Minnesota Food Maker Streamlines Packaging and Palletizing with Fully Automated Delkor System
Mrs. Gerry’s grew from a small kitchen to a 200,000+ sq ft plant producing 50M lbs yearly, then used FANUC automation to boost throughput and add flexibility.
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Challenges
Labor intensive hand packing process requiring up to 12 employees
Inconsistent product orientation
Need for rapid, multiple daily changeovers
Space constraints within existing facility
Results
Gained rapid, flexible changeovers without slowing production
Transitioned from 12 packaging employees to two-three
Increased throughput to 36 million pounds annually
Achieved full capacity production within 10 days of installation
Story
Founded on family recipes and a commitment to quality, Mrs. Gerry’s has grown from a 1,100 square foot kitchen in 1973 to a more than 200,000 square feet facility, producing more than 50 million pounds of salads and sides each year. As demand increased, the company sought a way to streamline packaging while maintaining the high standards that define the brand.
Their existing hand packed line required 12 employees and struggled to keep pace with production needs. Additionally, products exiting the spiral chiller arrived in inconsistent orientations, creating bottlenecks and inefficiencies.
Mrs. Gerry’s turned to FANUC Authorized System Integrator Delkor Systems—known for turnkey automation and expertise in food packaging—to design a fully integrated solution. The new line incorporates FANUC’s M-10iA robot, the M-2iA Delta robot for high speed picking, and the heavy-duty M-410iB/700 robot. Together, these systems automate orientation, case packing, sealing, forming and palletizing.
Despite the complexity of the project, Delkor delivered a remarkably fast installation. “We needed to have this project up and running in 10 days,” said Stuart Ness, Director of IT and Project Management at Mrs. Gerry’s, and that’s the impressive timeline that was met.
The impact was immediate. Labor requirements for this particular process dropped from 12 employees to two or three, while throughput increased significantly. The system now supports roughly 36 million pounds of product annually across three shifts with just 24 people.
Equally important, the line offers the flexibility needed for frequent changeovers. “We’ll sometimes go from a 2 pound bag to a 5 pound bag” in order to meet customer demand, said Ness. “The Delkor line doesn’t ever hold us up.”
From case forming to palletizing, the system “just runs”—so reliably that monitoring it has become one of the calmest jobs in the plant.
One of the smoothest installs we ever went through… We went from our hand packed line to the fully automated line in about a week. Not at 50% capacity, but at full capacity within 10 days.
Stuart Ness Director of IT and Project Management – Mrs. Gerry’sFANUC Products Used
M-2iA/3SL
The FANUC M‑2iA/3SL is a long arm 4‑axis delta robot model ideal for clean room applications that require an extended envelope.
- Max Payload:
- 3 kg
- Reach:
- 1130 mm
M-410iB/700
The FANUC M‑410iB/700 is a 4‑axis palletizing robot boasting the best payload capacity of the range, this robot will lift up to 700 kg.
- Max Payload:
- 700 kg
- Reach:
- 3143 mm
Delkor Systems Inc.
Delkor Systems is a leading U.S. manufacturer of advanced robotic packaging systems for the food, beverage and consumer products industries. We’re more than just a supplier—we’re your automation partner, delivering cutting-edge packaging equipment and turnkey systems tailored to your unique needs. Our secondary packaging and end-of-line solutions, along with advanced technologies like pouch case packing, pick and place robotics, and vision-guided systems, help you achieve maximum efficiency and guaranteed results.
Whether you’re packing flexible or rigid products, Delkor smooths your transition from package concept to production. Our 350 employees are dedicated to developing engineering solutions for you out of our 300,000 square foot manufacturing campus. We rely on over 50 years of history to offer perfectly integrated packaging systems and trustworthy aftermarket support to enhance your plant’s efficiency and capacity.
Mrs. Gerry’s
Mrs. Gerry’s was founded in 1973 by Gerry and Jerry Vogt in Albert Lea, Minnesota. What began as a small family operation producing potato salad from a cherished family recipe has grown into a national brand offering more than 250 products, including pasta salads, coleslaws, salad kits, specialty salads, and the popular Premium Mashed Potatoes. The company remains committed to quality, small batch production, and sourcing local ingredients—90% of the potatoes used are grown within 15 miles of the plant. Today, Mrs. Gerry’s products are sold nationwide in grocery stores, restaurants, universities, healthcare facilities and more.