21.05.2026
From Manual Cheese Handling to Fully Automated Production Lines
Benefits
Hygienic and Washdown-Ready Production
The production line was designed for handling soft and sticky cheese products where frequent cleaning with chemicals and high-pressure washdown is essential. BJ-Gear’s premium stainless steel gearboxes and motors ensure reliable operation in demanding foo
Increased Automation and Production Efficiency
Integrated robotics and automated handling systems significantly reduced manual intervention throughout the production process. Robots automatically pick, unpack, stack and process cheese blocks, improving throughput, consistency and operational efficienc
Robust Components with Long Service Life
FF Engineering selected BJ-Gear’s waterproof NG bearing units and stainless steel transmission solutions based on previous positive experience in wet environments. The robust construction and long operational lifetime reduce maintenance requirements and s
Company profile
FF Engineering specializes in advanced process and packaging systems for the food industry. The company develops highly automated production equipment with a strong focus on robotics, hygiene and production efficiency. Through innovative engineering and customized automation solutions, FF Engineering supports modern food manufacturers with scalable and reliable production technologies.
Problem Statement
The customer required a large-scale automated cheese processing solution capable of handling soft and irregular cheese blocks without damaging either the product or packaging. At the same time, the system needed to comply with strict hygiene standards involving continuous washdown and chemical cleaning.
The complexity of the project increased further due to the required production capacity, precise robotic handling and the need for highly durable transmission components capable of operating reliably in wet and aggressive environments.
Solution
To meet these requirements, FF Engineering developed a fully automated de-foiling and cheese processing line integrating advanced robotics, transport systems and automated waste handling.
BJ-Gear supplied premium stainless steel worm gearboxes, stainless steel motors and waterproof NG bearing units specifically selected for demanding hygienic production environments. In total, the installation included fifteen Series 42 premium stainless steel worm gearboxes and two Series 61 premium stainless steel worm gearboxes with mounted stainless steel motors.
The solution enables stable, high-capacity operation while ensuring easy cleaning, long service life and reliable performance throughout the production process.
Development and Engineering Phase
Over a two-year period, FF Engineering designed and developed its largest process and packaging system ever built. The project included extensive engineering, testing and optimization to ensure reliable automated cheese handling.
Full-Scale Testing and Final Preparation
Due to the physical size of the system, FF Engineering rented an additional production hall to assemble and test the complete installation before shipment to the international customer.
Ergebnisse
Results
1. Fully automated de-foiling and cheese processing line
2. Capacity of 576 cheese blocks per hour
3. Processing capacity of approximately 5.3 tons of cheese per hour
4. Improved hygiene and cleanability in production
5. Standardization on BJ-Gear waterproof NG bearing solutions for future projects
Lessons Learned
Food production systems operating in high-risk environments require transmission components specifically designed for aggressive cleaning procedures and wet operating conditions.
The integration of robotics and automated handling significantly improved production efficiency while ensuring more consistent product handling and reduced manual intervention.
Long-lasting and washdown-resistant gear and bearing solutions play a crucial role in minimizing downtime and ensuring stable production in demanding food processing applications.