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.

06/19/2026

🤖 Let us give you a hand with your high-volume carton picking.

Designed specifically for automated picking applications, this carton flow rack system features a layback frame that allows robotic arms to reach every shelf level with ease.

Gravity delivers cartons to the pick face. The robot handles the picking. A takeaway conveyor keeps products moving.

Simple, efficient, and built for the demands of modern fulfillment operations.

See how thoughtful gravity flow rack design helps automation perform at its best.

2" centers or 3" centers—which flows better?We recently put two full roller pallet flow rack lanes through a side-by-sid...
06/17/2026

2" centers or 3" centers—which flows better?

We recently put two full roller pallet flow rack lanes through a side-by-side Engineering Test Lab evaluation using identical loads and operating conditions.

The difference in flow speed was smaller than you might expect.

What had the biggest impact? Pallet condition.

Watch the test video and see why broken boards, damaged stringers, and pallet quality can be just as important as roller spacing when designing a gravity flow system.

https://bit.ly/4owOwUJ

06/16/2026

📦 The best flow rack design starts long before installation.

Every inventory profile is different. Pallet style, load weight, SKU characteristics, and storage requirements all influence how your flow rack system should be configured.

That's why testing is such an important part of the process.

Before a design is finalized, the Mallard Engineering Lab can evaluate your inventory and system configuration to help verify performance and identify opportunities for optimization. The goal isn't just to build a rack system. It's to build the right rack system for your operation.

Could you use 4 more inches of vertical space per shelf level?For many carton flow rack systems, those inches add up qui...
06/10/2026

Could you use 4 more inches of vertical space per shelf level?

For many carton flow rack systems, those inches add up quickly—creating opportunities for additional shelf levels, more SKU facings, and greater storage density without expanding the footprint.

Take a look at our recent flow test and see how the right roller design became the secret ingredient for finding additional vertical space while delivering a washdown-friendly, easy-to-use, cost-effective solution for faster order picking.

https://bit.ly/3RYgFrx

06/08/2026

Bring the pick position to the picker.

Mallard’s pallet flow + lift table integration helps reduce bending, reaching, and twisting by keeping product moving smoothly into an ergonomic pick position.

With Ergo Cell separators controlling the flow, operators can raise, rotate, and pick more efficiently—with less strain and fewer interruptions.

06/05/2026

Would a little separation bring your picking operation together? 📦

Slim-Fit full-length dividers help create clean, designated SKU lanes between cartons and totes — making it easier to organize inventory, maximize shelf space, and support accurate picking.

Already have carton flow tracks in place? No problem.

Our custom Slim-Fit divider brackets are designed for easy retrofit installation into existing carton flow systems, helping you upgrade organization without a full system overhaul.

Watch the video to see how quickly these brackets install and how simple it can be to improve flow lane separation in your operation.

Layer picking in cold storage demands precision, safety, and speed. Mallard’s LP Separator is the key to unlocking effic...
06/03/2026

Layer picking in cold storage demands precision, safety, and speed.

Mallard’s LP Separator is the key to unlocking efficient, high-volume picking from pallet flow lanes—replacing floor stacking with SKU-segmented, automatically replenished storage.

🎥 See the test in action + read the blog ➡️ https://bit.ly/4x6Tmvy

06/02/2026

Outside temperatures may be rising… but Magnum Wheel pallet flow stays cool under pressure. ❄️

Built for heavy-duty pallet flow applications, Magnum Wheel delivers smooth, reliable flow performance — even in demanding cold storage and freezer environments where consistency matters most.

From high-capacity loads to tough operating conditions, this system is engineered to keep products moving efficiently while helping maximize warehouse throughput and storage density.

When the pressure’s on, trust gravity flow solutions designed to perform.

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

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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