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

Mallard Manufacturing

Name: Mallard Manufacturing
Address: 101 Mallard Road, Sterling, IL, 61081, US
Telephone: (815) 626-7307
Price range: $$

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Mallard Manufacturing

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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.

10/21/2026

Snack packs, bottled beverages, and some seriously tricky packaging. 📦💧

Can they all go with the flow?

We put Cart-Trak with bearing rollers and Dyna-Flo HD through their paces with a food distributor's diverse inventory. Both passed — but what we learned along the way shows why the little details matter!

See what we learned. 👇 https://bit.ly/4sdh33k

10/20/2026

Custom carton flow work cells

Put gravity flow exactly where their team needs it.

🔹 Tilt trays for better product visibility and easier access at the pick face
🔹 Gravity-fed FIFO lanes automatically replenish the pick face
🔹 Mobile construction to reposition the work cell as operational needs change
🔹 Custom carton flow configurations matched to the inventory being handled

For picking, kitting, assembly, or replenishment, mobile carton flow gives you an adaptable work cell built around the way your team works.

Need carton flow somewhere new? Roll it in.

10/16/2026

Tough applications call for a tougher pallet flow wheel.

Mallard Magnum Wheel is built for demanding pallet flow applications—from heavy loads to freezer environments and deep-lane storage.

✓ Loads over 3,000 lbs.
✓ Temperatures down to -40°F
✓ High-density lanes 20+ pallets deep
✓ Lifetime Abuse Warranty

10/14/2026

Big things are happening in Sterling.

Mallard has made a major investment in carton flow manufacturing: a new 40,000 sq. ft. facility, nearly double the space of our previous operation, with robotic assembly at its core.

The new robotic cell builds rails for our full Dyna-Flo, Dyna-Flo HD, and Dyna-Deck lineup, and new in-house machines now produce components we once imported from overseas. For our customers, that means shorter lead times, consistent quality, and more capacity when you need it.

Take a look inside and see the robots in action. 👇
🔗 Read the full story: https://bit.ly/4yIc4Kt

10/13/2026

A lane divider may seem like a small detail—until you’re picking hundreds of orders a day.

Slim-Fit full-length lane dividers are designed to keep carton flow lanes clearly defined and organized while standing up to the demands of busy picking operations.

🔹 Quick to position and re-profile with adjustable slotted brackets
🔹 Securely locked in place to prevent rotation in high-activity environments
🔹 Slim profile helps maximize available shelf space
🔹 Smooth, rounded end pieces help reduce the risk of hand injuries
🔹 Color options support visual organization and picking

The patent-pending design is compatible with Dyna-Flo, Dyna-Flo HD, and Dyna-Deck for both new installations and retrofits.

10/09/2026

Bring the product to the picker—not the picker to the product.

This case-picking setup integrates a hydraulic lift table directly into the pallet flow lane, with the Ergo Cell Separator controlling reserve pallets behind it.

The result? The active pallet can be raised and rotated to give the picker better access throughout the picking cycle.

🔹 Adjust the pallet to a comfortable working height
🔹 Rotate the load for easier access to all sides
🔹 Keep reserve pallets controlled in the flow lane
🔹 Reduce bending, reaching, and twisting during case picking

▶️ See how the integrated system works.

10/07/2026

Empty pallet positions? That wasn’t the plan.

For one operation, floor-level case picking had become enough of a safety concern that hundreds of pallet positions were being left unused.

So, our team tackled the problem from a different angle: bring the pallet to the picker.

The result? The new Pallet Access Cart (PAC)—designed to make floor-level case picking more accessible while putting valuable pallet positions back to work.

See the application that inspired PAC and watch it in action → https://bit.ly/4rTTAUO

10/06/2026

Loading and unloading push-back flow rack correctly is key to keeping pallets—and your operation—flowing smoothly.

Our latest demo walks through proper techniques, including:

🔹 Inspecting pallets and loads before placing in the lane
🔹 Proper pallet positioning and placement
🔹 Controlling rear pallet advancement during unloading
🔹 What to do if a pallet doesn’t advance as expected

A few simple best practices can help protect your system, prevent flow disruptions, and support reliable performance.

▶️ See these best practices in action.

10/02/2026

Today, we celebrate the people who make manufacturing happen.

At Mallard, manufacturing brings together skilled people across our operation—from engineering and problem-solving to the hands-on work of fabricating, assembling, and testing the gravity flow systems we build every day.

Manufacturing Day is a chance to recognize the skill, craftsmanship, and innovation that go into making products here in the U.S.—and to show the next generation the opportunities available in modern manufacturing.

We’re proud of the people behind our products and proud to be part of an industry that keeps America moving forward.

Happy Manufacturing Day!

09/30/2026

More pallets. Same warehouse. Now what? 👀

If you have significant pallet volume for some of your SKUs—and LIFO inventory rotation works for those products—push-back rack could help you make better use of your warehouse cube.

But that's only the beginning.
🔵 How deep can you store?
🔵 What pallet types and sizes will work?
🔵 What if your loads vary?
🔵 Can existing rack be retrofitted?
🔵 What about freezer storage?

Our latest FAQ breaks down the application questions that can help determine whether the push-back rack is the right fit for your inventory.

👉 Get the answers, then put the power of gravity to work in your operation: https://bit.ly/4rOxEu7

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

http://www.mallardmfg.com/

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