How to Successfully Upscale Ready Meal Production While Maintaining Quality
For food manufacturers, upscaling ready meal production is often an exciting if challenging milestone. The need to increase output can arise for various reasons – new contracts with large supermarket chains, spikes in seasonal demand around periods like Christmas, or rapid growth within an expanding market segment. However, expanding production without compromising product quality can be complex. Here are some key strategies we recommend to maintain quality during this scaling-up process.
1. Assess and Optimise Existing Processes
Upscaling is not simply about increasing output; it’s about ensuring that growth happens without sacrificing quality. For food manufacturers, the first step is to rigorously assess and optimise current processes. By identifying and rectifying inefficiencies, bottlenecks and quality control issues, companies can create a robust foundation for expansion. Minimising downtime and addressing existing issues, such as inconsistent production or quality control shortfalls, are crucial to preparing for upscaled ready-meal production. This optimisation also prevents minor issues from becoming major setbacks as production levels rise, helping to ensure a seamless, high-quality scale-up.
2. Invest in High-Quality, Scalable Food Processing Equipment
When demand suddenly increases – whether due to a new contract or a seasonal surge – relying on high-quality food processing equipment becomes a strategic advantage. For companies transitioning from small to large-scale ready meal production, investing in durable, scalable food processing systems designed for higher capacity is essential. High-quality equipment tends to require less frequent repairs, provides greater operational stability and delivers consistent results across large batches. Though the upfront cost may be higher, these machines help reduce maintenance and downtime costs in the long term, providing reliability and efficiency in high-stress production environments
3. Ensure Equipment is Built for High-Volume Ready Meal Production
Ready-meal manufacturers expanding to serve supermarket chains or retail contracts often find their existing machinery unsuitable for handling the jump in volume. This is especially true in ready meals, where food must be cooked, packed and stored under stringent quality controls. Expanding manufacturers need to consider production tools that can handle high-volume output while maintaining product quality. Equipment tailored for mass production, such as DC Norris’ Cook Chill System ensures that products meet high standards without losing the flavour, texture or freshness that consumers expect. Using the Cook Chill method, food can be prepared in bulk in advance and stored in refrigerated conditions for up to 45 days until needed.
4. Embrace Automation for Consistency and Quality
Automation is a vital element for manufacturers looking to upscale their ready-meal production without sacrificing quality. Automation Software systems such as Recipe Manager and Virtual Chart Recorder enhance product consistency and help maintain standards by reducing human error. For example, automated Cook Chill systems in ready-meal production can ensure meals are prepared and cooled at precise temperatures, resulting in uniform texture and flavour every time. As food manufacturers shift towards automation, employees can focus on quality control and innovation, allowing companies to deliver consistent, high-quality products that meet the expectations of supermarket partners and consumers alike.
Why Upscaling Matters for Food Manufacturers
Securing contracts with major retailers or meeting increased seasonal demand represents a huge opportunity for food manufacturers, especially in the highly competitive ready-meals market. Supermarkets often look for suppliers that can deliver quality and quantity reliably, and an upscaled operation can open the door to lucrative, ongoing partnerships. However, scaling up presents unique challenges, and a well-executed expansion strategy can mean the difference between short-term growth and long-term market positioning.
With a structured approach that optimises processes, invests in scalable equipment, prioritises automation, and selects systems built for high-volume ready-meal production, manufacturers can ensure that increased demand is met without compromising quality. In doing so, companies position themselves as reliable, quality-driven partners to supermarkets, ready to capture new opportunities and solidify their presence in a growing market.
A Real-life Example – Blue Earth Foods:
Blue Earth Foods faced an unexpected surge in production volume, requiring a swift solution to increase capacity whilst maintaining quality. Without additional industrial cooking equipment, they risked delays in delivering their products.
They quickly enhanced their production capabilities by acquiring a 300-litre steam jacketed kettle from DC Norris, complete with Jet Cook technology, an inclined agitator, in-vessel emulsifier and a drop-down valve.
Dave Styler – Blue Earth Foods commented, “The new steam jacketed kettle will enable us to meet deadlines and cook efficiently and reliably. The integration of new technologies, such as the Jet Cook system will help with energy savings and boost productivity.”
Get in touch with our Product & Process experts and get personalised advice on how to scale up your ready meal production efficiency.
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