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Contents
Cover Story 12 | Leaving Them Hungry for More Since 1974, Grecian Delight Foods has prided itself on a variety of Greek and ethnic foods. Find out how this Elk Grove Village, Ill.-based company is expanding beyond its roots.
Photos by Vito Palmisano
Plant Story 22 | Pita Plant and More Family-owned Grecian Delight Foods recently opened a second production facility, devoted to producing frozen flatbreads. Take a tour of the state-of-the-art, 130,000-sq.-ft. facility.
Columns 6 | Editor’s Note Editor-in-Chief Lauren R. Hartman discusses a new book published about wheat and why consumers should be wise when cutting it out of their diet.
38 | The Nutritional Corner Contributing columnist and president of the Grain Foods Foundation (GFF), Judi Adams, recaps the highlights from GFF’s grains nutrition panel discussion held at All Things Baking.
51 | Engineering Management In today’s world, it’s tough enough just to find people to fill certain permanent roles, but very easy to fill them from outside of the fence line. Contributing columnist Jeff Dearduff suggests a call of duty.
64 | The Final Word Executive Editor Marina Mayer sounds off on 10 things she’s thankful for in the snack and bakery market.
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SNACK FOOD & WHOLESALE BAKERY (ISSN 1096-4835) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or
[email protected].
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Contents
28 Production, Technology & Product Development Solutions for a Changing Industry. November 2011 Vol. 100 No. 11
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Market Trends
28 | One Size Doesn’t Fit All
Bars don’t have to be a one-size-fits-all segment. That’s why today’s bar producers make it possible for consumers of all health desires, cravings and lifestyles to find a bar just right for them.
36 | New Products
John Schrei Publishing Director
[email protected]
Tom Imbordino Group Publisher
[email protected]
Jeff Heath Publisher
[email protected] 224-554-9154
44
New Products
For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail
[email protected] www.snackandbakery.com
Editorial
Lauren R. Hartman Editor-in-Chief
[email protected] 847-405-4015
Marina Mayer Executive Editor
Read about some of the most recently introduced products, including pork sticks, dairy-free pumpkin pie, onion rings and flavored tortilla chips and all-natural, vegan and gluten-free bars.
[email protected] 847-405-4008
Patty Catini Art Director
Advertising & Internet Sales Barbara Szatko Senior Sales Manager
[email protected] 630-527-9927
Special Report
Suzanne Sarkesian Classified Sales
[email protected] 248-786-1692
40 | Designed for Safety
Food safety has never been more of a critical issue than it is now. Every baker and snack manufacturer needs to know what equipment is available that meets the highest sanitation standards and latest trends in sanitary equipment. Find out what several food safety and sanitary equipment specialists have to say about new advances in the market and what customers can expect from them.
Ingredient Technology 46 | The Fountain of Youth
Many of today’s ingredient suppliers are making it so consumers can turn back the clock of time with the help of antioxidant- and Omega-rich foods.
Production Technology 52 | Forming, Filling, Sealing to Perfection
These days, having the right form/fill/ seal equipment can make the difference in how a product is bagged. Thankfully many of today’s manufacturers aren’t taking any chances in putting together the right system that offers efficiency, speed, flexibility and accuracy.
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Jill L. DeVries Corporate Reprint Manager
[email protected] 248-244-1726
Support Services
Liz Wright Marketing Coordinator
[email protected] 248-786-1652
Audience Development
Kourtney Bell Audience Development Manager Stephanie Hunt Multimedia Specialist Carolyn M. Alexander Audience Audit Coordinator List Rental Postal contact: Kevin Collopy at 800-223-2194 x684
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Email contact: Michael Costantino at 800-223-2194 x748
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BNP Corporate
John R. Schrei Publishing Rita M. Foumia Corporate Strategy Ariane Claire Marketing Vincent M. Miconi Production Lisa L. Paulus Finance Michael T. Powell Creative Nikki Smith Directories Marlene J. Witthoft Human Resources Scott Krywko Information Technology Beth A. Surowiec Clear Seas Research BNP Media Helps People Succeed in Business with Superior Information
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Editor’s Note
Be Wise About Wheat I
’ve been seeing a lot of press and blogs referring to the controversial book, “Wheat Belly: Lose the Wheat, Lose the Weight and Find Your Path Back to Health,” recently released by Milwaukee-based cardiologist William Davis. In the book, Davis writes about the health risks associated with the wheat that most of us eat in various forms, and the symptoms, health problems and solutions that can be related to wheat. The book hit the best-seller lists and made national news. Davis is a medical director of the Track Your Plaque program and an advocate of early heart disease prevention and reversal. According to numerous online reports and social media channels, his book doesn’t particularly recommend that we all stop eating wheat. But it does provide some examples of the potential health Lauren R. Hartman risks that wheat
[email protected] poses, if we include wheat in our diet. The book also indicates that the wheat produced and eaten today is quite different than the wheat consumed just 40 years ago and even farther back to einkorn, which was the first form of cultivated wheat grown by farmers more than 10,000 years ago. I have only read excerpts of this book, but the articles and releases I’m seeing sound pretty disconcerting, especially because wheat has been a part of our lives since childhood and is something that we need to consume more of to remain healthy. He also claims that changes in these wheat proteins, allegedly brought about by
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invasive breeding programs, caused wheat to negatively change. According to the Grain Foods Foundation (GFF), Ridgway, Colo., “while breed has produced wheat that relies upon fewer pesticides and water and is more weather-resistant, there is no evidence that the nutritional value in new [wheat] varieties has changed.” Davis asserts that modern wheat stimulates hunger, and compared with ancient wheat, has a glycemic index of 72, which, he writes, exceeds table sugar (glycemic index of 59). He also says carbohydrates in modern wheat are so easily digestible that eating whole grains results in the same blood sugar impact as an equivalent amount of highly processed flour. White bread, with less of the whole wheat grain, comes in at 70. A Snickers candy bar comes in lower with a glycemic index of 41. This is very confusing. Cutting back on or eliminating carbohydrates may be a good measure for certain people because they may have an allergic reaction, develop intolerance or some other health problem. But, GFF says cutting out wheat entirely means missing out on a wealth of essential nutrients needed for good health, including fiber, antioxidants, iron and B vitamins. And we know that eating more enriched grains helps reduce cholesterol and provides essential folate. Complex carbohydrates in bread and other grain-based foods provide essential fuel the body needs. Dedicated to advancing the public’s understanding of the important role grainbased foods play in a healthful diet, GFF
strives to ensure positive news about grains to balance any coverage to the contrary. “In his book, cardiologist William Davis asserts that wheat consumption is solely responsible for Americans’ health ills, and that cutting wheat from our diets is the cure-all solution to conditions like obesity, diabetes, celiac disease and rheumatoid arthritis,” adds GFF. “Wheat is the basis for a number of healthful whole and enriched grain foods, including breads, cereal, pasta and wheat berries that provide valuable nutrients to the American diet and have been shown to help with weight maintenance.” GFF also mentions that Davis’ advice runs counter to the 2010 Dietary Guidelines for Americans, which call for the average healthy American to consume six 1-oz. servings of grain foods daily, half of which should come from whole grains and the other half from enriched grains. Certainly, people with certain bread and wheat issues, including celiac disease and gluten intolerances, require complete abstinence from gluten-containing grains, including wheat. GFF points out that it regularly collaborates on programs to support the needs of the gluten-free community. Healthy folks should really discuss with their doctors the prospect of avoiding foods containing wheat. I agree with the GFF when it says, we must “let common sense prevail. When it comes to nutrition advice, look to the real experts and remember that weight control is all about one key equation: Calories in must equal calories out.” SF&WB
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Business Briefs Exclusive TIA Convention Cooks up Flavorful Offerings This year’s TIA Convention & Trade Exposition was jam-packed with new developments in tortillas and flatbreads. Lauren R. Hartman, Editor-in-Chief
he bustling 22nd annual Tortilla Industry Association (TIA) Convention and Trade Exposition, held Sept. 12-13 at Caesar’s Palace in Las Vegas, featured an upgraded venue, an expanded exhibitor list and exhibit space that quickly sold out. The dynamic and well-attended event provided more new equipment, components, ingredients, packaging and finished products than ever, as well as lots of buzz about the changing trends from various tortilla and flatbread producers. Sponsored by Arlington, Va.-based TIA, the most important tortilla industry event of the year set a new record for the 22 years it has taken place. Delegate attendance was more than 675, which broke a previous record of 620 in 2008, and many of the 97 exhibitors had a larger booth than before. The convention also gave attendees many networking opportunities and sponsored conference sessions as well as a Hall of Fame award presentation. Hall of Fame winners include Dorothy Cruz, Mi-Rancho Tortillas; Irwin Steinberg, founder of TIA (1990); and Frank and George Puentes of Don Pancho Authentic Mexican Foods, Inc. An intriguing conference program highlighted Monday and Tuesday morning, as speakers discussed improving tortilla production, boosting tortilla freshness with oxygen adsorbers in packaging and maintaining and creating new business relationships and businesses without forgetting traditions and heritage. Other sessions focused on the effect of enzymes on tortillas and new enzyme products, keys to successful product innovation, new frameworks for nutrition and a look at new bakery and tortilla products made from masa and flour. “Innovation is a key word for us,” says Ivan Ahumada, national retail sales manager at Minsa Corp., Muleshow, Texas,
T
which presented a discussion about new products under the Soulmaize umbrella. “Customers want things like fiber, low-fat, low calories, more protein-enriched products, allergen-free, trans-fatfree and low-cholesterol products. They’re interested in more healthy and wellness ingredients and gluten-free, lower-sodium, convenient alternatives.” With expertise in corn products in four segments—tortillas, snacks, bakery and extruded snacks— Minsa introduced various bakery products a year ago, such as donut, pancake and churro pre-mixes. Motivational speaker Consuelo Kickbusch, president of Educational Services Inc., Cottonwood, Ariz., spoke about going forward without forgetting the past. “Carrying on the legacy is critical but we need to see tortillas in a different way,” she says. “We grew up with tortillas—they’re everywhere now. Our food staple is all over the world now. But we still need to bring the values of yesterday to today. As we modernize and add more machinery to our production facilities, we still shouldn’t forget the reason we’re in this [business] and on this journey.” John Fannon, vice president technical services at Allied Blending & Ingredients, St. Louis, Mo., explained the significance of various enzymes in tortilla applications. “They can be used to alter starch and protein properties and help extend shelf life,” he stressed. “Bacterial amylase from fungal sources can be used in dough conditioning to prevent staling in storage and maintain a soft crumb. When tortillas are cooked, starch is dispersed in water and forms a soft, pliable gel. Amylase takes those starch molecules and breaks them into pieces so to control and slow degradation.”
Hispanic diet Sylvia Melendez-Klinger, founder of Hispanic Foods Communications, discussed new concepts for Latino nutrition. “There are 50.5 million Hispanics in the United States, based on the 2010 U.S. Census, and they rank as the second largest group here outside of Mexico. Emerging Latinos are younger, live longer, have higher birth rates and worry about their health, though there is a broad definition of health that includes traditions, traditional healing, a strong religious component and mainstream medicine,” she says. “The Hispanic diet is influenced by core elements of the country of origin. And mothers are looking for healthier options and are reading package labels in efforts of finding lower fat and sodium. But also with Hispanics, the key health issues are obesity, heart disease, diabetes and cancer, so there’s still a lot of education needed on healthy options. Tortilla companies also really need to look at fortifying tortilla products with folic acid, a vital way of preventing certain birth defects.” Conferences aside, the exhibits were filled with new tortilla bagging equipment and shrink wrappers, form/fill/ seal systems, weighers, tortilla presses, counters, cutters, dividers, stackers, conveyors, dough processors and more, as well as flexible and rigid packaging and containers, gums, ingredients, milling needs, flours—the list goes on. With an event jam-packed with ideas and opportunities rolled up into just a few days, visitors certainly got their money’s worth. For more information about the 2012 TIA Convention & Trade Exposition, which will take place Sept. 11-12, 2012 at Caesar’s Palace in Las Vegas, go to www.tortilla-info.com. SF&WB
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Business Briefs
people
Continued from page 8
supplier news The Kaak Group of Terborg, The Netherlands, names Naegele, Inc. Bakery Systems its exclusive U.S. representative. As a result, Naegele is moving to a larger facility in Alsip, Ill., doubling its size. The agreement includes five Kaak Group companies in four countries, enabling the two companies to combine the best components available to create the optimum integrated solution for customers “from silo to truck.” Butter Buds Food Ingredients receives an “Excellent” rating as a result of its recent audit under the Safe Quality Foods (SQF) program, which is recognized by the Global Food Safety Initiative and links primary production certification to food manufacturing, distribution and agent/broker management certification. Blue Diamond Growers approves a plan to purchase 88 acres located at North Washington and Fulkerth Road in Turlock, Calif. The three-phase project is expected
to provide training and other new opportunities for current employees in Sacramento, Salida and, eventually, in Turlock. Heat and Control, Inc. purchases Spray Dynamics, Ltd. The acquisition helps Heat and Control expand its selection of coating systems and seasoning applicators and provides food processors with complete single-source support. Solazyme, Inc. and Roquette Frères sign a joint venture agreement for the production, commercialization and market development of microalgae-derived food ingredients. The JV is 50% owned by each parent company and is named SolazymeRoquette Nutritionals. Synergy Flavors acquires Sethness Greenleaf, providing additional scale for Synergy in the bakery market. This acquisition follows Synergy’s acquisition of Sensus, which was completed on Sept. 21 and announced separately.
