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Food Industry Case Studies


Pie Shell Stacker

The older pie shell stacker in one of the production lines of a large pie manufacturer was not able to keep up with the current production rate of 110 pies per minute. In addition, it was sensitive...

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Pie Shell Press Machine

A pie manufacturer requested Graybill to build a pie machine to press pie shells using multiple dough recipes. Their existing method was labor intensive, did not have a sufficiently high output...

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Sugar Wafer Book Cutter

A customer developed a low fat sugar wafer product that used cream so soft and sticky that conventional cutting techniques did not work. Books buckled and cracked, cut pieces stuck together and book cutter jams were frequent....

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Vertical Stack Accumulator

A confectionary customer’s sugar wafer product had evolved over time into a different configuration than that for which the production line was originally designed. The line had 2 wafer ovens; if they ran one oven, the line could not reach maximum output...

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Honeybuns Replacement Guillotine

A customer was having large amounts of lost production and waste due to honeybuns being folded over, loaded one on top of another, hanging off ends of proofer trays, or otherwise misplaced at the proofer tray loading...

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Automated Pretzel Jug Fillers

A pretzel manufacturer was filling plastic jugs by hand placing them under the output of a combination scale. This was a boring, repetitious job, and the operator was continually showered with salt from the scale. A more automated filling method was needed...

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Chocolate Moulding Depositor

A confectionary customer was making their product on an early 20th century depositor that was manually cycled for a chocolate deposit into a hand-placed mould, which was then hand transferred to cooling. This technique was slow, and had inaccuracies in shape and weight of deposit...

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Cupcake Paper Cup Placer

A contract baker was using large amounts of hand labor to un-stack and place foil cupcake pans onto a conveyor, and then separate tightly stacked cupcake papers to hand place them into the foils before guiding them under a depositor....

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Pastries Cones

A customer’s pastry manufacturing operation required a large number of people performing hand operations to remove the cones on which the cream horn (French Twirl) pastries were baked, and to fill the pastries with cream...

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Boston Cream Pie Machine

A contract baker was making Boston Crème Pies (cakes) by hand, and needed to reduce the labor required, as well as improve the quality. These pies were made by cutting a cake, depositing filling on the bottom, pressing the cake top in place, and applying icing...

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Caramel Piece Handling

A confectioner wanted to manufacture a new product that looked like a peanut butter cup, but instead of peanut butter had a caramel center with whole peanuts in it. The customer had tested a process to cut the sticky caramel center material...

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Cake Collator

A baker of snack cakes had a clever and compact device originally concepted by the Franklin Institute that moved cakes from 18 lanes into 3 lanes in a short length of production line. However, this device did not meet modern sanitary standards...

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Washdown Sanitary Machine

A bakery customer’s existing food machinery had been built many years before out of carbon steel, and was showing considerable rust. Numerous unsanitary components were in the product zone, and long structural pieces lay along the floor...

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Automated Dough Wrapping

A manufacturer of cream horn pastries was finding that their sales potential was greater than their ability to produce the product. Wrapping the dough on the cones on which they are baked required a long operator training period for the rapid repetitive motions...

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Product Stacking

A confectionary customer needed to package chocolate products shaped like potato chips. These products were produced using a non-conventional proprietary process that produced an output of 16 individual lanes of product not aligned in rows...

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Moulding Cookies in Chocolate

A contract confectioner was asked to make a product that required placing cookies and moulded chocolate together precisely with both the chocolate and the cookie visible in the finished product...

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High Efficiency Pie Line

A snack pie baker was replacing two aging pie lines with one new pie line and desired to maximize his line efficiencies. On the old lines, multiple operators had to manually rack off pies ahead of packaging any time there were difficulties...

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Customized Equipment

A baked goods manufacturer attempted to buy a complete new snack cake production line package from another vendor; however, after repeated efforts he failed to convince the vendor to tailor the vendor’s equipment to the customer’s snack cake manufacturing processes...

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Apple Bagger

An apple packing house was hand loading apples into plastic tote bags. As demand for the tote bags grew, this operation consumed an increasing amount of hand labor...

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Tomato Harvesters

A scarcity of laborers willing to hand pick tomatoes, along with university work on firmer tomato varieties with more uniform ripening, was causing local farmers to consider mechanical harvesting...

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Phone 717.626.5221 Fax 717.626.1886
221 W. Lexington Rd. Lititz, PA 17543