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Robotic deli sandwich assembly and packing line

Deli-counter quality,
at production-line pace.

A complete, JLS-integrated deli sandwich assembly line. Automatic slicing and vision-guided IP69K-capable delta robots place sliced deli meats, cheese, and toppings onto bread, rolls, or wraps — building a consistent sandwich every cycle. JLS integrates slicing, component in-feeds, robotic assembly, packaging, inline inspection, and case packing into one line.
Talk to a line integration specialist See what's in the line
Layer by Layer
Vision-guided stacking
Hot & Fresh
Consistent builds every cycle
IP69K-capable
Delta robots — washdown-rated
8 Robots
On one proven line
Multiple PatentsAll in Food Packaging Automation
In-House ProgrammingControls, Vision & Robotics Expertise
Factory-Tested ReliabilityBacked by JLS Service & Support
World-Class ServiceDedicated Installation, Startup & Support
24–26 Week Delivery WindowFor Standardized Platforms

The JLS Deli Sandwich Assembly Line is an integrated robotic line that assembles, wraps, and case-packs deli sandwiches. Automatic slicing and vision-guided IP69K-capable delta robots place sliced meats, cheese, and toppings onto bread, rolls, or wraps in sequence — building a consistent sandwich every cycle. JLS integrates the full line: component in-feeds, robotic assembly, packaging, inline inspection, and case packing — designed, programmed, and FAT-tested in-house.

In action

See the JLS deli sandwich line run

JLS Talon — vision-guided pick & place JLS Talon

JLS Talon — vision-guided pick & place

See JLS vision-guided delta robots locate, pick, and place food product at full production speed — the robotics behind the sandwich line.

Why the JLS deli sandwich line

Building deli sandwiches by hand is a labor problem waiting to scale you out.

Manual sandwich assembly is repetitive, labor-intensive work that is hard to staff and hard to keep consistent at volume — and direct hand contact with sliced meats and cheese raises food-safety concerns. At higher output, every layer depends on an operator, and the consistency and throughput both suffer.

Components in. Consistent sandwich out. The JLS integrated line is configured around your recipe, components, and facility — so one of the most repetitive jobs in prepared foods becomes one of the most predictable.

Applications & package types

The sandwich line — pick, stack, pack

JLS builds the complete deli sandwich assembly line and takes full system responsibility. Automatic slicing and vision-guided IP69K-capable delta robots place sliced deli meats, cheese, and toppings in sequence, building a consistent sandwich every cycle. JLS integrates the full line: automatic slicing, coordinated component in-feeds, vision-guided robotic assembly, thermoform or flow-wrap packaging, inline inspection, and robotic case packing — FAT-tested in York, PA.

Products handled

Sub & Hoagie RollsDeli classic
Sliced BreadStacked sandwiches
Ciabatta & ArtisanPremium
Wraps & FlatbreadsRolled formats
Other PreparedTalk to our engineers

What's in the line

Automatic SlicingMeats & cheese, portioned
Component In-FeedsBread, meats, cheese, toppings
Custom End-of-Arm ToolingConfigured per component
IP69K-Capable Delta Robots + VisionSanitary, washdown-rated
Thermoform / Flow WrapSealed for shelf life
Inspection + Case PackingCheckweigh, x-ray, case pack

The Challenge

The gap most food lines share — and the system built to close it.

✕The Problem

Manual handling at this station is hard to staff — and harder to keep consistent

The same repetitive work, every shift — capping throughput and adding food-safety risk.

The repetitive manual work at this step is increasingly difficult to staff, and consistency slips across shifts. When people fall behind, the line slows, rework climbs, and hand contact adds a food-safety exposure. Add high annual turnover, rising ergonomic claims, and a shrinking labor pool, and the cost of doing it by hand keeps climbing.

Chronic
Turnover in manual packing roles
24–36 mo
Typical full-payback window
Line rate
Throughput manual handling can't sustain
✓The Solution

Engineered robotic automation configured to your exact product

JLS engineers, tests, and installs the system — proven before it ships.

JLS designs the system around your product, package, and line — robots, tooling, vision, and controls engineered and programmed in-house. We prove it on your actual product in our York, PA Flight Lab before final design, so the line runs at rate, holds consistent placement every cycle, and stands up to daily washdown.

24–36 mo
Typical ROI timeline
Minutes
Recipe-driven changeover
In-house
Controls & software, by JLS

Test before you commit

See your product run on a JLS line
before you commit.

Send us your product. We'll run it in our York, PA lab — picked, stacked, and packed on real JLS robotics with tooling configured for each component — and prove out the line before any capital commitment.

