The Thomas Tunnock factory, located just outside Glasgow, features a continuous flow of hot caramel that plays a crucial role in the production process.

This caramel, made on the second floor, travels down to the first floor via conveyor belts, filling the building with a warm, sweet aroma that is unmistakable.

However, working with caramel is a complex task that requires precision and teamwork; a team of 12 experienced workers must ensure the caramel reaches the correct consistency before applying it in five layers to create the signature Tunnock's wafer biscuit.

According to Stuart Louden, the company's engineering and transport manager and a fifth-generation member of the Tunnock family, the factory produces approximately 20 tonnes of caramel daily.

To achieve the perfect consistency, operators rely on a combination of visual inspection and tactile testing, often squeezing the caramel to assess its texture and quality.

Once the caramel is ready, it is transported to the floor below via a conveyor belt, where a dedicated team is responsible for applying it to the wafers.

As Mr Louden notes, spreading caramel onto wafers is an extremely challenging task due to its sticky nature, which demands a high level of skill and attention to detail.

While this particular aspect of the production process is labor-intensive, the majority of the factory's operations are automated, highlighting the company's efforts to balance traditional techniques with modern technology.

As a smaller player in the snack food industry, Tunnock's must adapt to stay competitive with larger companies like McVitie's and Fox's, and investing in advanced technology has been crucial in this endeavor.

Mr Louden emphasizes the importance of utilizing cutting-edge machines to maintain output and remain competitive, stating that as a "small fish in a big pond," the company must be strategic in its use of technology.

Although machines are used to spread caramel at night, the human workforce offers greater flexibility and requires less space, making it an essential component of the production process.

The combined efforts of humans and machines result in the production of approximately seven million wafer bars and 4.5 million tea cakes every week.

For Tunnock's, increasing output while preserving traditional methods is a delicate balancing act, one that requires careful consideration of the company's heritage and values.

The production of marshmallow, like caramel, is closely monitored by human supervisors to ensure the highest quality and consistency.

The company's commitment to traditional methods is also evident in its approach to packaging, where the wafer bar is wrapped rather than sealed, a decision that prioritizes quality over speed.

Mr Louden notes that the company's products often evoke nostalgic memories, with many customers recalling their childhood experiences with Tunnock's treats.

A new robotic arm developed for the cake industry aims to bridge the gap between traditional techniques and modern automation, offering a potential solution for companies like Tunnock's.

Unifiller, a technology brand of Coperion Group, has spent years developing the HIRO robot arm, designed to decorate cakes with a variety of toppings, including caramel.

The HIRO robot arm is capable of handling a range of toppings and can be used with various decorating tips, providing a high level of flexibility and precision.

According to Derek Lanoville, research and development manager at Coperion, the robot arm can work with any topping that can be squeezed through a pastry bag, making it a versatile tool for cake decoration.

Developing equipment for the food industry poses unique challenges, with hygiene being a top priority; equipment must be easy to disassemble and clean to prevent contamination.

Mr Lanoville emphasizes the importance of designing equipment that is easy to clean, stating that if it is not simple to disassemble, it may not be properly cleaned, compromising hygiene standards.

Unifiller collaborated with Swiss robotics firm Stäubli to develop the HIRO robot arm, which features a design that prioritizes ease of cleaning and maintenance.

Another challenge in the food industry is the inherent variability of products like cakes, which can differ in size and shape, posing a challenge for automation.

In most industries, components are uniform in size, but in baking, cakes can vary slightly in size and shape, requiring equipment that can accommodate these differences.

Mr Lanoville notes that the HIRO robot arm is designed to adapt to these variations, ensuring that it can decorate cakes accurately and efficiently, even when they are not perfectly uniform.

For Anomarel Ogen, head baker at The Bread Factory, human involvement is essential to the baking process, particularly when it comes to handling delicate dough.

The Bread Factory, which supplies products to the café chain Gail's, operates 24 hours a day, 365 days a year, and produces up to 40,000 loaves daily using around 16 tonnes of flour.

Although the bakery uses machines to mix and divide the dough, the process still requires a high level of human oversight and skill, particularly when working with sustainable, delicate flours.

The bakery's use of sustainable flours, which prioritize soil health, results in a more delicate dough that demands gentle handling and careful monitoring.

Machines are used to mix and divide the dough, but human workers play a crucial role in shaping the loaves, a task that requires years of experience and skill.

The bakery's commitment to sustainability is evident in its choice of flours, which are sourced from farms that prioritize soil health and environmentally friendly practices.

Mr Ogen highlights the importance of gentle handling when working with delicate dough, noting that the worker's touch and movement are critical in shaping the loaves.

The presence of human workers in the factory also allows for greater flexibility and adaptability, enabling the bakery to adjust its production process in response to changes in the recipe or dough.

As Mr Ogen notes, having staff on hand to monitor the production process and make adjustments as needed is essential for maintaining quality and consistency.

Introducing new technology to a production line requires a careful balance between automation and human oversight, according to Craig Le Clair, principal analyst at Forrester.

Mr Le Clair emphasizes the importance of developing a hybrid model that integrates automation with human involvement, preserving the unique qualities of handcrafted products while improving efficiency and consistency.

He notes that automation should be applied only to areas where it can bring significant benefits, such as speed, volume, and consistency, while leaving core value-added elements to human workers.

This approach allows companies to leverage the advantages of automation while preserving the essence of their products and the skills of their human workforce.

At Coperion, Mr Lanoville is already planning to develop the HIRO robot arm further, exploring new applications and refinements to enhance its performance and versatility in the cake decorating process.

The current priority is to refine the company's scanning, vision, and safety systems, allowing customers to work seamlessly without robotic interference.

In Glasgow, Mr. Louden is considering an upgrade to his production line, but the project's feasibility depends on the current financial climate, which has been affected by fluctuating cocoa prices over the past two years.

With a potential investment of £2.5 million in equipment, the company is adopting a cautious approach, delaying the decision due to the unfavorable market conditions of the past two years, and seeking to avoid any financial risks that could have a negative impact.