Challenge

Hardy Buoys Smoked Fish, a Canadian smoked fish producer supplying major grocery chains, faced significant operational challenges as demand for its products grew. Prior to automation, the company relied on a largely manual packaging process that required a large workforce making it difficult to scale output. Compounding this, the facility experienced persistent labor shortages, especially on the plant floor, and struggled to recruit workers despite high unemployment rates. As demand increased, Hardy Buoys was forced to reduce some orders, limiting its ability to expand customer relationships and meet market needs.

Solution

To address these hurdles, Hardy Buoys partnered with PLAN IT Packaging Systems to introduce automation into its packaging line. The core of the solution was an automated bagging line featuring:

• Semi-Automatic Multi-Head Scale: This replaced much of the manual weighing previously done by hand, improving consistency and throughput.
• RotoBagger System: A pre-made pouch bagging machine with multi-head weighing, a platform, and a sanitary washdown inclined conveyor to automate the transition from fill to bagging.

By selecting a system capable of handling far more volume than existing production able to support up to 10,000 packages per day, Hardy Buoys positioned itself for both current and future growth.

Implementation

The implementation involved installation of the RotoBagger line and training for plant operators. Although the COVID-19 pandemic delayed the initial setup by a few weeks, the line was successfully integrated into operations with support from Plan It Packaging’s technicians. Operators received two phases of training primary equipment familiarization and formal set-up procedures, enabling them to quickly operate and maintain the new system. Minor challenges such as incorrect bag sizing were resolved with Plan It’s responsive service and adjustments.

Results

The transition to automated packaging delivered measurable benefits:

• Reduced Labor Costs: The automated line cut labor requirements from 14 people to just six for the same output level, saving approximately $3,500 per week in labor expenses.
• Increased Capacity: The equipment’s high capacity allowed Hardy Buoys to target up to 10,000 packages per day, helping eliminate previous bottlenecks and support business growth.
• Improved Scalability: Customers reacted positively to the expanded capability, with co-packing clients increasingly willing to partner with Hardy Buoys due to its enhanced production capability.
• Operational Flexibility: The line enabled the company to maintain inventory and meet peak demands, such as around the holiday season far more efficiently than before.

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Royal Food Products, a third-generation family business based in Edmonton, has grown into one of Canada’s leading manufacturers of frozen savory pastries, producing more than three million kilograms annually. With demand for their signature sausage rolls continuing to rise, the company faced increasing pressure to boost throughput without sacrificing product quality or profitability. Their existing manual packaging process was labor-intensive and created bottlenecks that limited growth.

Solution

To support their expansion goals, Royal Food Products partnered with PLAN IT Packaging Systems to automate and modernize their packaging operations. The solution included a MarsCompak vertical form-fill-seal (VFFS) line paired with an integrated ELITEWEIGH™ multihead scale.

Key elements of the solution included:

• High-Speed, Accurate Weighing: The ELITEWEIGH™ multihead scale delivered consistent, accurate weights to improve finished product quality and reduce giveaway.
• Automated VFFS Packaging: The MarsCompak VFFS system replaced a manual process, significantly increasing throughput while reducing labor requirements.
• Scalable Automation: The turnkey system was designed to support current demand while allowing room for future growth.

“The equipment we recently purchased has significantly increased our throughput and is helping us maintain our profit margins. It also allows us to reinvest in our employees and future equipment.” - Paul Meyer, President, Royal Food Products

Implementation

PLAN IT Packaging worked closely with Royal Food Products to ensure a smooth startup and seamless integration into their existing production environment. The PLAN IT team provided hands-on training and responsive ongoing support, enabling operators to quickly adopt the new system and maximize performance from day one.

“PLAN IT has been excellent to work with from start to finish. They have a responsive support network, and I’d be happy to work with them again.”- Paul Meyer

Results

Since commissioning the new automated packaging line, Royal Food Products has seen immediate and measurable improvements:

• Increased Productivity: A 24% productivity increase on day one, with output gains ranging from 56–80% depending on the product.
• Improved Accuracy & Reduced Waste: Better finished weights, more accurate counts, and less product waste.
• Lower Labor Requirements: Automation simplified operations and reduced the need for manual handling.
• Higher Throughput: Removal of packaging bottlenecks unlocked new capacity to support continued growth.

