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High-speed frozen patty case packing

More than 1,000 patties a minute,
straight off the frozen line.

The Patty Hawk clears IQF patty stacks off the discharge as fast as your line makes them — running at more than 1,000 patties per minute. Laser-guided, non-camera delta robotics and mechanically actuated grippers keep it reliable at -10°F, with an IP69K full-system washdown rating.
See the Patty Hawk run your product View specs
1,000+/min
Patties per minute
-10°F
Freezer-rated operating temp
IP69K
Full-system washdown rating
Laser-guided
Non-camera detection
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
JLS Patty Hawk watercolor bird illustration

The JLS Patty Hawk is a high-speed case packer for round frozen IQF patties, running at more than 1,000 patties per minute. A laser-guided, non-camera delta robot with mechanically actuated grippers stacks and packs beef, poultry, pork, and plant-based patties in environments down to -10°F. IP69K full-system washdown rating. Engineered, built, and programmed entirely in-house by JLS.

JLS Patty Hawk laser-guided delta case packer for frozen IQF patty stacks

In action

Watch the Patty Hawk stack and pack — at full production speed

Patty Hawk — Frozen Patty Case Packing System Live Production Line

Patty Hawk — Frozen Patty Case Packing System

Stacking and packing frozen beef patties at more than 1,000 patties per minute. Laser-guided, non-camera delta robotics with mechanically actuated grippers.

Why Patty Hawk

More than 1,000 patties a minute, off the frozen line.

The Patty Hawk automates high-speed case packing of frozen IQF patties — running at more than 1,000 patties per minute, consistently loading stacks into corrugated or poly-lined cases while reducing manual handling. The quality that IQF freezing delivers is protected all the way into the case.

It holds that speed because it doesn't rely on cameras. Laser-guided, non-camera delta robots position mechanically — nothing to frost, nothing to recalibrate — and mechanically actuated grippers handle cold, wet, or frost-covered patties that defeat suction-cup tooling. Every Patty Hawk is configured around your round patty geometry, stack count, and case format.

Applications & Package Types

The Patty Hawk — Frozen patty case packing

Running at more than 1,000 patties per minute, the Patty Hawk stacks and packs round beef, poultry, pork, and plant-based frozen patties in environments down to -10°F. Laser-guided, non-camera delta robot. Mechanically actuated grippers configured to your patty geometry. IP69K full-system washdown rating. Single- or dual-head configurations. Easy to operate.

Industries Served

Beef & ProteinBurgers, beef patties
PoultryChicken, turkey patties
PorkSausage patties, formed pork
Plant-BasedAlt-protein frozen patties
IQF / FrozenFormed frozen proteins

Case & Patty Formats

RSC CasesRegular slotted container
HSC CasesHalf slotted container
Retail-ReadyDisplay-ready case formats
Club-StoreLarge-count club formats
Multi-Stack2-, 3-, 4-patty stacks

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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 the Patty Hawk run your
product before you commit.

Send us your frozen patties. We'll run them on a live Patty Hawk in our York, PA Flight Lab — with gripper tooling configured to your exact patty geometry, stack count, and case format — 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 Precision

The Patty Hawk was purpose-built for frozen protein packaging — not adapted from a general-purpose case packer. Every component, from the IP69K full-system frame to the non-vision delta robotics to our mechanically actuated grippers, was engineered for the demands of the freezer floor.

Stainless steel construction icon
IP69K* Full System

Built for washdown

Stainless tubular frame, sloped surfaces, open cable channels, and NEMA 4X controls — engineered for daily caustic washdown in USDA/FSIS-inspected freezer facilities from day one. Not retrofitted.

IP69K* Full System Minimal Harborage NEMA 4X
Non-vision delta robotics — laser-guided
Laser-Guided · Non-Camera · Full Speed

Non-vision delta robotics

The Patty Hawk's laser-guided delta robot positions mechanically with non-camera detection — no optics to frost, no false rejects from condensation — so it holds full speed in the freezer, cycle after cycle.

No Camera Fog -10°F Rated Freezer-Proven
Mechanically actuated gripper tooling icon
No Suction Cups · No Vacuum Failures

Mechanically actuated grippers

The Patty Hawk picks and places frozen patty stacks using mechanically actuated grippers — not suction cups. Mechanical actuation means no vacuum seal failures on cold, wet, or frost-covered product. Reliable grip at −10°F, cycle after cycle.

Mechanical Actuation Freezer-Reliable
Tool-less changeover — under 5 minutes
Quick-change tooling

Tool-less changeover — under 5 min

Select the new recipe on the HMI, swap the end-of-arm tooling by hand, and run. Every SKU your plant produces is pre-loaded before the system ships — no wrenches, no programming, no maintenance call.

<5 Min SKU Swap Pre-loaded Recipes
Multi-cell, multi-head modularity
Index · Fill · Discharge

Precision case management

Automatic case indexing, laser-guided patty positioning, and hands-free discharge — handling RSC, HSC, retail-ready, and club-store formats. Case format changes happen through the same HMI as product changeover.

