In episode 28 of The Downtime, WTWH Media’s weekly manufacturing podcast, co-hosts Sarah Wynn and Sheri Kasprzak talk with Jordan Stroud, inside sales at Fallas Automation. The trio discussed the company’s machinery, including case packers, erectors, and sealers for confectionery products, and how the business aims to use digital tools to make its equipment smarter and more operator-friendly.
Case packing company with a sweet spot in candy
Fallas Automation was founded in 1979 and specializes in machinery for case erecting, packing, and sealing with a focus on loose-filled bags, including candy, sauces, rice, and beans.
“We pack about three-quarters of what you see in the Halloween candy aisle,” said Stroud.
While Halloween is a big season for its customers, the company supports confectionery manufacturers year-round. “It’s the big event that everyone’s been working towards, but there’s also no off-season. By the time we get to Halloween, they’re already packaging Valentine’s Day candy and working on Easter,” said Stroud. “We stay busy year-round.”
Engineering-focused machinery with easy changeovers
Working alongside engineers, OEMs, and system integrators, Fallas Automation’s machinery includes programmable logic controllers (PLCs) and features tool-less changeovers. “We know that manufacturers need to stay flexible for what their customers are requesting. So, we keep our changeover process very simple,” said Stroud.
This includes machines like the Adabot-LV, a robotic case packer that can handle both lay-flat and stand-up pouches. Only the pick head needs replacement during changeovers. Stroud also highlighted the G400 gravity drop case packer, which features Bombay doors and a bull nose conveyor, making it ideal for frozen foods.
The company is exploring ways to make its equipment easier for operators to use and manage. “We’re trying to integrate AI to perform diagnostics on the machine, and then just smarter recovery of our machines able to clear a jam on its own, so operators can be used for a higher value task,” Stroud said.
At Pack Expo Las Vegas, Fallas Automation also demonstrated a new human-machine interface (HMI) for its Adabot LV, designed to be simple and intuitive for operators.
Packaging trends: Smaller footprints, optimized tasks, smarter machines
Looking ahead, Stroud sees packaging machinery evolving toward compact footprints and optimized operator tasks. She emphasized the value of incremental improvements.
“If we can make machines 5% more self-sufficient, that’s 5% more time you can spend on really critical operations,” she said, showing how small enhancements can free operators to focus on higher-value work.
Listen to the full episode to hear more about Fallas Automation’s candy packaging innovations and insights on the future of case packing technology.
Episode 28: Downtime of the Dead | Show notes & time stamps
00:17 – The co-hosts start the show by revealing their Halloween costumes
02:57 – Wynn discusses PAC Machinery’s autobaggers with integrated robotics from Pack Expo Las Vegas
03:51 – Kasprzak encourages listeners to subscribe to Plant Engineering’s newsletters
04:40 – The co-hosts introduce this week’s interview segment with Jordan Stroud, inside sales at Fallas Automation. Stroud joins the show for a discussion on packing Halloween candy
05:18 – Interview with Stroud begins
05:35 – Stroud introduces herself and shares the history of Fallas Automation
06:45 – The trio discusses bag handling, including loose-filled bags of candy, beans, and sauce. Stroud says Fallas Automation packs about 75% of the candy seen in the Halloween aisles at stores
08:18 – Stroud explains the challenges of handling different bag and candy formats, such as flexible packaging
09:40 – Stroud shares insight on tool-less changeovers and maintenance
10:55 – The co-hosts and Stroud discuss programmable logic controllers (PLCs) used on Fallas Automation’s machines, including case sealers and case erectors
11:22 – Stroud talks about collaboration with engineers and system integrators
12:06 – Stroud discusses upcoming technologies at Fallas Automation, including human-machine interfaces and artificial intelligence (AI) integration
13:10 – Stroud highlights Fallas Automation’s C400 gravity drop case packer
15:39 – Stroud shares the trends she is seeing in packaging and how Fallas Automation approaches working with customers
17:30 – Interview with Stroud ends, and the co-hosts thank her for joining the show
17:55 – Kasprzak urges listeners to follow The Downtime on LinkedIn and Instagram
18:38 – Start of “Goosebumps” game segment with manufacturing-themed horror stories
22:53 – The dynamic duo discusses plans for a zombie apocalypse and how to podcast during the event
24:09 – The co-hosts wrap the episode by showing their Halloween costumes
About The Downtime podcast and co-hosts
The Downtime is a weekly manufacturing podcast from WTWH Media that features insights from its automation and controls publications. It’s co-hosted by Wynn, who serves as the senior editor (digital) for Packaging OEM, and Kasprzak, who is the executive editor for Plant Engineering, Control Engineering, and Consulting-Specifying Engineer.
Check out The Downtime’s recent episodes
Episode 23: Hoosier Feeder’s centrifugal system for coffee pods
Episode 24: Leadership lessons from an engineer in sustainable design
Episode 25: Inside WTWH Media’s “Can’t Stop, Won’t Stop” B2B content strategy
Episode 26: Unpacking Pack Expo, a journalist’s perspective
Episode 27: Conveying Halloween candy and material handling trends with Flex-Line Automation
