Central Kitchen Automation Packaging Solution

I. Background

1. 1 Development Trends and Demand of Central Kitchens

Central kitchens have rapidly developed in Europe and the U.S. as the core model for centralized food production and distribution. The growing demand for healthy, convenient, and high-quality foods has driven the expansion of ready-to-eat meals, prepared foods, and delivery services. In this context, automating central kitchen production is essential to improve efficiency, ensure consistency, and maintain food safety.

1.2 Solution Objectives

This solution aims to provide central kitchens in European and American markets with an efficient, intelligent automated packaging system covering a variety of food types such as salads, main dishes, and fast food (wraps, pizzas, hot dogs, hamburgers). By utilizing three independent production lines, the solution achieves automation from material distribution to sealing and packaging, reducing labor costs, enhancing production stability, and ultimately improving customer satisfaction and market competitiveness.

II.Solution Overview

2.1 Production Line Layout

This solution consists of three fully automated packaging production lines, each designed for efficient packaging of different food types:

Line A (Salad Packaging Line): Dedicated to the packaging of various salad products. The automated filling system accurately dispenses ingredients (such as vegetables, proteins, sauces, etc.) into the designated positions in trays, followed by sealing to ensure hygiene, safety, and freshness.
Line B (Main Dish Packaging Line):Suitable for packaging main dishes such as pasta, rice, and meats. The automated filling system precisely portions pre-prepared main foods and side dishes into trays at set ratios, followed by sealing to ensure product integrity and consistent packaging.
Line C (Fast Food Packaging Line): Focused on convenient foods like wraps, pizzas, hot dogs, and hamburgers. Unlike Lines A and B, this line involves manually placing the food into paper trays, which are then conveyed to a pillow-packaging machine for sealing, ensuring packaging efficiency and product quality for fast foods.

These three production lines operate independently but can collaborate, with a well-planned layout that balances production efficiency and space utilization, meeting the high operational demands of central kitchens.

2.2 Target Capacity

The designed production capacity of the project’s production lines (based on an 8-hour workday) is as follows:

Line A (Salad Packaging): Up to 2,000 trays/hour, with a daily production capacity of approximately 16,000 servings.
Line B (Main Dish Packaging): Up to 2,000 trays/hour, with a daily production capacity of approximately 16,000 servings.
Line C (Fast Food Packaging): Up to 2,400 servings/hour, with a daily production capacity of approximately 19,200 servings.

With the three production lines working in collaboration, the total daily capacity can reach 51,200 servings. The actual capacity can be adjusted according to demand to meet the market needs of clients of varying sizes.

III.Production Line Design

The central kitchen automated packaging solution consists of three main production lines: the Salad Packaging Line (Line A), the Main Dish Packaging Line (Line B), and the Fast Food Packaging Line (Line C). These lines collectively form a highly efficient, flexible, and fully automated production system, designed to meet rigorous food safety and quality standards.

Key Design Highlights

○ Automation and Flexibility

The integration of main lines and auxiliary lines ensures flexible adjustment according to production needs, maintaining high efficiency while quickly adapting to market demands.

○ Hygiene and Safety

All equipment utilizes food-grade materials and features hygienic, easy-to-clean designs. Multiple inspection and detection systems are incorporated to ensure product integrity, prevent contamination, and comply with food safety regulations.

○ High Efficiency and Intelligent Management

Each production line is equipped with an intelligent control system (PLC + HMI) for real-time production monitoring, process optimization, and data management. This approach significantly enhances production efficiency, reduces manual intervention, and lowers operational costs.

3.1 Line A: Salad Packaging Line

3.1.1 Production Process Overview

Line A is dedicated to the automated packaging of various salad products, covering the full process from precise ingredient dosing to final sealing. The entire process is highly automated to minimize manual intervention, enhance packaging efficiency, and ensure food safety and consistency.To accommodate diverse salad formulations, the line includes an optional sub-line in addition to the main packaging line.