Multiple Case Formats Auto Index & Discharge
In-house programming and HMI icon
York, PA · Designed & Programmed In-House

Operator HMI & In-House Software

Touchscreen interface designed for plant-floor operators — select a recipe and run, no engineer required. Software is written and owned entirely by JLS, so new recipes and remote support come directly from the team that built your system.

No 3rd-Party Software ERP/MES Ready

Options & Add-Ons

More ways to fit your line.

Optional
Layer sheet friction feeder
Friction feeder places separator sheets between product layers inside the case — stabilizing stacked product during transit and protecting product during shipping.
Optional
Product shingling
Overlapping product placement for formats that require shingled pack patterns — enabling tighter pack densities and specific retail presentation requirements.
Optional
Dual-head configuration
Two robots on a shared frame for higher throughput — engineered for high-volume operations running multiple SKUs at full line speed.
Configure your system
Need something specific?
Every Patty Hawk is configured to your patty format, stack count, and facility. Talk to a JLS application engineer.
Talk to an engineer →

Talk to a JLS application specialist

See exactly how the Patty Hawk fits your line.

Our application specialists know frozen protein lines — not just robots. Share your patty format, line layout, and throughput targets. They'll tell you what configuration makes sense and what to expect from commissioning through full ROI.

Application Engineering & Integration

Configured for your product. Scalable across your line.

No two frozen protein lines run the same — but every Patty Hawk ships from the same proven platform. Our application engineers tailor mechanical gripper tooling, infeed conveyors, and number of cells to your exact product and case format — whether you're packing beef, poultry, pork, or plant-based IQF patties. One team, one facility, one integration.

Fits your line. Day one.

The Patty Hawk picks frozen IQF patty stacks and places them into corrugated or poly-lined cases — in environments down to -10°F. Non-vision laser guidance eliminates the camera failures that stop competing systems in cold plants. Start with a single case packing cell and expand to a fully integrated frozen line without replacing what's already running. The Patty Hawk handles single, stacked, or shingled patty loads and configures around your case format — RSC, HSC, retail-ready, or club-store trays. Mechanically actuated grippers require no suction cups, no vacuum generation, and no vision calibration. Built entirely in-house by JLS — designed, programmed, and supported under one roof.

UPSTREAM Portioner / thermoformer PATTY HAWK FROZEN PATTY CASE PACK LASER-GUIDED · IP69K PER APPLICATION DOWNSTREAM Case sealing & labeling OUTPUT Distribution
JLS + Reiser: Expertise across the line

Planning more than just case packing?

JLS builds complete end-of-line systems — case erecting, robotic loading, case sealing — integrated as a single solution from one team.

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

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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

Specs & Configuration

Patty Hawk technical specifications

Configuration snapshot

The Patty Hawk runs at more than 1,000 patties per minute and ships in single- or dual-head configuration, scaled to your line throughput and floor space.

Single head
Application-dependent*
Standard configuration for most frozen patty lines.
Dual head
Application-dependent*
High-volume operations running multiple SKUs at full line speed.

*Rates vary by product, tooling, and configuration. JLS confirms the right setup during a line assessment.

Specification Value
Throughput — single head Application-dependent*
Throughput — dual head Application-dependent*
Operating temperature -10°F to +50°F (freezer-rated)
Robot type Delta robot, laser-guided (non-vision)
End-of-arm tooling Mechanically actuated grippers, tool-swap capable
Robot guidance Laser-guided, non-vision (no camera)
Control system B&R Automation
Electrical supply 480V ±10%, 3-phase, 60Hz
Air supply 80 PSI, clean, dry, lube-free
Sanitation rating IP69K full system (frame + joints)*
Frame construction Round-tube stainless frame (standard); open-channel frame available as an option
Electrical enclosures NEMA 4X rated; UL/cUL listed
Reliability Factory-tested reliability — validated at FAT with your product
Lead time Contact JLS — varies by configuration and scope

*Estimated rates vary by product, tooling, and configuration. Specifications may vary by configuration — contact JLS for your specific application.

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What solution(s) are you interested in?* Select all that apply.

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

Compare

Patty Hawk vs. the field

Feature Manual Packing Competitor case packers Patty Hawk
Throughput 30 patties/min 60–90 ppm More than 1,000 patties/min*
Freezer operation (-10°F) Not suitable Limited — camera fogging Purpose-built, fully rated
Vision system N/A Camera-based (fogs in freezer) Non-vision laser-guided
Washdown rating N/A IP65–IP67 (partial) IP69K* full system
Labor required 2–4 packers/line 1–2 operators Eliminates manual packers
Changeover time N/A 15–30 min <5 min tool-less
Typical ROI N/A 24–36 months 24–36 months
In-house programming N/A ✗ 3rd-party contractors ✓ 100% in-house

Based on typical frozen patty line installations. Actual results vary by configuration. *Patty Hawk systems in operation are rated at 980 pieces per minute and have been observed running at higher rates; actual throughput depends on patty size, stack pattern, and configuration.

