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    Shearers History

    Production Capabilities

    Manufacturing Capabilities
    Shearer's Foods offers a full complement of manufacturing capabilities and production processes for the consumer salty snack category. Products range from standard sliced and rippled potato chips, kettle cooked potato chips, pretzels, tortilla and whole grain extruded chips, and other extruded product such as cheese curls and puff corn (also known as hulless popcorn).

    The company is conversant over a variety of base ingredients, including potatoes; yellow, white, blue, and organic corn; and seasonings and flavors developed both by our in-house R&D group, as well as with key partners. Tortilla chips are produced using company produced masa.Production capabilities include:

    • Hand kettles for production of kettle cooked potato chips
    • Continuous potato chip lines for standard and rippled chip production
    • Tortilla chips lines
    • Standard pretzel production
    • Extruders for production of curl and puff product
    • Twin screw extrusion production
    • Distribution via company owned routes and a network of select distributors throughout the Midwest United States, New England, and parts of Canada from six distribution centers in Ohio and Pennsylvania.
    • Wastewater management facilities comply with state Environmental Protection Agency requirements and increase environmentally-friendly company commitment.


    Packaging Capabilities
    Shearer's Foods employs the most advanced of high-speed packaging systems to provide product packaging and case packing expertise to a variety of consumer snack lines and over a range of packaging sizes. Branded chips are produced from smaller, sample and single serving packs of 1 oz. - 2.5 oz. to family packs of 11 and 16 oz. while kettle cooked product ranges from 1.75 oz. to a 13 oz. bulk package. Tortillas are packaged in 9 to 12.5 oz. sizes, pretzels in 1 through 12 oz., and pork rinds in 1.5 oz. packs. Extruded product comes in 6 to 9 oz. sizes, and the whole grain extruded line consists of a 10 oz. size as well as snack packs and 100 calorie packs.

    Materials and features also range broadly, with new inclusions being a re-sealable bag configuration.

    Packaging equipment and capabilities include the following:

    • State of the Art form/fill/seal machines
    • Vertical Form and Fill Bags
    • Horizontal Overwrap
    • Bag in a Box Point-of-Purchase (POP)
    • Nitrogen-Flush
    • Shrink Wrapping/Assembly
    • Bulk