Rademaker designed its robotic solutions to become one with the line and aid processing at various stages, from depositing various materials or entire products to product shaping and sorting. The point-of-contact tools, designed in-house, specifically address each material they need to handle.
To further enhance the automation level of its lines (or any other production lines), Rademaker developed robots for diverse applications, from depositing solid materials, including any number of pastry fillings, or depositing and positioning products, to product shaping and sorting. In dough processing, robots fill in a gap where current automated systems still often rely on manual labor. Implementing robotics automates these steps, too, with all the benefits automation brings: product consistency is ensured, as well as a higher output.
That’s not all: utilizing information from the line, gathered and ‘translated’ by the vision quality control system, robots can also handle quality checks and sorting, where only products deemed good enough are allowed to stay on and continue the process steps. Output efficiency is reliably increased.
Rademaker highlights the flexibility robotics bring for various applications in production: “For increased process efficiency, also consider processes that can be automated by robots where a high flexibility in tooling is desired. Time is saved when not having to exchange large tooling when recipes change over; the robots’ grippers are the only parts that need to be swapped, according to what’s next in the production schedule. This is another form of time efficiency, where a robotic system can have a positive effect,” explains Patrick Dauwe, Manager Business Development, Rademaker.
The good news is that they are not difficult to bring into production. Rademaker’s robotic cells are designed to be easily integrated into production lines, and have the ability to transform an industrial dough handling line into a high-throughput, flexible, hygienic and data-driven operation. With robotics, not only can manual labor be spared, but also the product quality and consistency will be improved by automating tedious, repetitive and quick-reaction movements.
What does Rademaker understand by ‘seamless robot integration’? Dauwe explains: “Robotic integration by Rademaker means that all robotics design, as well as fast controls, are fully integrated into the main Rademaker processing line, just like any other module. This results in ease of operation and intuitive controls, where robotic control and line control are all in the same operating panel.” He underlines: “Reproducibility is a key feature. Different interacting functions that enable the robots to guarantee quality and the highest productivity are combined.” The Dutch specialist focuses a segment of its work entirely on perfecting the interfaces that come with its standalone and combined equipment, for which it also provides assistance and maintenance.
“The unique integration of the vision expertise and flexible software solutions allows Rademaker to excel in data dashboarding of various quality control parameters, thus controlling product conformity at an early stage in the dough handling process.”
Patrick Dauwe, Manager Business Development, Rademaker
Delta robots, from A to Z
Delta robots are a popular choice in automated manufacturing for several reasons, starting with their ability to act very fast: they can perform up to 300 picking actions per minute, accurately and consistently. Rademaker’s Delta robots specialize in two types of tasks: placing solid fillings, which can be as varied as chocolate bars, sausages, cheese sticks, or fruit, and handling dough products.
Both types of actions are carried out completely safely: for the product’s hygiene and integrity, and posing no risks for the staff working in the production area, as they are safely enclosed behind glass. “Small footprint and hygienic executions are the staples of the Rademaker robot design,” Dauwe underlines. The grippers of the robot’s arm are designed by Rademaker to match the product that needs to be handled and ensure it is lifted, moved and released gently.
Dauwe explains the priorities in the development process: “Rademaker robots have a high focus on hygienic design, implementing only food-safe materials. Sweet or savory fillings and raw dough products impose this level of food safety. Techniques such as open/fast vacuum gripping, as well as gentle soft gripping, can be designed and executed.” The product to be handled is key to perfecting the process and the accessory. “Rademaker grippers have a product-specific design, with durability in mind.”
Just like with any module of a line, the robotics unit is not just easy to install on the system; it is also immediately ready to start working, as the software it requires is also a part of the line’s ‘brain’. In this way, product consistency can be controlled from the beginning of the process and then throughout, which effectively reduces product and material losses to a minimum.
To ensure the unit’s installation and functioning will be smooth, testing is carried out via 3D computer simulations, and at the Rademaker Technology Center (RTC), which is equipped with a robotic cell holding two delta robots. Demonstrations and tests can analyze depositing solid fillings onto pastries made on a universal makeup line and a croissant section. On an artisan bread line, the robotic unit can also be placed in-line.
Although they only take up little space, they cover a wide working area and can come in versions with various degrees of movement freedom. The design and setup take into consideration that space is more often than not limited in the processing area of an industrial bakery, unlike the packaging area. “Rademaker’s robotic design has been optimized for full reach for wide make-up conveyors, while still having a compact footprint,” the specialist underlines. The Rademaker delta robot has a unique configuration in comparison to a classic delta robot, which allows it to save the floor space needed by 20%.
