Productivity Solutions: Mrs. Gerry’s automates packaging to keep up with demand
The new line cut staffing from 12 employees to two or three while handling frequent product changeovers.
From the September 2026 Issue of
Modern Materials Handling
Productivity Solutions: Mrs. Gerry’s automates packaging to keep up with demand
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Mrs. Gerry’s was growing, but its packaging line was becoming a bottleneck. Minnesota-based maker of refrigerated salads and side dishes relied on a hand-packing process that required as many as 12 employees.
Frequent product changeovers and inconsistent product orientation also slowed production, making it harder to keep pace with demand while maintaining efficiency.
Instead of adding more labor, the company invested in automation. Working with an integrator (Delkor Systems), Mrs. Gerry’s installed a fully automated packaging and palletizing line (FANUC) with robots. The system automates product orientation, case packing, case forming, sealing and palletizing, creating a continuous flow from the spiral chiller to finished pallets.
The new line delivered immediate results. Labor requirements dropped from 12 employees to two or three, while the automated system now supports production of approximately 36 million pounds of product each year. Just as important, the company reached full production within 10 days of installation, minimizing downtime during the transition.
Beyond reducing labor, the automated line created a more consistent packaging process. Products now move through case packing and palletizing in a continuous flow, reducing manual handling while making it easier to maintain throughput throughout the day. The automated system also gives Mrs. Gerry’s the flexibility to respond to changing customer orders without slowing production.
“We needed to have this project up and running in 10 days,” says Stuart Ness, director of IT and project management at Mrs. Gerry’s.
Automation also solved one of the company’s biggest day-to-day challenges: frequent product changeovers. Because Mrs. Gerry’s packages a variety of refrigerated salads in multiple bag sizes, production schedules often require switching between products several times a day.
The new system was designed to handle those changes quickly, allowing the company to keep production moving as customer demand shifts.
“We’ll sometimes go from a 2-pound bag to a 5-pound bag in order to meet customer demand,” Ness says. “The Delkor line doesn’t ever hold us up.” The speed of the installation proved to be another productivity gain. Rather than spending weeks bringing the new line online, Mrs. Gerry’s replaced its manual packaging process and reached full production in less than two weeks.
“One of the smoothest installs we ever went through,” Ness adds. “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.”
For Mrs. Gerry’s, the project wasn’t simply about reducing labor. It also created a packaging operation that could handle frequent product changes, maintain throughput and get up to speed quickly after installation, giving the company room to grow without adding people to the line.
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About the Author
Andy GrayAndy Gray is the Editorial Director of Supply Chain 24/7. He oversees coverage of supply chain, logistics, and materials handling news, providing readers with clear and practical insights.
A graduate of Columbia Journalism School, Andy spent 13 years at Sports Illustrated and also worked at lululemon, JP Morgan, and the fitness startup MIRROR. He lives on Cape Cod with his wife, son, and their dog, Larry.
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September 2026 Modern Materials Handling
Productivity Solutions: Mrs. Gerry’s automates packaging to keep up with demand
The new line cut staffing from 12 employees to two or three while handling frequent product changeovers.
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