Live
Robotic test with real product
U.S. Built
U.S. built automation
No
Commitment required
Test your product in the Flight Lab

Core technology

The engineering behind the line

Every part of the sandwich line was designed, built, and programmed under one roof — from custom end-of-arm tooling to IP69K-capable vision-guided delta robots to component in-feeds, flow wrapping, inspection, case packing, and a single control platform. Backed by multiple patents and a proven track record assembling food products at production speed.

IP69K-capable · Hygienic design

Designed to get wet — IP69K-capable washdown

Open-frame design, sloped surfaces, and NEMA 4X controls rated to IP69K-capable levels for the high-pressure, high-temperature washdown of a hot prepared-foods environment. The delta robots and tooling are built for the food zone from day one.1

IP69K-capable Minimal harborage NEMA 4X
Locate · Pick · Load

Vision-guided delta robotics

Vision identifies the exact position and orientation of each component as it arrives, so IP69K-capable delta robots pick and stack it precisely — bread, sliced meats, cheese, then toppings — with no fixed guides. Repeatable, vision-controlled placement builds a consistent sandwich every cycle.

Vision-guided Gentle handling High-payload delta
Per-component · Food-safe

Custom end-of-arm tooling

Each component — bread or rolls, floppy sliced meats, cheese, toppings — needs a different touch. JLS designs and lab-tests custom end-of-arm tooling for every component so robots handle even tacky, draping slices gently and reliably at speed. Tooling is food-safe and built for washdown, configured to your exact recipe.

Per-component Lab-tested Food-safe
On-the-fly · HMI-driven

On-the-fly changeover

Switch sandwich recipes and formats from the HMI. Recipes drive the robots, component in-feeds, and packaging so different SKUs run with minimal mechanical adjustment — keeping a fast-moving prepared-foods line productive across its product mix.

Seconds on HMI Back-to-back SKUs
One integrated line

Full-system integration

JLS integrates the whole line — coordinated component in-feeds, vision-guided robotic assembly, flow wrapping, inline checkweighing, x-ray and metal detection, and robotic case packing — as one system with single-source accountability. The complete line is proven with a full-system factory acceptance test (FAT) before it ships.

In-feed → case pack Full-system FAT
Designed & programmed in-house

Single control platform & in-house software

One B&R platform runs the component in-feeds, robots, wrapping, and inspection from a single HMI — no patchwork of separate control systems. Software is written and owned entirely by JLS, so new recipes and remote support come directly from the team that built your line.

No 3rd-party software ERP/MES ready

Options & add-ons

More ways to fit your line.

Multi-component builds & formats

The robots build the full stack — bread, sliced meats, cheese, and toppings — in the sequence and count your recipe calls for, from a simple two-layer build to a fully loaded sandwich. Vision keeps every layer aligned, sandwich after sandwich.

Components and sequence are part of the recipe — switching is an HMI change, with no mechanical re-tooling.

Full stack
Bread, meats,
cheese & toppings
Any recipe
Sequence &
count to spec
HMI-driven
Recipes change
on the HMI
Coordinated component in-feeds
JLS coordinates separate in-feeds for each component — bread, sliced meats, cheese, toppings — presenting them to the robots in registration so assembly runs as one system.
Integrated sanitary infeed
JLS coordinates sanitary infeed conveyors that present product cleanly and consistently to the robots — the steady, even supply vision-guided picking depends on.
Additional assembly robots
For higher production rates, add assembly robots to increase throughput — the platform and single B&R control architecture scale without re-engineering the line.
Configure your system
Need something specific?
Every JLS sandwich line is configured to your recipe, components, and facility. Talk to a JLS application engineer about your exact requirements.
Talk to an engineer →

Talk to a JLS application specialist

See exactly how an integrated JLS line fits your operation.

Our application specialists know food production — not just robots. Share your product, your line layout, and your throughput targets. JLS takes full system responsibility — concept, design, integration, full-system FAT, install, and training — and our PMP-certified project team runs it start to finish.

Precision in motion

How the JLS sandwich line assembles, wraps, and packs

Five integrated steps. Components in, wrapped and inspected sandwich out — built layer by layer.