“It’s surpassed our expectations—an amazing asset.” - Paul Meyer

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This partnership helped Royal Food Products improve efficiency, protect quality, and position their operation for long-term, scalable growth—demonstrating the real-world impact of smart automation.

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Ready to elevate your packaging line? Connect with our team today for a free consultation and discover how smart automation can transform your operation.

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How The Carnivore Bar tripled its output and eliminated costly downtime with PLAN IT Packaging and FORT Capital

The Challenge: Premium Product, Primitive Packaging

The Carnivore Bar, a company that makes shelf-stable, all-meat nutrition bars for outdoor adventurers and zero-carb purists, faced a packaging dilemma. The product needed airtight, high-integrity sealing—but the company’s initial equipment ultimately fell short of Carnivore’s high standards. After investing in a low-cost, imported flow wrapper, the team found themselves constantly troubleshooting breakdowns, wasting product, and manually sealing every bar by hand. “It was fine for launching, but it capped us. We couldn’t grow with it,” shared Carnivore founder Phillip Meese.

The Turning Point: Choosing Quality Over Quick Fixes

After two years of production delays, equipment band-aids, and escalating waste, Phillip knew it was time to scale—properly. “We needed a real machine. A professional-grade solution that would work every single day,” he said.
But premium packaging machinery comes with a premium price tag, and Carnivore wasn’t ready for the cash flow hit. That’s when Phillip met the PLAN IT Packaging team—and through them, discovered FORT.

The Solution: Precision Meets Possibility

PLAN IT Packaging recommended a top-tier horizontal flow wrapper built for consistent performance and rugged durability. And FORT Capital stepped in to make it all attainable.
Rather than applying for traditional financing and enduring a drawn-out process with unclear outcomes, FORT pre-approved Carnivore Bar quickly, structured flexible payments, and got the deal done without red tape.
“FORT felt more like a partner than a lender,” said Phillip. “They understood our cash flow, our business stage, and they made it incredibly easy to say yes.”

The Results: 3X Output, Zero Downtime

With professional-grade packaging in place and financing that fit the business, The Carnivore Bar flipped the script. Production scaled, and wasted product vanished. Freed from the constant distractions of faulty machinery, Phillip’s team finally had the focus to drive real growth. 

“Our old setup capped our growth. PLAN IT and FORT uncapped it,” Phillip said. “Now we can say yes to big orders, knowing we can deliver.”

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About Carnivore Bar
Carnivore Bar is on a mission to provide clean, shelf-stable nutrition for people who need it most—soldiers, adventurers, and everyday carnivores seeking real food without compromise. Designed for extreme durability and nutrient density, each bar is made with only meat, fat, and salt—no preservatives, no fillers. In a world where emergency rations often mean processed junk, Carnivore Bar exists to offer a better option: food that’s portable, unprocessed, and built to sustain. Learn more at carnivorebar.com.

About WG Pro

A Legacy of Innovation and Growth

WG Pro’s journey began with managing reclaimed and returned products for a major pharmaceutical company. Over the years, the company has evolved into a powerhouse in the co-packing industry, offering a comprehensive range of services, including ambient, frozen, and refrigerated product packaging. Their commitment to innovation and quality has earned them the trust of high-profile clients like PepsiCo, Laura Secord, Nestlé, and Kellogg’s.

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“We’ve always focused on providing a controlled environment where we can handle packaging for our clients,” says Wirtz. “This approach has allowed us to alleviate congestion in their spaces and offer streamlined services.”

Challenge

Meeting Challenges with Automation

In the second year of the COVID-19 pandemic, businesses across various industries struggled to maintain efficient operations, and WG Pro was no exception. Labor shortages became a critical challenge for the company, severely impacting production rates and overall efficiency. These shortages and increased demand for packaged goods created a bottleneck that traditional manual labor systems could not handle effectively.

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To address these challenges, WG Pro turned to PLAN IT Packaging Systems for an automated solution that could offset the labor gap and streamline its operations. PLAN IT Packaging Systems, known for its innovative automated packaging machinery, provided a tailored system incorporating advanced robotics and automation. This allowed WG Pro to increase production capacity without relying heavily on manual labor, reducing operational downtime and increasing throughput.