Shearer’s Foods, Inc., Brewster, Ohio Michael Parks is named vice president of manufacturing, responsible for providing leadership and direction to Shearer’s five manufacturing facilities as well as the engineering group. Mark Schwerdtfeger is the new vice president of sustainability, safety and wellness, responsible for carrying out the company’s initiatives of taking care of people and the planet. John Baist joins the company as executive vice president of sales, where he will provide a single point of leadership for the sales team. QualiTech Inc., Chaska, Minn. Mike Hodgens is promoted to chief operating officer, responsible for corporate operations, quality assurance, supply chain and product development as well as overseeing the IT and marketing departments. Meanwhile, Kye Ploen moves up to vice president of business development, responsible for continuing to grow relationships and business within the food division. Rudy Roesken advances to general manager/ corporate vice president of food ingredients, responsible for the management and strategic development of the division.
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“Ross helps me serve my recipes to the world.” “I’m a chef at heart, not a manufacturer. I believe that all food should start with fresh, local ingredients and deliver awesome flavor! “That’s why our Cheese Tortas are such a success. We start with premium cheeses, fresh butter and herbs. And thanks to Ross, we can now produce them fast enough to satisfy customers everywhere — through retailers like Whole Foods, Costco, Neiman Marcus, Harry and David, Safeway and Balducci’s.” Looking for a new mixing strategy to boost production and improve product quality? Call 1-800-243-ROSS. Or visit www.mixers.com.
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Leaving Them Hungry for More Since 1974, Grecian Delight has prided itself on a variety of Greek and ethnic foods such as flatbreads, pita breads, pastries, Mediterranean specialties, bakery items, flatbreads, pita pockets and specialty meats for foodservice and retail markets. Its commitment to quality products and the finest ingredients has helped it climb a steady path to growth since it started. Opaa! Lauren R. Hartman, Editor-in-Chief
H
olding what it says is more than a 40% share of the gyros market, Grecian Delight Foods (GDF), Elk Grove Village, Ill., is always looking to innovate in the rapidly expanding category of Greek and Mediterranean ethnic food manufacturing and distribution. Expanding beyond its roots,
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the company today produces whole wheat pita chips, various sizes of pita flatbread (including New York and Chicago Styles), wheat pocket breads, perforated pitas, pita folds, white pita pockets, Mediterranean pita chips, artisan focaccia, lavash, multigrain pita squares, artisan-style naan flatwraps, Skinny Buns (flat sandwich buns), custom flatbreads, pizza shells, customized/ hybrid products and more. It also sells flatbreads (one line has 16 stock-keeping units [SKUs], that go by the company’s One Republic brand name for retail and foodservice items) as well as pita breads, dips, spreads, pizza shells, gyros meal kits and sandwiches to supermarket delis and a number of retail items under the Opaa! brand. The products are sold nationwide and abroad and shipped by common carrier
Peter Parthenis, Sr., chairman and owner of Grecian Delight Foods, and his son, Peter Parthenis, Jr., president and CEO, present just a “handful” of the many different Mediterranean bakery items and other specialties the company offers, including pita pockets, its most popular bakery item, and the new Skinny Buns flat sandwich rounds.
through some 400 ethnic and broadline foodservice distributors to restaurants and national chains. As of 2009, it’s reported that GDF accrued more than $1 billion in sales over its existence. “And we still remain one of the leading gyros manufacturer and brand nationally,” says Peter Parthenis, Jr., president and CEO. Consumer demand for ethnic foods is on the rise, so the company is capitalizing on this need, with more new quick and
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AT A GLANCE
Photo by Vito Palmisano
easy to prepare flatbreads that can be used to complement its line of dips, as a base for pizzas and bruschettas and as an accompaniment to salads and entrees or as a portable sandwich device.
Paving the way for more growth Today, Parthenis, Jr. says the company has been on a smooth road to steady growth, thanks to his father, who built everything from the ground up. Born and raised in
Greece, Peter Parthenis, Sr. immigrated to Chicago in the early 1960s, determined to succeed. Studying to be an automation engineer, he soon developed a vertical broiler for cooking gyro meat called the Autodonor, which has become a Greek food industry staple. He then decided to start his own company and established a small gyro meat distribution business, GDF, and produced and sold gyros meat, baklava and tzatziki
Company: Grecian Delight Foods Inc. Headquarters: Elk Grove Village, Ill. Website: www. greicandelight.com Plant sizes (two locations in square feet): 200,000 and 165,000 sq. ft. Production lines: Bakery, sauces, specialty meats and entrées No. of Employees: 200-plus Years in Business: 37 Products: Flatbreads, pita bread, wraps,
focaccia, buns, pizza shells, specialty meats, sauces, spreads KEY PERSONNEL: President: Peter Parthenis, Jr. COO: Ted Sawicz V-P., Sales (Foodservice): Bill Poulos Dir., Mktg.: Amy Fattori Dir., Opers.: Bill Solomon Treasurer/V-P., Procurement: George Georganas
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November 2011 - Snack Food & Wholesale Bakery
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Photos courtesy of Grecian Delight Foods
Continued from page 13
sauce. But in every subsequent decade, the company added significant capacity and expanded into new product categories and distribution channels. After 30 years at the helm of the company, Parthenis, Sr., currently chairman of the board, handed the GDF business over to his son in 2007. This could be a tall order for anyone at first, but Parthenis, Jr. dove in head-first, as he spent more than 15 years learning every aspect of the business before taking over. He worked on the production floor, in sales and marketing, in finance and as a regional manager. As the responsibility of the company became his, Parthenis, Jr. began to take on new business ventures in the foodservice sector. He had great plans to pave the way for growth, including doubling the size of the company and making it a best-in-class provider to the Mediterranean food segment through continued innovation, quality ingredients and an eye on customer needs. Indeed, the company faces many challenges in this difficult economy, Parthenis,
Parthenis, Jr. “We continuously work toward our vision statement: ‘When the food industry, as a whole, thinks of and desires Greek and other Mediterranean food products, Grecian Delight is the preferred company of choice. Our core values include: Pursue profitable growth; act with integrity; drive for results; have a passion for excellence; have respect for people; and demonstrate accountability.”
Key trends Jr. says. “Things such as market volatility on key commodity ingredients. In the past three years, the industry has experienced historical highs in the cost of flour/wheat, dairy, lamb and meat. We have to manage profits, gross margins and return on investment (ROI) at acceptable levels for shareholders during this market volatility.” But GDF is weathering the economic storm and surging ahead with new projects and lots of high-energy enthusiasm, whether it’s rolling out gyros to non-commercial and non-traditional foodservice operators, developing new flatbread products, or working with customers to create new and unique merchandising programs, GDF provides a vast choice of products. The company provides 450 SKUs overall, including private-label; “Roughly one-third of these SKUs are bakery,” Parthenis, Jr. explains. Employing more than 250 people, the company also has a highly trained direct sales force and occupies 200,000 sq. ft. in its original location. Highly involved in community efforts, GDF received the 2010 Illinois Family Business of the Year Community Service Award from Loyola University, Chicago. “This reinforces our core value standards,” says
Today, Parthenis, Jr. and the GDF team see several key trends driving bakery sales. “We’re noticing the demand for healthier alternative products (betterfor-you)—things that are lower in calories and fat, products with no preservatives and smaller portion sizes. We’re working on lower sodium breads right now,” he points out. “Currently, we are conducting a company-wide examination of sodium in all of our product categories and are testing products that have a sodium reduction in a range of 10-40%. We are focused on providing better options for all segments.” Last year, GDF launched its popular Skinny Buns line, which is a group of thin sandwich rounds made with whole grain that has only 90 calories for one serving. “They are also reduced-sodium, have no trans-fats and are made with whole wheat,” explains Parthenis, Jr. “We have also entered new product categories with Indian flatbread, naan [the naan comes in classic and multigrain varieties], Middle Eastern flatbread, Lavash and traditional handstretched-style pizza crusts and flatbreads.” The top seller is still the company’s traditional pita bread, he says. “There hasn’t been a big shift there. We’ve seen consistent growth in our bakery products,” he adds. Amy Fattori, director of marketing, points out more features. “We’re offering new flavors such as Maple, Italian Herb, and many more and are also focused in multigrain breads. We also introduced a new grill-marked flatbread for restaurant Continued on page 16
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Squeeze it Feel the difference
New POWERFresh® Bread bakery enzymes with G+ Imagine with us Imagine you could keep your bread feeling significantly fresher for days longer1 than any other choice on the shelf. New POWERFresh® Bread with G+ technology makes it a reality. Developed together with the baking industry, POWERFresh® Bread and POWERFresh® Special bakery enzyme products are carefully tailored to make a difference that can be felt with a single squeeze. And that means more on-the-spot sales – plus customers who keep coming back for more. If you need to squeeze it twice, it probably wasn’t made with POWERFresh®. To learn more about POWERFresh® with G+ visit www.powerfresh.info
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Continued from page 14
new sizes, from minis to 4x18 in., in May. “We also have noticed the demand for private-label [products] has increased significantly and the quality of private-label products has also increased,” Parthenis,
operators, which has that just-grilled look that many of them have been asking for.” The grill-marked flatbreads were launched in July and the Lavash flatbreads debuted in
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The company is constantly evolving and has really changed a lot in the past five years, Parthenis, Jr. observes. Striving to convey the right image to customers is very important, he points out. “The overall image Grecian Delight conveys is quality, food safety, consistency, being a trusted brand and being a trusted company. We’re dedicated to expanding the company’s products and to providing value to our customers.” GDF added a second production location, also in Elk Grove Village, which
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opened in November 2010. The facility has 130,000 sq. ft. of space, which was renovated extensively to increase GDF’s flatbread production, including a new high-speed bakery production line, which has in-line freezing and packaging capabilities, and as well as a separate distribution company. “We drastically increased our capacity and product offerings and increased our manufacturing footprint [with the new plant] to accommodate our aggressive strategic growth plans,” Parthenis, Jr. adds. “In January 2010, we made an investment to purchase and remodel a second, first-class, manufacturing facility, which is used predominately for bakery and other Mediterranean products.” This is where GDF now produces pizza crusts, the new Skinny Buns sandwich rounds, pitas, pita pockets, naan and other Continued on page 18
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Continued from page 16
operators as well as a variety of restaurants, retailers, the Chicago Public School System and hospitals. The other 10% makes up our growing retail business,” she says. Another key improvement that the
flatbreads, Fattori notes. “The vast majority (as much as 90%) of the products are shipped and sold frozen to foodservice customers—the traditional ethnic fast-food
Quality Assurance Sifters
company made recently was to start tracking machine reliability, and if downtime becomes a reoccurring problem, it conducts lifecycle analysis studies, followed by equipment strategy sessions carried out by production personnel to see if machinery should be repaired, rebuilt or replaced. Among other new features, the second production site houses a large, fully equipped maintenance room as well as a testing lab, ample warehouse storage space and plenty of space for another production line or two.
