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Reliable Sealing, Multiple Products! ANKO Automates Pierogi Production for a Polish Frozen Food Manufacturer Expanding into New Product Lines
This client is a well-known frozen food manufacturer in Poland, with products that are popular among local consumers. As market demand grew, the client wanted to automate Pierogi production to stabilize quality and increase capacity. Working together with ANKO's local agent in Poland, ANKO supplied the HLT-700U Multipurpose Filling and Forming Machine, successfully helping the client transition to automated Pierogi production. In addition, to get ahead in the competitive frozen food market, the client also wanted to create a more diverse product range. With ANKO's professional support, the client not only produces Pierogi consistently but also developed customized forming molds, enabling the same machine to produce products in different shapes and successfully enter new product markets.
Pierogi
ANKO Team Research Problem Solving or Solution Delivery
Solution 1. Breakthrough in Recipe Details! Successfully Solving Pierogi Seal Opening After Boiling
The client's Pierogi tended to open along the sealed edge after boiling, which not only affected the product's appearance but could also expose the filling. The ANKO team first reviewed the client's existing production conditions, then helped adjust the recipe and dough thickness, running multiple forming and boiling tests to verify the seal. After the adjustment, Pierogi weighing approximately 26 g kept a tight seal and plump shape after boiling, enabling smooth and stable mass production. As for the key to the adjustment, we used…… (Contact ANKO now for more details!)
Pierogi are automatically formed by the HLT-700U and delivered by the conveyor
Pierogi seals opening after boiling, affecting appearance and integrity
Inspecting the edge seals of the formed Pierogi
Each Pierogi weighs approximately 26 g
After adjustment, boiled Pierogi keep their edge seals intact and tight
Solution 2. Custom Forming Molds Create Diverse New Products! ANKO Helps Client Capture the Frozen Food Market
In addition to Pierogi, the client also wanted to launch more diverse products to capture the frozen food market. ANKO helped the client develop customized forming molds: dumplings are first formed in a half-moon shape with a standard dumpling forming mold, then manually folded into traditional Polish Uszka. ANKO also developed a square Ravioli forming mold, so that simply changing the mold lets the same machine switch products quickly, easily expanding the product line and entering new product markets.
Produced with a standard dumpling forming mold
Then manually folded into traditional Polish Uszka
Custom forming mold directly forms Ravioli with wave-edge pattern
The client uses ANKO’s HLT-700U Multipurpose Filling and Forming Machine to produce Pierogi weighing approximately 26 g each. Because the client’s downstream process requires boiling, ANKO specially designed a conveyor that automatically transfers the formed Pierogi to the boiling equipment, seamlessly connecting the upstream and downstream processes and delivering an automated solution from filling and forming to boiling.
Food Equipment Introduction
- Place dough in the dough hopper
- Load the hopper with pre-mixed filling ingredients
- Press the start button
- Pierogi are produced automatically
Flexible Pairing with the EA-100KA Forming Machine: Extending from Pierogi to Xiao Long Bao and More Dim Sum
The client uses the HLT-700U to produce Pierogi, but the machine can also be paired with the EA-100KA Forming Machine to extend production to Xiao Long Bao, soup dumplings, and more. The HLT-700U first encloses the filling in dough and extrudes a filled dough tube, which the EA-100KA then forms. The EA-100KA can create up to 12 pleats, and the client chose a 9-pleat shutter, producing a delicate, handmade-style appearance at up to 6,000 pieces per hour. Through this equipment pairing, food manufacturers can build on their existing filling and forming machine to expand into the Asian dim sum market, flexibly responding to different customer groups and market demands.
The HLT-700U extrudes the filled dough tube, which is then formed by the EA-100KA
Xiao Long Bao with delicate pleats and a handmade look
Steamed Xiao Long Bao with a plump appearance
- Solution Proposal
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Integrated Pierogi Production Line: From Preparation to Packaging, Achieving Efficient Automated Production
From dough mixers, vegetable cutters, and meat grinders to the HLT-700U Multipurpose Filling and Forming Machine and downstream packaging equipment, ANKO can integrate front-, mid- and back-end equipment based on the client's space and labor configuration to build a one-stop Pierogi production line. For products entering retail channels, a quick freezer and X-ray inspection machine can also be added to ensure food safety and consistent quality. A complete line not only boosts production efficiency but also reduces labor requirements and operational complexity, allowing manufacturers to focus on new product development and market expansion. To learn more about automated Pierogi production, please click Learn More or submit the inquiry form below.
