BATCH OR CONTINUOUS PRODUCTION?
for efficiency and consistency. Once the system is up and running, it is able to deliver a steady output of product with very tight process control. This helps ensure uniformity in texture, flavour, and appearance – essential qualities in today’s competitive confectionery market. Esmée argued that continuous lines
are especially beneficial for high-volume products, where minimising downtime and maximising throughput is critical. “Automation reduces the dependency on manual intervention, and energy usage can be optimised across the line, often leading to lower production costs per kilo,” she says. On the downside, continuous systems
do typically require a higher initial investment and more planning before installation. They are less flexible when it comes to frequent product changes, so for companies producing many small SKUs, batch systems may remain more practical. Esmée believes that, for chocolate,
fondant, nougat, and aerated products, continuous systems can often deliver the best results thanks to the need for consistent structure and large production volumes. Conversely, she believes that artisanal-style products, specialty inclusions, or limited-
edition runs would probably benefit more from the agility of batch processing. “We are increasingly seeing hybrid
approaches gaining popularity,” she says. “For example, a manufacturer might use a continuous line for the base mass of a product, then complement it with batch operations for the finishing touches or for creating specialty variants. At Tanis Food Tec, we work closely with clients to analyse their product portfolio, production goals, and market demands, and then tailor solutions that can evolve with their business. So, it would appear that the choice
between batch and continuous processing is not simply a matter of ‘one being better than the other.’ It’s about selecting the right tool for the right job. Continuous systems shine in efficiency and consistency for large-scale production, while batch systems remain invaluable for flexibility, variety, and innovation. As Esmée pointed out, it is also possible to employ both production methods. It’s all about striking the right balance to ensure you are able to meet today’s demands while also being ready for future opportunities.
Batch -v- continuous production in confectionery: Key tradeoffs FEATURE/FACTOR Flexibility
BATCH PRODUCTION
High – easy to switch recipes and variants
Capital investment Product variety Throughput Labour requirements Quality control Energy efficiency Cleaning and changeovers Product sensitivity Waste and rework Scale-up potential Lower – modular and scalable
Ideal for small series and seasonal SKUs
Lower – limited by batch size and downtime
Higher – more manual handling and oversight
Strong – discrete batches support traceability
Moderate – energy use varies per batch
Frequent – required between different batches
Suits complex or delicate formulations
Lower for small runs – better control
Constrained – may hit physical limits
CONTINUOUS PRODUCTION
Low – best for long, uninterrupted runs
Higher – significant up-front system costs
Less suited – changeovers can be disruptive
Higher – consistent, high-speed processing
Lower – automation reduces manual input
High – closed-loop control aids consistency
High – better integration and recovery systems
Infrequent – changeovers are longer and more complex
Suits stable, mass-flow friendly products
Potentially higher – faults affect long runs
Strong – ideal for growing high-volume operations
OCTOBER 2025 • KENNEDY’S CONFECTION • 33
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