Application Example · JLS Patty Hawk Frozen Patty Case Packing

Manual stacking couldn't keep up with a high-speed frozen line. The Patty Hawk cleared the bottleneck at -10°F.

A large US beef processor running a high-volume frozen patty line needed to automate case packing in a full freezer environment. Manual stacking had become a productivity bottleneck and a staffing challenge — increasingly difficult to staff consistently on a night shift. The line ran at high speed with multiple SKUs and required a system that could operate continuously at -10°F. JLS engineered and installed a Patty Hawk delta robotic case packing system. The non-vision delta robot eliminated the camera fogging failures the plant had experienced with a competing vision-based system. Mechanically actuated grippers secured every stack before placement, and the IP69K full-system rating held up to daily caustic washdown. The system reached full speed within days of commissioning.

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FAQ

Questions our engineers get asked most

Frozen patty case packing, throughput, non-vision robotics, sanitation, and ROI — answered by JLS application engineers.

Patty Hawk pricing varies by configuration, throughput target, and case format, and is confirmed during the proposal process. Most JLS Patty Hawk projects evaluate payback in the 24–36 month range, depending on labor cost, shift schedule, line speed, uptime improvement, and the specific application. Labor savings scale with the platform, line speed, and labor model, with added value from improved throughput and more consistent product handling. JLS reviews your product, package format, line speed, staffing model, and current production challenges to determine where a Patty Hawk creates the strongest return.

Speed. Running at more than 1,000 patties per minute, the Patty Hawk clears IQF stacks off the discharge as fast as a frozen line makes them so product doesn't accumulate or back up. It holds that speed with laser-guided, non-camera detection and mechanically actuated grippers — no optics to frost and no vacuum seals to fail on cold, wet, or frost-covered product — so it runs reliably at -10°F.

Yes. The Patty Hawk is rated for operating temperatures of -10°F to +50°F (-23°C to +10°C). The full system — frame, joints, and controls — carries an IP69K rating, meaning it is engineered for high-pressure caustic washdown in addition to sustained freezer operation. This is a full-system rating, not a component-level rating. Contact JLS for details specific to your facility and product.

The Patty Hawk handles beef, poultry, pork, and plant-based frozen patties. End-of-arm mechanically actuated gripper tooling is configured to your specific patty geometry, diameter, thickness, and stack count during the engineering phase. Multiple SKUs are supported with recipe-based changeover on the HMI — operators select the new product recipe and swap end-of-arm tooling by hand, no wrenches required.

The Patty Hawk integrates with all major patty forming and portioning equipment. JLS application engineers handle the full integration scope: mechanical interface, controls communication, and line timing synchronization. The system is engineered to operate as a seamless extension of your existing upstream equipment, not a standalone island requiring manual handoff.

Most Patty Hawk installations eliminate 2 to 4 manual packing positions per line. In freezer environments, labor costs are typically higher than in ambient zones due to PPE requirements, fatigue rates, and turnover — which typically shortens the payback window versus ambient-zone installations, before accounting for throughput improvement and reduced product damage from inconsistent manual stacking.

Most Patty Hawk installations achieve full payback in 24 to 36 months. ROI in freezer environments tends to be faster than in ambient zones because of higher labor costs, greater turnover, and the additional savings from eliminating vision-system maintenance costs. JLS provides an engineering-led line assessment that includes a detailed ROI projection specific to your operation.

Yes. The Patty Hawk is designed as a modular system. Many plants start with a single case packer, prove the ROI, and then add JLS modules — additional heads, case erecting, end-of-line integration — without reworking the existing installation. JLS also offers complete line integration as a single-source solution for plants ready to automate the full packaging floor.

Yes. Before any capital commitment, JLS runs your actual product on a Patty Hawk in our York, PA Flight Lab with tooling configured for it, and validates the application on your real product — validating tooling, pick method, and placement before final design and reducing project risk.

To scope a Patty Hawk system, JLS typically reviews your product type and dimensions, photos or video of the current line, package format, target speeds, SKU mix, labor model, sanitation requirements, available floor space, and the main production problem to solve. Clear application detail up front makes it easier to recommend the right configuration and estimate scope.

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* The Patty Hawk is offered with IP69K-rated components and full-system IP69K capability. System-level ingress protection varies by configuration. Contact your JLS representative for full details on your application. Patty Hawk systems in operation are rated at 980 pieces per minute and have been observed running at higher rates; actual throughput depends on patty size, stack pattern, and configuration.

Find out what your line is capable of.

We evaluate your frozen patty line, your product, and your constraints — then show you what will work, what won't, and deliver a detailed ROI projection. No guesswork. No force-fitting.

Request a line assessment Call (717) 505-3800

Over 1,000 custom installs. Predictable, fast performance. Premier, dedicated service.

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