Food safety, other initiatives In April, the family-owned company also
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completed Level 2 out of 3 SQF (Safe Quality Food) certification. Level 2 is a certified Hazard Analysis Critical Control Point (HACCP) food safety plan benchmarked by the Global Food Safety Initiative (GFSI) program, whereas Level 3 is even more comprehensive and incorporates Level 2. “SQF is the new standard for retailers and foodservice providers internationally, and Grecian Delight Foods is excited to be among the first in the foodservice industry to anticipate this critical and credible qualification for food safety,” says Fattori. The bakery is also certified by the California Certified Organic Farm (CCOF), Santa Cruz, Calif., to run certified organic breads. “The company continues to invest in quality in an effort to stay true to its brand commitment of delivering the highest quality, and food safety is the No.1 priority,” states Parthenis, Jr. “With our achievement of SQF Level 2 certification, Continued on page 21
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we will continue to proceed to Level 3 in the near future.” If that’s not enough, GDF also completed an energy conservation project in 2009 for its lighting system through BlueStar Energy, Chicago, which made its lighting 80% more efficient than “standard building models,” and included a 5% electricity reduction. Per the Environmental Protection Agency (EPA), on an annual basis, BlueStar was able to help Grecian Delight reduce 442,331 kilowatt hours of energy and 308 tons of greenhouse gases and carbon dioxide pollution. This is equivalent to 86 cars off the road for one year or 7,899 trees planted and absorbing pollution for 10 years. More exciting news at the company will be taking place next year, Parthenis, Jr. hints. The company continues to juggle all of its customer demands, high-speed production, new product development, environmentalism and charitable endeavors
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with a strong sense of family heritage and a commitment to quality. “I’m most proud of our ability to invest and expand our products and value to our customers in a difficult economic time,” he adds. “I’m proud of our long-term commitment to be a leader in our space of specialty ethnic and Mediterranean foods.” How does GDF and Parthenis, Jr. do it? “What keeps me going is that I truly enjoy the challenges and stress that comes along with all of this,” says Parthenis, Jr. “When it comes to taking over a family business, growth drives me. Strategy drives me and building a team and expanding our products to deliver long-term sustainability for Grecian Delight Foods, Inc. drives me. Where will we see the company in five years? Continuing our course of expanding our presence in different segments through new products and customers and through growth by acquisition.” SF&WB
November 2011 - Snack Food & Wholesale Bakery
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Pita Plant and More Family–owned Grecian Delight Foods, a leading national manufacturer and marketer off Mediterranean-inspired foods, recently opened its second production facility, which it’s currently devoting to better-for-you, frozen flatbread products. Tour the 130,000-sq.-ft. facility, which features a state-of-the-art flatbread production line and room to grow. Lauren R. Hartman, Editor-in-Chief
C
ontinuing the plan of expanding its presence in different product segments through developing new products and cultivating more customers, Grecian Delight Foods (GDF), Elk Grove Village, Ill., recently boosted its production capacity, product offerings and manufacturing footprint in a dramatic way with the addition of a newly renovated bakery production plant, a few miles away from its original site. Opened in November 2010 to accommodate an aggressive growth strategy, the existing facility had at one time been a baking operation and went through at least a year’s worth of renovations and equipment installations, explains GDF president and chief executive officer Peter Parthenis, Jr. “We made an investment to purchase and remodel the second manufacturing facility into a firstclass operation that occupies 130,000 sq. ft. This second facility predominately bakes and produces a variety of Mediterranean products. The addition of a new state-of-
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Snack Food & Wholesale Bakery - November 2011
the-art bakery line for various flatbreads, buns and pizza crusts and more has enabled us to expand our product offering for our customers.” Though the recent economic downturn has been difficult for most food manufacturers, GDF hasn’t skipped a beat in its efforts to fulfill its mission and goals. Since it first opened in 1974, it has produced enough gyro sandwiches to feed 18.5% of the world’s population. Demand for its large line of Mediterranean foods and traditional Greekstyle dishes, flatbreads, pizza shells and pitas has kept the company on a brisk pace, says Parthenis, Jr. “We strive to produce quality according to customer’s specifications and our brand’s specifications first. I like to think this always trumps quantity,” he says. But quantity and high customer demand have been great enough for the company to open this second production plant with a high-speed bakery line.
Expanded capabilities Also located in Elk Grove Village, the second plant and the new line include several
Photos by Vito Palmisano
new features that GDF is especially proud of, Parthenis, Jr. says. Equipped with a large ingredient storage corridor, in-line packaging and freezing, a large maintenance room, customer/quality assurance testing lab that can be used for auditing microbial content, shelf life and other customer-specific needs and, to the delight of the staff, a well-appointed employee workout room, the spacious facility was
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Clockwise from left: A large batch of Skinny Buns dough mixes in one of the plant’s pair of new mixing systems. Line operators inspect the freshly-made product at various points on the line and also measure them and check size, color and thickness. Skinny Buns convey through stacking and overwrapping stations prior to bagging.
remodeled completely and is onstream to produce about 30 of the company’s stock-keeping units (SKUs). These include products in new categories, such as Indian flatbread, naan (available in classic and multigrain varieties), Middle Eastern flatbread, Lavash, traditional pitas and handstretched-style pizza crusts in a variety of flavors, shapes and sizes. “[The new facility] allows us to increase
our range of proofing time and has broadened our production capabilities to better meet our customers’ needs,” Parthenis, Jr. notes. “We are working diligently to fill production capacity for our new line. Our success will come to fruition by working closely with customers to meet their menu and consumer and operational needs and deliver effective solutions. We also expect to grow through acquisition.”
His father, company chairman and founder, Peter Parthenis, Sr., regularly walks around each department. “He is notorious for his saying, ‘the customer is No.1, so let’s make sure we satisfy and take care of their needs,’” says Parthenis, Jr. GDF has been able to start tracking machine reliability and closely monitor downtime using lifecycle analysis studies, followed by equipment strategy sessions. Continued on page 24
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November 2011 - Snack Food & Wholesale Bakery
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running the 90-calorie, whole wheat Skinny Buns that are packed into eight-count clear film bags containing 11.2 oz. each. Two large-capacity stainless-steel mixers at the head of the line mix up flour, oil, sugar and other ingredients as two operators look on before the mixers deposit the batch of dough into large bins. Flour, oil, sugar and other ingredients are pumped into the mixer hopper from large silos and tanks outside of the facility. Various types of flour can be used, such as whole grain, whole wheat, white and more, depending on what’s being produced
Continued from page 23
These are carried out by production personnel to see if machinery should be repaired, rebuilt or replaced. That’s not a major issue with the new bakery line systems, which include automatic docking, metal detection, x-ray technology, automatic pallet wrapping and computer controls. “We perform Hazard Analysis Critical Control Point (HACCP) checks all along the line,” says quality assurance director Mary Funteas. Along with daily maintenance and sani-
specifications, Funteas adds. “We have the capability to adjust the proofer so that our line speeds stay the same, to keep up with the rest of the production,” says Funteas. For proprietary reasons, the company prefers not to discuss line speeds or proofing/baking temperatures. Once proofed, the sandwich rounds enter the topping station before conveying toward a massive oven. “We can apply all sorts of toppings, such as seeds, dried cheeses, herbs, oats and a number of other things,” she points out. The rounds are then automatically baked in a multi-zone straightline oven,
At the time of Snack Food & Wholesale Bakery’s visit, the new line was running eightpacks of Skinny Buns, which are automatically bagged in-line with baking.
tation functions, among its other features, the second production site has plenty of warehouse storage space for frozen and refrigerated products and raw ingredients. Food safety is very important at the facility, and Funteas ensures strict sanitation procedures. Various practices of environmental, food safety, quality control and other measures have also been put into place at the facility. Upon entering the mixing room, everyone is required to wash their hands. “The line at this plant usually runs a 10hour shift, six days a week,” she observes.
Run time for buns At the time of Snack Food & Wholesale Bakery’s visit, the new flatbread line was
on the line at the time. Next, the large bins of dough are brought to an extruder hopper and are dumped into the hopper to be extruded into a flat sheet below. As the dough conveys through a sheeter, which progressively flattens it via a series of reducing rollers, the thickness decreases to a specific standard before it proceeds into a cutting section. The dough is then cut into rounds, and the line then progresses to a large-capacity spiral-conveyor proof box to relax and rise. Products can be proofed at various temperatures for anywhere from 0-45 min. and at various relative humidity (RH) percentages, depending on the quantity, customer requests, product type and other
says Funteas. Each zone also is set at a certain temperature (up to 1,000°F), depending on the product’s requirements. After baking, random samples of the rounds are measured by line operators at a quality control point and the rest of the rounds convey through a vision-inspection station where several key parameters such as color, cell structure, size, thickness, weight and shape are checked both by operators and by the system, which automatically displays details on a large flat-screen monitor. The rounds then wind their way onto a spiral conveyor to cool at ambient temperatures. Exiting the spiral conveyors, the cooled sandwich bun rounds then pass through a metal detection system and the conveyor Continued on page 26
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splits into lanes on its way to the packaging department. An operator checks color and shape as the rounds head into a slicer and are stacked into groups of four. The stacks travel single-file into a film overwrapper and are grouped into rows prior to bagging as eight-packs in clear multicolor-printed film bags. The bags are immediately clipped closed with a bag clip imprinted with production information before the filled, closed bags are checkweighed and sent through another metal detector for an additional safety/quality check. If the filled bags don’t measure up to GDF’s standards, the checkweigher will kick them offline into a tote. The finished bags then make a left turn on the conveyor for a final packoff into corrugated shipping cases, 12 bags per case. Other products that are supplied to local retailers can be tray-packed in open-topped plastic
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Snack Food & Wholesale Bakery - November 2011
crates (some customers use returnable trays for environmental reasons). Operators then direct the cases into an automatic tape sealer. An open date coder applies an expiration date and a Julian date before the cases of Skinny Buns are palletized manually. Usually, the palletized loads are then automatically stretch-wrapped and transported by forklift to a spacious freezer (approximately 30,000 sq. ft.) that has four-high rack capacity. The loads are then transported to a local distribution center for shipment nationwide by common carrier. The shelf life on the many different frozen bakery products varies, but is usually around six months, reports Amy Fattori, director of marketing.
Room to grow The efficiencies built into the new plant offer room to add more production lines in the future,” Funteas says. “This is a deceptively large facility. We could actually be
poised for two more lines. Depending on what product we need to run and what our customer requirements are, we change the equipment over to accommodate them. We can produce several flatbread sizes, shapes and flavors on this line.” Says Parthenis, Jr., “There is so much potential here. The only downfalls in a family business and at least for me, are that you don’t ever turn the work switch off at 5 p.m. It’s on your mind 24/7, and it’s the topic of discussion at every dinner and family gathering. So it’s a challenge to manage the workload and balance family and personal time.” But it’s worth it, he says. “Our ability to invest and expand with new products and value to customers in a difficult economic time is something I’m proud of as well as our long-term commitment to be a leader in specialty ethnic and Mediterranean foods.” It wouldn’t be surprising to see more expansions at GDF in the works. SF&WB
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Market Trends Bars
One Size Doesn’t Fit All Whatever the craving, the lifestyle or the health need, today’s bar manufacturers are breaking the mold by creating products that cater to the everyday consumer. Jen Roth, Contributing Writer
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ull up a seat and settle in with your favorite bar. There’s a variety of choices. Perhaps you’re looking for a new breakfast option, a quick, on-the-go bite or a supplement to a nutrition or exercise plan. Whatever the case may be, today’s bar producers are shedding the one-sizefits-all mantra and providing consumers of all health desires, cravings and lifestyles a bar just right for them. On the front line is Hearthside Food Solutions, a Downers Grove, Ill.-based contract manufacturer that enables its clients to stay on top of prevalent trends and formulate new ways to deliver innovative bars. “People expect bars to have a certain shape and size,” states Brian McNamara, vice president of sales. “Trusted brands continually try to push the envelope, deliv-
ering products that meet the customer’s expectations for what a bar should be while still offering a dizzying variety of formulations, flavors and options.” In fact, McNamara has seen an increase in targeted marketing and manufacturing for specific consumers such as women and moms, gluten-free snackers, organic food cravers and kids. “If a customer wants a certain size, color, texture, ingredient or formulation, our role is to help them get a quality product to market as quickly and efficiently as possible,” he adds. Meanwhile, gluten-free is a big trend in the bar category. That’s why Rise Bar of Escondido, Calif., is paying close attention
Bar Segment Totals (For the latest 52 weeks ending Aug. 7, 2011)
% Change vs Previous Year (in millions)
Unit Sales vs. Previous Year (in millions)
Unit Sales %Previous Year
Rank
Segment
Dollar Sales
1.
Granola
$1,002.3
+5.2
378.9
+2.8
2.
Nutritional/Intrinsic Health Value
$933.6
+14.6
430.4
+11.3
3.
Breakfast/Cereal/Snack
$707.8
-0.7
275.6
-0.4
4.
All Other Snack/Granola
$2.6
+2.0
1,09.2
+13.8
$2,646.4
+6.6
1,086.0
+5.1
Total*:
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Wal-Mart)
to consumers’ gluten-free demands. “Today’s consumers are becoming increasingly savvy, conscious and mindful of the ingredients that go into the foods they purchase, so it’s critical for food manufacturers to provide a product that has the nutritional benefits they come to expect,” states Peter Spenuzza, chief executive officer. Rise Bars underwent an energizing rebrand to provide consumers an allnatural energy boost. The Breakfast option, which comes in Crunchy Cashew Almond, Crunchy Cranberry Apple, Crunchy Honey Walnut, Crunchy Macadamia Pineapple and Crunchy Perfect Pumpkin, is made with hearty chunks of fruits and nuts, while the Energy+ kind (Apricot Goji, Blueberry Coconut, Cherry Almond, Coconut Acai and Raspberry Pomegranate) is laden with superfruits such as acai, goji and pomegranate mixed with toasty nuts and seeds. “[For the Energy+ kind], we incorporated goji berries and acai into our bars before they were considered ‘mainstream,’ and we look forward to being at the forefront of innovation as far as nutrition and flavor are concerned,” says Spenuzza. Rise Bar’s Protein+ bars are developed for those with an active, sporty lifestyle. They are made with five ingredients or less, packed with 17 g. of protein and come in Almond Honey and Crunchy Carob Chip. Continued on page 30
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Market Trends Bars
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“We also participate in a lot of athletictargeted events with a strong focus on sampling and promotional items, which allows attendees to try our bars on-the-spot and provide feedback,” Spenuzza says. Superfruit Nutrition, LLC of Wolverine Lake, Mich., also uses simple ingredients to create its version of a gluten-free bar. That’s it. fruit bars are made with only two fruit ingredients, which helps satisfy the U.S. Department of Agriculture (USDA)recommended two- to four-fruit servings a day. “Each bar has two servings of fruit, only 100 calories and 3 g. of fiber, which is great for weight management as well as satiety,” says Lior Lewensztain, president.