Main Line: Handles conventional salad components such as vegetables, proteins, nuts, and dressings.
Sub-Line: Specially designed for ingredients like vermicelli or konjac noodles, featuring customized conveying and dosing systems to ensure smooth feeding and accurate packaging.

The workflow is as follows:

(1) Weighing and Filling:

Main Line: A multihead weigher accurately dispenses ingredients (e.g., lettuce, chicken breast, nuts) into designated sections of the tray, followed by automatic dosing of liquid dressings.
Sub-Line:Specialized multihead weighers handle unique ingredients such as glass noodles or konjac strips, ensuring precise filling into trays.

(2) Tray Conveying and Sealing:

Filled trays are conveyed to the tray sealing system, which utilizes a two-stage process combining pusher-style and chain conveyor sealing to ensure airtight packaging and product freshness.

(3) End-of-Line Packaging:

Sealed trays proceed to the downstream packaging area, where they undergo online printing, inspection, labeling, and sorting, ensuring the final products meet distribution and retail standards.

3.1.2 Key Configuration

Line A consists of three main sections: the weighing station, the tray sealing system, and the end-of-line packaging and auxiliary equipment. Each section includes the following core components:
(1) Weighing Station (Precision Portioning and Liquid Dosing)
○ Multihead Weighers: Designed for precise dispensing of various salad ingredients
● Main Line Configuration:

Dual-spiral design with 14 x 1.6L weighing hoppers to ensure efficient and accurate ingredient distribution.
Dual scraper hoppers and 55° discharge chutes to prevent material retention.
Product distribution system to optimize material flow and maximize loading accuracy, ensuring consistent portioning for each salad.

○ Sub-Line Configuration:
● First Weigher (for standard solid ingredients):

Dual-spiral design with 14 x 1.6L weighing hoppers to ensure efficient and accurate ingredient distribution.
Dual scraper hoppers and 55° discharge chutes.
Product distribution mechanism for even allocation of ingredients like vegetables and proteins.

● Second Weigher (for special materials such as vermicelli and konjac noodles):

14 x 2.5L weighing hoppers suitable for stringy and strip-shaped products.
U-shaped tray + roller + screw conveyor to prevent tangling and improve feeding smoothness.
Distribution system to ensure even product spread and minimize clumping.

● Third Weigher (for small-portion toppings):

Standard model with 10 x 0.5L weighing hoppers, suitable for small granule items (e.g., nuts and dried fruits).
V-shaped vibrating pan to distribute product evenly and enhance weighing precision.

○ Working Platform: Provides structural support for the weighing systems, ensuring stable operation.
○ Bucket Elevator: Lifts raw ingredients to the feeding stations, ensuring a continuous supply and improving production efficiency.
○ Liquid Dosing Filler: Precisely dispenses sauces or dressings such as vinaigrettes and salad creams, ensuring consistent flavor profiles across all products.

(2) Tray Sealing Unit (Two-Stage Sealing Process for Enhanced Freshness)

○ First Stage – Pusher-Type Line (Automatic Tray Denesting & Transfer)

Automatic Denesting Unit: Accurately dispenses empty trays, ensuring seamless integration with the downstream processes.
Clamping Transfer Unit: Ensures tray stability during transport, reducing spillage and misalignment.

○ Second Stage – Chain Conveyor Line (Vacuum + MAP)

Tray Rim Cleaning Unit: Removes oil and residue from the sealing area, enhancing seal integrity.
Manual Feeding Station: Allows manual addition of special ingredients, enhancing production flexibility.
Tray Sealing Machine: Performs vacuum or modified atmosphere packaging (MAP) to preserve freshness.
Pneumatic Tray Ejector: Automatically ejects sealed trays for efficient downstream transfer.
200 m³ Vacuum Pump: Provides a stable vacuum environment, ensuring packaging quality.
Easy-Tear Film Mechanism: Adds an easy-peel feature to the sealing film for improved user experience.

