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Food Manufacturing Automation

Ready-to-Eat Food Manufacturing Automation
Busy lifestyles means many grab a bite on the go. Ready to Eat / Heat foods come in handy here. The market for these foods is on a fast growth trajectory. Cybernetik keeps you ahead through the Ready to Eat / Heat solution for rapid cooking with flavour and nutrient retention, customizability, hygiene, and safety.  

Options are available to design the solution to various global standards. Besides the system uses least possible water for sanitization, optimizes product shelf life, and minimizes raw material wastage.

Grow Your Business

Bring the power of industrial automation to your food business.
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Assembly Line

Main
Secondary
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We develop efficient Turnkey Solutions for your food business

Cybernetik_Chocloate_Scroll_Mobile
Ready-to-Eat (RTE) Food Manufacturing Automation Assembly - Main Line
Grinding
Cocoa Beans Unloading
Blending
Moulding
Separator / Aligner
Secondary Packaging
Tertiary Packaging
Carton Erector

The Cybernetik Advantage

Quality Check

  • High-speed vision and magnetic metal detectors
  • Detection for incorrect orientation, chip off, and metal ingress
  • In-line row rejection

Vibratory Conveyor

  • High capacity and speed
  • Bulk and overhead transfer to minimize footprint
  • Up to 30-deg upward conveying
  • Precise feed rate control via vibration frequency modification
  • Up to 6m product elevation

Grinding

  • Rapid, high-speed operation at 2000-6000 rpm
  • Inbuilt durability and redundancy
  • Easy maintenance-replacement
  • Air cooled Seals and high-performance Bearings
  • Silencers and Inlet Magnets for smooth functioning
  • Hi-tech Polymer Belt for Drive Motor
  • Hygienic, cGMP built

Cocoa Beans Unloading

  • De-dusting Mechanism
  • Magnetic Metal Separator of 10,000 - 12,000 (± 500) gauss
  • Safe and ergonomic loading system
  • Hygienic, cGMP built
  • In-built Hopper

Blending

  • Dust free, smooth operation
  • Flavour preservation for authentic taste
  • Texture control via particle size control
  • Tamper-proof storage
  • Resident time control for required flavour and texture
  • Thorough blending

Moulding

  • Maintains texture through temperature control, preheating of moulds, and vibration table.  
  • Integrated granule dosing unit and granule-chocolate mixer for chocolates with granules.   
  • Automatic or semi-automatic.  
  • Mould material options: Plastic, polycarbonate, or rubber moulds.  

Separator / Aligner

  • Precise row-based separation.  
  • In-line live belt aligners and feeders.  
  • Metal detector and in-line row rejection.  
  • Product singling by 45-deg conveyors.  
  • International standard compliance.  

Roasting

  • Real time Brix checks for rapid operation
  • SCADA for total parameter (temperature, pressure, Brix) control
  • High-strength limpet / dimple jacket design
  • In-built mechanisms to prevent burn-on, mix thoroughly

Primary Packaging

  • Hygienic, cGMP built
  • Precision: Tracking systems for pick-place on moving conveyors
  • High speed: Up to 120 naked chocolates pick-place per minute
  • Orientation based packaging with incorrect position-orientation detection
  • Versatility: Handles various chocolate types and sizes
  • Optimized flow wrapper feeding and distribution

Secondary Packaging

  • Programmable with user-friendly HMI
  • High speed: Servo/Pneumatic end-of-arm customized grippers for palletizers
  • Precision: Weight-based, metered filling systems
  • Large payload capacity
  • Pneumatic holding, fail safe clamping, and stitching / sealing arrangement for bag packing
  • Hygienic, cGMP built

Tertiary Packaging

  • High speed: Servo/Pneumatic end-of-arm customized grippers
  • Heavy duty construction
  • Customized pallet matrix formation
  • Modular, purpose-built design with upstream-downstream integration
  • Flexibility: Automatic, end-of-arm tooling change
  • Multiple unit palletizing in some cases 

Carton Erector

  • Customized pallet matrix formation
  • Servo/pneumatic end-of-arm customized grippers for high speed
  • Multiple cartons simultaneously palletized
  • Optional automated pallet storage and dispensing system
  • Integration with empty pallet dispensing station
  • Integration with slip sheet pick and place for top sheet and bottom sheets
Cybernetik_Chocloate_Scroll_Mobile
Ready-to-Eat (RTE) Food Manufacturing Automation Assembly - Secondary Line
Grinding 1
Cocoa Beans Unloading 1
Blending 1
Moulding 1
Separator / Aligner 1
Secondary Packaging 1
Tertiary Packaging 1
Carton Erector 1

