ST. LOUIS — Marson Foods, a waffle product manufacturer for K12 and foodservice, recently celebrated the opening of its new $35 million bakery in Hazelwood, MO.
The 147,000-square-foot distribution center features 12,000 square feet of fully automated freezer capacity, end-to-end R&D capabilities, automated production lines to increase sales capacity, and space for five additional production lines.
“Our facility’s advanced technologies will allow us to continue to use the highest quality ingredients to create millions of nutritious meals,” said Jan Marson, co-owner of Marson Foods, who also noted that the facility supports the company’s potential to assist potential private label and co-manufacturing customers with full end-to-end product formulation. “With our R&D capabilities and space for additional production lines, we are eager to expand our offerings and excited about the prospect of new partnerships for co-manufacturing and private label clients.”
Marson Foods began operations at its Hazelwood facility in October 2023 with 16 employees. It currently produces about 25,000 waffles per hour, with capacity for 150 million waffles per year.
“We custom-tailored the facility infrastructure as well as our processes with full automation in mind,” said Tyler Wallace, COO of Marson Foods. “In addition, we hand-picked some of the top equipment vendors in the world to be a part of this project. Starting with a raw material handling and traceability system, automated mixing system, authentic Belgian waffle line and oven manufactured in Belgium, packaging systems from Switzerland, as well as end-of-line robotics and conveying from the US. The on-site refrigeration for finished goods storage also includes a fully automatic ASRS system to eliminate personnel from working in the harsh freezer environment. All in all, the decision to leverage automation allows us to maintain the highest level of food safety and quality at a lower price point to the consumer.”
Dave Marson, co-founder of Marson Foods, shared that the bakery’s location in Hazelwood benefits both the company and its customers.
“Hazelwood offers an experienced workforce, and logistically we are perfectly geographically situated to pair grain and flour producers with our advanced manufacturing lines,” he said. “With easy access to many major highways and extensive freezer storage space, the new facility opens up many co-manufacturing opportunities for us.”
The Marson’s previous company, Nature’s Bakery, was operated out of a facility in Hazelwood prior to its acquisition by KIND Snacks, under the Mars, Inc. umbrella, in December 2020.
