Jaffa Cakes: Back to the Future - without changing the product
At Jaffa Crvenka, the challenge wasn’t building something new—it was upgrading something that already worked.
Products like Munchmallow had been produced for years, with a very specific texture, structure and consumer expectation. Any change in the process risked changing the product itself.
At the same time, the existing line needed to be modernised and automated to improve reliability and efficiency—without stopping production.
Upgrading the process, not the product
The objective was clear: increase efficiency while preserving what made the product successful.
This meant the focus shifted away from simply installing new equipment, and towards understanding how each process step influences the final product. Depositing, sandwiching and handling all had to be validated carefully.
Through extensive trials and close collaboration, the new line was configured to replicate the existing product characteristics—while improving consistency and repeatability.
In practice, this approach avoids a common pitfall in upgrades: improving the process at the cost of product identity.
Integrating automation into a running factory
A second constraint was continuity. Production could not simply stop for a full rebuild.
The installation was therefore executed in a way that allowed the line to be brought back online quickly, with minimal disruption. As described by the customer, “our production was back up and running in no time, and more efficient than ever.”
This highlights a different type of project risk—not technical feasibility, but operational downtime.
Adding flexibility without losing control
With the upgraded line, Jaffa gained more than just efficiency. The system now allows handling of different fillings and formats—such as chocolate, creams and jams—while maintaining consistent quality.
At the same time, features such as controlled depositing and product detection ensure repeatability across runs, which becomes critical when scaling production or introducing variations.
