The DiKoRo project, funded by the German Federal Ministry of Education and Research under the code 281A504F19, ran from 1 December 2020 to 30 November 2023 and was carried out by a consortium of academic and industrial partners. The core objective was to create a digital process model for a collaborative robot that can perform individualized decoration and shaping of baked goods and confectionery in small‑to‑medium enterprises (SMEs). The research was led by the Hochschule Hannover with SimPlan AG as the project coordinator, while J. G. Niederegger GmbH & Co. KG, Heinrich Schulze Ladencafé GmbH, Ingenieurbüro Rolf Peters, and Lupeg GmbH contributed industrial expertise. A temporary collaboration with Gehard Schubert GmbH supplied advanced image‑recognition capabilities.
Technically, the project delivered a comprehensive, transferable system architecture that integrates food‑technology, machine‑technology, operational‑organization, business‑economics, and information‑technology parameters. A digital twin was developed that couples a SCARA robot and an Igus 3‑axis system—both linked to an excentric screw pump—with a laboratory‑grade CNC mill and a 3‑D plastic printer. This setup enabled the automated 3‑D printing of high‑viscosity, paste‑like materials such as marzipan, and the subsequent shaping of marzipan medallions. Compared with conventional robot‑assisted 3‑D printing, the new approach improved image quality, recipe consistency, and reduced production time per unit. The project reached Technology Readiness Level 4 (validated in laboratory conditions) and set a target of TRL 5 by the second quarter of 2024, focusing on the automated forming of marzipan medallions.
An unexpected challenge was the prolonged pandemic, which caused two cost‑neutral extensions. These extensions allowed the team to broaden the scope to include additional manufacturing methods and to refine the digital twin. The research also revealed that a fully collaborative robot operating in the same workspace as a human operator is neither safe nor cost‑effective for the intended application. Instead, a hybrid approach—direct manual control of the robot and dosing system via a game controller—proved to be a promising bridge technology. This method offers superior responsiveness to varying surface conditions and viscosity changes, and delivers economic advantages for small‑batch production compared with fully automated, image‑based systems.
The outcomes of DiKoRo have been disseminated through numerous conferences and trade fairs, including BLE Bonn, Agrathaer GmbH, DLG Frankfurt, NaGeB Bremen, VVD TU Dresden, Anuga FoodTec 2022 and 2024, Fachpack Nürnberg, and Interpack Düsseldorf. Since the project’s conclusion in November 2023, ongoing development continues in partnership with SimPlan AG and J. G. Niederegger, aiming to elevate the technology to TRL 5 and to explore industrial uptake by robotics and automation system providers. The DiKoRo project therefore demonstrates a viable pathway for SMEs to adopt digital transformation while preserving the artisanal character of their food production.