The That’s it. bars also contain vitamins A and C and beta carotene. These koshercertified, gluten-free, diabetic-friendly bars come in Apples & Cherries (one apple, 10 cherries), Apples & Pears (one apple, one pear) and Apples & Apricots (one apple, three apricots). “It is very difficult to find products that have less than five ingredients, let alone two,” says Lewensztain. “Hopefully, our products will show that it is possible to combine taste, nutrition and convenience with as few ingredients as possible.” Earnest Eats also discovers the benefits of using natural ingredients in bar products with its launch of Granola Planks granola bars. “Here at Earnest Eats, we use naturally sweet-dried fruits and brown rice syrup to sweeten our bar the natural way instead of using high-fructose corn syrup, and all of our foods are vegan and wheat-free,” says Andrew Aussie, president and co-founder of the Solana Beach, Calif., company. “Many people don’t have time for a bowl of cereal in the morning, and our Granola Planks offer delicious versatility. They can be
eaten on-the-go, crumbled over fresh yogurt, mixed into oatmeal or even toasted and topped with almond butter for a superfood energy breakfast.” Granola Planks come in Pomegranate Walnut Crisp, Blueberry Vanilla Crackle and Maple Almond Crunch options, contain 0 g. transfats and are an excellent source of phytonutrients. Earnest Eats also debuted Baked Whole Foods bars, which contain at least 5 g. of protein, 4 g. of fiber and 190 mg. of Omega 3s. They come in Chocolate Peanut Butter, Almond Trail Mix, Cran Lemon Zest and Apple Ginger varieties, with Double Chocolate Espresso and Refugee Harvest Dark Chocolate Mint options, which will join the line in 2012. “With on-the-go consumers, we’ve learned that our Baked Whole Foods bars are very popular for breakfast, as they’re a convenient, tasty and healthy way to eat while on-the-run,” says Aussie. “We’ve also learned that moms like the taste and the fact that we use clean, wholefood ingredients.” Earnest Eats also partnered with the International Rescue Committee (IRC), a New York-based non-profit organization, “to create a ground-breaking nutrition bar made with refugee-grown and harvested ingredients,” says Aussie. “Our Earnest Eats Dark Chocolate Mint Baked Whole Food bar will have actual mint grown by refugees on IRC community
farms in the U.S.” As bars become more prevalent in the busy 21st-century, consumers are turning to manufacturers to not only create a product that can be eaten on-the-go, but also supplement or replace a meal, yet still maintain a healthy lifestyle. To get rid of that post-exercise hunger, consumers can turn to Smart for Life protein bars, produced by Smart For Life, Boca Raton, Fla. “Our protein bars are all-natural, organic, preservative-free, gluten-free, low in calories and used as meal replacements,” says Richard Kayne, chief operating officer. “We feel our greatest opportunity is the functionality of our products to be used as unique meal replacements by suppressing hunger, making it easier to reduce caloric intake.” Smart for Life bars are available in Chocolate and Green Tea options and deliver 180-190 calories and 18 g. of protein. For those craving something a bit more salty or spicy for a mid-day nosh, Journey Bar, Chicago, filled the gap, thanks to a savory line of nutrition bars. “We wanted to show consumers that they could get a bar that tasted like real food, not like a candy bar,” says Marguarette Dau, co-founder. Journey bars are 100% natural, savoryflavored “travel” bars that combine the nutrition of organic whole grains with real-food flavors. Inspired by Japanese cuisine, for example, Wasabi Ginger boasts flavors such as soy sauce, ginger and wasabi, whereas Mesquite Barbeque provides a smoky, sweet, yet slightly tangy taste mixed with healthy Continued on page 32
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Market Trends Bars Continued from page 30
whole grains. The Italy-inspired Parmesan Romano variety contains oats, flaxseed, amaranth and millet mixed with Parmesan and Romano cheese and Italian spices. And the Thailand-inspired Coconut Curry variety blends a host of curry flavors to deliver a soft, but firm texture. “We believe there are consumers out there that are tired of the sweet bars and are looking for a nutrition bar that tastes like real food [that’s] also really healthy for them,” states Dau. “We think we’ll see others making this leap into totally savory soon.”
Ladies’ night Several bar manufacturers target women with their new products, specifically providing the right nutrients and added benefits to meet their needs. Women are a strong consumer force in the bar market, says Peter Wilson, president and CEO of Balance Bar. That’s why the Valahalla, N.Y., company introduced nimble.
“nimble for women is the first bar that conveniently combines beauty and nutrition in a delicious, indulgent bar, fortified with rich antioxidants to provide vital nutrients for healthy skin, and protein, vitamins and minerals for nutrition,” Wilson says. Introduced in July, nimble is an energy, beauty and nutrition bar all in one. Based on the same 40-30-30 ratio of carbohydrates, protein and fat as other Balance bars, nimble is made with Truvia sweetener, FloraGLO Lutein and beta-carotene for the skin. Each bar contains just 120 calories and provides fiber, protein, calcium, vitamin B6, iron and folate. They come in Peanut Butter and Yogurt Orange Swirl options. “The new nimble is also a great example of providing active, busy women with a daily health and beauty regimen all in one convenient, delicious, 120-calorie
bar,” Wilson says. Clif Bar and Co., Emeryville, Calif., targets women with LUNA bars, which are designed to deliver nutrition in a convenient, protein-packed bar.“The protein trend is hot for women right now, and our recent product launch, LUNA Protein, which is now gluten-free across all flavors, has been a huge success,” says Michelle Ferguson, executive vice president of brand marketing. LUNA Protein bars offer 12 g. of protein and 3 g. of fiber and come in Chocolate, Chocolate Peanut Butter, Cookie Dough, Chocolate Cherry Almond and Mint Chocolate Chip varieties. “Our customers have made it clear that they appreciate portable, healthy snacks made Continued on page 34
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Market Trends Bars
Continued from page 32
with nutritious and organic ingredients that taste delicious,” Ferguson adds. “We have been able to meet this challenge by offering a variety of foods with organic and nutritious ingredients and creating exciting flavor combinations.”
Sports bars Many bars originated as supplements for athletes and fitness enthusiasts. That’s why Health Warrior, Richmond, Va., the makers of Health Warrior brand chia seeds, expanded to include a 100-calorie, all-natural Peanut Butter Chocolate Chia energy bar made with chia seeds. This product features numerous health benefits and is said to have an ability to energize, rejuvenate muscles, hydrate, improve cardiovascular health, support de-
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toxification, augment strength, bolster endurance, stabilize blood sugar, induce weight loss and aid intestinal regularity.
“We want our brand to motivate customers to better, stronger health, to make them part of our tribe and to win the daily battle,” says Shane Emmett, chief executive officer. “Our goal with the bars was to create a genuinely healthy, functional product containing as few ingredients as possible and to make chia the No. 1 ingredient.” The folks at Health Warrior promote its products at marathons, triathalon expos, fitness events and various health-food restaurants, and have plans to launch a 100-calorie Acai Berry variety in the near future. “They [will] have an analogous nutrition profile and taste berry, berry good,” Emmett says.
Additionally, Grecian Ideal Nutrition, Allendale, N.J., also targets an active client base with its all-natural Focus Food bars, which are all-natural protein bars with 22 g. of protein and 6 g. of fiber per bar. They come in a Chocolate Fudge Brownie option. “The two most unique attributes of the product are its Focus Blend of caffeine,” says Chris Karsos, president. “The Focus Blend provides a quick and long-lasting source of energy to the consumer. When you combine this with a good source of protein and fiber, you feel satisfied and full of energy.” It’s clear that bars are not one-sizefits-all, but today’s bar producers make it possible for consumers of all health desires, cravings and lifestyles to find a bar just right for them. SF&WB
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Company: Liberty Orchards, Cashmere, Wash. Website: www.libertyorchards.com Introduced: September Distribution: West Coast Suggested Retail: $1.59 to $1.99 for a Company: Wholly Wholesome, 1.6-oz. bar Chester, N.J. Product Snapshot: Orchard bars are Website: www.whollywholesome.com all-natural, vegan and gluten-free bars Introduced: October that are loaded with premium fruits, Distribution: National nuts, sunflower seeds and flaxseed and rich in antioxidants (vitamins A and C) Suggested Retail: $10.39-11.79 for a and Omega-3s. They come in Blueberry 25.5-oz. box Pomegranate & Almond, Pineapple Product Snapshot: Wholly Wholesome expands its team of bake-at-home, Coconut & Macadamia and Strawberall-natural and organic frozen desserts to ry Raspberry & Walnut varieties. include an 8-in. dairy-free pumpkin pie. Ingredients (Pineapple Coconut Reformulated from the company’s tra& Macadamia): Fruit (fruit juice from ditional recipe, this option is made with concentrate [organic apple, pineapple], all-natural pumpkin and tofu puree. pineapple, coconut, organic apple flake), organic evaporated cane syrup, organic Ingredients: Pumpkin, water, organic tapioca syrup, nutmeats (macadamias, cane sugar, tofu puree (water, whole cashews, brazils), seeds (sunflower, non-GMO soybeans, magnesium chloflax), soy protein nuggets (soy protein ride, calcium chloride), organic wheat isolate, tapioca starch, salt), fruit pectin, flour, palm oil, non-GMO egg replacer citric acid, natural flavors, sodium (soy flour, wheat gluten, corn syrup citrate, ascorbic acid, vitamin E (to presolids, sodium alginate), organic whole serve freshness). Contains: macadamias, wheat flour, sea salt, cinnamon, ginger, cashews, Brazil nuts, and soy. nutmeg, cloves. Contains: wheat, soy.
2
1
Pork Sticks Company: Rudolph Foods Co., Inc.,
Lima, Ohio
Website: www.rudolphfoods.com Introduced: September Distribution: South and Southwest Suggested Retail: 99 cents for a 1-oz. stick
Product Snapshot: New to the South-
ern Recipe lineup are Pork Sticks, a convenient, on-the-go snack that is said to fight man-size hunger. Each snack contains 5 g. of protein, 7 g. of fat and is only 90 calories. Ingredients: Pork, water, salt, corn syrup solids, sodium diacetate, citric acid, mustard, dehydrated garlic, natural smoke flavoring (maltodextrin), sodium nitrate, stuffed in beef collagen (beef, caramel, annatto, Red 3).
Orchard Bars
Dairy-free Pumpkin Pie
4
Onion Rings & Flavored Tortilla Chips
Company: Axium Foods, South Beloit, Ill. Website: www.axiumfoods.com Introduced: October Distribution: National Suggested Retail: $1.00 for a 3.5-oz.
bag of Pajeda’s onion rings; $2.99 for a 10-oz. bag of Fiesta Crunch tortilla chips Product Snapshot: Pajeda’s onion ringflavored chips join an already successful line of $1 snacks. Fiesta Crunch tortilla chips come in Nacho, Ranch and mole options, the latter maintaining a complex sauce typically made with chilies, chocolate and spices. Ingredients (Onion Rings): Corn meal, vegetable oil (consists of one or more of the following: corn, cottonseed, canola, palm, soybean oil), whole milk solids, dehydrated onion, maltodextrin, salt, onion powder, sugar, toasted onion powder, monosodium glutamate, yeast extract, natural flavors, spices, less than 2% garlic powder, citric acid, paprika, caramel color, silicon dioxide (anticaking). Contains: dairy.
Edi tor ’s N ote: G o to www. s n a cka n d b a ke ry. c o m to re a d a b o u t mo re n e w p ro d u ct s.