(3) End-of-Line Packaging and Auxiliary Equipment(Inspection, Labeling, and Sorting)

○ TTO Printer (installed on the film feeding unit): Mounted on a mobile stand integrated with the tray sealing machine; used for real-time printing of production dates, batch numbers, and other information.

○ Tray Output Conveyor: Transfers sealed trays to the inspection and labeling section.

○ Integrated Metal Detector and Checkweigher: Integrates metal detection and weight inspection to ensure compliance with food safety standards.

○ Double-Sided Tray Labeler: Applies precise labels on both the top and bottom surfaces of trays, meeting packaging specifications.

○ Rotary Collection Table:

Collects and arranges finished trays, facilitating subsequent packaging and logistics operations.

3.1.3 Key Technical Features

● High-Precision Automatic Dosing: The combination of multihead weighers and liquid filling machines ensures accurate portioning of both solid and liquid ingredients, enhancing product consistency.

● Dual-Stage Sealing Technology: The integration of pusher-type and chain-type tray sealing enables both vacuum and MAP (modified atmosphere packaging), extending product shelf life.

● Automated Cleaning and Inspection: The sealing surface oil removal unit and integrated metal detector & checkweigher guarantee product quality and minimize manual intervention.

● Smart Data Management: With the TTO printer and PLC control system, the line supports traceable production data and enhances visualized process control.

● Flexible Packaging Adaptability :Manual loading stations and adjustable sealing modes allow for efficient handling of various salad formulations and packaging requirements.

3.1.4 Packaging Result Display

3.2 Line B：Main Dish Packaging Line

3.2.1 Production Process Overview

Line B is dedicated to the automated packaging of main dishes, suitable for a wide range of ready meals such as pasta, rice, meats, and side dishes. The production process covers the entire workflow from portioning to final packaging, ensuring efficiency, consistency, and food safety.

The workflow is as follows:

(1) Weighing & Distribution

Three sets of multihead weighers accurately portion ingredients. Depending on the specific product requirements, the system selects the appropriate weighing and distribution configuration to ensure precise ratios of each ingredient.

(2) Automated Filing

The portioned ingredients are automatically dispensed into designated sections of the tray via filling units. The trays are then conveyed to the next stage.

(3) Sealing & Packaging

Based on product needs, trays are sealed using either vacuum or modified atmosphere packaging (MAP). After sealing, the packaged trays enter the downstream process.

(4) Post-Packaging Process

This includes online printing, product inspection (e.g., metal detection, weight checking), and label application. Finally, a sorting unit organizes the trays for either secondary packaging or direct distribution.

3.2.2 Configuration

Line B consists of three main sections: the weighing station, the tray sealing unit, and the downstream packaging with auxiliary equipment. Each section includes the following key components:

(1) Weighing Station(Accurate Portioning of Main Dishes)

○ Multihead Weighers: Three sets, each tailored for different types of main dish ingredients:

FirstWeigher (for Meat Products)
Dual-screw design with 14 × 1.6L weighing hoppers.
Twin scraper hoppers and a 55° inclined discharge chute for smooth product flow.
The product distribution system ensures uniform feeding and improves filling accuracy.

● Second Weigher (for special materials such as vermicelli and konjac noodles):

14 x 2.5L weighing hoppers suitable for stringy and strip-shaped products.
U-shaped tray + roller + screw conveyor to prevent tangling and improve feeding smoothness.
Distribution system to ensure even product spread and minimize clumping.

● Third Weigher (for small-portion toppings):

Standard model with 10 x 0.5L weighing hoppers, suitable for small granule items (e.g., nuts and dried fruits).
V-shaped vibrating pan to distribute product evenly and enhance weighing precision.

(2) Tray Sealing Unit (Two-Stage Sealing Process for Enhanced Freshness)

○ First Stage – Pusher-Type Line (Automatic Tray Denesting & Transfer)

Automatic Tray Denester: Precisely places empty trays, improving production efficiency.
Clamping Transfer Unit: Ensures stable tray movement during transport and prevents ingredient spillage.

