A family-owned bakery in the Midwest needed to improve efficiency and reduce labor demands on their pie production line. Their team was manually interleaving and stacking pie lids onto pie shells, a process that required several operators each shift. They aimed to automate the line, improve throughput, and reallocate operators to other areas of the plant.

The customer produced a wide range of pie sizes and needed a system that could handle multiple formats without complicated changeovers. Labor shortages and rising costs made manual work unsustainable, limiting throughput and increasing the risk of errors and waste. Limited space on the production floor meant any new equipment had to be retrofitted into the existing line without compromising reliability or quality. With cost savings at the center of the project, they needed automation that delivered efficiency gains without requiring expensive custom engineering.

Pacproinc provided a complete solution with a ProLeaver 13100 Interleaver paired with a Prostax 13” Drop Stacker and interleaving materials, designed to fit the plant’s workflow and product range. Our Engineering, Sales, and Service teams collaborated closely with the customer, supported by in-house testing and ongoing communication, to ensure the system met production expectations. Onsite training prepared operators to efficiently run, maintain, and troubleshoot the new equipment.

Automation increased throughput by 20–30% for the plant’s full range of products and allowed the team to relocate three of five operators to other roles, saving approximately $234,000 annually in labor costs. The bakery continues to work with Pacproinc as a full-service supplier, providing ongoing support, interleaving materials, and service to maintain reliable, efficient operations.