Gear

Berkley Fishing plant tour

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Some of the <em>Bassmaster</em> Editorial staff had a cool opportunity recently to tour the Berkley factory/facility in Spirit Lake, Iowa. The following is a virtual tour and an inside look at some of your favorite pieces of tackle and line. <em>Bassmaster</em> Magazine editor James Hall is once again adding a little spice to this meatball.
Some of the Bassmaster Editorial staff had a cool opportunity recently to tour the Berkley factory/facility in Spirit Lake, Iowa. The following is a virtual tour and an inside look at some of your favorite pieces of tackle and line. Bassmaster Magazine editor James Hall is once again adding a little spice to this meatball.
Let's start with fishing line. Berkley produces miles and miles and miles of fishing line every year, and it goes through rigorous testing and packaging before hitting the shelves at your local tackle shop.
Let’s start with fishing line. Berkley produces miles and miles and miles of fishing line every year, and it goes through rigorous testing and packaging before hitting the shelves at your local tackle shop.
This is near the beginning of the manufacturing process where the line gets separated into its individual strands.
This is near the beginning of the manufacturing process where the line gets separated into its individual strands.
Each strand of line enjoys several baths before being strung on a spool.
Each strand of line enjoys several baths before being strung on a spool.
The line continues its journey down the
The line continues its journey down the “assembly line.” Note the sponges keeping the line free of any sort of abrasion as it gets created.
Seems like you could play some sort of music here...
Seems like you could play some sort of music here…
The line continues...
The line continues…
Here the line makes its final run to the shipping spools.
Here the line makes its final run to the shipping spools.
Here's the opposite end of that image. These spools are being filled with line mileage.
Here’s the opposite end of that image. These spools are being filled with line mileage.
All of the line gets tested on a regular basis, which creates a bit of waste. But that waste is recyclable to be used again. Thanks for holding up the excess line, Mr. Hall.
All of the line gets tested on a regular basis, which creates a bit of waste. But that waste is recyclable to be used again. Thanks for holding up the excess line, Mr. Hall.
These two trash barrels get filled up with tested line on a regular basis.
These two trash barrels get filled up with tested line on a regular basis.
Recognize these things? They are empty spools, the types you'll pick up at the store loaded with your favorite line types.
Recognize these things? They are empty spools, the types you’ll pick up at the store loaded with your favorite line types.
I won't pretend to know exactly what's going on in this picture, but it's a critical part of the line spooling process. I think if James Hall were in this image, it would have helped tremendously.
I won’t pretend to know exactly what’s going on in this picture, but it’s a critical part of the line spooling process. I think if James Hall were in this image, it would have helped tremendously.
Here the loaded spools are awaiting packaging materials.
Here the loaded spools are awaiting packaging materials.
Lots and lots of stickers for various types of Berkley fishing line.
Lots and lots of stickers for various types of Berkley fishing line.
Thanks to James for bringing more personality to this one, but what you're looking at here is a machine that preps the packaging process.
Thanks to James for bringing more personality to this one, but what you’re looking at here is a machine that preps the packaging process.
And this spool of line is ready to hit the shelves.
And this spool of line is ready to hit the shelves.
This picture shows how extensive the line manufacturing process is. A very impressive operation, for sure.
This picture shows how extensive the line manufacturing process is. A very impressive operation, for sure.
I won't even try to explain what's happening here.
I won’t even try to explain what’s happening here.
Here's another style of line spool awaiting line.
Here’s another style of line spool awaiting line.
And, the folks at the Berkley plant use a Toyota forklift. How cool is that?
And, the folks at the Berkley plant use a Toyota forklift. How cool is that?
Moving onto the bait manufacturing side of things... Berkley Gulp! runs the line.
Moving onto the bait manufacturing side of things… Berkley Gulp! runs the line.
This is a mixing vat for the small cans of dough bait.
This is a mixing vat for the small cans of dough bait.
Interestingly, this is one of the company's biggest sellers.
Interestingly, this is one of the company’s biggest sellers.
It smells wonderful, and I think James Hall believes it tastes just as good.
It smells wonderful, and I think James Hall believes it tastes just as good.
They have lots of colors and flavors to choose from.
They have lots of colors and flavors to choose from.
Stepping back to the fishing line realm, Berkley builds all of those black spools. Makes great sense when you consider the many thousands of spools they require to put line in your local tackle shop. This picture shows one of the machines required in that process.
Stepping back to the fishing line realm, Berkley builds all of those black spools. Makes great sense when you consider the many thousands of spools they require to put line in your local tackle shop. This picture shows one of the machines required in that process.