Step 1: sliced components arrive on in-feed conveyors
1

Components arrive on coordinated in-feed conveyors

In-feed
›
Step 2: vision locates each component
2

Vision locates each component’s position & orientation

Locate
›
Step 3: tool stacks each layer
3

Delta robots pick and stack each layer in sequence

Stack · Vision-guided
›
Step 4: sandwich packaged and sealed
4

Finished sandwich is placed and flow-wrapped or thermoformed

Wrap
›
Step 5: sandwich inspected and case-packed
5

Wrapped sandwich is inspected and case-packed

Inspect · Pack

Vision-guided delta robots stack each component with custom tooling for a consistent, repeatable build, while JLS-built vision software and a single B&R control platform run the whole integrated line — pick, stack, wrap, inspect, and case-pack — configured to your recipe.

JLS + Reiser: Expertise across the line

Ready to spec your deli sandwich line?

JLS and Reiser help deliver complete integrated lines — from slicing and in-feed through robotic stacking, wrapping, inspection, and case packing — engineered and FAT-tested as one coordinated solution.

Full food production line — JLS + Reiser: expertise across the line Ten production-line stages across four zones. JLS-built robotic automation stages are shown in purple; stages available through Reiser's OEM portfolio in blue; customer-selected or partner equipment in gray. Dashed lines mark coordinated integration points. Prepare. Portion. Form. Load. Seal. Case. Carton. Collate. Stack. Secure. 01Mixing &blendingGrindingEmulsifyingMarinatingTumblingAvailable throughReiser portfolio 02Forming &portioningStuffingExtrudingPatty formingDepositingAvailable throughReiser portfolio 03FurtherprocessingSlicingDicingShreddingTenderizingAvailable throughReiser portfolio 04PrimaryloadingPick & placeVision-guidedLane loadingProduct collationJLS TALON®JLS KESTREL™JLS Automation 05PrimarypackagingThermoformingTray sealingVacuum / MAPSkin packAvailable throughReiser portfolio 06CasepackingRobotic case loadingRobotic loadingWashdown configurationsHygienic optionsJLS OSPREY®HAWK™ · PATTY HAWK™Case erecting & sealing via partner equip.JLS Automation 07CartoningForm, load,close cartonsCompact footprintWashdown-capable designJLS PEREGRINE® ISPEREGRINE ISJLS Automation 08Collation /bundlingCount & stackBundle packMultipackPartner equipmentscope-dependent 09PalletizingLayer buildingRobotic palletizingSlip-sheet placeLayer padPartner equipmentscope-dependent 10LoadsecurementStretch wrapBandingCorner boardTop sheetPartner equipmentscope-dependent Tier 1 Primary Packaging The package that touches the product Tier 2 Secondary Packaging Cases, cartons, and multipacks for retail or distribution Tier 3 Tertiary Packaging Stretch wrap, ship-ready unit

Together, JLS and Reiser help food manufacturers develop coordinated processing and packaging lines—from product preparation and primary package loading and sealing through cartoning, case packing and load securement.

Illustrative line architecture. Stages, equipment suppliers and sequence vary by product and project scope. Not every food line uses every stage, and slicing, cooking, freezing, inspection and other processes may occur in different positions.

Scroll left and right to scan the full line. Open the printable line map →

JLS-built robotic automation Available through Reiser’s OEM portfolio Customer-selected / third-party equipment Coordinated integration point

Reiser role across the line

Food-processing expertise, application development, equipment selection, product testing, and sales & lifecycle support.

JLS role at robotic packaging stages

Robotic engineering, product & package handling, controls interfaces, and integration & FAT when included in project scope.

Let’s talk more about planning your full line.

Tell us who you are and a bit about your line. An automation expert will reach out — and we’ll bring the right people from JLS and Reiser to the conversation.

Your details
Facility location
Your line today
What you're planning
What solution(s) are you interested in?* Select all that apply.
Project timeline

By submitting, you agree that JLS Automation and Robert Reiser & Co. may contact you about your inquiry.

The automation process is smooth, precise, and highly consistent, allowing our packaging lines to maintain production targets with greater reliability and less downtime.
Carlos O'Neill, Plant Manager Family Food Products · JLS Kestrel Collate & Load

Line configuration

Deli sandwich assembly line — what goes into it

Every deli sandwich line is configured to the product, the facility, and the target rate. The table below shows the typical components JLS and integration partners (Reiser) bring together. Contact JLS to scope yours.