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The Nutritional Corner
Nutrition Education at All Things Baking
W
hen it comes to nutrition, the grains industry is at a crossroads. With digital and social media channels allowing for faster sharing of information, this also gives rise to faster sharing of misinformation, especially when it comes to nutrition and health. Because of this shifting media landscape, it’s crucial that we, as members of the food industry, stay abreast of the latest nutrition informa-
ence studying health, fitness and body weight. He is a professor and director of the Healthy Lifestyles Research Center and the Exercise and Wellness Program, both at Arizona State University, Phoenix. Then, Melendez-Klinger, a registered dietitian and founder of Hispanic Food Communications, provided attendees with information about the latest studies surrounding folic acid and the importance
Members of the Grain Foods Foundation’s scientific advisory board gathered to discuss the latest in nutrition research. tion. To help you better understand the most pressing trends being covered in the media, we hosted a grains nutrition panel during the All Things Baking conference, titled, “Grains Nutrition Update: The Issues Affecting Our Industry.” The panel consisted of three members of the Grain Foods Foundation’s scientific advisory board—chairman Glenn Gaesser, Sylvia Melendez-Klinger and Shelley Case. During his presentation, Gaesser discussed why carbohydrates are beneficial, particularly when it comes to maintaining a healthy weight and following the latest 2010 Dietary Guidelines for Americans. Gaesser is an expert on weight maintenance and has years of research experi-
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Snack Food & Wholesale Bakery - November 2011
Judi Adams, president, Grain Foods Foundation and the Wheat Foods Council
It was an engaging session that allowed for open dialogue between the panelists and members of the industry. I’d like to extend a big thank you to everyone who attended the seminar. For those of you who were unable to make it, a webcast of the panel will be available through the Grain Foods Foundation’s website,
From left, Sylvia Melendez-Klinger, GFF chairman Glenn Gaesser, Shelley Case and GFF president Judi Adams.
of enriched grains as a source of this vital nutrient. She also covered how enriched grains can be part of the solution to some of the health and nutrition problems our population faces, specifically the Hispanic population. Finally, Case, author of “Gluten-Free Diet, A Comprehensive Resource Guide,” concluded the panel with a discussion about the gluten-free diet. She offered background on what medical conditions require a gluten-free diet (a diet that omits any gluten-containing food, including anything made from wheat, barley and rye) for treatment as well as the latest statistics about these conditions, which include celiac disease and gluten sensitivity.
www.gowiththegrain.org. Aside from the nutrition panel, the conference was also an opportunity to reconvene members of our multidisciplinary scientific advisory board. This group of health experts gathered on Oct. 2 following the panel to discuss the latest nutrition research and identify opportunities for collaboration. The insights from this meeting will help us as we prioritize issues and develop new influencer programs. In closing, I hope everyone enjoyed All Things Baking as much as we did. We look forward to attending next year’s conference, Sept. 9-11 in Houston, and sharing with you all the great things that came out of this year’s meeting. SF&WB www.snackandbakery.com
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Special Report:
Sanitary Equipment Design
Designed for Safety
Food safety has never been more critical than it is now. Every baker and snack manufacturer needs to know what equipment is available that meets the highest sanitation standards and latest trends in sanitary equipment. Find out what several food safety and sanitary equipment specialists have to say about new advances in the market and what customers can expect from them. Photo courtesy of Sani-Matic, Inc.
Lauren R. Hartman, Editor-in-Chief
I
t’s not easy to control allergens and pathogens on equipment running in any production facility, but it has to be done to reduce the chance of having a food safety problem, and must be in accordance with new Food and Drug Administration (FDA) food safety guidelines. With cases of salmonella, listeria and E.coli outbreaks and large food recalls, food safety is a very real concern. That’s why sanitary production equipment design is integral to food safety. But challenges exist in creating such equipment within budget and with as much energy efficiency as possible. In many ways, it pays for bakers and snack manufacturers to use the latest technology and processes to lower food safety risks. It also pays to keep pace with associations that have a presence in Washington. The American Bakers Association (ABA), Washington, D.C., for example, filed comments in August with the FDA on how bakeries are addressing preventative controls in their facilities in response to the FDA’s request for information, as bakeries move forward with implementation of the Food Safety Modernization Act. The ABA notes that “key elements for any agency preventative control guidance should contain flexible guidelines to meet the needs of
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individual baking companies, both large and small, recognizing that bakeries have different issues and resources, and that a ‘onesize-fits-all’ approach isn’t appropriate.” The association also points out that guidance should be science-based and cost-effective, specifically relative to hazard analysis, process controls, validation, sanitation requirements, allergens, environmental monitoring, microbial testing, food defense and the impact on small bakers.
Future issues Likewise, the American Institute of Baking International (AIB), Manhattan, Kan., looks at how current and potential future issues are driving machine design improvements. “Manufacturers of low-moisture foods have serious concerns over microbiological contaminants and disease-causing pathogens,” says Jon Anderson, head of Occupational Safety and Health Administration (OSHA), Washington, D.C., and compliance and educational product development at AIB International. “The need for control of allergenic foods during production has also become a driving force
in equipment design improvements. Just as important, the end user of equipment, or the food manufacturer, is beginning to make significant demands for improved design in production equipment.” In the past, higher performance was always the top priority, he says. But now, there is more discussion about safe design. “Sanitary design is beginning to establish a significant foothold in the discussions and decision-making processes when it comes to buying new machinery,” he says. The recent, well-publicized foodborne illness issues have been hard lessons in the need for efficient design and prevention of pathogenic contamination, Anderson points out. “Certain companies have been involved in costly, time-consuming efforts to correct and eliminate the source of contamination. They realized that recog-
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Special Report:
Sanitary Equipment Design nized and common design characteristics could help prevent such issues or at least make the resolution of problems more economical and less invasive in terms of the consumer’s trust with a particular type of product or company’s brand name.” When it comes to purchasing equipment, a most important factor to consider is efficiency, Anderson says. “Many companies operate on a 24/7 basis, and the window of opportunity to deep clean is extremely narrow. The more efficient a piece of equipment is in terms of time saved during cleaning, the more time is provided to production. But food manufacturers know the need for production time doesn’t preclude the need for effective cleaning to remove soil, microbes and pathogens and to prevent allergen contamination. Food manufacturers look at equipment design to provide a time-efficient ability to break down the equipment, clean and sanitize and return the equipment back to production, ensuring safe and quality foods.” AIB noticed that major food manufacturers and retailers expect maintenance personnel and engineers at a supplier’s location be given training, education and a working knowledge of effective sanitary design to added or existing equipment. “Major manufacturers want to see that at a fundamental level, suppliers understand sanitary design, and use these concepts when purchasing equipment or building their own production equipment,” says Anderson. Purchasers are also concerned about the cost of downtime, from both a labor and materials perspective and in terms of lost production time. Gale Prince, who leads Cincinnati-based Sage Food Safety Consultants, which tailors specialized food safety consulting services to organizations looking to improve food safety measures, maintain regulatory compliance and protect their brand identity, says that as firms look for greater efficiencies (such as maximizing equipment usage and reducing downtime), they are also looking to reduce liabilities and protect their customers and their financial health. “The cost of a product recall for a
food manufacturer is enormous,” he says. “Those that think of a recall in terms of product costs only are very short-sighted… the expenses of a recall can add up to many times more than the value of the product.” “Food firms have identified design deficiencies as a contributing factor in product contamination, of which some have led to product recalls,” he adds. “Some design deficiencies have made it difficult or nearly impossible to adequately clean equipment. Currently, the leading cause of food recalls is microbiological contamination or food allergens, both of which require very detailed and precise cleaning methods. However, the labor costs of cleaning and sanitizing are a major reoccurring expense that firms have recognized with some of the equipment currently in use.”
Time, cost to clean Gabe Miller, senior technical engineer at Sani-Matic, Inc., a Madison, Wis., supplier of assorted washing and cleaning systems, says the two main issues driving sanitary equipment design is the time required to clean processing equipment and the cost of cleaning it, including the labor, water, energy and chemicals. “Everyone recognizes that [production] equipment must be properly cleaned, and the liability of poor sanitation is too significant to overlook, but they need to clean faster and at reduced cost,” Miller points out. “Customers Photo courtesy of Sani-Matic, Inc.
require processing equipment to meet industry sanitary design standards and want it to have ‘clean-in-place’ features where possible to minimize labor and time.” So what are snack food and bakery equipment manufacturers doing now to address these concerns? Sani-Matic adapted conventional cleaning systems to new process applications that are suitable for parts traditionally cleaned by hand or in tanks. The M223 cabinet washer, for instance, uses eight gallons of water to wash parts in an automated 10-minute cycle and was developed to be cost-competitive with manual cleaning systems. An electrochemically activated water (EAW) system uses sodium chloride to generate cleaning detergent and sanitizer on-site. This eliminates the cost and safety issues of purchasing bulk concentrated chemicals for cleaning and sanitizing, Miller says. Also new is the TS-5 tanker spray system for over-the-road tankers, which improves the cleaning process using less water, time, energy and chemicals. The TS-5 can dramatically boost tanker cleaning versus traditional drop-in sprays, according to Miller. “Manufacturers who develop the most cleanable process equipment that’s also cost-competitive will have a significant market advantage,” he adds. “The big challenge is that many process equipment manufacturers often don’t understand design requirements for CIPability. The designers understand process requirements such as mixing, drying, blending, etc., but the design requirements for cleaning are very different and sometimes in conflict.”
Detachable parts and belting Kevin Lemen, vice president of sales and marketing at Douglas Machines Corp., Clearwater, Fla., a manufacturer of automated washing and sanitizing equipment, sees a trend toward washing detachable scale parts and conveyor belting. “Both trends are being driven by a need for quick turnaround and compliance with food safety and labeling initiatives,” he says. “Labor savings is another strong motivator Continued on page 42
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November 2011 - Snack Food & Wholesale Bakery
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Special Report:
Sanitary Equipment Design Continued from page 41
for investing in this type of equipment.” Lemen cites a white paper relating to his company’s scale parts washers. He says the company-produced paper explains that food processors are turning to manufactures of automated washing equipment to overcome issues associated with labor- and time-intensive washing. Specialized wash racks have been developed to hold specific parts in the proper orientation to spray arms to maximize cleaning effectiveness and protect them while cleaning and in transport. The other task has been to maximize wash rack capacity, so many parts as possible can be washed in a batch. Roll-in type batch washers with specialized wash racks for buckets, feeder pans and chutes are also effective, he says. Each wash cycle is followed by a 30-second sanitizing rinse at 180-190°F to provide sanitizing without the use of expensive chemicals. The rinse water is routed back
to a recirculating washtank. The primary benefits of automated washing systems include developing a standard operating procedure; offer consistent results time after time; save water, labor and energy; minimize turnaround time; clean and sanitize in one step and extend parts life.
Other special features In September 2010, Buhler Aeroglide, Cary, N.C., which produces dryers, ovens, roasters, toasters, blanchers and coolers, among other equipment, initiated a comprehensive study by visiting several customer sites, driven by its food and feed customers who were concerned by the heightened focus on sanitation. “We met with engineers, operators, mechanics, cleaning personnel and food safety delegates,” explains Steve Blackowiak, food safety manager for Bühler Aeroglide. After compiling more than 400 responses, the company created a list of features and improvements to use in the development, design and manufacture of a new, improved drying system that addresses specific areas related to food safety and sanitation. Nearly complete in its development and engineering, the new sanitary dryer system will be installed in February 2012, Blackowiak says. Remaining cost effective, the new features include an open structural frame formed from stainless steel, which prevents moisture from entering hollow tubes that could otherwise allow moisture to enter. Other attributes include sanitary door panels with continuous welds on inner and outer skins; new water collection troughs that inhibit wash water from accessing the plant floor or adjacent wall; new options for water collection; a “slab” floor construction that’s easy to clean and promotes water runoff; sanitary dryers with a new conveyor design that eliminates conventional roller chains and traveling side guides and a lightweight design. The basic sanitary model will be available with modules that can be supplemented to meet specific customer needs. For example, cus-
Photos courtesy of Douglas Machines Corp.
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tomers can add modules such as Sanitary Plus (a wash system for the conveyor bed), the basic sanitary dryer (a CIP option) or a Validation module, which offers validated kill steps and sanitizers. “Sanitary designs that reduce horizontal shelves and minimize cracks and crevices reduce the places for debris and/or bacteria to accumulate,” adds Blackowiak. “Reducing accumulation shortens the cleaning time and bacteria risks. Customers focus on costs to clean equipment, which has had an impact on our sanitary design. When a dryer is cleaned, obviously it cannot produce any product, so downtime is very costly.” “Production facilities are starting to incorporate more washdown features in the flooring and walls and equipment is being upgraded to more corrosion-resistant materials like plastic and stainless steel,” says John Kuhnz, director of marketing for Dorner Manufacturing. The Hartland, Wis.-based company produces a variety of sanitary conveyor automation solutions that Kuhnz says are evolving every day. These include conveyors for dry areas and wipedown and washdown systems available in both aluminum and stainless steel. “Each time equipment is manufactured, suppliers and customers are working on ways to make the equipment more sanitary,” he adds. “The equipment is engineered to be more hygienic in order to make the sanitation process fast and effective. These changes are the result of the more consistent production area sanitation requirements.” Plus, Dorner’s washdown products have tip-up tails that provide quick access to the internal frame for sanitation, Kuhnz says. “On our dry conveyor platforms, we have developed the SmartSlot that creates a smooth side on the exterior but allows for the fast attachment of automation components. In other words, the conveyors won’t have T-slots that can catch product debris.” Dorner’s top-selling sanitary equipment is the AquaPruf, which is designed for fast, effective sanitation that often saves on the cost associated with daily washdowns, Kuhnz says. “We also continue to invest Continued on page 44
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Special Report:
Sanitary Equipment Design Continued from page 42
in smart conveyance. These features go beyond sanitation into conveyors that are easier to implement, communicate with and interface with emerging technologies and packaging.”