A new partnership
At the beginning of 2025, Rademaker partnered with SENSURE, joining the Italian company as a minority shareholder. Their collaboration was first introduced to the industry at iba 2025. SENSURE specializes in advanced vision inspection systems powered by Artificial Intelligence and self-learning technology.
The systems developed by SENSURE support a wide range of industrial applications, such as:
+ Automating quality control, with automatic rejection of non-compliant products
+ Real-time monitoring and analytics for continuous process improvement
+ Optimizing robots’ pick-and-place operations with vision guidance
SENSURE’s solutions are designed for a wide diversity of products such as biscuits, bread, pastries, pizza, snack bars, and more. With this collaboration, Rademaker is working on accelerating the development of digital products and services.
All about the vision
Interfacing, necessary for the supply of solid fillings, is to Rademaker a vital part of the robotics solutions it designs. The goal is to ensure seamless integration and communication. Quality control parameters and trends can be displayed on an intuitive dashboard. In this way, the operators can have a complete picture of the process and control of the entire line, for optimal production comprehension and conditions.
Vision is key as a reliable input for robotics when handling any products. Rademaker partnered with SENSURE, a specialist in Quality Control Vision Systems, to develop their robot’s keen ‘eyesight’ – via state-of-the-art imaging and data collection. Different setups can be custom-built according to each project, from the available types of cameras that can generate 2D and 3D images of individual products at the desired accuracy. The software allows different quality control parameters to be defined freely. Moreover, this is a smart system, so it will improve its performance over time. The self-learning SENSURE software, combined with fast data rates, results in fast and precise robotic movements when handling the measured products.
The specialist highlights: “The unique integration of the vision expertise and flexible software solutions allows Rademaker to excel in data dashboarding of various quality control parameters, thus controlling product conformity at an early stage in the dough handling process.” Product conformity is a process parameter, meaning that any item falling outside of preset values can be either rejected or automatically bypassed during the production processes, as required.
Multitasking
For a product or a recipe changeover, only the grippers attached to the robots need to be switched. Other parameters automatically switch over when a new recipe is selected in the operating panel. Rademaker features guidance steps for gripper changeover via the operating screen. The quick gripper release system has a secure fit, for safety. The need for a quick-release system is vital for a clean, automated process using robots. As the grippers themselves are the only part of the robotic system that comes into continuous contact with the product, special attention went into designing them and, similarly, it should go into monitoring them. Sometimes, they can collect a build-up of product sediment, since they are the ‘hands’ dealing with variable product rheology or changing dough behavior. To mitigate downtimes when it’s necessary to clean the grippers, spare ones can be mounted in a matter of minutes, Rademaker explains.
Retrofitting
A Rademaker robotic cell can be fitted into an existing production line – available space being the only prerequisite. Controls and safety can either be integrated or stand alone, as required. An operating panel can be added to the robotic cell or the make-up line where it is used. As layouts are unique for each bakery, the fitting process is always custom, following a project that determines in detail what can be achieved, without compromising the necessary access to the line.
“Since the Rademaker robotics have an optimized footprint design, robotic cells placed on a line can occupy a similar or even a smaller floor space than the module they replace,” the specialis explains. For example, conveyors that are used to accommodate staff’s manual work can be removed to free up space, once a robot is installed.
Nimble upkeep and complete safety
Scheduling maintenance correctly cannot be overstated, when production uptimes are as critical as they are in a bakery. Maintenance on a robotic cell from Rademaker is fairly straightforward, the company explains, because generally none of the robotic accessories and peripherals wear significantly over time. “The hygienic Rademaker design makes the cleaning and lubrication checks easy. Inspections on flour accumulations in the joints is particularly necessary,” Dauwe points out.
Maintenance personnel receive step-by-step guidance through periodical checks, which are necessary to ensure the robot’s reliable operation over time at the desired accuracy levels.
The design also includes features designed for the safety of the operator: Rademaker robots run inside a fenced-in frame, preventing hazards to the staff while they perform their tasks. The safety fencing can be opened for cleaning, tool changes, or maintenance. During cleaning, gripper exchange and maintenance, the delta robots can be manually released safely. A double safety measure is in place, ensuring the robot will not move when located in an unsafe position, to ensure the safety of the stop and start procedures.
With this quick upkeep done, robots are ready to work at high speeds and deliver consistent results, day after day.
