Automated Guided Vehicles (AGVs) are the next big step – on wheels – to intelligent handling automation. They move equipment safely and reliably, while ensuring the complete traceability of their deliveries with shareable diaries.
Automating the transport of heavy containers greatly improves process efficiency and convenience. AGVs are one of the new-generation solutions that quite literally keep things moving in a bakery, reliably and effortlessly. They can take over a number of cumbersome tasks, from transporting raw materials from delivery or storage to production areas to mixing and batching, and bakeware handling. An AGV performs any in-house transport task with a perfect track record, while the staff no longer needs to manually carry, push, or pull heavy boxes or bowls. In the process, workers are safe from both strenuous physical effort and from the AGVs themselves: people and robots can all see to their own tasks while easily staying out of each other’s way, while products steer clear of any contamination risks, too.
AMF Bakery Systems designed AGVs in collaboration with DTA, specifically designed for bakery environments. DTA designs and manufactures AGVs that can be integrated into any heavy industry. The company has over 30 years of experience in building these vehicles, which can come with various technologies for guiding their movement, ensuring both efficiency and safety. The AGVs designed by specialists from both companies use omnidirectional wireless technology, allowing smooth, trackless navigation across production areas. “These vehicles seamlessly integrate into bakery layouts, handling dough troughs and pans with precision and minimal operator interaction, improving overall efficiency and safety,” explains Andrey Bulatov, Sales Support Engineer, AMF Bakery Systems.
Safety comes first
What makes this co-produced AGV particularly suited for bakeries? It was designed to handle the unique challenges of food production environments, such as high humidity, temperature variations, and strict hygiene requirements. To accommodate these conditions, the AGVs feature stainless steel construction (ANSI 304) for easy sanitation, minimizing contamination risks.
AGVs lifting systems – comparison sheet
Electric Lifting System:
+ Offers precise, smooth lifting, making it ideal for handling delicate dough troughs
+ More energy-efficient and requires less maintenance since it has fewer moving parts
+ Quieter operation, which is beneficial in production areas where noise reduction is important
+ Works well for lower-weight capacities and environments with strict hygiene requirements since there are no hydraulic fluids involved
Hydraulic Lifting System:
+ Designed for heavy-duty applications, capable of lifting heavier loads with higher force output
+ More durable under extreme usage, making it suitable for bakeries moving very large or dense loads
+ Higher lifting capacity than electric models, making it a better choice for multi-level storage operations
+ May require more frequent maintenance due to hydraulic fluid use, though modern designs minimize leakage risks
With sealed components, they are protected against flour dust and moisture, ensuring durability in bakery settings. Their movement is one of the crucial features that must be perfected with zero room for error. The trackless navigation system allows the AGVs to move smoothly across different surfaces without the need for physical guides. In this way, they can adapt to layouts that may change over time and can learn new routes as bakeries grow and upgrade.
Safety is a top priority, that of the people working in production and of the products being maneuvered. “AGVs specifically engineered for bakeries are equipped with soft-stop technology and precise positioning, to ensure delicate handling of dough troughs and pans, while preventing spills,” Bulatov highlights. Their omnidirectional movement capabilities are particularly useful in tight bakery spaces, which allow them to navigate efficiently even in crowded production areas. Additionally, they comply with CE safety standards, meaning they meet the strict regulatory requirements for food processing environments, the specialist notes.
AMF’s specialist underlines the vehicles’ built-in safety design: “Safety is maintained with 360° laser scanners, emergency stop buttons, automated braking, and controlled acceleration/deceleration to prevent sudden jolts. Audible alarms and LED signals notify nearby workers when an AGV is in motion.”
To ensure that dough troughs are safely secured aboard, fork pockets, clamps, or automatic locking mechanisms are used. Some AGVs have clamping or pin-locking systems to keep the load in place, ensuring it remains stable even during sharp turns or sudden stops.
Working efficiency
An AGV is only as good as its ability to navigate. This model is built to move efficiently to complete its tasks, using pre-programmed routes, which are managed through an HMI. The routing is optimized for efficiency and can be adjusted in real-time: using laser scanners and sensors, they detect obstacles and either stop or reroute accordingly. “The start process involves receiving a task from the system, moving autonomously to the pickup point, and securing the load. At the docking station, AGVs automatically position themselves for recharging or awaiting the next task,” Bulatov illustrates.
