Project H

Machine Upgrade - Cheesecake Machine Adaptation for Multi-Purpose Production 

Project Overview 

This project focused on transforming an existing cheesecake production machine into a multi-purpose system capable of manufacturing both cheesecakes and rectangular apple crumbles. The work was carried out for the UK’s largest cheesecake manufacturer and built on previous upgrades, where Custom Controls had redesigned the machine’s control system and debasing functionality. 

Expanding the Machine’s Capabilities 

Originally engineered solely for circular cheesecake pots, the machine needed to be adapted to handle rectangular trays of varying sizes, reverse its product layering process, and switch seamlessly between two very different production workflows. 
This required extensive mechanical, software, and systems redevelopment, far beyond conventional machine re-tooling. 

Key Requirement: Rapid Switching Between Product Types

A critical objective was enabling operators to quickly switch between Cheesecake Mode and Crumble Mode with minimal manual intervention. This flexibility provided major operational value given the high cost of equipment and the limited factory floor space. 

Baseline System: Single-Purpose Cheesecake Manufacturing

Prior to this project, the machine was designed exclusively for circular cheesecake production. Its core components included:

• Circular pot dispensing system 
• Suction cups for placing round cardboard bases 
• Biscuit crumb depositor  
• Stomping heads for base compression
• Depositors for cheesecake mix and optional swirl

The system had no capability for handling rectangular containers or reversing the order of filling required for crumble production (filling first, crumble topping second).

Industry Context

Food production machinery is typically designed for one product format and size, with limited flexibility. There is no standard industry practice for re-engineering equipment to run both circular and rectangular product lines interchangeably. 
No known machinery exists that can produce both cheesecake and apple crumble or handle circular and rectangular containers on the same line.

Technical Challenges & Uncertainties

The project required solving several complex engineering uncertainties, including:

1. Mechanical Compatibility

Determining whether systems designed for circular pots—such as dispensers, grippers, and suction mechanisms—could be adapted to handle rectangular trays without compromising precision or throughput.

2. Software Control Logic

Developing new control logic to support two distinct production processes, each requiring different sequencing, timing, and sensor inputs, while ensuring operators could switch modes easily.

3. Tooling Reach & Precision

Redesigning suction cup mechanisms to extend and reposition accurately for both rectangular and circular containers.

4. Tray Orientation & Stability

Engineering new platens capable of securely holding trays of multiple sizes and orientations, without requiring physical changeover of parts.

5. System Integration

Integrating third-party depositor systems through new communication protocols and ensuring they operated reliably under both production modes.

Innovation Through Iteration

These challenges could not be addressed through routine engineering. The project required iterative design, prototyping, testing, and refinement to achieve a robust, multi-format production system that maintained the client’s required speed, accuracy, and product quality standards.