Case Study: Upgrading from Manual to Automated Cookie Capping (Malaysian Foods Analysis)
Author: Mr. Loon (Production Manager, Hwa *Foods) | Technical Review: David Wang (EverSmart)C ategory: Factory Automation Case Studies
Editor's Note: This case study details the strategic evaluation process undertaken by a leading Malaysian biscuit manufacturer when upgrading their sandwich biscuit line.
As a production manager with over two decades in the industrial baking sector, I have learned that growth isn’t just about capacity; it’s about efficiency. At Hwa Tai Foods Sdn, our manual sandwiching process was the bottleneck preventing us from scaling.
This report outlines our criteria for selecting a
1. The Production Challenge: The Limits of Manual Labor
Before automation, our sandwich biscuit line relied on manual alignment and filling.
Throughput Cap: We were limited to 80 pieces per minute (ppm) per lane.
Inconsistency: Manual filling resulted in weight variations of ±1.5g per biscuit, affecting our cost control.
Hygiene Risk: Increased human handling raised the risk of contamination.
The Goal: We needed a system capable of 600 ppm with a cream deposit accuracy of ±0.2g.
2. The Evaluation Criteria: Why "Cheaper" Was Too Risky
We evaluated three suppliers: a European brand, a low-cost local fabricator, and EverSmart. A cheaper machine with frequent breakdowns would quickly erode any initial savings through lost production. We used a Total Cost of Ownership (TCO) model to compare them.
(For a detailed breakdown of how we calculate these costs, read EverSmart’s guide on
Why We Chose EverSmart:
Sanitary Design: The EverSmart capper featured a cantilevered frame, allowing crumbs to fall directly into collection trays. This reduced our cleaning downtime by 40%.
Lane Flexibility: Their manifold design allowed us to run 2, 4, or 6 lanes depending on oven output.
Local Support: The availability of technical support via their partner network meant we weren't left alone after installation.
3. Implementation: Integrating the Capper with Cooling Conveyors
The biggest technical challenge was not the machine itself, but the integration. We needed to connect the new capper to our existing cooling tunnel without causing a pile-up.
EverSmart engineered a customized
Automatically aligns random biscuits from the oven.
Uses row-multipliers to feed the capper smoothly.
Result: We achieved a 99.5% feed rate with zero jams during the Factory Acceptance Test (FAT).
4. The Results: Measuring Success
Six months after installation, the data speaks for itself.
| Metric | Manual Process | Automated Capper (EverSmart) | Improvement |
| Speed | 80 ppm | 600 ppm | +650% |
| Cream Accuracy | ±1.5g | ±0.2g | Significant Material Savings |
| Labor Req. | 6 Operators | 1 Operator | -83% Labor Cost |
| Reject Rate | 4% | <0.5% | Waste Reduction |
5. Conclusion: Strategic Automation
Investing in the right sandwich biscuit machine is not just about buying hardware; it is about buying a guaranteed output. By prioritizing hygienic design and precise integration over the lowest sticker price, Hwa Tai Foods has secured its production stability for the next decade.
Ready to upgrade your line?
Watch: See the [Cookie Capper in Action (Video)].
Consult: Contact Sofia (Export VP) to discuss your specific sandwiching requirements.
WhatsApp: +86 137 9461 9343
Email: [email protected]
Ready to start your journey toward a customized solution? Contact me directly on WhatsApp to begin the conversation.
