Automating Recipe Batch Blending to Improve Consistency and Throughput for Food Manufacturing
Client Overview
McCormick & Company (McCormick Europe) is a leading producer of herbs, spices, and condiments, operating high-volume manufacturing facilities across the region. At their Littleborough plant in the UK, they manage complex batch processes to produce a wide range of liquid and semi-liquid food products.
The Challenge
As production demand increased, McCormick needed tighter control over their batch blending processes. Recipes had to be executed with absolute accuracy while maintaining flexibility to handle frequent product changeovers.
Their existing setup made this difficult. Manual intervention increased the risk of inconsistency, traceability was limited, and scaling production without compromising quality became a growing concern. At the same time, any new system had to integrate with existing plant infrastructure and avoid disruption to ongoing operations.
The Approach
Practicon worked closely with McCormick’s engineering and operations teams to understand not just the process, but the day-to-day realities of running the plant.
This wasn’t a standard, off-the-shelf install. The solution had to reflect:
- A wide and evolving recipe portfolio
- Strict food safety and traceability requirements
- Integration with existing vessels, dosing systems, and controls
- The need for intuitive operation by plant personnel
Over a long-standing relationship—spanning more than 15 years—Practicon became a trusted partner, supporting both new capital installations and incremental system upgrades.
The Solution
The project combined two core systems into a fully integrated platform, Practicon implemented the ProTrace Recipe Dispensary Weighing System together with the ProTrace Recipe Batch Blending System, designed specifically around McCormick’s production environment.
ProTrace Recipe Dispensary Weighing System
A controlled dispensing system that guides operators through precise material weighing, ensuring:
- Accurate ingredient handling for every batch
- Step-by-step operator instructions
- Real-time validation to eliminate errors
- Full traceability of all dispensed materials
ProTrace Recipe Batch Blending System
- Automated recipe management ensuring precise control of ingredient dosing
- Batch tracking and full traceability, critical for food manufacturing compliance
- Integrated control of blending processes, coordinating multiple inputs and vessels
- Flexible production capability, allowing operators to switch between recipes efficiently
The system was engineered to sit seamlessly within the existing plant, enhancing capability without requiring wholesale replacement of infrastructure.
The Outcome / Results
The impact was immediate and sustained:
- Improved batch consistency, reducing variability across production runs
- Significantly reduced manual intervention, lowering the risk of human error
- Enhanced traceability, supporting quality assurance and compliance
- Increased production efficiency, enabling smoother scheduling and faster changeovers
- Scalable operations, allowing the plant to handle growing demand with confidence
Just as importantly, the system gave operators greater visibility and control over the process, making day-to-day production more predictable and manageable.
Added Value
What stands out in this project isn’t just the technology—it’s the relationship.
Practicon has supported McCormick UK for over 15 years, responding reliably during critical breakdowns and playing an active role in long-term project delivery. That continuity has allowed solutions to evolve alongside the plant, rather than being replaced.
As McCormick UK puts it:
“Practicon is held in high regard within our business. They have never failed to respond in times of crisis, and in calmer times they are an integral part of our project delivery strategy.”
Closing Statement
By implementing a tailored batch blending system built around real operational needs, Practicon helped McCormick Europe improve consistency, efficiency, and control across their production process—demonstrating the long-term value of well-engineered, client-specific automation.
For further information about the technology used in this case study, please review the ProTrace Recipe Dispensary Weighing System and ProTrace Recipe Batch Blending System webpages.