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The automated solutions from PLAN IT, such as their vertical form-fill-seal (VFFS) machines and robotic case packers, not only ensured consistency in packaging but also allowed for rapid scaling of operations to meet the growing demand. By integrating these automated systems, WG Pro was able to maintain business continuity, improve efficiency, and reduce the risks posed by future labor shortages. The collaboration also reinforced the importance of automation in creating resilient supply chains, especially during unprecedented global disruptions like the pandemic.

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“I’ve known Mark Evangelista, PLAN IT’s Director of Sales, for many years, so when we faced labor challenges, I knew PLAN IT’s automated solutions could be the key to our continued growth,” Wirtz recalls. “The flexibility and efficiency of their equipment, particularly the portable bagger, were exactly what we needed.”

Solutions

WG Pro faced significant operational challenges due to labor shortages and increased demand for packaged goods. To address these issues, WG Pro turned to PLAN IT Packaging Systems for a reliable solution. Our Mars Vertical Form Fill and Seal (VFFS) machine played a crucial role in combating these challenges by automating the packaging process, reducing dependency on manual labor, and enhancing production efficiency.

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The Mars VFFS machine allowed WG Pro to maintain consistent output, improve production speed, and meet rising customer demands, all while minimizing downtime and ensuring business continuity. This partnership not only helped WG Pro overcome immediate obstacles but also positioned them for future operational resilience.

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The Mars ComPak allows us to produce approximately 40 bags per minute, a task that would have required about 24 to 25 personnel to accomplish manually

Karl Wirtz, WG Pro Manufacturing

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Implementation

WG Pro’s facilities are now equipped with cutting-edge machinery from PLAN IT Packaging, including the Mars ComPak vertical form/fill/seal (VFFS) bagging machine. This advanced system has transformed WG Pro’s operations by delivering high-speed, precise packaging with minimal manual involvement.

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“The Mars ComPak allows us to produce around 40 bags per minute—a task that would have previously required 24 to 25 employees,” says Wirtz. “This machine has significantly boosted our efficiency and flexibility, making it easy to handle a variety of products.”

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The Mars ComPak is also integrated with automated weighing systems, ensuring accurate measurements and full compliance with weight regulations, which is crucial for maintaining consistent package weights and minimizing product waste. Along with PLAN IT’s complete range of automated packaging equipment—including filling, sealing, and labeling systems—WG Pro has streamlined its processes, reduced labor costs, and enhanced overall operational efficiency.

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Challenge

Mom’s Best Cookies, like many cookie processors, struggled with handling damage during the packaging process. This issue not only affected the appearance and integrity of their products but also led to increased waste and operational costs. To maintain their commitment to delivering high-quality cookies to their customers, it was crucial for Mom’s Best to find a solution that would minimize damage while streamlining their packaging operations.

Solution

PLAN IT Packaging stepped in to address these challenges with their state-of-the-art ELITEWEIGH™ weigher and ROTOBAGGER™ bagging system. The solution included:

Advanced Weighing Technology: The ELITEWEIGH™ weigher offered precise, high-speed weighing that ensured consistent product weight, reducing the likelihood of over or under-filled packages.

Gentle Handling Mechanisms: To minimize damage, the ROTOBAGGER™ bagging system featured gentle handling mechanisms that carefully transported cookies from the production line to the packaging stage.

Automated Bagging: The ROTOBAGGER™ system streamlined the process, significantly reducing the need for manual handling and the associated risks of product damage.

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“We’ve slashed labour costs with this turnkey scales/bagging line”

Robert Cappola, President of Mom’s Best Gourmet Foods

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Implementation

The implementation process was smooth and efficient. PLAN IT Packaging worked closely with the team at Mom’s Best Cookies to customize the solution to their specific needs. This collaborative approach ensured that the new system seamlessly integrated with their existing production line, minimizing downtime and disruption.

Results

The results of deploying the new scales and bagging line were impressive:

• Reduced Handling Damage: The gentle handling mechanisms and precise weighing technology significantly reduced the occurrence of damaged cookies.
• Improved Efficiency: Automation streamlined the packaging process, resulting in a 20% increase in production speed and a 15% reduction in labor costs.
• Enhanced Product Quality: With less damage, Mom’s Best Cookies were able to maintain their high standards of quality, leading to increased customer satisfaction.
• Increased Throughput: The new system allowed Mom’s Best Cookies to process up to 60 bags per minute, doubling their previous output.