○ Second Stage – Chain Conveyor Line (Vacuum + MAP)

Tray Rim Cleaning Unit: Removes oil and residue from the sealing area, enhancing seal integrity.
Manual Filling Station: Allows manual addition of special ingredients, increasing production flexibility.
Tray Sealer: Performs vacuum or modified atmosphere packaging (MAP) to extend product shelf life.
Pneumatic Tray Ejector: Automatically ejects sealed trays, improving line continuity.
200 m³ Vacuum Pump: Provides a stable vacuum environment, ensuring packaging quality.
Easy-Peel Film Feature: Adds a consumer-friendly easy-tear tab for improved user experience.

(3) End-of-Line Packaging and Auxiliary Equipment(Inspection, Labeling, and Sorting)

○ Tray Outfeed Conveyor: Transfers sealed trays to the inspection and labeling section.

○ Combined Metal Detector and Checkweigher: Integrates metal detection and weight inspection to ensure

compliance with food safety standards.

○ Top-and-Bottom Tray Labeler: Applies precise labels on both the top and bottom surfaces of trays, meeting

packaging specifications.

○ Rotary Accumulating Table: Collects and arranges finished trays for easy handling in subsequent packaging

or logistics processes.

☆Optional Sub-Line Configuration:

The sub-line is designed to provide flexible production capacity. When output demand is low, the sub-line can operate independently to meet production needs. When higher output is required, the sub-line works in conjunction with the main line to increase overall efficiency.

○ Manual Loading Station: Operators manually place ingredients into trays.

○ Tray Sealing Machine: Equipped with a pusher-style sealing unit; after sealing, trays are conveyed to the end-of-line process.

○ TTO Printer: Installed on the sealing machine for printing production dates, batch numbers, and other traceability information on the tray surface.

○ Conveyor (Integrated with Main Line): The sub-line conveyor can be connected to the main line’s end to ensure seamless integration and automated coordination.

3.2.3 Key Technical Features

Flexible Capacity Adjustment:Line B adopts a combined main line and sub-line design, allowing for adaptable production capacity. The sub-line can operate independently to meet lower production demands, while the main and sub-lines can work together to boost output when higher capacity is required.
Efficient Weighing and Distribution:Three multihead weighers with integrated distribution systems ensure accurate portioning of various ingredients, minimizing waste and optimizing production efficiency.
Two-Stage Sealing Process:A pusher-style and chain-conveyor sealing system supports both vacuum and MAP (Modified Atmosphere Packaging), effectively extending product shelf life.
Food Safety Inspection: An integrated metal detector and checkweigher unit ensures compliance with food safety standards.
Intelligent Data Management: A TTO printer combined with a PLC control system enables full traceability and enhances visualized production management.

3.2.4 Packaging Result Display

3.3 Line C：Fast Food Packaging Line

3.3.1 Production Process Overview

Line C is designed for packaging fast food items such as burgers, wraps, and hot dogs. It combines manual operation with automation to ensure product integrity and high packaging quality. The production process includes the following key stages:

○ Manual Food Placement: Operators place prepared fast food items (e.g., burgers, wraps, hot dogs) into paper trays.

○ Conveyor Transfer: Trays containing the food are conveyed to the flow wrapping machine.

○ Flow Wrapping: The flow wrapper seals the trays, ensuring hygiene and portability of the packaged food.

○ Post-Packaging Arrangement: The packaged trays are arranged by a rotary collecting table, making them easier to box and transport.

3.3.2 Main Configuration

○ Conveyor Line: Transfers trays loaded manually with food products to the packaging machine.

○ Flow Wrapper: Wraps the food trays with packaging film to form pillow-style packages. Suitable for various types of fast food, it ensures tight sealing and food safety.

○ Rotary Collecting Table: Arranges the packaged products for easy handling in downstream packing and logistics processes.

