Case Study: How Meili Family Scaled Bread Production with a High-Efficiency 4-Line Production Solution

Customer Background

Meili Family is a well-known regional bakery chain based in Zhejiang, China, operating over 100 retail stores across Zhejiang and neighboring provinces. The brand focuses on fresh bread, cakes, and seasonal bakery products, supplying both in-store baking and centralized factory distribution.

As its store network expanded, Meili Family gradually transitioned from traditional workshop-style production to a standardized central kitchen model.

Challenges Before the Upgrade

Before introducing the new production line, Meili Family faced several operational bottlenecks:

1. Production Capacity Constraints

Existing single-line equipment could no longer support the rapidly growing daily order volume from retail stores.

2. High Labor Dependency

Manual forming, cutting, and tray arranging required a large workforce, increasing labor costs and management complexity.

3. Inconsistent Product Quality

Differences in dough handling and shaping led to size deviations and unstable appearance across batches.

4. Limited Scalability

The original production layout made it difficult to increase output without significantly expanding factory space.

Meili Family needed a solution that could multiply capacity while maintaining product consistency and operational stability.

Solution: 4-Line High-Capacity Bread Production Line

After technical evaluation and on-site discussions, Meili Family selected a 4-line bread production line configuration, designed for industrial-scale standardized bread manufacturing.

Production Line Configuration

• Dough Pressing Machine
• Dough Dividing & Shaping Machine
• Three-Wheels Main Forming Machine
• Pinching Machine
• Automatic Tray Arranging Machine

This system enables four parallel product streams within one continuous production process.

Why This Configuration Was Chosen

High Output in Limited Space

The 4-line design delivers 3–4 times the output of a conventional single-line system without proportionally increasing factory floor space.

Flexible Product Adaptation

By switching between the pinching machine and the cutting machine, the line supports:

• Round bread
• Long bread rolls
• Sandwich bread
• Filled bread varieties

Automation Where It Matters Most

Automatic forming and tray arranging significantly reduce manual intervention, stabilize quality, and lower labor dependency.

Implementation Process

The project was completed in three phases:

Process Design & Layout Planning

Equipment layout was customized according to the client’s factory workflow and space limitations.

Installation & Commissioning

Machines were synchronized and tested using Meili Family’s actual dough formulas.

Operator Training & Ramp-Up

Production staff received structured training covering operation, maintenance, and product changeovers.

The line achieved stable mass production shortly after commissioning.

Results After Deployment

Production Capacity

Daily output increased by approximately 3.5 times compared with the previous system.

Labor Efficiency

Manual labor in forming and tray arranging was reduced by over 50%.

Product Consistency

Bread weight deviation and size differences were significantly reduced, improving shelf presentation and brand consistency.

Order Fulfillment Stability

The central kitchen can now reliably support peak demand during holidays and promotional seasons.

ROI Analysis: Investment vs. Return

Estimated Investment Structure

The 4-line bread production line investment typically includes:

Core production equipment

Installation and commissioning

Operator training

Basic spare parts package

This represents a medium-to-high capital investment, designed for long-term continuous operation.

Key Return Drivers

1. Labor Cost Reduction

Before upgrade:
8–10 operators per shift

After upgrade:
4–5 operators per shift

Estimated saving:
3–5 workers × annual labor cost per worker

In most markets, this alone can recover 30–50% of equipment cost within 1–2 years.

2. Production Capacity Increase

Typical comparison:

Traditional single-line: 2,000–3,000 pcs/hour

4-line system: 7,000–10,000 pcs/hour

Benefits:

No need for extra shifts

Better utilization of ovens and proofing rooms

Fixed factory costs distributed over more products

3. Reduced Product Loss and Rework

Automation improves:

Weight consistency

Shape uniformity

Tray placement accuracy

Resulting in:

Lower rejection rate

Less rework

Higher sellable yield per batch

Sample ROI Scenario (Reference)

Assumptions:

Additional output: 5,000 pcs/hour

Working time: 6 hours/day × 300 days

Net profit per bread: USD 0.05

Labor savings: USD 35,000/year

Calculation:

Additional profit:

5,000 × 6 × 300 × 0.05 = USD 450,000 / year

Total annual benefit ≈ USD 485,000

If total investment = USD 250,000–350,000

Payback period: 6–10 months

3-year ROI: 300%–500%

(Actual figures vary by market conditions.)

Business Impact for Meili Family

The new production line enabled Meili Family to:

• Support rapid store expansion
• Maintain unified product standards
• Control long-term labor costs
• Build a scalable production foundation for future automation

Rather than simply increasing speed, the solution transformed their production model into a more predictable, controllable, and scalable industrial system.

Conclusion

For growing bakery brands, equipment investment is not just about speed, but about building a stable production infrastructure.

The 4-line bread production line provided:

• High-capacity manufacturing
• Product flexibility
• Reduced labor reliance
• Consistent quality
• Long-term scalability

This project demonstrates how the right production line configuration can directly support commercial growth while maintaining operational control.

Considering Upgrading Your Bread Production?

If your factory is facing:

• Capacity bottlenecks
• Rising labor costs
• Inconsistent product quality
• Limited factory space

A multi-line bread production solution may be your next strategic step.

We provide customized line planning based on:

• Product types
• Target output
• Factory layout
• Budget and growth stage

Contact us to explore a solution tailored to your production needs.