- Machines
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HLT-700U
In this case, the HLT-700U Multipurpose Filling and Forming Machine handles automated Pierogi production. Forming molds can be swapped to suit product requirements, producing Handmade Pleat, Wave Edge, or Thin Edge appearances, while parameter settings adjust wrapper thickness and filling amount, supporting products from 13 to 100 g. Beyond Pierogi, paired with custom forming molds it can also produce Dumplings, Uszka, and other diverse products at up to 12,000 pieces per hour. Once started, it needs only 1 or 2 operators and occupies less than 1.5 square meters. The built-in IoT system allows remote production monitoring and maintenance reminders, helping food factories manage their production lines steadily.
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Poland
Poland Ethnic Food Machine And Food Processing Equipment Solutions
ANKO provides our clients in Poland with advanced automated food production technology for making Pierogi, Dumplings, and Empanada. We also offer integrated solutions for popular foods such as Blini, Pelmeni, Puff Pastry, and more. Our professional team assists clients with a smooth transition from manual to automated manufacturing to enhance their production efficiency and consistency. Every ANKO success story showcases how we support our clients in their automated manufacturing food business, from food preparation and machine procurement to production line design to troubleshooting and after-sales service. Please feel free to click on the following successful case studies to discover how we can work together to optimize your food production.
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- Category
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- Food Culture
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Pierogi are traditional Polish dumplings made with thin dough wrappers and a variety of savory or sweet fillings. They are among Poland's most iconic dishes and are commonly served at family meals, festive occasions, and gatherings. The name comes from Slavic languages, with pieróg as the singular form and pierogi as the plural. Originally an everyday meal for ordinary people, Pierogi have become a staple of Polish cuisine.
The most classic variety is Pierogi Ruskie, filled with potatoes and Twaróg (Polish farmer's cheese). Other popular fillings include meat and sauerkraut with mushrooms (Kapusta i Grzyby). In summer, sweet varieties filled with blueberries or strawberries are also popular. Pierogi are typically boiled first and may then be pan-fried with butter, onions, or bacon. Savory Pierogi are often served with sour cream (Śmietana), while sweet versions are enjoyed with sweetened sour cream or jam.
Pierogi are also an important part of Poland's Christmas Eve supper, known as Wigilia. Traditional festive dishes include Pierogi filled with sauerkraut and mushrooms, as well as Uszka ("little ears"), small dumplings served in clear beetroot soup (Barszcz). In cities such as Kraków, the annual Pierogi Festival (Festiwal Pierogów) celebrates both traditional recipes and creative variations. Similar dumpling dishes are also found in neighboring countries, including Pirohy in Slovakia, Varenyky in Ukraine, and Kalduny in Belarus.
Frozen Pierogi are widely available in Polish supermarkets, offering consumers a convenient way to prepare traditional dumplings at home. Brands such as Jawo, Proste Historie, Virtu, and Pierogi Kobiela offer a range of products featuring classic fillings like potato and cheese, meat, and sauerkraut with mushrooms, as well as other varieties such as spinach and cheese and sweet fruit fillings.
Typically sold frozen and prepared by boiling or pan-frying, these products bring traditional Polish dumplings into everyday home cooking. Their presence across supermarket frozen food sections also highlights the retail potential of Pierogi as a convenient, ready-to-prepare food product. - Handmade Recipe
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Food Ingredient
Dough: All-purpose flour/Unsalted butter/Egg/Water/Salt; Filling (classic Pierogi Ruskie): Potato/Twaróg (Polish farmer's cheese)/Onion/Unsalted butter/Salt/Black pepper
Dough Preparation
(1) Mix the all-purpose flour and salt evenly, then make a well in the center. (2) Pour in the beaten egg, melted unsalted butter, and warm water. Mix into a dough, then knead for about 5 minutes until the surface is smooth. (3) Wrap the dough in plastic wrap and let it rest for 30 minutes.
Filling Preparation
(1) Peel and slice the potatoes, then boil them in salted cold water for about 15 minutes until soft. Drain and mash. (2) Finely chop the onion and sauté it in unsalted butter until golden. (3) Mix the mashed potato, Twaróg (Polish farmer's cheese), and sautéed onion evenly. Season with salt and black pepper, then let cool.
Assembly and Cooking
(1) Roll out the dough to about 3 mm thick and cut out round wrappers about 7.5 cm in diameter with a round cutter. (2) Place a tablespoon of filling in the center of each wrapper, dab a little water along the edge, fold it into a half-moon shape, and pinch the edges tightly to seal. (3) Boil in boiling water for about 5 minutes, until the Pierogi float, then remove. (4) Serve with sour cream (Śmietana) and fried onions.
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