With over 70 SKUs produced on a single line, Breadsource, a Canadian Toronto-Based bakery, was pushing the limits of its semi-automated operations. Frequent changeovers, labor availability challenges, and the demand for consistent, high-quality products across every shift made the need for a smarter, more automated solution clear.
In 2022, Breadsource embarked on its automation journey with a clear vision: evolve progressively while maintaining operational excellence. To ensure a smooth transition, the team chose to automate the scoring process and partnered with ABI. For two years, they operated the Katana Robotic Scoring System—a two-robot cell manually fed at the inlet, with trays handled manually at the outlet. This solution allowed operators to get comfortable working with robotic equipment while improving throughput and cut quality. From the start, Katana was designed to be easily integrated into a fully automated line once Breadsource was ready. ABI teams worked closely with Breadsource to train operators and ensure seamless adoption.
The second phase of Breadsource’s growth marked the biggest milestone: committing to full automation. They partnered with MECATHERM to design their first fully automated production line, the MECAFLEX. Designed to address increasing flexibility requirements in industrial production, it features M-UB proofing technology, an M-TA tunnel oven, an automated conveying system, a depanner equipped with three end-of-arm tools, and a custom storage gantry system for pan management. A pivotal moment in their decision process was their visit to our demo center in France. This visit allowed them to collaborate with our team of expert bakers and design a line capable of achieving the exact quality they required. “It is very unusual to see a demo center with full-scale equipment,” noted Arif Sunderji, VP of Operations at Breadsource.
Producing a wide range of premium products with varying baking times and throughput requirements can be challenging, but the flexibility of the M-UB combined with the agility of the M-TA oven made it possible. Each module is fully independent and separated by height-adjustable curtains, with individual control of temperature, heating mode (radiant and/or convection on top and bottom), and steam injection/extraction. This modular control allows precise baking profiles to be configured for a wide range of products.
“The line has been very efficient for us. We’ve tripled our capacity and reduced waste to under 3%,” shared Arif. The benefits extended beyond productivity—employee morale improved significantly. “Employees are not stressed, and because of that, they bring their ideas forward,” he added.
Changeovers, previously a major pain point, were also addressed through a co-designed custom storage gantry system that manages 17 pan sets. This fully-automated solution, which can also be manually fed during production, enables Breadsource to run a diverse mix of products throughout the day with minimal downtime.
The trust Breadsource placed in MECATHERM and ABI to support such a major transformation is a testament to the power of true partnership. Supporting our customers along their growth journey remains our greatest source of pride.
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