Mallard Manufacturing

Mallard Manufacturing Your Gravity Flow Specialists. Results Supplied… Daily

Mallard is, and has always been, family owned. What’s the real Mallard Difference?

Started by Jack Wahl (of Wahl Clipper) in 1960, Mallard is now owned by Mike Gunderson and Kevin Risch. Under their leadership, Mallard has earned a reputation as the market leader in Pallet Flow, Carton Flow and Gravity Flow Conveyor Systems. The answer is simple, reaching well beyond the quality of our products – It’s our team – and solving your material flow problems is our responsibility every

day. Every single project is supported by Mallard’s sales, engineering and design teams who have the most extensive, specialized product expertise in the industry. The result – custom storage solutions to help you optimize space, improve productivity and decrease labor and operational costs, guaranteed! We support an extensive integrator and distributor network throughout the world providing value-added engineering, product testing and sales support from our recently expanded 120,000 square-foot facility in Sterling, Illinois. Our in-house testing lab ensures the performance of your system; load capacities, flow rates, space allocation and rollability. To get more information about us or our services please don't hesitate to visit us at http://www.mallardmfg.com or give us a call at 1-800-243-6694.

05/29/2026

Your case picking team is working hard to keep orders moving. Let’s make the empty pallet handoff safer, cleaner, and easier.

Empty Pallet Return Lanes streamline what happens after the last case is picked. Instead of stacking empty pallets in the pick aisle, they get loaded onto the return lane to flow away from the work area.

EPR Lanes help operations:
✅ Improve pick area efficiency
✅ Reduce pick aisle congestion
✅ Enhance worker safety
✅ Protect empty pallets from damage
✅ Support faster restocking workflows

Pick faster, safer and smarter.

Explore Mallard’s EPR lane design options to optimize your pick zone.

Order picking efficiency starts at the pick face. In this best practices blog, the Mallard team breaks down how to choos...
05/27/2026

Order picking efficiency starts at the pick face.

In this best practices blog, the Mallard team breaks down how to choose between Dyna-Pick and carton flow rack based on SKU velocity, product type, space, and replenishment flow — helping teams pick faster, reduce wasted motion, and use labor resources more efficiently.

https://bit.ly/4o30Yv1

A Memorial Day tradition hidden in plain sight.The flag’s movement from half-staff to full-staff carries a powerful mess...
05/22/2026

A Memorial Day tradition hidden in plain sight.

The flag’s movement from half-staff to full-staff carries a powerful message of remembrance, resolve, and respect.

From all of us at Mallard, we honor and remember.
https://bit.ly/43lHND7

05/20/2026

Need parts storage that can keep up with production changes?

Mobile Carton Flow Work Cells are built for flexible, on-the-move assembly support. Roll them where they’re needed, reconfigure them for SKU or line changes, and keep parts organized with FIFO flow.

Built to help teams:
✅ Support faster assembly change-overs
✅ Keep parts organized and accessible
✅ Adapt to SKU changes
✅ Support good ergonomic positioning
✅ Support JIT production and short-run manufacturing

Move it. Stage it. Flow it.

Explore Mobile Carton Flow Work Cells for flexible parts storage and assembly setup.

05/19/2026

Dyna-Pick turns overlooked rack space into organized, high-density picking power.

Designed for small parts storage and piece picking, Dyna-Pick suspends rugged canvas bins below standard pallet racking to create efficient SKU storage right where teams need it. It helps make better use of space below the first beam level while improving visibility, access, and pick accuracy.

More SKU capacity. Faster picks. Smarter use of space.

Explore how Mallard Dyna-Pick can help streamline high-density warehouse bin storage.

05/15/2026

Manufacturing inventory moves fast. Your storage system should keep up.

Mallard’s Dyna-Flo HD carton flow system helps manufacturers store a wide variety of SKUs — from small parts to finished goods — in organized, easily accessible pick lanes.

Paired with Slim-Fit full-length dividers, Dyna-Flo HD keeps products separated, aligned, and ready for efficient picking. In this tech manufacturer demo, see how a durable carton flow solution can support busy operations without sacrificing organization.

Mallard customizes gravity flow systems around your inventory specs, product mix, and throughput goals.

Let’s build a better flow for your manufacturing operation.

Can one push-back rack design handle a super sack and boxed inventory loads in the same application?Mallard’s Engineerin...
05/13/2026

Can one push-back rack design handle a super sack and boxed inventory loads in the same application?

Mallard’s Engineering Test Lab put a custom 3-rail wheeled push-back flow rack lane to the test for a food processing customer.

The goal: confirm reliable flow and restart for varied pallet profiles in a dense LIFO storage application.

See how the team configured the lane, what the test revealed, and why testing matters when pallet loads vary. https://bit.ly/3PA1u6W

05/12/2026

The next evolution of mixed-SKU pallet building is here.

The patent-pending Ergo Build system pairs robotic layer picking with pallet flow lanes to streamline inventory flow, increase throughput, and support pick accuracy for a wide variety of SKUs.

The layout stays smart and simple: pallet flow lanes flank the pick aisle, moving inventory into position and completed pallets out of the work zone.

The big upgrade? A robotic pick arm doing the heavy lifting.

Take mixed-SKU pallet building to the next level with Ergo Build.

Address

101 Mallard Road
Sterling, IL
61081

Opening Hours

Monday 8am - 5pm
Tuesday 8am - 5pm
Wednesday 8am - 5pm
Thursday 8am - 5pm
Friday 8am - 5pm

Telephone

(815) 626-7307

Website

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