Key Takeaways
- Marson Foods has inaugurated a new $35 million, 147,000-square-foot baking facility in Hazelwood, Mo.
- The facility features advanced automated systems, increasing production capacity to 150 million waffles annually.
- With integrated R&D capabilities, the company aims to expand product offerings and explore new co-manufacturing partnerships.
New Facility Enhances Production Capabilities
Marson Foods, LLC, which specializes in waffle products for K-12 schools and foodservice sectors, has opened a state-of-the-art baking facility in Hazelwood, Missouri. The new $35 million facility spans 147,000 square feet and includes sophisticated automated systems designed to enhance production efficiency and food safety.
One of the key features of the new facility is its substantial frozen storage capacity, which includes 12,000 square feet dedicated to fully automated freezer systems. These innovations are part of Marson Foods’ commitment to maintaining high-quality standards while meeting a growing demand for nutritious meals. According to co-owner Jan Marson, the facility will enable the company to “continue to use the highest quality ingredients to create millions of nutritious meals.”
Production capacity at the new facility is impressive, currently allowing for an output of 420 waffles per minute, equating to around 25,000 waffles an hour and up to 150 million waffles annually. This dramatic increase in capacity is supported by the installation of automated production lines tailored for maximum efficiency.
Tyler Wallace, the chief operating officer, detailed how the facility was designed with full automation in mind. Key equipment has been sourced from top vendors worldwide, ensuring a streamlined operation from raw material handling to finished product packaging. The facility features an automated mixing system, an authentic Belgian waffle production line and oven from Belgium, advanced packaging systems from Switzerland, and end-of-line robotics from the U.S. This comprehensive automation strategy not only boosts production rates but also aims to keep prices competitive while ensuring the highest level of food safety and quality.
Wallace also emphasized the facility’s innovative infrastructure, including a fully automatic Automated Storage and Retrieval System (ASRS) for finished goods, which ensures safe management of products in freezer environments without exposing personnel to harsh conditions.
The location holds significance as Marson Foods’ new baking facility is positioned at 1590 Tradeport Drive in Hazelwood, previously home to Nature’s Bakery, a company that was sold to KIND, a member of the Mars family of companies. With the established presence in the region, Marson Foods plans to leverage the facility not only for its current production needs but also to foster new partnerships with co-manufacturing and private label clients. The company is enthusiastic about the opportunities this new venture presents for expanding its product line and enhancing collaboration in the food industry.
Overall, Marson Foods’ investment in this cutting-edge facility signifies its dedication to quality, efficiency, and innovation within the competitive food manufacturing landscape. As the company embarks on this new chapter, the potential for growth in healthy food options for schools and foodservice seems promising.
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