Ultrasonic Cutting in the Food-to-Go Sandwich Industry

In high-volume sandwich production, cutting sandwiches can be a surprisingly complex task, so we’ve designed the RoboSONIC IV (Inline with Vision) to address this. We’ll be at PPMA 2025 in Birmingham from 23rd to 25th September. Pay us a visit on Stand E94 – we’ll be happy to answer all your slicing, picking, warehousing and automation questions!

Cutting sandwiches at scale: the challenges

Sandwich manufacturers face challenges that impact yield, presentation, and efficiency, which include:

Product variability Sandwiches built from soft breads, varied fillings, and moist ingredients such as tomato or cheese can drag or smear when cut with mechanical blades, leading to product loss.
Presentation standards Food-to-go sandwiches must display distinct, clean layers when sealed into retail packs. Mechanical slicing can pull fillings apart or compress delicate wraps.
Throughput and line balance Cutting operations must match the pace of upstream assembly and downstream packaging. Traditional blades require frequent stops for cleaning or adjustment, which reduces overall efficiency.
Hygiene and operator safety The variety of ingredients used in sandwiches can create hygiene challenges. Microbes such as listeria can be brought in with ingredients such as eggs and chicken, and product lines can become contaminated with allergens. Blades need to be kept scrupulously clean and sharp, which can be time consuming and can present further safety risks.

Why ultrasonic cutting makes a difference

Ultrasonic cutting uses a titanium blate that vibrates at high frequency to create a near-frictionless edge and delivers several measurable benefits with operational and commercial gains:

Cleaner cuts that prevent deformation of breads and fillings.
Reduced adhesion, which avoids smearing and minimises blade-cleaning stoppages.
More consistent portion weights, reducing product giveaway.
Faster changeovers, supported by integrated cleaning and quick-release components.
Smoother integration into conveyor lines, helping maintain throughput.

The RoboSONIC IV (Inline with Vision)

The RoboSONIC IV integrates ultrasonic cutting with sophisticated vision-guided robotics to deliver highly accurate portioning of sandwiches, wraps, and ciabattas. The system employs a Cognex In-Sight vision camera that provides sharp, rapid imaging to guide precise cuts. Advanced image-processing algorithms can be trained to disregard protruding elements such as lettuce to ensure consistent cutting quality, and the 6-axis robotic arm offers flexibility, reliability, and optimised throughput on your production line.

The integral wash tank with air-dry is a key feature of the Robosonic IV and supports continuous, high-volume production by enabling inline blade cleaning, which minimises downtime and maintains high standards of hygiene. It ensures swift sanitation between cycles, reduces the risk of contamination and maximises throughput.

The benefits of the RoboSONIC IV

The RoboSONIC IV is built around the needs of high-volume sandwich manufacturing, with features that include:

Preloaded programs for halves, quarters, and de-crusting, eliminating the need for bespoke setup.
Vision-guided cutting and conveyor tracking, allowing the robot to compensate for positional drift and operate inline without stopping the belt.
A six-axis robotic arm, enabling precise angled or diagonal cuts and flexibility for mixed SKUs.
An ultrasonic titanium blade that delivers clean, smear-free cuts, even in soft or filled breads.
Automated rinse-and-dry cleaning, reducing downtime and supporting allergen control.
A colour touchscreen interface with role-based access, simplifying changeovers and enabling remote diagnostics.
Stainless steel, food-grade construction with quick-release belts, designed for high-care environments and easy sanitation.

In food-to-go production, sandwich cutting is far from trivial. Mechanical blades struggle with product variability, hygiene demands, and line efficiency. Ultrasonic cutting addresses these issues directly, improving presentation, yield, and throughput while reducing downtime. The RoboSONIC IV enhances these benefits further with vision tracking, robotic flexibility, and automated hygiene features. For manufacturers, this combination represents a practical route to higher efficiency and consistent product quality in a highly competitive market.

Find out more about the Robosonic IV