Kitchen Batching Systems: Precision and Efficiency for Commercial Kitchens

Although “batch” is commonly associated with food items, the industry in general began associating automated process control methods in the mid-20th century with “batch processing.” Systems for managing data were useful in the early days of computer programming, which in turn began to be used more frequently within industrial processes as these became automated during this period. Computerized controls are used now in various industrial processes, including the food and beverage industry. In many ways, modern batch processing systems stem from the 19th century, with the emerging chemical processing industry.

Advantages of batch processing systems over manual processes include: 

• Speed: With the ability to process more material in less time over manual methods, batch processing systems streamline production.
• Quality control: These systems help reduce the likelihood of contamination and enable processors to identify issues with specific batches much more easily, enabling better quality control than with manual processing.
• Lower costs: Processing in batches helps businesses cut labor and other operational costs compared to manual methods, enabling greater productivity.
• Improved quality: When abnormalities are discovered, the batch from which they come can be more easily flagged to prevent poor-quality products from reaching the customer.
• Greater efficiency: They allocate resources to ensure more efficient material handling than manual methods.
• Better use of resources: Processing in batches allows workers to utilize equipment and other resources more efficiently than for work done manually.
• Automation: They are either automatic or semi-automatic, enabling work with fewer workers.

A batch processing system recognizes when one step in the batching process of a required recipe or formula is finished; it automatically sets the batch up for the next step. When applied to food preparation, this system helps with preparing a recipe more accurately by bringing together the correct proportions of each ingredient in the recipe. These processing systems can generally be used to create many different recipes one batch at a time and can enhance the efficiency of the entire food production process. When used by a commercial kitchen, these systems can improve the food production process to help eliminate human error and make the end product as consistent as possible. 

These systems are often used for food processing applications, enabling the production of more significant amounts of one product at once. This can prove beneficial to a commercial kitchen in many different ways. They also allow kitchens to produce multiple food products in successive batches, switching out the production of one item for another. This provides greater flexibility while enabling advanced preparation to meet forecasted and unplanned increases in demand.

The benefits of batch processing for food production include:

• Ability to quickly change ingredients or recipes as needed.
• Allowing specific changes to be made to test replacement ingredients or new recipes more easily.
• Enabling the automation of ingredient lot tracking and batch validation, including data collection, management, and integration to higher systems (such as ERPs) to meet regulatory requirements.
• Minimizing waste by creating a standardized food product process, including ensuring specific ingredient amounts.
• Reducing contamination risk of food products by separating ingredients and allergens and ensuring cleanliness of the batching system.
• Permitting the production of specialized or highly diverse batches of food.
• Shortening how much time it takes to produce food products compared to manual methods.

Though batch processing systems are automated, some, such as semi-automatic systems, may require an operator to manually feed ingredients into batch containers that are then automatically weighed by the system. The operator’s ingredient weighing actions are controlled by the system. Generally, automatic systems do not require operator involvement beyond selecting and starting recipe batches.

Automatic batch processing systems are also known as minor ingredient batching systems. Semi-automatic systems include the hand-prompt batching station and the kitchen batching system.

When looking at which system best suits food production, throughput speed is generally quicker with automated continuous processing systems rather than batch processing. Systems designed to produce batches typically require each recipe to undergo all processing steps before reaching the endpoint of a completed batch for the selected recipe, making them slower. However, batch processing is usually chosen for food production due to flexibility, traceability, lower complexity, flexibility in scaling production from small to medium, and a lower upfront investment. 

The benefits batch processing systems can bring to commercial kitchens are many and varied, though consistency and the streamlining of food preparation are two main reasons for their use. These systems for batch processing allow kitchens to separate tasks so that a worker requires training only for the manual operations of one point within the overall food preparation and production process. This means a worker at a certain workstation only needs to be trained for the kitchen operations at that point, with specialist workers performing specific tasks.

Additionally, making food in batches allows equipment like fryers, mixers, ovens, and stoves to be used more efficiently. This, in turn, allows commercial kitchens to correctly predict the usage of ingredients, which extends efficiency to inventory management. In this way, these systems allow kitchens to control better what they keep in stock and ensure enough ingredients are available whenever needed, reducing the need to overstock or out-of-stock conditions for ingredients. Commercial kitchens can then purchase ingredients in quantities that often save considerable cost.

Food quality is also improved as it becomes easier to standardize food prepared in batches and add ingredients with greater accuracy. Utilizing batch processing in kitchens ensures consistent taste, mouthfeel, and appearance of food, guaranteeing uniform quality across all dishes. Making food with consistent flavors and textures also allows chefs in commercial kitchens to prepare batches of new dishes, enabling experimentation in ingredients and cooking techniques.  

Through the planning required for batch processing, systems in commercial kitchens can also reduce food spoilage and wastage in general, as it requires chefs to use food ingredients more efficiently. These processes even extend to controlling the temperature at which batches of food are cooked, stored, and reheated, significantly decreasing the chance of sickness resulting from improperly heated or cooled food.

Scalability

One important advantage of batch processing is the ability to scale food production, especially with automatic type systems. Batch processing enables commercial kitchens to handle big orders more easily or cater to large events, for which punctuality and reliability are vital. This ability to scale up production when needed and then scale down when there’s lower demand makes it easier to meet customer needs while still ensuring top quality.

Standardization enables commercial kitchens to easily scale up and handle bigger orders with minimal extra effort. Batch processing systems make it simpler to seize opportunities that would be challenging with manual processes. Precision in producing large quantities of quality food requires thorough planning, including managing production costs and reducing waste.

With over 50 years of expertise in custom engineering process control & automation systems, material weighing, ingredient batching, liquid handling, and other bulk material handling and complete process solutions, Sterling Systems & Controls proudly has the experience to assist you in a holistic approach to complete process automation systems. Contact us today to discuss how our knowledge and experience can align with your goals and how you can continue your journey toward manufacturing excellence!  We can provide you with testimonials for our equipment and systems in various industries, including animal feed, animal nutrition, baking and food processing, pet food manufacturing, thermoplastic compounding, and more.