Labor Saving Automatic Cookie Line 60-120 Pieces Per Minute Fewer Operators Needed

Labor availability is now the binding constraint for most mid size bakeries, not oven capacity. A conventional cookie line needs five or six people per shift to form, transfer, lay trays and unload, and that headcount is increasingly difficult to hire and retain. This labor saving automatic cookie line brings the same output down to two operators by synchronizing forming, arranging and tray handling into one continuous flow at 60 to 120 pieces per minute.

The forming head deposits dough onto a PU belt, a servo gantry picks each piece and places it on a denested tray at a programmable pitch, and the filled tray is discharged directly to the oven loader. Because the pitch is programmed rather than eyeballed, rows stay square, which keeps downstream cooling and flow wrapping in step. Recipes are stored on the touch screen with speed, drop count and pitch, so a shift change does not require a skilled setter to reset the machine by hand.

• One Flow From Dough To Tray: Forming, arranging and tray loading happen inside a single synchronized line, so cookies are no longer hand transferred between stations.
• Servo Gantry Arranging: A servo gantry picks and places each piece at a programmable pitch, which removes the two or three workers normally needed to lay trays by hand.
• Automatic Tray Denesting: Trays are denested, filled and discharged without an operator touching the stack, keeping the packing end of the line continuous.
• Speed Matching: The inverter lets the line run at 60 pieces per minute for delicate recipes and 120 for robust shortbread, without changing mechanical parts.
• Consistent Placement: Programmed pitch keeps rows aligned, so oven loading, cooling and flow wrapping downstream stay in step with the forming section.
• Single Point Control: The 10 inch touch screen starts and stops the whole line in sequence, preventing the jam that happens when stations are started independently.

Designed for bakeries producing butter cookies, shortbread, chocolate chip cookies, sandwich biscuit shells and frozen cookie dough pucks. It fits plants replacing manual tray laying, and it can be integrated upstream of a tunnel oven or downstream of a cooling conveyor with minimal civil work.

Conveyor modules are separated, wrapped in stretch film and fixed to plywood cases with steel bases. Alignment pins are marked to speed reassembly on site, and the shipment includes an English commissioning checklist, wiring diagram and a set of spare belts and proximity switches.

For a plant paying six operators per shift, the headcount reduction usually pays the equipment cost back inside one production year, which is the argument most of our buyers bring to their own finance team.