Opportunities today and tomorrow AIB’s Anderson says the greatest opportunity for equipment manufacturers would be to design and build equipment that can be easily cleaned and sanitized in a way that will control pathogens and allergens in low-moisture foods produced in a dryclean environment. “The challenges in equipment design include the need to avoid conflicting interests with food safety, employee safety and OSHA compliance,” he adds. “Improving accessibility within machinery and allowing for thorough cleaning while preventing exposure to moving parts and hazards to employees will be a big help to the end user.” Tim Talbert, food expert at materials handling equipment manufacturer Triple S Dynamics, Dallas, says that all stainlesssteel, passivated equipment designed according to USDA 3A dairy/pharmaceutical standards is becoming popular. Such equipment is increasing food safety and decreasing food spillage. In terms of production facilities, the trend is to have production cycles with reduced changeover/cleanup times. “Customers want to minimize [the amount of] painted surfaces required, including those on drive motors and reducers,” says Talbert. “They also want exposed foodstreams to be covered, so as to prevent accidental contamination from allergens or foreign material such as paint chips. We’re meeting these needs with stainless-steel conveyors that include stainless-steel drive assemblies and stainlesssteel motors. We also feature stainless-steel support frames with round or diamond-set tubes that eliminate flat surfaces where dust and/or water could collect, as well as round standoffs for bearings and other mounted components. This eliminates tight crevices that are difficult to clean.” Triple S is currently testing a pancleaning device for its horizontal-motion conveyors. The device is powered by the
conveyor pan motion and removes food dust and residue from product contact surfaces of the conveyor pan,” Talbert says. Triple S typically has many questions for customers who want a high degree of sanitation, he adds. “We ask if their conveyor will be installed in a washdown area, if they will use caustic cleaners and if so, they may need 316 stainless-steel [components] instead of the more traditional 304 stainless-steel,” he says. The company also notices great opportunities with food processors that haven’t traditionally used dairy- or pharmaceutical-grade equipment to handle finished product at the packaging end of the line. “And though we have been manufacturing the Slipstick accumulator for more than 20 years, more customers are switching to them because their gentle horizontal conveying motion minimizes product degradation and the seamless conveyor pan eliminates cracks, crevices and moving parts in the foodstream.” Ensuring that food contact surfaces can be easily accessed and cleaned without the use of tools is tricky, Talbert says, because typically, tools can only be used by maintenance personnel and in most cases, the equipment is cleaned by the line operators. “Also, lead times on the purchase of some stainless-steel components can be very long and can cause challenges when trying to meet project delivery schedules,” he adds. In addition, while some design improvements can be executed with no impact to costs, others will be more expensive, attests Buhler’s Blackowiak, such as finish requirements that will involve more labor.
Design standards activities AIB says three ongoing activities have an impact on
design standards and the understanding of design criteria. They include a review and update of the current Baking Industry Sanitation Standard (BISSC). The standard is officially referred to as the ANSI/ASB/ Z50.2-2008 Sanitation Standard for the Design of Bakery Equipment. Prince’s Sage Food Safety Consultants has been retained to facilitate the review and modification of the standard per committee consensus. Working groups formed to generate suggestions for modifications of the standard expect to have a completed draft of a revised standard by February 2012. “Work has begun on ‘revamping’ the BISSC, which has been around since the 1940s. Spurred on by recent recall and regulatory activity, trade associations such as ABA, AIB, ASB [American Society of Baking], BISSC and BEMA have joined together to revitalize the standard, which gives guidance to equipment manufacturers and designers on industry expectations for design-based cleanability. Since equipment cleaning is a reoccurring cost over the life of the piece of equipment, the cleanability it provides is a selling point. But designers need to work with the maintenance personnel and production employees in designing the equipment to see the cleaning challenges their equipment brings forth.” Machinery manufacturers can also attend a series of equipment design seminars such as the “Equipment and Plant Design Workshop for Allergen/Pathogen Control” which provides an overview of equipment design and the issues that poor design and maintenance create. (For more details, contact AIB at www.aibonline.org or www. bema.org). Another activity is a certified equipment design seminar for BISSC certification, which provides a practical and applied approach to design standards, allowing participants to review the criteria line by line, requirement by requirement, giving them the ability to apply design concepts to their equipment and then apply for certification under the BISSC seal. SF&WB
Photo courtesy of Triple S Dynamics
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Snack Food & Wholesale Bakery - November 2011
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Ingredient Technology Antioxidants & Omegas
Omegas: The Fountain of Youth
Many of today’s ingredient suppliers are making it so that consumers can turn back the clock with the help of antioxidant- and Omega-rich foods. Marina Mayer, Executive Editor
T
and give baked goods a lush taste, broad appeal and clean label, Payne notes. “The emphasis on healthy finds a ready market in every demographic, from childhood concerns about obesity to adult interest in health-perpetuating lifestyle and eating habits,” he adds. “These concerns bode well for ingredients consumers view as good-for-them. When food producers develop products with blueberries, even in today’s crowded marketplace, they can be confident consumers will view their blueberry-based products as healthy, thus enhancing the probability of launching a successful product.” Tart cherries also deliver a unique phytonutrient profile that works in unison to
he fountain of youth is a legendary spring full of restorative powers that reinstates the youth of anyone who drinks out of it. But, since this fountain of youth doesn’t really exist, consumers turn to alternative, age-defying methods, such as cosmetic surgery, excess exercise and a diet overhaul. That’s why many of today’s ingredient suppliers are making it so that shoppers don’t have to go to extremes to ward off wrinkles, lines and gray hair— all they have to do is turn to antioxidant- and Omega-rich foods to help restore their youth.
A healthier you Several health professionals tout antioxidants as the “knights in shining armour”—always in position to fend off disease and promote a healthier you. “Antioxidants are thought to help protect the body against the damaging effects of free radicals and the chronic diseases associated with the aging process,” says Tom Payne, industry specialist for U.S. Highbush Blueberry Council, Folsom, Calif. “Blueberries contain many of these naturally occurring antioxidants.” Blueberries maintain a flexible portfolio, as they are synergistic with oats, amaranth, buckwheat, chia, millet, quinoa, sorghum, teff, kamut, farro, spelt and more, Payne says.
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Photos courtesy of the U.S. Highbush Blueberry Council
“With heightened interest in gluten-free products, blueberries are a popular ingredient. Their presence lends gluten-free formulations a homey and old-fashioned attraction,” he adds. “Blueberries can serve as the basis for vegan snacks and other special-diet foods. They are also compatible with nuts and seeds.” Blueberries are also linked to heart health, anti-aging, cancer prevention and improved eyesight and memory,
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Ingredient Technology
Antioxidants & Omegas
Photo courtesy of the Cherry Marketing Institute
“deliver a powerful antioxidant punch,” says Phil Korson, president of the Cherry Marketing Institute, Lansing, Mich. “Known for their bright red color, cherries are particularly rich in anthocyanins— compounds linked to reduced inflammation associated with heart disease, arthritis and even muscle recovery post-exercise,” he adds. “Available year-round as dried, frozen and juice, tart cherries can provide an ingredient advantage to the growing
healthy snack foods market.” Tart cherries also can be promoted as a versatile superfruit, lending a sweet-tart flavor to granola, scones, muffins and more. “Tart cherry ingredients can deliver natural technical advantages for some of today’s toughest product development challenges, such as clean ingredient labels, extending the shelf life of food, keeping baked goods moist and mold-free, reducing fat and sodium and safely eliminating some food additives (specifically chemical preservatives),” Korson notes. For its part, Kemin Food Technologies developed FORTIUM, a line of natural extracts and plant-derived antioxidants that include tertiary butylhydroquinone (TBHQ), mixed tocopherols, rosemary and rosemary and green tea extracts. “FORTIUM can conserve the appearance, taste and nutritional value of many bakery and snack applications without changing their flavor, color or odor profiles,” says Betsy Blades, marketing manager for the Des Moines, Iowa, ingredients supplier. “These antioxidants and natural plant extracts can be added to oil used for frying bakery and snack food items, as an ingredient in the product formulation or included in a seasoning packet.”
The FORTIUM line can be used in a variety of applications, including nuts, bread, whole grain products, chocolate, chips and more. Kemin also introduced GT-FORT, a natural flavor designed as an alternative to synthetic antioxidants and tocopherols commonly used in frying oils. This greentea-based, water-soluble liquid extract is oil-dispersible and said to slow the deterioration of frying oil, thus reducing oxidative rancidity, even at high temperatures. “Delaying oxidative changes means reducing the off flavors that occur near the end of shelf life,” Blades says. “Depending on the freshness of the raw materials, extract usage level and packaging, natural extracts can increase shelf life by several weeks, if not months.”
The Omega overhaul While antioxidants stand at the front of the line, Omega 3, 6 and 9 fatty acids maintain a rather significant position as well. “I think, like most of the food and beverage industry, [bakers and snack manufacturers] are being challenged to become healthier and offer more value to the consumer,” says Sarah Sullivan, direcContinued on page 48
Photos courtesy of Kemin Food Technologies
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Ingredient Technology Antioxidants & Omegas Continued from page 47
tor of strategy and new product planning for the Nutritional Lipids division of DSM Nutritional Products, Columbia, Md. That’s why DSM created life’sDHA, a vegetarian source of DHA Omega 3 that can be used in snacks and baked goods, such as breads, tortillas soft cookies and
muffins, and DHA+EPA (life’sDHA plus EPA), a more commercial version. Both oils are derived from a vegetarian source and offer a clean sensory profile. They stem from algae—not fish, which is the more commonly used omega source—allowing bakers and manufacturers to claim cleaner
labels, such as “vegetarian” or “free from animal byproducts.” “Historically, most Omega 3 (DHA and EPA) ingredients have been derived from fish, and therefore food manufacturers have been challenged with masking the fishy taste and smell associated with these oils,” says Sullivan. “But, because we offer Omega 3 products derived from algae, that have a cleaner sensory profile, manufacturers are not faced with the same formulation challenges.” Meanwhile, QualiTech Inc., Chaska, Minn., and Omega Protein Inc., Houston, teamed up to deliver Flavor-ettes with OmegaPure, an Omega-rich solution that can be “tacked” onto Flavor-ette granules at the end of processing, thus further ensuring protection of the long chain Omega 3 fats, according to Katherine Bond, director, business development for Cyvex Nutrition, an Irvine, Calif.-based partner of Omega Protein’s. “Just 100 g. of Flavor-ettes with OmegaPure contains 10% ultra-fresh refined fish oil, providing 2,000 mg EPA+DHA,” Bond adds. “Upwards of 50 mg of EPA+DHA can be provided per food serving. This proprietary formulation is specifically designed for dry-mix applications and is available in sweet and savory varieties to add flavor, mouthfeel and
Photo courtesy of Dow AgroSciences
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Photo courtesy of Dow AgroSciences
visual appeal to bakery, snacks, cereals and frozen entrées.” Flavor-ettes with OmegaPure also come in several different flavors such as cinnamon, blueberry, strawberry, lemon, chocolate, jalapeño and more. Last year, Cincinnati-based Cargill Oils & Shortenings launched Clear Valley Omega 3, a unique canola-flax oil blend that provides food manufacturers with a method to add a source of alpha-linolenic acid (ALA) Omega 3 to shelf-stable products without affecting product taste, mouthfeel or shelf life, says Willie Loh, vice president of marketing. “With Clear Valley Omega 3 oils, food manufacturers can make a ‘good source of ALA Omega 3’ nutrient content claim with as few as 0.53 g. of fat per serving and an ‘excellent source of ALA Omega 3’ nutrient content claim with as few as 1.07 g. of fat per serving in shelfstable products without the fishy taste or odor,” he adds. In addition, Clear Valley Omega 3 oil is said to work well in cookies, breakfast/energy/granola bars, crackers and muffins. Aside from Omega 3 products, Omega-9 oils can help maintain important functional product qualities, such as flavor, shelf life, texture and mouthfeel, while incorporating “good fats” in baked goods, snacks and packaged foods, says David Dzisiak, commercial leader oils for Dow AgroSciences, Indianapolis, Ind. “Omega-9 sunflower oil is all-natural and can support an all-natural package claim, as the oil comes from NEXERA seeds, which were developed by Dow AgroSciences through traditional plant-breeding,” he adds. Available for sampling in 2012 with a 2013-14 projected launch timeframe, this Omega-9 sunflower oil is designed for cookies, crackers, tortillas, potato chips, muffins and microwave popcorn. “When formulating with Omegas, challenging factors include offflavors, instability, rancidity and oxidation. Omega 3s in particular tend to have a fishy aftertaste,” Dzisiak adds. “While food manufacturers may mask this taste with preservatives, Omega-9 oils ingredient solutions taste neutral and maintain the flavor characteristics of the original product without additives.” Thanks to a plethora of antioxidant and Omega solutions, consumers can restore their youth in no time, all while enjoying great-tasting snacks and baked goods. SF&WB
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Ingredient Briefs
ADM’s VegeFull beans offer a simple way to add big nutrition to bakery and snack products. Cooked, ground and ready to use, VegeFull delivers all of the health benefits of beans, including fiber, protein, vitamins and antioxidants. VegeFull comes in a variety of formats, such as noodles, pieces, grits and powders, and is derived from multiple classes of beans. Archer Daniels Midland Co. Decatur, Ill. 800-637-5843 www.adm.com/vegefull
Drum-dried carrots from Van Drunen Farms add the nutrition and rich flavor of carrots to new and existing bakery products. Drum drying is achieved by drying pureed, raw ingredients at relatively low temperatures between two rotating high-capacity drums. This results in a continuous sheet of dried product that is then milled into a flake or powder format. The product easily reconstitutes and retains much of its flavor, color and nutritional value, and is an economical ingredient choice. They come in both conventional and organic forms. Van Drunen Farms Momence, Ill. 815-472-3100 www.vandrunenfarms.com