The Cybernetik Advantage tab 2

Quality Check

  • High-speed vision and magnetic metal detectors
  • Detection for incorrect orientation, chip off, and metal ingress
  • In-line row rejection

Vibratory Conveyor

  • High capacity and speed
  • Bulk and overhead transfer to minimize footprint
  • Up to 30-deg upward conveying
  • Precise feed rate control via vibration frequency modification
  • Up to 6m product elevation

Grinding

  • Rapid, high-speed operation at 2000-6000 rpm
  • Inbuilt durability and redundancy
  • Easy maintenance-replacement
  • Air cooled Seals and high-performance Bearings
  • Silencers and Inlet Magnets for smooth functioning
  • Hi-tech Polymer Belt for Drive Motor
  • Hygienic, cGMP built

Cocoa Beans Unloading

  • De-dusting Mechanism
  • Magnetic Metal Separator of 10,000 - 12,000 (± 500) gauss
  • Safe and ergonomic loading system
  • Hygienic, cGMP built
  • In-built Hopper

Blending

  • Dust free, smooth operation
  • Flavour preservation for authentic taste
  • Texture control via particle size control
  • Tamper-proof storage
  • Resident time control for required flavour and texture
  • Thorough blending

Moulding

  • Maintains texture through temperature control, preheating of moulds, and vibration table.  
  • Integrated granule dosing unit and granule-chocolate mixer for chocolates with granules.   
  • Automatic or semi-automatic.  
  • Mould material options: Plastic, polycarbonate, or rubber moulds.  

Separator / Aligner

  • Precise row-based separation.  
  • In-line live belt aligners and feeders.  
  • Metal detector and in-line row rejection.  
  • Product singling by 45-deg conveyors.  
  • International standard compliance.  

Roasting

  • Real time Brix checks for rapid operation
  • SCADA for total parameter (temperature, pressure, Brix) control
  • High-strength limpet / dimple jacket design
  • In-built mechanisms to prevent burn-on, mix thoroughly

Primary Packaging

  • Hygienic, cGMP built
  • Precision: Tracking systems for pick-place on moving conveyors
  • High speed: Up to 120 naked chocolates pick-place per minute
  • Orientation based packaging with incorrect position-orientation detection
  • Versatility: Handles various chocolate types and sizes
  • Optimized flow wrapper feeding and distribution

Secondary Packaging

  • Programmable with user-friendly HMI
  • High speed: Servo/Pneumatic end-of-arm customized grippers for palletizers
  • Precision: Weight-based, metered filling systems
  • Large payload capacity
  • Pneumatic holding, fail safe clamping, and stitching / sealing arrangement for bag packing
  • Hygienic, cGMP built

Tertiary Packaging

  • High speed: Servo/Pneumatic end-of-arm customized grippers
  • Heavy duty construction
  • Customized pallet matrix formation
  • Modular, purpose-built design with upstream-downstream integration
  • Flexibility: Automatic, end-of-arm tooling change
  • Multiple unit palletizing in some cases 

Carton Erector

  • Customized pallet matrix formation
  • Servo/pneumatic end-of-arm customized grippers for high speed
  • Multiple cartons simultaneously palletized
  • Optional automated pallet storage and dispensing system
  • Integration with empty pallet dispensing station
  • Integration with slip sheet pick and place for top sheet and bottom sheets
Cybernetik_Chocloate_Scroll_Mobile
Ready-to-Eat (RTE) Food Manufacturing Automation Assembly - Optional Line
Grinding 1
Cocoa Beans Unloading 1
Blending 1
Moulding 1
Separator / Aligner 1
Secondary Packaging 1
Tertiary Packaging 1
Carton Erector 1

The Cybernetik Advantage tab 2

Quality Check

  • High-speed vision and magnetic metal detectors
  • Detection for incorrect orientation, chip off, and metal ingress
  • In-line row rejection

Vibratory Conveyor

  • High capacity and speed
  • Bulk and overhead transfer to minimize footprint
  • Up to 30-deg upward conveying
  • Precise feed rate control via vibration frequency modification
  • Up to 6m product elevation

