Industrial Bakery Production Line
Fermentation, dividing, and baking are handled by dedicated equipment; robots come in for bag feeding, tray handling, feeding the packaging line, case packing and palletizing, and transport. Public cases from Japanese bakeries are scarce, so overseas bakeries and adjacent Japanese food plants (confectionery, rice, beverages) fill the gaps.
全部9道工序中，有6道工序共13项作业可由机器人承担。
工序流程
点击工序可跳转到对应作业。
- 1Receiving1项
- 2Mixing2项
- 3Bulk fermentation
- 4Dividing
- 5Shaping2项
- 6Baking
- 7Depanning & cooling1项
- 8Packaging2项
- 9Packing5项
工序来源：厚生労働省 製パン 職業能力評価基準 関連資料 / 福岡労働局「今月はパン職人」 / 大林組 製パン工場（施設計画）
各工序的替代作业
按工序列出人工作业中已有机器人承担实例的项目，可从右侧链接查看候选机型与导入实绩。
- 可机器人化
Ingredient receiving & storage
Receive flour, yeast, fats, and sugars. Flour goes to silos; minor ingredients stay in bags and are weighed the day before.
- 日本已导入Moving ingredients from the warehouse to the production areaB-5 Transport, Storage & RetrievalIn-factory Inter-process Transport
Suntory Osaka plant (beverages, adjacent case) × Phoxter: AMRs carry heavy ingredients on routes that never cross forklift traffic (Sep 2025).
- 可机器人化
Weighing & mixing
Mix the ingredients into dough. Opening and tipping bagged ingredients is manual, as is checking dough consistency and temperature.
- 海外有实绩Depalletizing 25 kg ingredient bags, opening them, and tipping them into the hopperB-1 Raw Material Feeding & SupplyMaterial Feeding & Machine Tending
BYR automatic bag opener sold by Sojitz Machinery (food-grade, 120 bags/hour depalletizing). AZO (Belgium) feeds 25 kg bags of milk powder to the opener with a sealed robot and AI vision at 95% grasp success.
- 日本已导入Opening cartons, lifting out inner bags, cutting, tipping, and clearing emptiesB-1 Raw Material Feeding & SupplyMaterial Feeding & Machine Tending
Kirin Beverage (adjacent case) × FANUC: three robots fully automate feeding tea leaves (up to 25 kg), saving 1,870 hours of feeding and 521 hours of weighing a year.
- 专用设备
Bulk fermentation
Ferment the dough in a proofing room at controlled temperature and humidity.
Handled by the fermentation room; there is no handling work.
- 专用设备
Dividing, rounding & resting
Divide the dough by weight, round it, and rest it in an intermediate proofer.
Dividers, rounders, and intermediate proofers run at high speed; there is little room for a robot arm.
- 可机器人化
Shaping & tray loading
Shape by hand or machine and place in tins or on trays. Pulling trays and boards and arranging dough are manual.
- 海外有实绩Pulling trays and boards from racks, laying baking paper, and arranging dough on traysB-1 Raw Material Feeding & SupplyMaterial Feeding & Machine Tending
Malzers (Germany) × ADM Automation: Yaskawa MOTOMAN GP180 (400 trays/hour), MPK2F (paper laying), four MPP3H (placing dough on trays); food-grade grease and washdown paint.
来源：Yaskawa 事例
- 海外有实绩Unloading loaded trays from the freezer and stacking them onto rack trolleysB-5 Transport, Storage & RetrievalIn-factory Inter-process Transport
Görtz (Germany) × ADM: four Yaskawa MOTOMAN GP180 FGG with layer grippers, up to six trays at a time, 1,000 trays/hour (running since Nov 2024).
- 专用设备
Final proof & baking
Proof the trays in the final proofer and bake in the oven; people decide temperature and time.
Handled by the proofer and oven; settings are decided by people.
- 可机器人化
Depanning & cooling
Remove baked goods from tins and trays and cool them under controlled temperature and humidity.
- 海外有实绩Lifting baked goods off trays and out of tins (robotic depanner)B-2 Assembly & ProcessingAssembly & Collaborative Work
GEA Robotic depanner: picks directly with needles, suction, or grippers onto the next conveyor; head changes cover loaf bread, croissants, and cakes (product page).
- 可机器人化
Slicing & packaging
Slice and bag loaf bread; wrap sweet buns individually. Feeding the wrapper and collating packs are manual.
- 海外有实绩Picking products at the oven exit to feed the wrapper, then collating packs into multipacksB-1 Raw Material Feeding & SupplyMaterial Feeding & Machine Tending
ULMA Packaging automated baked-goods line: two articulated robots feed the flow wrapper from the oven exit; another collates packs into the multipack machine.
- 日本已导入AI image inspection of baked goods for shape defects, chips, and foreign matterB-3 Inspection & Quality ControlInspection & Quality Checks
Silvia (doughnut line, adjacent case) × Sensethings Japan ZENAI: inspects 180 pieces a minute, relieving skilled visual inspectors.