Mr. Hall shows off two of the finished products.
Mr. Hall shows off two of the finished products.
Some Berkley Gulp! ready for packaging.
Some Berkley Gulp! ready for packaging.
The Gulp! bags are being prepped for bait.
The Gulp! bags are being prepped for bait.
At this point, the baits are bagged.
At this point, the baits are bagged.
And they are ready to be bundled and shipped.
And they are ready to be bundled and shipped.
Who could deny Mr. Hall the chance to touch and smell fresh PowerBait?
Who could deny Mr. Hall the chance to touch and smell fresh PowerBait?
These bait molds are for the famous 10-inch worm, perhaps even a black and blue PowerWorm, one of the most famous of all time.
These bait molds are for the famous 10-inch worm, perhaps even a black and blue PowerWorm, one of the most famous of all time.
All of these are injection molds creating a plethora of soft plastics.
All of these are injection molds creating a plethora of soft plastics.
Who can name this one?
Who can name this one?
And more ....
And more ….
... and even more PowerBait.
… and even more PowerBait.
That jug is likely future PowerWorms.
That jug is likely future PowerWorms.
Then we moved onto the hard bait section of the factory.
Then we moved onto the hard bait section of the factory.
This is a CNC machine that kicks out crankbaits to be developed and tested.
This is a CNC machine that kicks out crankbaits to be developed and tested.
Hard baits in process...
Hard baits in process…
Here is a look at unfinished hard baits fresh off the CNC machine.
Here is a look at unfinished hard baits fresh off the CNC machine.
Can you believe that Berkley has been around for more than 75 years?! Impressive staying power in a very competitive market.
Can you believe that Berkley has been around for more than 75 years?! Impressive staying power in a very competitive market.
Here is a box of baits awaiting some testing.
Here is a box of baits awaiting some testing.
The line testing facility shares a space with the hard baits. Here's a look at new Berkley Solutions line.
The line testing facility shares a space with the hard baits. Here’s a look at new Berkley Solutions line.
How much scent dispersion is the new PowerBait MaxScent capable of? This image shows the level of attractant.
How much scent dispersion is the new PowerBait MaxScent capable of? This image shows the level of attractant.
All these boxes include original designs that were tested. Some were turned in to your favorite PowerBait patterns. Some didn't make the cut.
All these boxes include original designs that were tested. Some were turned in to your favorite PowerBait patterns. Some didn’t make the cut.
Here's another mold for a familiar pattern.
Here’s another mold for a familiar pattern.
This one is older, and indicates the level of change Berkley PowerBait has undergone over the years. Talk about advancement!
This one is older, and indicates the level of change Berkley PowerBait has undergone over the years. Talk about advancement!
Stacks and stacks of old molds. Some still in use today, others have been retired.
Stacks and stacks of old molds. Some still in use today, others have been retired.
James Hall shows you an impressive stack of molds.
James Hall shows you an impressive stack of molds.
Even more molds.
Even more molds.
Of course a bait-making company has to have it's target audience on-hand to prove their effectiveness.
Of course a bait-making company has to have it’s target audience on-hand to prove their effectiveness.
Now we move into the testing facility. James Hall on the far left is joined by B.A.S.S. CEO Bruce Akin and legendary angler and bait tester Mark Sexton on the right. Mark has the best job in the world, period.
Now we move into the testing facility. James Hall on the far left is joined by B.A.S.S. CEO Bruce Akin and legendary angler and bait tester Mark Sexton on the right. Mark has the best job in the world, period.
...and the bass determine the outcome.
…and the bass determine the outcome.
It is literally a laboratory.
It is literally a laboratory.
Then onto hard bait testing.
Then onto hard bait testing.
Each lure is perfected before it is shipped.
Each lure is perfected before it is shipped.
It's a time-consuming process, but one that ensures fish-catching qualities fresh out of the package.
It’s a time-consuming process, but one that ensures fish-catching qualities fresh out of the package.
Berkley's hard bait engineer Dan Spengler talks to James Hall about the testing process.
Berkley’s hard bait engineer Dan Spengler talks to James Hall about the testing process.
It's a very impressive program!
It’s a very impressive program!
There's even a tank beneath the floor where testers and engineers can view how each lure swims.
There’s even a tank beneath the floor where testers and engineers can view how each lure swims.
James Hall gets a first-hand look at what's being tested and perfected.
James Hall gets a first-hand look at what’s being tested and perfected.
Mr. Spengler gives further explanation about how each bait is designed and tested. Talk about a very enjoyable tour of the world famous Berkley facility. What makes this whole process even better is the obvious level of passion these people exhibit about the sport we all love. Berkley has it going on!
Mr. Spengler gives further explanation about how each bait is designed and tested.

Talk about a very enjoyable tour of the world famous Berkley facility. What makes this whole process even better is the obvious level of passion these people exhibit about the sport we all love. Berkley has it going on!

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