• Smaller footprint needed for one machine that is cantilevered to existing lines
• Only one machine to operate and maintain
• Flexible operation to slice multiple food products
• Reduced product waste and improved yield
• Enhanced food safety with no human handling

Cons:

• Best suited for single to a few lane wide operations

For manufacturers that make foods that require assembly or further processing, combining slice and apply into one machine ensures the most efficient production.

Slice and Apply Applications:

• Prepared foods that require assembly, such as sandwiches, meals, stuffed baked goods, cordon bleu, and more
• Products that require further processing, such as bacon and jerky that are sliced onto baking belts and screens, bread chips onto trays, and more

What Slice and Apply Solution Do You Need (Now and In the Future)?

Determining whether to move to the next stage of automation depends on factors like production volume, labor availability, product consistency needs, and long-term growth plans. If your current process involves extensive manual labor, frequent bottlenecks, or inconsistent ingredient application, transitioning to an automated slice & apply solution may be the logical next step. Selecting separate solutions or a one-machine setup depends largely on your application, footprint, throughput, and budget.

Grote’s slice & apply slicers offer a streamlined, reliable solution for food processors looking to maximize efficiency while maintaining high product quality. If you’re considering further automating your food processing operation, contact Grote today to learn how we can help take your production to the next level.

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