来源：AIsmiley
- 可机器人化
Case packing, palletizing & shipping
Pack wrapped goods into crates and cartons, apply date labels, palletize, and ship.
- 日本已导入Applying shipping labels per bread crate, and supplying, discharging, and stacking the cratesB-4 Packing & PalletizingPalletizing & Truck Unloading
Takaki Bakery Tsukuba plant × SATO: a Yaskawa MOTOMAN-HC10 cobot handles four crate types, MOTOMAN-MPP3S applies 3,000 labels/hour; 56 SKUs, about 23,000 items/day, staff 5 → 2, payback 1.8 years.
- 海外有实绩Picking bagged loaves and rolls from a moving conveyor into shipping cratesB-4 Packing & PalletizingPalletizing & Truck Unloading
A major Finnish bakery × KINE Robotics: Stäubli TS2-60 SCARA with a ToF 3D camera that sees clear bags; 25–30 bags a minute, previously two workers.
来源：Zebra 事例
- 海外有实绩Tray-packing baked pastries and case-packing wrapped loavesB-4 Packing & PalletizingPalletizing & Truck Unloading
Dulcesol (Spain): ABB IRB 340 delta robots tray four pastries at a time (100 a minute); an IRB 1600 case-packs seven loaves at once.
来源：ABB 事例 (PDF)
- 日本已导入Case palletizing with a compact cobot palletizerB-4 Packing & PalletizingPalletizing & Truck Unloading
MK Cheese (Kanagawa, adjacent case): two Closer Palletizy units stack 700+ cases a day up to 10 kg; installed in one day.
- 海外有实绩Moving finished-goods pallets from the packaging line to the warehouseB-5 Transport, Storage & RetrievalWarehouse Transport
Pimad (a Grupo Bimbo bakery): two ABB stacker AMRs move four pallets per trip, linked to WMS and ERP.
一览
| 工序 | 可由机器人承担的作业 | 阶段 | 应用指南 |
|---|---|---|---|
| 1. Ingredient receiving & storage | Moving ingredients from the warehouse to the production area | 日本已导入 | Transport, Storage & Retrieval |
| 2. Weighing & mixing | Depalletizing 25 kg ingredient bags, opening them, and tipping them into the hopper | 海外有实绩 | Raw Material Feeding & Supply |
| 2. Weighing & mixing | Opening cartons, lifting out inner bags, cutting, tipping, and clearing empties | 日本已导入 | Raw Material Feeding & Supply |
| 5. Shaping & tray loading | Pulling trays and boards from racks, laying baking paper, and arranging dough on trays | 海外有实绩 | Raw Material Feeding & Supply |
| 5. Shaping & tray loading | Unloading loaded trays from the freezer and stacking them onto rack trolleys | 海外有实绩 | Transport, Storage & Retrieval |
| 7. Depanning & cooling | Lifting baked goods off trays and out of tins (robotic depanner) | 海外有实绩 | Assembly & Processing |
| 8. Slicing & packaging | Picking products at the oven exit to feed the wrapper, then collating packs into multipacks | 海外有实绩 | Raw Material Feeding & Supply |
| 8. Slicing & packaging | AI image inspection of baked goods for shape defects, chips, and foreign matter | 日本已导入 | Inspection & Quality Control |
| 9. Case packing, palletizing & shipping | Applying shipping labels per bread crate, and supplying, discharging, and stacking the crates | 日本已导入 | Packing & Palletizing |
| 9. Case packing, palletizing & shipping | Picking bagged loaves and rolls from a moving conveyor into shipping crates | 海外有实绩 | Packing & Palletizing |
| 9. Case packing, palletizing & shipping | Tray-packing baked pastries and case-packing wrapped loaves | 海外有实绩 | Packing & Palletizing |
| 9. Case packing, palletizing & shipping | Case palletizing with a compact cobot palletizer | 日本已导入 | Packing & Palletizing |
| 9. Case packing, palletizing & shipping | Moving finished-goods pallets from the packaging line to the warehouse | 海外有实绩 | Transport, Storage & Retrieval |
导入前的确认点
- Hygiene guideline: comply with MAFF's 2024 guideline on introducing and operating robots in food plants, which sets out HACCP-aligned steps and required features for food-grade robots.
- Food-grade specification: food-grade grease, washdown paint, and sealing. For robots touching dough, confirm the direct/indirect contact class and cleanability.
- Clear bags: bagged bread is hard to locate with 2D cameras; ToF 3D cameras that capture shape have a track record.
- Gripping soft products: choose the hand per product — suction, needles, layer grippers, or soft grippers.
- High mix: bakeries often run 100+ SKUs; automating changeovers, such as sensing crate or tray types, becomes a requirement.
- Main-ingredient feeding is usually out of scope for robots: flour is supplied from silos by pneumatic conveying, so bag feeding applies to minor ingredients.
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带上贵司的工序表，我们将一起梳理易于替代的作业、候选机型与 PoC 推进方式。