SF&WBtv 50
Danisco’s PinVita phytosterols are derived from a natural sustainable pine source to help reduce cholesterol absorption and decrease plasma cholesterol levels. Available in free or esterified forms for use in bars and other bakery products, PinVita phytosterols make it so that less than 5% of phytosterols are absorbed. Danisco USA Inc. New Century, Mo. 913-764-8100 www.danisco.com
SweetWorks introduces the Celebration line of sixlets, pearls, gumballs and ovation bits (small pieces of dark chocolatecovered mint truffle sticks) to be used as toppings for cakes and cupcakes. The sixlets come in 4.5-oz jars featuring 12 colors and three seasonal mixes and 14-oz. bags of 14 colors. Pearls are available in 4.5-oz. jars, in 12 colors and three seasonal mixes. Gumballs come in 8-oz. peg bags of eight individually-packaging colors. The ovation bits are available in a 14.5-oz. bulk case. SweetWorks, Inc. Buffalo, N.Y. 716-204-0733 www.sweetworks.net
Sweet ‘n’ Neat Hon-E-Shine from ADM/ Matsutani is composed of Fibersol-2 soluble corn fiber, honey and purified steviol glycosides and contains 78% soluble dietary fiber on a dry solids basis. Sweet ‘n’ Neat Hon-E-Shine is formulated to reduce calories and sugar, increase fiber and offer a heat- and acid-stable option for snacks, confections and baked goods. ADM/Matsutani LLC Itasca, Ill. 217-451-4377 www.fibersol2.com
Palsgaard introduces SA 6600, an activated powdered cake emulsifier that provides a high degree of convenience, security and low cost to industrial cake manufacturers. SA 6600 contains only one emulsifier and one food carrier, which greatly simplifies labeling. It’s also based on 100% vegetable raw materials, is kosher- and Halalcertified and can carry high amounts of oil, making it a flexible ingredient to use in sponge cakes, Swiss rolls, cupcakes, muffins and other cake products with a high fat content. Palsgaard Inc. Morris Plains, N.J. 973-998-7951 www.palsgaard.com
View videos demonstrating the newest bakery & snack food ingredients by visiting
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Engineering Management
Call of Duty: ‘Pack Ops’
I
t’s a battlefield out there. The bakery production line roster is taking casualties every day, with operators moving on to other jobs, industries and careers. We have struggled to keep the trenches full of able-bodied troops that can do battle with the toughest of enemies. Those enemies are long hours, high-pressure work and hot environments. But, when it’s time to call in the special forces, where do we get them and where do we put them? Back in the day, when a bakery management team would find itself needing an extra hand to fill a gap or cover a shift, there would be a call-in list filled with troops who were begging for extra duty, always for overtime. In return, these folks received experience in the process. If that same bakery had to reach outside of its own battalion, there was one, maybe two places they could go for temporary labor. That day’s temporary workforce comprised people who had been laid off at other factory jobs, could easily adapt to the bakery process and worked hard. But in today’s world, it’s tough enough just to find people to fill all of the roles in a permanent manner, but easy to fill from outside of the fence line. Every city in America now has a multitude of temporary agencies to draw from. This new temporary workforce doesn’t seem to have a lot of experience with anything. So at this point, filling the trenches with personnel is doable, but how do we best determine how to utilize these inexperienced workers? We tend to send these rookies out to the packaging room and dock. Why? Well, packaging is where we think there isn’t as much technical ability required as up in the mixing or oven rooms. We think that the key people in our operations need to be watching the dough mixer shake and ovens bake. The problem with this is that all of that good work that went on up front can go to waste quickly when we put inexperienced people in the positions where quality
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Jeff Dearduff
[email protected]
inspection and accounting are most of the responsibility and critical to the bottom line. A rookie can be taught rather quickly how to put a basket on a line or even change bags on a machine, but teaching them the quality attributes of a variety of products in a short time, for a short time, just doesn’t work. A lot of waste accrues when we put temporary people in the wrong positions. Good product can get tossed and bad product can get sent out to the customer when we depend on temporary workers to handle such a critical set of tasks. If we are faced with the use of temporary workers, and we decide that when we use them they need to be in packaging, how do we make the situation better? One word: Automation. Everybody knows that the baking industry is becoming more and more automated. If a company is avoiding investment in automation for the packaging room, they could be adding risk to their business that doesn’t need to be there. When we look at the production process from the end of the cooler conveyor to the dock door, the game can be won or lost with the focus, or lack of focus, we automate. Product inspection is the first critical step in the packaging process. We have
two main options for this today. First, we can place people in key areas to watch the product with their eyeballs and reject the bad ones all based on subjectivity, or we can add vision systems to the line that measure product dimensions and scan for product attributes like crust color and reject product based on objectivity. Vision systems can not only measure and scan, they also can speak back to the ovens, proofers and bakers and provide clues about what is going on in real time, not to mention collect data for look-backs and future improvements. There’s no way that any human or a host of humans, permanent or temporary, can guarantee that the product going to the plastic bag meets specification like a vision system can. The last critical step managed by the packaging room squad is the total counts. Bad counts of product, baskets, cases or pieces can throw off plant efficiencies and profit and loss in a big way when not handled correctly. Historically, this has been handled by humans as well. The best of employees, while trying as hard as they can, will still on occasion miss a stack, a pallet or even a full truckload. How do we make this situation better? One word: Automation. There are a host of companies that can come in and automate case counting from the end of the packer to the truck, without fail. Bar codes, radio-frequency identification (RFID) chips and a number of creative things can be deployed in this area of the plant. Again, this takes the responsibility off of temporary workers who have been placed at the end of the line to handle your product. Just like the special forces that defend our country, backed by smart technology, you need to back up your workforce with smart technology will help you win the small battles and the big war. SF&WB
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Production Technology Form/Fill/Seal Equipment
Forming, Filling, Sealing to Perfection Many of today’s form/fill/seal manufacturers aren’t taking any chances in putting together the right system that offers efficiency, speed, flexibility and accuracy. Marina Mayer, Executive Editor Photo courtesy of Heat and Control Inc.
T
hese days, having the right form/fill/ seal (FFS) equipment can make the difference in how a product is packaged. Thankfully, many of today’s FFS manufacturers aren’t taking any chances in putting together systems that offer efficiency, speed, flexibility and accuracy. “Snack processors increasingly need to deliver more and different stock-keeping units, and they need to continue introducing new products to remain competitive,” says Jeff Almond, snack food industry manager for packaging systems at Heat and Control Inc. That’s why the Hayward, Calif., manufacturer introduced the Ishida Atlas 233
bagmaker, which is designed for potato chips and other products that don’t require ultra-high speed. “Atlas 233 uses a single ‘D’ motion sealing jaw to produce tight, wrinkle-free seals at up to 125 bags per minute,” Almond says. “It’s available in standalone or direct-mount models with a single tube format or nested for twin-tube applications.” Meanwhile, the Ishida Atlas 202 offers versatility and flexibility, as it can be used for many different bag formats, including flat-bottom, hem-seal, gusseted and pillow bags, Almond says.
“It requires significantly less floorspace than the typical machine used to make flat-bottom or hem-seal bags,” he adds. “For increased versatility, Atlas 202 is available with automatic film splicing, banner attachment, hole punch, tear notch, perforated and zig-zag cuts, air or nitrogen flushing. When integrated with an Ishida multihead weigher, the entire system is operated from a single remote control for maximum speed and efficiency.” OCTAL, Muscat, Oman, introduced FFS equipment using its patented DPET technology, which relies on a single-phase reactor to integrate polyethylene terphthalate (PET) resin and sheet manufacture. The technology bypasses the expensive PET drying and melting process of conventional clear rigid sheet manufacturing, producing PET sheet with superior optical and mechanical properties and using 65% less energy. “[The] DPET lines allow us to run a unique type of laminate material with clarity levels and mechanical properties never seen before in the industry,” says PJ Corcoran, converted products manager. “The laminate will enable our customers to
Photo courtesy of OCTAL
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Production Technology provide packaging that increases aesthetic appeal on the shelf and improve protection for their product.” As with any snack producer, the key question is how to maximize profitability within existing production lines, says Shayne De la Force, group marketing manager. The Coppell, Texas, company resolves this issue by focusing on product transfer, seal integrity and film handling. “Product transfer refers to the handling of product through the scale into the bag and is one of the most critical challenges produces face,” De la Force says. “Seal integrity (i.e. ensuring a strong seal of the bag material whereby no oxygen can enter the product) is crucial to prolonged product shelf life. Lastly, film handling refers to the controlled unwinding of the film from the roll, its transportation through the FFS system to the former—which creates the bag type/size—and then sealing.” As a result, it created the robag 3c series, which offers high-performance packaging solutions. “Stand out VFFS [vertical form/fill/seal] equipment must deliver the highest levels of performance, flexibility and simplicity,” De la Force adds. “Some machines boast high levels of one or the other of these attributes, but it’s a combination of all three that’s essential to exceed customer demands. Performance refers to the number of good bags per minute and uptime, whereas flexibility extends to everything from product changeovers to upstream and downstream equipment integration. Simple but sophisticated design is crucial for operational ease, service/ maintenance and everything in between.” Whichever route today’s FFS manufacturers choose to travel,
the future for bagmakers remains bright. “Choice will be the biggest impact in the future of FFS,” De la Force says. “If we compare the degree of choice on the supermarket shelves that we have today to that of, say, 10 years ago, it is clear that
food manufacturers will need to pack more products in more pack formats in more pack sizes.” Thankfully many of today’s FFS systems are in position to offer high performance.
SF&WB
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Equipment Briefs Sifter Parts & Service recommends the use of FDA-approved polyurethane screen-cleaning balls and cubes to prevent sifter screens from clogging with product. These polyurethane balls are said to be more abrasion-resistant than screen cleaners manufactured out of other materials
Charles Ross ribbon blenders cater to a wide range of bulk densities. They’re suitable for sanitary or industrial applications. All units are direct-driven by an inverterready gear motor, an integral design superior to belt- and chain-driven blenders that suffer from losses in horsepower and efficiency through slippage. Charles Ross & Son Co. Hauppauge, N.Y. 800-243-7677 www.mixers.com
and provide a longer life. Unlike rubber or neoprene, polyballs are nonporous and oil-, moisture- and chemical-resistant. They range in size from 5/8-in. to 2-in. diameter. Sifter Parts & Service, Inc. Wesley Chapel, Fla. 800-367-3591 www.sifterparts.com
Equipment - Installation - Parts - Service
American Fabric Filter adds new precision power stretching equipment to expand its production capabilities for re-screening most adhesive bonded screen frames. The equipment produces tighter, more uniform fabric tension, increases product throughput and offers more accurate control of particle sizes and improved screen durability. American Fabric Filter Co. Wesley Chapel, Fla. 800-367-3591 www.americanfabricfilter.com
Koenig Bakery Systems Rich Breeswine, General Manager + 1-804-564-3997
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Let our high efficiency lines improve your profits and put your company on a roll. Contact us today for an efficiency evaluation!
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Equipment Briefs 800-866-0322 www.lantech.com
Lantech’s RL automatic stretch wrapper is an ultra-high-speed ring straddle-style stretch wrapper capable of wrapping up to 200 loads per hour, whereas the SL automatic is an overhead straddle wrapper with throughput capabilities up to 120 loads per hour. Both machines feature LeanWrap innovations that build specific stretchwrapping quality measures into each load that’s wrapped. And they’re claimed to provide more film choices, higher operating speeds, improved productivity, reduced film breaks, less maintenance and lower cost per load. Lantech Louisville, Ky.
Performance, Economy, and Flexibility. Recipe for Success.
Kemutec appointed exclusive distributors of the GKM Siebtechnik range of flat-deck screeners for the North American market. This new addition is a fit into Kemutec’s powder processing equipment portfolio, helping it become a leading sieving and screening supplier for the baking and snack food industries. Kemutec will also be adding GKM test equipment to conduct proving trials on the flat-deck screeners as well as the vast range of Kek centrifugal sifters. Kemutec USA Bristol, Pa. 215-788-8013 www.kemutecusa.com
7\SH0)DEUL3XOVH® &RPSDFW%DJ+RXVH
Hinds-Bock tabletop depositors are said to be the answer for bakers with limited space. Handling all batters with gentle care, they maintain the integrity of quality products. These simple-to-operate, tabletop depositors are the economical, maintenance-free workhorses of the smaller bakery. They can handle a wide variety of pan configurations such as muffin, cupcake, sheet cake and rounds with simple and fast changeover. They are available with up to seven pistons. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com
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Snack Food Today Snikiddy, Whole Planet Foundation Offer Exclusive Snack Snikiddy, Bethesda, Md., releases an exclusive 10-oz. bag of Snikiddy Cheddar All-Natural Baked Fries in support of Whole Planet Foundation, an Austin, Texas-based non-profit dedicated to poverty alleviation programs in the United States and developing world countries that supply products to Whole Foods Market stores. For every bag sold, Snikiddy will donate 10 cents to Whole
Planet Foundation. Made from simple, wholesome ingredients, Snikiddy Baked Fries are baked with real potatoes and corn and contain 50% less fat than traditional potato chips. To learn more about Snikiddy, go to www.snikiddy.com. To learn more about Whole Planet Foundation, go to www. wholeplanetfoundation.org.
