Minor production issues can become costly as a business grows. For the food company Jätten Cater, additive manufacturing – commonly known as 3D printing – became a way to achieve greater precision, increased flexibility and a better working environment.
Jätten Cater produces ready meals and meal solutions for the grocery retail sector and the public sector, amongst others. The business has grown steadily since its inception thirteen years ago, but along the way it became clear that the company needed to start operating in a more industrial manner.
– We don’t really come from an industrial background. I’m a former chef and my business partner comes from the retail world. But as we grew, we realised that it’s not just the cost of raw materials that matters; production costs are just as important,” says Andreas Unger, co-owner and production manager at Jätten Cater.
As the company grew, it also began to work more systematically with workflows and how different processes could be standardised and simplified. That was also where the interest in additive manufacturing was sparked.
Small changes can have a big impact
One of the first challenges concerned portion sizes and standardisation. Previously, the company used manual measurements and estimates in production – something that worked less well as the business expanded.
– It quickly became clear that, for example, ‘a handful of prawns’ could mean very different things depending on who was on the production line.
Previously, bespoke tools were expensive and time-consuming to produce. But with 3D printing, the company was able to start developing its own solutions tailored to its specific needs.
Half a tonne too much
Today, specially developed measuring units are used for various raw materials and products. One example is Jätten Cater’s Caesar salads, where the contents needed adjusting when raw material prices rose sharply. When the recipes changed, the company also developed new measurements for production.
– But after a while, we noticed that the old measurements were still being used out in the workplace. Over a few months, we had used about 250 kilos of Parmesan and 250 kilos of bacon too much. From that alone, we were able to finance virtually the entire initiative.
With the help of CAD drawings and our own 3D printer, the measurements can now be adjusted quickly when conditions change.
– It takes a matter of minutes to change a drawing and perhaps a day before we have a finished solution up and running.
Over a few months, we had used about 250 kilos of Parmesan and 250 kilos of bacon too much. From that alone, we were able to finance virtually the entire initiative.
Employees drive development
Additive manufacturing has also become a way of capturing ideas from within the company. Many of the solutions come directly from the staff.
In addition to portioning tools, ergonomic aids, holders and customised components for the production lines have been developed. Among other things, they use various angle blocks that ensure raw materials end up in better positions for the staff.
– It’s not just about working faster. Staff should be able to work ergonomically and sustain that over the long term as well.
According to Andreas Unger, this approach has created a clear sense of commitment within the organisation.
– I’ve never received as many suggestions for improvement as I do now. People are constantly coming up with ideas. And when they’ve been involved in developing something themselves, they also become ambassadors for the solution.
It’s not just about working faster. Staff should be able to work ergonomically and sustain that over the long term as well.
From pilot project to in-house capability
Work on testing additive manufacturing began in 2023 when Jätten Cater, together with RISE, explored how additive manufacturing could be used in its own production, including through the 3D Action project and in collaboration with RISE’s test and demonstration environment, the AM Center. For the company, it became a way to test the technology with lower risk whilst building up its own knowledge and capacity.
– RISE has been a very important pillar of support. We didn’t have the expertise ourselves from the start. This has been ‘learning by doing’ for us, says Andreas Unger.
Today, they have invested in their own 3D printer and are working increasingly independently with additive manufacturing. At the same time, Andreas Unger sees great potential for the future, including for other small and medium-sized enterprises.
– You don’t need to start with large, advanced systems. It is often the small things that make the biggest difference in everyday life. Buy a small printer and start testing. That’s when the ideas start to flow.
About Jätten Cater
Jätten Cater has grown from a business-oriented initiative with roots in the ICA retail chain into a food company with around 50 employees, approximately 100 shops and around 1.5 million portions produced per year. Today, the company uses additive manufacturing to develop tools and solutions directly for its day-to-day operations.
About Additive Manufacturing at RISE
RISE helps companies explore and utilise additive manufacturing in practice, from early-stage testing and prototyping to solutions that work in day-to-day operations. Through testing facilities, industry-focused projects and broad expertise in materials, design and production, we support companies seeking to develop smarter, more flexible and resource-efficient ways of working.
Read more about RISE’s additive manufacturing offering here.
