Digitalization and Smart Technologies in Baking: How Software and Process Control Solutions Are Transforming the Industry
The baking industry, deeply rooted in traditional craftsmanship, is moving into a new era defined by digitalization and smart technologies. Leading software and process control providers such as Rockwell Automation, Siemens, CSB-System, and ProLeiT are at the forefront of this evolution, delivering intelligent solutions that enhance operational efficiency, product quality, and business scalability.
As bakeries of all sizes seek to remain competitive amid tightening margins, labor shortages, and evolving consumer expectations, the deployment of smart manufacturing systems is a sound business decision.
Rockwell Automation: Digitalizing Bakery Operations
Rockwell Automation exemplifies how strategic implementation of digital solutions can bring measurable benefits. The company’s collaboration with Irish baked-goods manufacturer West-Bake Ltd. offers a practical example. Traditionally reliant on paper-based systems for inventory and quality control, West-Bake transitioned to the Plex Smart Manufacturing Platform. This cloud-based system digitized the company’s records, leading to a profound improvement in operational transparency and decision-making.
PJ Shanks, IT Manager at West-Bake, commented on the transformation: “By digitalizing our inventory and quality records, we anticipate significant time, effort and cost savings.” The move also bolstered supply chain management, with real-time data allowing for more accurate forecasting and stock optimization. As Shanks further noted, the new system positioned the company for scalability: “Having a digital system will also help us expand, as we now have a platform that can grow with us.”
Beyond individual case studies, Rockwell Automation’s broader strategy underscores a shift toward smart manufacturing platforms that integrate IoT, cloud computing, and AI analytics. By offering scalable, modular systems, Rockwell enables bakeries to adopt technology at their own pace while ensuring seamless integration across operations. The Plex suite, part of their smart manufacturing portfolio, exemplifies this adaptability, catering to both small artisanal bakeries and large industrial producers.
Siemens and the Power of the Digital Twin
Siemens, another major player in the digitalization space, approaches transformation through its “Digital Enterprise” concept. This framework encompasses software, hardware, and services, providing a continuous data model that spans the entire plant lifecycle. At the core of Siemens’ offering is the digital twin — a virtual replica of physical assets, processes, and systems, which enables simulation, monitoring, and optimization.
Jürgen Brandes, former CEO of the Process Industries and Drives Division at Siemens, captured the essence of this approach: “We are the first provider ever to offer an end-to-end data model along the entire plant life cycle, from integrated engineering and integrated operations through to data-based services.” For bakery manufacturers, this means unprecedented flexibility in designing, operating, and maintaining their production lines. Digital twins allow bakeries to simulate recipe changes, optimize energy consumption, predict maintenance needs, and troubleshoot issues before they impact production.
Siemens’ software portfolio also includes powerful MES (Manufacturing Execution Systems) like SIMATIC IT and MindSphere, a cloud-based, open IoT operating system. These platforms enable real-time performance monitoring, predictive maintenance, and machine learning integration, empowering bakeries to transition from reactive to proactive management models.