In the early 2000's, another expansion was completed to add production capacity and improve product flow. Six hand-kettle cookers, a state-of-the-industry potato peeling system, distribution and transfer conveyors, and a new seasoning system were installed. Snack Food and Wholesale Bakery magazine named Shearer's "Snack Manufacturer of the Year". We purchased 33 acres next to our current location, giving the company 77 acres in total. A portion of our warehouse operation was relocated to Massillon, nine miles from our headquarters. The move increased our warehouse efficiency, resulting in a financial savings for the company.

In 2004, a new logo and new packaging were introduced, along with many new products. A new Factory Outlet Store was completed on premises, showcasing Shearer's complete line of snack products. Shearer's increase its presence in the Columbus market area. Our $2.6 million dollar wastewater treatment plant was completed in the spring. Six more hand-kettle cookers were installed along with a new packaging area, making Shearer's one of the largest manufacturers of kettle-cooked potato chips in the nation.

In 2005, the company manufactured a record 57.5 million pounds of our award-winning snacks, while receiving honors for continued growth, manufacturing excellence, outstanding customer service, new products, human resources practices and community service. In the plant, a new raw potato de-stoner was installed to support our hand-kettle operation. Two new robotic pick-and-place vertical case packing systems enable our Production Teams to maintain top speed, while expanding our small bag manufacturing capabilities. State-of-the-art racking systems were added in our Brewster and Massillon warehouse facilities. We designed/implemented a Manufacturing Information Portal, a website application that centralizes the required data for manufacturing into one single source of information. A dedicated Research and Development Department was created in July, and several new potato chip flavors were introduced to meet the increased demand for new and exciting flavors. A distribution center was opened in Geneva, Ohio. Shearer's was honored with the prestigious NorthCoast 99 Diamond Award as one of the top three employers in Northeast Ohio.