Line station Typical equipment / capability
Slicing & in-feed Automatic slicing of meat, cheese, and toppings; gravity or conveyor in-feed to assembly zone
Component singulation Centrifugal feeders or indexing belts to present components in orientation for pick
Vision-guided stacking IP69K-capable delta robots with 2D/3D vision locate and place each layer — meat, cheese, condiment, topping — onto bread or roll
Robot type 4-axis delta robots, IP69K-capable (washdown-rated); typically 6–8 robots per line
End-of-arm tooling Custom EOAT per product; vacuum or mechanical; tool-less swap for changeover
Primary packaging Flow wrap (horizontal or vertical) or thermoform; integrated inline with robotic assembly
Inspection Checkweigher, metal detection, or vision inspection — inline before case packing
Case packing Automated case erecting (upstream), loading, and sealing — Hawk 2-axis robot arm or delta-based case packer
Controls B&R Automation; single HMI across all stations; recipe-driven changeover
Sanitation level IP69K-capable delta robots; construction level configured per facility (cleanable or full washdown)
FAT & commissioning Full-line FAT in York, PA with customer product before shipment
Integration partner JLS Automation + Reiser (primary partner); line-specific scope confirmed at assessment

Application Example · JLS Deli Sandwich Assembly Line

Sliced, stacked, sealed — consistent deli sandwiches at scale.

A US sandwich manufacturer needed to automate multi-component assembly of deli sandwiches. Manual stacking of sliced meats, cheese, and toppings onto rolls was slow, inconsistent, and difficult to staff across multiple shifts. Hand contact at the assembly step raised food safety concerns, and throughput targets were hard to hit reliably.

JLS engineered and integrated a complete assembly line: automatic slicing, component in-feeds, and a team of IP69K-capable vision-guided delta robots that locate, pick, and precisely place each layer — meat, cheese, condiment — onto bread moving along the conveyor. The assembled sandwiches feed directly into flow wrap packaging, inline inspection, and case packing as one coordinated system. The full line was FAT-tested in York, PA on the customer’s actual product before shipment.

We went from four people on that station to one person monitoring three lines. The math is easy.

— Plant Manager, Regional Sausage & Deli Processor

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Questions about this application? Talk to an expert →

FAQ

Questions our engineers get asked most

Robotic assembly, vision systems, IP69K, throughput, integration, and ROI — answered by JLS application engineers.

Yes. Vision-guided delta robots locate each ingredient — sliced meat, cheese, condiment, topping — on a moving conveyor and place it precisely onto the bread or roll beneath. The system repeats this at full production speed, every cycle, with no variation between sandwiches. JLS runs this process on your actual product in the Flight Lab before the system ships.

A typical JLS deli sandwich assembly line uses 6 to 8 robots — one or more per ingredient layer depending on the number of components and the target rate. The exact configuration depends on how many ingredients are in the build, how fast they need to be assembled, and the footprint available. JLS scopes the right robot count for your product and line during a line assessment.

The line handles sliced meats (turkey, ham, salami, roast beef), sliced or portioned cheese, lettuce, tomato, condiments, and toppings — applied layer by layer. Custom end-of-arm tooling is engineered to the exact geometry, weight, and surface of each ingredient. Products that are challenging to handle individually (soft, irregular, or fragile) are confirmed in the Flight Lab before tooling is finalized.

The line works with sub and hoagie rolls, sliced sandwich bread, ciabatta and artisan rolls, wraps, and flatbreads. The conveyor and in-feed system is configured to your specific bread format and pitch. Changeover between bread types is recipe-driven from the HMI, with tool-less EOAT swaps where needed.

The delta robots on the line are IP69K-capable — they are washdown-rated to withstand high-pressure, high-temperature cleaning. The overall sanitation level of the line is configured per application and facility requirements. Contact JLS for the construction level that matches your washdown protocol.

Operators select the new recipe on the HMI and swap end-of-arm tooling by hand — tool-less, no wrenches required. Vision parameters update automatically with the recipe. For bread format or ingredient changes, changeover is designed to take under 10 minutes. JLS designs changeover into the line architecture from the start, not as an afterthought.

JLS Automation integrates the complete line, typically in partnership with Reiser for slicing and preparation equipment. JLS is the single point of contact for controls integration, FAT, commissioning, and ongoing service. You deal with one team, not multiple vendors pointing at each other when something needs attention.

To scope the line, JLS typically reviews your product type and build (ingredients, bread format), photos or video of the current process, target throughput, SKU count and changeover frequency, facility sanitation requirements, available floor space, and your main production challenge. A brief call or product video gets the conversation started — contact JLS at jlsautomation.com/contact.

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What can we help with? Optional — select any that apply.

By submitting, you agree that JLS Automation and Robert Reiser & Co. may contact you about your inquiry.

* The line’s IP69K delta robots are washdown-rated; sanitation levels are configured per application. Contact your JLS representative for full details on your line.

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