The Transformation of the Frozen Ready-Made Food Industry: From Traditional Pain Points to New Opportunities in Intelligent Manufacturing

I. Three Major Pain Points in the Traditional Bread-making Industry 

Efficiency bottleneck 

Manual production relies on skilled workers and the daily output is less than 5 tons. The labor cost accounts for over 35% and the quality fluctuates greatly. A certain chain brand once suffered a loss of 100,000 yuan worth of raw materials due to an operational error by human workers. 

The problem of food preservation 

The shelf life of room-temperature cooked food is only 2-3 days, and the cost of cold chain transportation can reach 18% of the retail price. Industry statistics in 2024 show that the loss rate due to spoilage is as high as 12.6%. 

Limitations of Innovation 

Traditional equipment can only produce single-sided products, and the development cycle of new products is as long as 6-8 months. A well-known enterprise disclosed that before launching its new flat noodles, they needed to repeatedly adjust the equipment parameters 23 times. 

II. Solutions from Gerdler Machinery 

Fully automated production line 

Using the PLC intelligent control system, the daily output has exceeded 50 tons, and the number of workers has been reduced by 70%. 

The modular design enables a quick model change in just 5 minutes, and it supports 8 types of pasta such as udon noodles and spaghetti. 

Breakthrough in fresh-locking technology 

The three-stage rapid freezing technology (-35℃ → -18℃ → -25℃) extends the shelf life to 12 months. 

The rehydration test showed that the elasticity retention rate of the noodles reached 92%, which was 15 percentage points higher than the industry standard. 

Cost reconfiguration advantages 

The thermal energy recovery system reduces energy consumption by 40%. 

A client case study shows that the investment payback period has been reduced from the industry average of 3.2 years to 1.8 years. 

III. Market Impact and Future Trends 

The market size of frozen cooked noodles is expected to reach 38 billion yuan by 2026, with a compound annual growth rate of 19%. Godeler Machinery has assisted over 30 enterprises in obtaining the export to the EU certification. Its equipment has seen a market share increase from 8% to 27% in the Southeast Asian market within three years. Industry experts point out: "This is not only an upgrade of equipment, but also a paradigm shift from 'experience-based production' to 'data-based production'."