3.3.3 Key Technical Features

Integration of Manual and Automated Operations: Line C combines manual loading with automated packaging, balancing product variety with high packaging efficiency. Manual placement ensures proper arrangement of food in trays, while automation boosts productivity.
High Flexibility: The system can be easily adjusted to accommodate trays of different sizes and shapes, making it suitable for packaging hamburgers, hot dogs, wraps, and other fast food items efficiently.

3.2.4 Packaging Result Display

IV.System Control & Operation Management

4.1 PLC + HMI Intelligent Control System

○ PLC Control System: Responsible for precise control of each piece of equipment, ensuring stable and efficient production. Real-time adjustment of parameters such as temperature and speed guarantees continuous and consistent operation.

○ HMI (Human-Machine Interface): Provides an intuitive interface for operators to monitor equipment status, adjust production parameters, and respond promptly to any abnormalities. The simple and user-friendly interface improves operational efficiency.

4.2 Production Data Monitoring & Management

○ Real-Time Data Collection: Sensors and smart devices continuously record key parameters such as temperature, humidity, and weight to ensure all metrics meet the required standards.

○ Data Analysis & Quality Management: The system analyzes production data to identify bottlenecks and potential issues, optimize production planning, and establish a traceable quality management system to ensure batch-level traceability.

4.3 Remote Operation & Fault Diagnosis

○ Remote Monitoring: Management can monitor equipment status in real time via a remote platform and receive fault alerts to ensure timely response.

○ Remote Operation: Enables remote adjustment of production parameters and minor fault fixes, reducing the need for on-site intervention and improving efficiency.

○ Fault Diagnosis & Self-Recovery: The system automatically analyzes equipment conditions, issues early warnings, and performs remote repairs to minimize downtime.

V.Food Safety & Hygiene Standards

5.1 Equipment Material and Sanitary Design

○ Food-Grade Materials: All components in contact with food are made of food-grade materials such as stainless steel, complying with food safety standards to prevent contamination.

○ Sanitary Design: Equipment surfaces are smooth and free of dead angles, ensuring easy cleaning. Detachable parts allow for regular washing, reducing the risk of cross-contamination.

○ Automatic Cleaning Function: Some machines are equipped with automatic cleaning systems to maintain hygiene during production and reduce manual cleaning costs.

5.2 Quality Control & Safety Inspection

○ Quality Control System: A comprehensive quality control process is implemented throughout the entire production—from raw material sourcing to final product packaging—ensuring every stage meets quality standards. Automated inspection equipment monitors key parameters in real time to maintain consistent product quality.

○ Safety Inspection: Each production line is equipped with metal detectors, X-ray inspection machines, and other detection systems to ensure products are free from foreign contaminants. Additional checks such as weight and dimension inspection guarantee that each product meets required specifications.

○ Traceability System: Every batch of product is traceable through the system, allowing for quick identification of the source in the event of a quality issue, ensuring efficient problem tracking and resolution.

VI.Summary

This automated packaging solution integrates advanced technologies and efficient production processes to meet the modern central kitchen’s needs for high efficiency, precision, and food safety. Through three distinct production lines—Line A (salad packaging), Line B (main dish packaging), and Line C (fast food packaging)—we provide a flexible, efficient, and scalable approach to food packaging.

○ Line A: Utilizes multihead weighers and precise automatic filling systems to ensure accuracy and productivity in salad packaging.

○ Line B: Incorporates multiple sets of multihead weighers and a flexible sub-line design, enabling the line to meet diverse production needs while optimizing overall capacity.

○ Line C: Combines manual and automated processes to accommodate the unique requirements of fast food packaging, enhancing both flexibility and efficiency.

Each production line is equipped with an intelligent control system that ensures real-time monitoring, data recording, and transparency throughout the production process—meeting the food industry’s stringent standards for safety, hygiene, and quality.

By implementing this project, we aim to significantly improve the automation level of central kitchen operations, boost production capacity, reduce labor costs, and optimize resource allocation—providing robust support for future market expansion and evolving demands.