Premier Forrester has helped Greggs significantly increase chocolate variation on its caramel shortbread line, cutting losses by 97.5% after replacing the existing manual operation with a precise automated setup.
Working with Greggs, the York-based food manufacturing specialist supplied a solution built around the Trikno TCM Depositor and the WOLF UF500 Temper Unit.
Alongside the major drop in waste, Greggs also realised faster throughput and a more consistent finish across production.
Automation helped reduce waste
Before the upgrade, all of the chocolate application for Greggs’ caramel shortbreads was done by hand. Chocolate was poured over cooled caramel, then levelled manually by operators turning and tapping the sheets.
This method was slow, labour-heavy, and produced high variation in the finished product, making it increasingly difficult to justify at higher volumes.
The team also had to work around existing rack ovens, which meant any new equipment needed to fit within a batch-based baking environment rather than a fully continuous line. That ruled out some standard options and called for a more considered approach.
Greggs initially explored the idea of using a chocolate curtain system. Premier Forrester’s Founder and Director, Mike Gee, advised against it, having concluded it would not deliver the level of control the line required.
Instead, he recommended a combination of depositing and tempering technology that would give Greggs more accuracy and a cleaner application. As well as the equipment, Premier Forrester also helped automated their existing chocolate delivery to the line.
Trikno and Wolf products chosen
The Trikno TCM Depositor was introduced to apply a controlled amount of chocolate to each product. Its precision nozzles and programmable settings made it possible to achieve a more even deposit across every batch while reducing excess chocolate usage.
Alongside it, the WOLF UF500 Temper Unit kept the chocolate at the right working condition throughout production, helping maintain appearance and texture consistency.
Since installation, Greggs has reduced chocolate waste from 60 grams per sheet to 1.5 grams. Production has also doubled, giving the business more capacity to meet demand while easing pressure on labour and improving overall efficiency on the line. This has also put Greggs in a stronger position to scale production in line with future growth.
Mike Gee said: “At Premier Forrester, we believe that the right technology can revolutionise any production line. Working with Greggs to integrate the Trikno TCM Depositor and WOLF UF500 Tempering Unit was about more than just automation—it was about precision, efficiency, and setting them up for scalable growth. This project highlights how innovation in food manufacturing can drive both quality and profitability.”
