Peeps Automatic Case Packing Case Study

A shift to retail-ready packaging pushed Just Born to replace manual case packing for Peeps with a fully automated, flexible secondary packaging system.

The Background: Transitioning from Traditional RSC Cases to Retail-Ready Packaging for Peeps

A move away from traditional RSC cases toward retail-ready packaging led Just Born to rethink its secondary packaging process for Peeps.

Previously, teams manually packed flow-wrapped products into top-load RSC cases. The shift to retail-ready formats required a more consistent, scalable approach—one that could support new packaging configurations while keeping pace with production.

The Challenge: Replacing Manual Case Packing with Flexible, High-Speed Automation

The existing process relied on six to 10 operators hand-packing 36-count cases, creating clear limitations around labor, consistency, and risk. The new system needed to:

• Keep up with two horizontal flow wrappers running at 200 products per minute
• Provide additional capacity for future upstream speed increases
• Handle multiple product formats (5-count, 10-count, and 15-count trays)
• Support frequent product changeovers with simple operation
• Accommodate operators with varying skill levels
• Reduce ergonomic and liability risks tied to manual packing

The team needed more than just speed. They needed a system that could improve efficiency without adding complexity.

The Solution: Integrated Case Packing, Accumulation, Inspection, & Palletizing System for Peeps

Aagard delivered a custom-engineered system that integrates accumulation, case packing, inspection, and palletizing into a single coordinated line.

At the core of the system is a merger-accumulator that provides up to six minutes of surge protection. This allows the line to maintain consistent operation and reach a guaranteed efficiency of 98%.

The system also includes:

• Automatic case packing into wraparound cases (18, 24, or 36 packs)
• Orientation inspection and quality control checks with automatic rejects
• Date coding and open flap detection
• Integrated printing before palletizing
• A palletizer capable of handling column stacks up to 100 inches tall

Designed for flexibility, the system supports multiple product configurations and enables fast, user-friendly changeovers—critical for a line with frequent product variation.

In terms of speed, the system operates at 500 products per minute, giving Just Born room to grow beyond current upstream rates.

Results: Reduced Labor, Improved Safety, & Retail-Ready Packaging Output

The move to automation delivered measurable operational improvements across the line:

• Significant labor reduction by eliminating manual case packing
• Improved safety through removal of repetitive, ergonomic-risk tasks
• Material savings from switching to wraparound cases instead of RSCs
• Retail-ready packaging capability for improved shelf presentation
• High system efficiency supported by integrated accumulation and controls
• Scalable throughput with capacity exceeding current production speeds

Beyond performance, the system simplified operations while giving the team flexibility to handle changing product formats without disruption.

As Rob Sweatman puts it, “We are now able to provide retail-ready display cases to our customers.” The team also reduced ergonomic risk, lowered labor costs, and improved overall line safety through automation.

Just Born also noted the partnership itself, stating that “Aagard has been a pleasure to work with from beginning to end. Their organization is highly skilled, professional, and very customer-focused.”