Rising costs, rising demand: the new recipe for bakery success

Baked goods are in higher demand than ever, but the rules of the game are changing. From the “free-from” trend and flexible packaging materials to data-driven production, both consumer behavior and production requirements are evolving. Here’s how you can successfully overcome these challenges.

Convenience and functional snacks on the rise

Purchase decisions are more conscious than ever. Consumers are seeking products that fit a healthy lifestyle: less sugar, more protein and fiber, and “free-from” options – all in convenient, on-the-go formats. Short ingredient lists build trust, while resealable single portions increase usability. The key is to meet different snacking occasions – from indulgent moments to functional energy boosts.

From standard to variety

More flavors, seasonal editions, new recipes – variety sells but increases complexity. Products with “free-from” formulations require gentle handling to minimize breakage. The answer lies in production lines that handle product and format changes with very short setup times – allowing portfolios to expand without cannibalizing the standard range.

Boosting efficiency, reducing waste

With rising raw material and energy costs, every percentage point of OEE counts. Gentle product handling, precise linear movements, and the right grippers ensure that delicate goods and chocolate surfaces remain intact. The result: less waste, stable margins – and consistent quality on the shelf.

Rethinking sustainability – focus on materials and sealing technology

The EU Packaging and Packaging Waste Regulation (PPWR) sets clear guidelines for recyclable packaging. Switching from composite materials to mono-materials or paper changes mechanical and thermal properties – and calls for innovative forming and sealing technologies. Flexible, modular systems capable of processing multiple pack styles and sustainable materials on the same line are becoming a key operational lever.

Higher product complexity, stricter hygiene design

As variety grows, so do food safety requirements: allergen management is becoming a permanent priority. Hygienic machine design with smooth surfaces and easily removable components shortens cleaning times, reduces downtime, and simplifies safe changeovers between recipes.

Labor shortages and cost pressure: automate where it matters

Fewer workers, same quality: automation provides relief along the entire line – from product infeed and inline quality checks to primary and secondary packaging. Combined with connected equipment, real-time monitoring and predictive maintenance enable demand-based servicing, fewer unplanned stops, and longer machine lifetimes.

Responding quickly to market dynamics

Standalone machines are no longer enough – manufacturers need well-thought-out, seamlessly integrated system solutions and a reliable, experienced partner. Syntegon positions itself as a problem solver: together with producers, it develops future-ready concepts backed by a global network and extensive experience from hundreds of bakery projects. Those who rely on such partners combine industry expertise with innovation – balancing quality, efficiency, flexibility, and sustainability in measurable ways.

The future belongs to automated, flexible systems that adapt quickly to market demands – from functional snacks to sustainable packaging styles. Those who invest now and partner with the right experts will secure lasting advantages in a market that expects more choice than ever before. With seamlessly integrated, efficient, and material-flexible solutions, manufacturers can turn rising demand into sustainable growth.

Learn more about Syntegon’s flexible packaging solutions:

Cookies & Crackers Packaging Machine | Flexible & Efficient