To optimize their maps and routes, bakery layouts are analyzed during installation. Then, AGVs are programmed to follow fixed or dynamic paths based on production needs. However, “Some AGVs use laser or vision-based mapping to learn their environment, allowing for more adaptive navigation,” Bulatov highlights.
Routing optimization is handled through fleet management software, he details, which determines the most efficient paths for AGVs while avoiding congestion. The system constantly communicates with AGVs, adjusting routes in real-time based on production demands and potential obstacles. If a standard path is blocked, the AGV can either stop safely or follow an alternate programmed route to maintain workflow.
Vertical integration
Since these AGVs are designed to work in bakeries, they not only transport their assigned loads, but can also accommodate loading and unloading at different heights. They are equipped with lifting mechanisms with two positions, which enable smooth and stable vertical movement.
“The lifting system can be hydraulic or electric, providing controlled elevation of dough troughs, which is just enough to clear the ground while ensuring stability. This prevents spills and allows for precise placement at mixers, fermentation areas, and dough dump stations,” Bulatov explains. Bakers can choose between electric and hydraulic lifting mechanisms based on their operational needs. Each system has distinct benefits. For precise lifting with a smooth upward movement, the electric lifting system is the recommended choice, for example, and is especially suitable for delicate dough troughs. This energy-saving system is also quieter while operating and maintenance-friendly, as it has fewer moving parts. Alternatively, the hydraulic lift is better suited for heavy-duty operations, as it has a more powerful lifting mechanism and increased endurance to handle heavier objects.
In many cases, bakeries opt for electric lifts when prioritizing energy efficiency, cleanliness, and precision, while those handling extra-heavy troughs or pan stacks may prefer the power of hydraulic systems, the specialist observes, from his experience.
”The start process involves receiving a task from the system, moving autonomously to the pickup point, and securing the load. At the docking station, AGVs automatically position themselves for recharging or awaiting the next task.”
Andrey Bulatov, Sales Support Engineer, AMF Bakery Systems
Make it your own!
Having the solution that is the best fit for the production environment is key in bakeries. AGVs also follow this rule: they can be customized in size, load capacity, and navigation systems to fit any number of specific bakery needs. They come with omnidirectional wheels for flexible movement, different sensor configurations for safety, and lifting mechanisms tailored for dough troughs or pan handling. Additional features can also be integrated, such as high-lift designs, stainless steel for washdown environments, and RFID/barcode scanning for batch tracking.
Standard bakery AGVs handle 1,000–3,000 lbs (450–1,360 kg), while heavy-duty models can transport up to 6,000 lbs (2,700 kg). This ensures they can move fully loaded dough troughs and large stacks of pans with ease.
For dough troughs, AGVs use forks, cradles, or U-shaped platforms to lift and transport troughs securely. For pan handling, AGVs can be equipped with flat platforms, rack-holding frames, or conveyor-based loading systems to transport pan stacks efficiently.
Once the exact design has been identified and the AGV is built to order, it is ready to join factory operations, by connecting it with production management software. In this way, the transport between mixing, fermentation, and baking can be automated and optimized for each facility. The system assigns tasks based on real-time production needs, ensuring troughs and pans move just in time. Wireless communication enables AGVs to interact with mixers, fermentation rooms, and dough dividers. “They replace manual labor in repetitive transport tasks, reducing human error and improving efficiency,” Bulatov underlines.
Once they have been set up, AGVs operate autonomously, requiring minimal supervision. Operators monitor the system via an HMI interface, which displays the AGV’s location, battery levels, and task status. They can manually adjust routes, override automation when needed, and respond to error alerts. Remote control options also allow for manual navigation if necessary, but AGVs are designed to function without constant human input.
As they are successfully deployed to day-to-day operations, AGVs require routine maintenance, including weekly cleaning, sensor inspections, and battery monitoring. Preventive service actions can include software updates, checking the mechanical components, and replacing worn-out parts. Most AGVs feature automatic docking stations for self-charging, reducing downtime and eliminating the need for manual battery changes. Annual inspections ensure continued efficiency with minimal disruption to production, AMF recommends.
The benefits are immediate: operating with minimum super-vision, AGVs free valuable human resources for better use in the baking facility, and do not interfere with them as they efficiently take over handling heavy equipment, often those with delicate contents.
