Can Tech Outshine Tradition in Baking and Biscuit Making?

The production of Tunnock's famous caramel wafer biscuits showcases a unique blend of traditional craftsmanship and modern technology. At the Tunnock factory just outside Glasgow, a team expertly handles around 20 tonnes of caramel daily, ensuring quality while balancing automation needs. The intricate process involves human skill to ensure the perfect consistency and layering of caramel, amidst the challenges of competing with larger snack brands. This article explores how Tunnock's navigates production challenges and the evolving role of technology in the food industry.

Last updated: 22 October 2023 (BST)

What’s happening now

The Tunnock factory in Uddingston, just outside Glasgow, is currently engaged in an intricate production process that highlights the tension between traditional manufacturing techniques and the push for technological advancement. With a daily output of approximately 20 tonnes of caramel, the factory employs a combination of skilled human workers and automated systems to maintain efficiency and quality. The focus remains on delivering a product that resonates with customers, many of whom have nostalgic ties to the brand.

Key takeaways

Tunnock's produces around 20 tonnes of caramel daily, relying on skilled workers for quality control.
Automation plays a significant role, but human oversight is crucial for maintaining traditional methods.
Innovative technologies, like robotic arms, are being developed to balance speed and craftsmanship in food production.

Timeline: how we got here

Since its establishment in 1890, Tunnock's has evolved significantly in response to changing market demands. Key milestones include:

1890: Tunnock's founded by Thomas Tunnock.
1950s: Introduction of automated processes in biscuit production.
2020: Significant investment in modernising production lines while preserving traditional methods.

What’s new vs what’s known

New today/this week

Recent discussions within the company indicate plans to upgrade production lines and explore innovative technology to enhance efficiency without sacrificing quality. However, financial considerations, such as fluctuating cocoa prices, have prompted a cautious approach to investment.

What was already established

Tunnock's has consistently prioritised a balance between tradition and innovation. The use of skilled workers to monitor caramel consistency and the layered spreading process is a hallmark of their production, differentiating them from mass producers.

Impact for the UK

Consumers and households

For UK consumers, Tunnock's products offer a nostalgic connection, often reminding them of their childhood. The continued production of these beloved snacks supports local jobs and contributes to the heritage of British confectionery.

Businesses and jobs

Tunnock's operates in a competitive landscape dominated by larger firms like McVitie's. Their approach ensures that they remain a relevant player while providing employment opportunities in the local area.

Policy and regulation

The food production sector in the UK is subject to stringent hygiene regulations, which impact how companies like Tunnock's must operate. Adhering to these regulations is crucial for maintaining product safety and consumer trust.

Numbers that matter

20: Tonnes of caramel produced daily at Tunnock's.
7 million: Wafer bars produced annually.
4.5 million: Tea cakes manufactured each year.
2.5 million: Pounds earmarked for potential production line upgrades.

Definitions and jargon buster

Automation: The use of technology to perform tasks without human intervention.
Hygiene regulations: Standards set to ensure cleanliness and safety in food production.

How to think about the next steps

Near term (0–4 weeks)

Tunnock's will continue to monitor cocoa prices closely and evaluate potential investments in new equipment. The focus will also remain on maintaining product quality amidst increasing demands.

Medium term (1–6 months)

As the company assesses market conditions, it may explore partnerships with technology providers to enhance automation while preserving artisanal qualities.

Signals to watch

Trends in cocoa pricing and its impact on production costs.
Consumer demand for traditional versus modern production methods.
Technological advancements in food production and their adoption by Tunnock's.

Practical guidance

Do

Stay informed about market trends that could impact production costs.
Embrace new technologies that align with your brand's identity.

Don’t

Compromise on product quality for the sake of speed.
Neglect the importance of skilled human labour in production.

Checklist

Assess your production line for areas where technology can enhance efficiency.
Evaluate the balance between tradition and innovation in your products.
Monitor external market factors that could influence your business operations.

Risks, caveats, and uncertainties

While Tunnock's seeks to innovate, uncertainties abound, particularly regarding fluctuating ingredient prices and changing consumer preferences. The balance between maintaining traditional practices and integrating new technologies presents risks that require careful management.

Bottom line

Tunnock's continues to navigate the complexities of modern food production by balancing innovation with tradition. As they explore new technologies and production methods, their commitment to quality and nostalgia remains central to their brand identity, ensuring they stay relevant in a competitive market.

FAQs

How much caramel does Tunnock's produce daily?

Tunnock's produces around 20 tonnes of caramel each day, showcasing their commitment to quality and volume.

What is the role of technology in Tunnock's production?

Technology plays a significant role in Tunnock's production, with automation used alongside skilled human workers to maintain quality and efficiency.

How does Tunnock's balance tradition and modern production?

Tunnock's balances tradition and modern production by employing skilled workers for critical tasks while integrating automated systems where appropriate.