Grinding

  • Rapid, high-speed operation at 2000-6000 rpm
  • Inbuilt durability and redundancy
  • Easy maintenance-replacement
  • Air cooled Seals and high-performance Bearings
  • Silencers and Inlet Magnets for smooth functioning
  • Hi-tech Polymer Belt for Drive Motor
  • Hygienic, cGMP built

Cocoa Beans Unloading

  • De-dusting Mechanism
  • Magnetic Metal Separator of 10,000 - 12,000 (± 500) gauss
  • Safe and ergonomic loading system
  • Hygienic, cGMP built
  • In-built Hopper

Blending

  • Dust free, smooth operation
  • Flavour preservation for authentic taste
  • Texture control via particle size control
  • Tamper-proof storage
  • Resident time control for required flavour and texture
  • Thorough blending

Moulding

  • Maintains texture through temperature control, preheating of moulds, and vibration table.  
  • Integrated granule dosing unit and granule-chocolate mixer for chocolates with granules.   
  • Automatic or semi-automatic.  
  • Mould material options: Plastic, polycarbonate, or rubber moulds.  

Separator / Aligner

  • Precise row-based separation.  
  • In-line live belt aligners and feeders.  
  • Metal detector and in-line row rejection.  
  • Product singling by 45-deg conveyors.  
  • International standard compliance.  

Roasting

  • Real time Brix checks for rapid operation
  • SCADA for total parameter (temperature, pressure, Brix) control
  • High-strength limpet / dimple jacket design
  • In-built mechanisms to prevent burn-on, mix thoroughly

Primary Packaging

  • Hygienic, cGMP built
  • Precision: Tracking systems for pick-place on moving conveyors
  • High speed: Up to 120 naked chocolates pick-place per minute
  • Orientation based packaging with incorrect position-orientation detection
  • Versatility: Handles various chocolate types and sizes
  • Optimized flow wrapper feeding and distribution

Secondary Packaging

  • Programmable with user-friendly HMI
  • High speed: Servo/Pneumatic end-of-arm customized grippers for palletizers
  • Precision: Weight-based, metered filling systems
  • Large payload capacity
  • Pneumatic holding, fail safe clamping, and stitching / sealing arrangement for bag packing
  • Hygienic, cGMP built

Tertiary Packaging

  • High speed: Servo/Pneumatic end-of-arm customized grippers
  • Heavy duty construction
  • Customized pallet matrix formation
  • Modular, purpose-built design with upstream-downstream integration
  • Flexibility: Automatic, end-of-arm tooling change
  • Multiple unit palletizing in some cases 

Carton Erector

  • Customized pallet matrix formation
  • Servo/pneumatic end-of-arm customized grippers for high speed
  • Multiple cartons simultaneously palletized
  • Optional automated pallet storage and dispensing system
  • Integration with empty pallet dispensing station
  • Integration with slip sheet pick and place for top sheet and bottom sheets

The Cybernetik Advantage

  • Rapid cooking with flavour and nutrient retention.
  • Automated, recipe-based feeding and SCADA for monitoring-control.
  • Hygienic, cGMP built with SS304/316 construction and mirror finish.
  • Minimal product loss during power outages and post-cooking treatment for shelf life extension.
  • Eco-friendly operation with least possible water use.
  • Available Certifications: CE, ASME U, HAZOP, EHEDG, DIN 11852.

Applications 

Mix Vegetable

Potato

Vegetable + Dal

Beans

Rajma Masala

Lentils

Chole Masala

Mushroom Masala

Dal Makhani

Vegetables + Paneer

Masala Rice

Tomato Rice

Pulao

Jeera Rice

Biryani

Sambar Rice

Barbeque Sauces

Pasta Sauce

Burger Sauce

Pizza Sauce

Mayonnaise Sauce

Tomato Paste

Onion Paste

Mixed Paste

Tamarind Paste

Products & Solutions

(6)
  • Buggy Solution for Food Manufacturing Process

    Buggy

  • Melter for Food Production Automation

    Melter

  • Tilting Kettle | Cybernetik

    Tilting Kettle

  • Cooking Kettle | Cybernetik

    Cooking Kettle

  • Buggy Lifter and Tilter for Food Production Automation

    Buggy Lifter and Tipper

  • Buffer Tank for Food Production Automation

    Buffer Tank

Automate your Ready-to-Eat / Heat food manufacturing assembly line

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Ready-to-Eat / Heat Process Automation Solutions

