HIGH-PRECISION ROBOTIC DOUGH PLACEMENT
- Three Schubert F4 pick-and-place robots
- Automated placement of dough balls into press pans
- One operator per shift instead of four
- Fast ROI with no loss of product quality
THE CHALLENGE
PRECISION MEETS FLEXIBILITY IN FROZEN PIZZA PRODUCTION
Molinaro’s Fine Italian Foods is Canada’s largest producer of private-label frozen pizzas, producing around 30 million pizzas annually across nearly 300 SKUs. The family-owned company supplies major retailers such as Costco, Metro, and Walmart and is known for its wide range of premium crust styles.
Facing increasing demand and labor challenges, Molinaro’s began selectively investing in automation, starting with a repetitive task on its cold press line. Operating in a high-mix environment where flexibility and quality are critical, the company targeted processes where efficiency could be improved without compromising the final product.
The cold press line presented a clear opportunity. Dough balls were manually placed into pans across three shifts, creating ergonomic strain, inefficiencies, and consistency issues—especially with 10 different crust sizes running on the same pan format.
- Precise, repeatable dough placement
- Improved ergonomics and labor reduction
- Seamless integration with existing equipment
- No compromise to crust quality
THE SOLUTION
FROM MANUAL PROCESS TO PRECISION AUTOMATION
Schubert implemented a solution using three F4 four-axis pick-and-place robots, equipped with scoop-shaped tools designed to gently handle dough balls. The robots place each dough ball precisely at the center of the pan before pressing, ensuring consistent crust shape and quality.
The system replaced a fully manual process with a reliable robotic solution that operates continuously and accurately, while remaining flexible enough to handle Molinaro’s wide range of crust formats.
Installation was completed over a single weekend by Schubert technicians, with no production downtime—a critical factor for Molinaro’s operations.
Immediate efficiency gains with long-term potential
- Labor reduced from four people to one per shift
- Improved consistency and repeatability
- Eliminated oil-handling complaints and ergonomic strain
- Fast return on investment
- Strong acceptance by plant personnel
Since commissioning, the robots have delivered reliable, low-maintenance performance. Minor adjustments can be completed in minutes, and Schubert’s local service support ensures rapid response when needed.
TECHNICAL DETAILS
- Three Schubert F4 four-axis pick-and-place robots installed on the cold press line
- Robots achieve speeds of up to 4.7 meters per second
- Robots automatically place dough balls into pans prior to pressing
- Designed for high-speed, continuous operation on fast-moving production lines
- Equipped with scoop-shaped tools for gentle handling of oil-coated dough balls
- Ensure precise center placement for consistent crust shape and quality
- Replace a fully manual process with automated, repeatable performance