Clients

The general stages in manufacturing RTE foods:
Unloaded raw materials are transported to the location of the cleaning equipment.
Removes dirt, dust, mud, stones, wood pieces and other such contaminants from the main raw materials. The cleaning stage may also include mechanisms for drying the raw materials wetted by the cleaning solution. Quality control check will affirm the efficacy of the cleaning process.
Cleaned raw materials are loaded into cooking kettles. Cybernetik’s Buggy Lifters have:
- 350 liter Eurobins to hold raw materials.
- Brake motor driven belt and pulley mechanism to lift the loaded Eurobin to the required height.
- Tipping system to tilt the bin to the necessary angle for unloading raw material into the cooking kettle. Workers don’t have to lift and tilt the bin, something which eliminates the risk of injury. Safety features include photoelectric sensors, emergency stops, and alarm interlocks.
Industrial cooking kettles are fundamental equipment in the food industry. These can cook, mix, stew, pasteurize, sterilize, or lower the moisture content in raw materials or partially processed foods.

High pressure cooking improves the shelf life and safety of foods, maintains their nutritional value, and saves energy costs while lending them better odor and taste, maintaining their attractive appearance, and minimizing cooking times.
Double/twin shaft paddle mixers are the favorite mixers of the food industry for over three decades for bulk solid mixing.
After pressure cooking, the mixture is buffered and checked for shelf life.
Maintaining or holding the temperature of cooked raw materials the required temperature for a specified duration prevents the growth of harmful disease causing microbes. Holding process can be hot holding or cold holding.

CASE STUDIES

 Manual Bagging Machine
Manual bagging machine is a precise and safe bagging solution with flow rate control and in-built stitching/sealing arrangement. Suited for…
Read More »
Flavour Mixing System
Flavour mixing system is a CE certified solution for exact blending of flavours in the required proportion. Built to GMP…
Read More »
Continuous Mixing & Extrusion System
Cybernetik’s Continuous Mixing & Extrusion System (Bhujia Extruder) achieves an important milestone for food automation – flavour and quality similar…
Read More »

BLOGS

 Automation in the Convenience (Ready-to-Eat / Heat) Food Segment
Automation & the Booming Demand for Convenience Foods Global populations are surging [1] and so are the number of people…
Read More »
Cooking Kettles in the Food Industry
High Pressure, Great Performance Industrial Cooking Kettles are among the fundamental equipment in food processing [1]. These enable heat treatment…
Read More »
Ready-to-Eat (RTE) Food Manufacturing Process
Safety: A Paramount Necessity Tertiary Food Processing delivers Ready to Eat (RTE) foods and Heat to Serve foods [1]. RTE…
Read More »

About Cybernetik

Successfully delivering turnkey automation solutions since 1989.

Cybernetik is an industrial automation company that blends experience with innovation to design, build, and install end-to-end, customized automation solutions for the food, pharmaceutical, chemical, and manufacturing industries across the world.

Cybernetik was set up as a consultancy in 1989 by a group of engineers from the Indian Institute of Technology (IIT)-Madras, India and the State University of New York at Buffalo, USA.

From 10 people operating in less than 100 sq.m. workspace, our footprint in India has expanded to 30,000+ sq.m. across four units, two each in Pune, Maharashtra and Nadiad, Gujarat. Cybernetik's cooking kettles, an integral part of their ready-to-eat food manufacturing automation solutions, offer precise temperature control and efficient cooking processes to produce high-quality food products.

Our global operations are based out of three international offices:

Vietnam (for Southeast Asia), Dubai (for Middle East and Africa) and United States (for North America).

 

READ IN DETAIL

Food production automation delivers an absolutely critical requirement for the food industry – reduction of bacterial load. Considering that recalls are the worst profitability killers in the industry, and that the chances of bacterial contamination are very real, automation of the food manufacturing process is crucial for the industry. 

Cybernetik Technologies automates the food manufacturing process as well as the food packaging process. One of our food production automation is the Industrial Cooking Line. Cooking Kettle is central to this automation, and it delivers rapid cooking without loss of nutrients or flavor. Raw material loading, cooking, buffering, and packaging is automated for high productivity, efficiency, safety, and cost effectiveness. 

Food processing automation companies have their task cut out to ensure that hygiene is maintained at all stages of the production process. This is of course in line with the stated requirement of minimizing the bacterial load. One way of doing this is to have automated and directly connectible CIP (Clean in Place) system linked to the food processing equipment. 

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