Pringles Launches Limited-Edition Star Wars Cans Procter & Gamble Co., Cincinnati, the makers of the Pringles brand, paired certain varieties up with different Star Wars characters—Darth Vadar Original, Skywalker Sour Cream & Onion, Han Solo Salt & Vinegar, Princess Leia Pizza, Chewbacca Cheddar Cheese and Boba Fett BBQ—in honor of the Sept. 16 release of “Star Wars: The Complete Saga” on Blu-ray. These customized cans are sold
exclusively at Wal-Mart stores through November.
Five Point Snacks Donates Percentage of Profits to U.S. Veterans Five Point Snacks is a new snack line with a social mission—to help U.S. veterans return to a better civilian life. In doing so, the New York-based manufacturer is donating at least 11% of its profits to organizations that support, care for and benefit veterans, and will also recruit and build out its entire sales organization by hiring only U.S. veterans. The packaging employs strong, military-themed graphics, each commemorating one of the five branches of the U.S. Armed Forces—Major Murphy’s (Kettle-cooked potato chips, Marines), Sailor Knots (mini pretzel knots, Coast Guard), Flotilla tortillas (whole grain, white corn tortilla chips, Navy), G.I. Crunches (cheddar cheese twists, Army) and Airmen popcorn (white popcorn, Air Force). Five Point Snacks launched in the East Coast in October.
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Shearer’s Foods Builds House For Habitat for Humanity The day after raising $90,000 for Pegasus Farm, a therapeutic riding center in Hartville, Ohio, Shearer’s Foods, Inc., Brewster, Ohio, began construction on the Shearer’s-sponsored Habitat for Humanity house in Massillon, Ohio. Bob Shearer, chief executive officer, Scott Smith, president, and Fritz Kohmann, chief financial officer, led a group of 11 vice presidents in framing the house located at 383 McKinley Avenue SW in the Columbia Heights district. The majority of the building process was completed in early November.
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EQUIPMENT FOR SALE
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INGREDIENTS
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EQUIPMENT FOR SALE
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EQUIPMENT FOR SALE
Z BROWNIE CUTTING SYSTEM Speed up your brownie, sheet cake or breakfast bar production using our unique half and full sheet pan pneumatic cutter. Our system can cut squares, rectangles or triangle shapes in many sizes while leaving the product in the pan.
“Cutting Rice Crispy Treats” “Cutting Product in Bakable Cardboard Box” “Nutrition Bars” and more Reduce cutting time by as much as 75% while producing a more uniform product. Triple your production and eliminate hand and wrist fatigue associated with cutting by hand. Spend more of your valuable time managing your business and marketing plan. All possible using our “Z” Brownie Cutting System. Call for details on our standard purchasing terms and our “In House” financing terms.
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CONSULTING
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SnackandBakery.com
Snack Food & Wholesale Bakery - November 2011
www.snackandbakery.com
Ad Index Company Website
Page
Company Website
Company Website
Page
Page
AAF International . . . . . . . . . . . . . . . . . . . . 55 www.AAFINTL.COM
California Raisin Marketing Board . . . . . . . 9 www.LoveYourRaisins.com
Moline Machinery LLC . . . . . . . . . . . . . . . . 34
ADM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC www.adm.com/milling
Caravan Ingredients . . . . . . . . . . . . . . . . IBC www.caravaningredients.com
North Dakota Mill . . . . . . . . . . . . . . . . . . . . 32
ALIT SRL . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 www.alit.com
ConAgra Mills . . . . . . . . . . . . . . . . . . . . . . 17 www.conagramills.com
Novozymes . . . . . . . . . . . . . . . . . . . . . . . . . 33
Arizona Instrument LLC . . . . . . . . . . . . . . . 21 www.azic.com
Danisco USA Inc . . . . . . . . . . . . . . . . . . . . 15 www.danisco.com
Ashworth Bros ., Inc . . . . . . . . . . . . . . . . . . 31 www.ashworth.com
Douglas Machines . . . . . . . . . . . . . . . . . . . 10 www.dougmac.com
Bay State Milling . . . . . . . . . . . . . . . . . . . . 39 www.baystatemilling.com
Formers International . . . . . . . . . . . . . . . . 53 www.formers.com
www.quickdraft.com
Blue Diamond Growers . . . . . . . . . . . . . . . 29 www.bluediamond.com
Great Western Manufacturing . . . . . . . . . . 18 www.gwmfg.com
www.reiser.com
Brolite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 www.bakewithbrolite.com
International Bakers Services, Inc . . . . . . . 21 www.internationalbakers.com
www.mixers.com
Brother Mobile Solutions, Inc . . . . . . . . . . . 3 www.brothermobilesolutions.com
Kluber Lubrication North America L .P . . . 27 www.klueber.com
www.blueberry.org
Buhler Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 www.buhlergroup.com
Koenig Bakery Systems . . . . . . . . . . . . . . 54 www.koenigusa.com
Cablevey Conveyors . . . . . . . . . . . . . . . . . 26 www.cablevey.com
Kwik Lok . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC www.kwiklok.com
Van Drunen Farms . . . . . . . . . . . . . . . . . . . 48
California Custom Fruits & Flavors . . . . . 35 www.ccff.com
MINSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 www.minsa.com
Viterra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
www.moline.com www.ndmill.com www.acrylaway.com Puratos . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 www.puratos.us Quickdraft . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Ross, Charles & Son Company . . . . . . . . . .11 U .S . Highbush Blueberry Council . . . . . . . 49 US Soy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 www.ussoy.com www.vandrunenfarms.com www.viterra.com/clusters
Statement of Ownership, Management, and Circulation (Requester Publications Only) Publication Detail 1 Publication Name 1 Publication Number 2 ISSN 3 Filing Date 4 Issue Frequency 5 Number of Issues Published Annually 6 Annual Subscription Price 7 Complete Mailing Address of Known Office of Publication 7 7 7 Contact Person 7 Telephone 8 Complete Mailing Address of Headquarter or General Business Office of Publisher 8 8 9 Publisher (Name and complete mailing address) 9 9 9 Editor (Name and complete mailing address) 9 9 9 Managing Editor (Name and complete mailing address) 9 9
BNP Media
155 Pfingsten Road, Suite 205, Deerfield, IL 60015 Phone: (847) 405-4000 Fax: (847) 405-4100
Owner 10 10 10 10 10
Also publishers of: Beverage Industry, BrandPackaging, Candy Industry, Dairy Foods, Flexible Packaging, Food & Beverage Packaging, Food Engineering, Food Master, Industria Alimenticia, Prepared Foods, Private Label Buyer, Refrigerated & Frozen Foods, The National Provisioner
Full Name BNP MEDIA II, LLC TAGGART E HENDERSON HARPER T HENDERSON MITCHELL L HENDERSON
Complete Mailing Address 2401 W BIG BEAVER RD STE 700, TROY, MI 48084-3333 2401 W BIG BEAVER RD STE 700, TROY, MI 48084-3333 2401 W BIG BEAVER RD STE 700, TROY, MI 48084-3333 2401 W BIG BEAVER RD STE 700, TROY, MI 48084-3333
Known Bondholders, Mortgagees, Other Security Holders 11 Line
Full Name
Complete Mailing Address
13 14
SNACK FOOD & WHOLESALE BAKERY 09/01/2011
LETTERS Lauren R. Hartman Snack Food & Wholesale Bakery 155 Pfingsten Road, Suite 205 Deerfield, IL 60015 E-mail: hartmanl@ bnpmedia.com SINGLE COPY SALES/BACK ISSUES Ann Kalb T: (248) 244-6499 E-mail:
[email protected]
REPRINTS Jill DeVries E-mail: devriesj@ bnpmedia.com T: (248) 244-1726
CUSTOM MEDIA Chris Wilson E-mail:
[email protected] T: (248) 244-8264
Email contact: Michael Costantino at 800-223-2194 x748;
[email protected]
LIST RENTAL Postal contact: Kevin Collopy 800-223-2194 x684;
[email protected]
www.snackandbakery.com
PRINT & INTERNET ADVERTISING Jeff Heath E-mail: heathj@ bnpmedia.com T: (224) 554-9154 Barbara Szatko E-mail:
[email protected] T: (630) 527-9927 CLASSIFIED ADVERTISING Suzanne Sarkesian E-mail: sarkesians@ bnpmedia.com T: (248) 786-1692
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Publication Title Issue Date for Circulation Data Below
15b3
No. Copies of Single Issue Average No. Copies Each Issue Published Nearest to Filing Date During Preceding 12 Months Extend and Nature of Circulation Total Number of Copies (net press run) 13828 13706 Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. (Include direct written request from recipient, telemarketing and Internet requests from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser's proof copies, and exchange copies.) 10811 10523 In-County Paid/Requested Mail Subscriptions stated on PS Form 3541. (Include direct written request from recipient, telemarketing and Internet requests from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser's proof copies, and exchange copies.) 0 0 Sales through Dealers and Carriers, Street Vendors, Counter Sales, and Other Paid or Requested Distribution Outside USPS 42 45
15b4 15c
Requested Copies Distributed by Other Mail Classes Through the USPS (e.g. First-Class Mail) Total Paid and/or Requested Circulation
15d1
Outside County Nonrequested Copies stated on PS Form 3541 (include Sample copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other soruces)
15 15a
15b1
Reader & Marketing Services
Line
SNACK FOOD & WHOLESALE BAKERY 499640 1096-4835 09/26/2011 MONTHLY 12 115.00 2401 W BIG BEAVER SUITE 700 TROY, OAKLAND, MI 48084-3333 CATHERINE RONAN (248) 244-8259 2401 W BIG BEAVER SUITE 700 TROY, MI 48084-3333 JEFF HEATH 155 N PFINGSTEN RD STE 205 DEERFIELD, IL 60015-5293 LAUREN HARTMAN 155 N PFINGSTEN RD STE 205 DEERFIELD, IL 60015-5293 MARINA MAYER 155 N PFINGSTEN RD STE 205 DEERFIELD, IL 60015-5293
15b2
0 10853
0 10568
2304
2495
0
0
15d4 15e 15f 15g 15h 15i
In-County Nonrequested Copies stated on PS Form 3541 (include Sample copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other soruces) Nonrequested Copies Distributed Through the USPS by Other Classes of Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Limit mailed at Standard Mail or Package Services Rates) Nonrequested Copies Distributed Outside the Mail (include Pickup Stands, Trade Shows, Showrooms and Other Sources) Total Nonrequested Distribution Total Distribution Copies not Distributed Total Percent Paid and/or Requested Circulation
16
Publication of Statement of Ownership
Publication of this statement will be printed in the NOVEMBER, 2011 issue of this publication
17 17 17
Signature and Title of Editor, Publisher, Business Manager, or Owner Title Date
RONA2C (Catherine Ronan)
Version
PS Form 3526, September 2007
15d2 15d3
0
0
136 2440 13293 535 13828 81.64
277 2772 13340 366 13706 79.22
09/26/2011 02:24:53 PM
November 2011 - Snack Food & Wholesale Bakery
63
The Final Word
Top 10 Things I’m Thankful For
Marina Mayer, executive editor
[email protected]
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Little Debbie Swiss rolls. Who can forget my obsession with Little Debbie Swiss rolls? If you type in “Little Debbie” in the search box of www.snackandbakery.com, you’ll find my ongoing commentary on this luscious treat. But what I’m most thankful for is the fact that the folks at McKee Foods, the Collegedale, Tenn.-based producer of Little Debbie products, hasn’t muddled with the formula, which means I’m not forced to find an alternative.
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Power of social media. In putting together this Top 10 list, I did what I sometimes tend to do, and that’s reach out to my 500 Facebook friends for a bit of assistance. I surveyed them to find out what they’re most thankful for when it comes to snacks and baked goods. Answers included donuts, Nutty bars, pies, Oreo’s, cheesecake, Danish and yes, even stretchy waistbands.
That’s what food friends are for. Between tornadoes, hurricanes and massive flooding, the food industry struggled to maintain business as usual while competing against the violent acts of Mother Nature. However, several companies stepped up to the plate to ship out samples to the hungry and homeless, build homes for Habitat for Humanity or donate a portion of the proceeds to various non-profit organizations.
What is old is new again. Part of being innovative isn’t necessarily creating something new from scratch, but rather enhancing a tried-and-true success. That’s why many bakers reinvigorated white bread, a type that was shunned because it didn’t offer as many grains or fiber as its wheat bread counterpart. But companies such as Flowers Foods and Sara Lee Co. enhanced white bread’s nutritional value to include higher fiber content, more nutrients and other better-for-you ingredients. Be thankful, not wasteful. Several packaging suppliers are making it so that consumers can do their part in saving the earth. It’s not every day that I can recycle the clear plastic packaging that houses beef jerky, or that my bag of chips is made of compostable materials. It’s also refreshing to see food makers doing their part. Earth will thank you later.
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tradeshow with bags of press kits, contacts and leads, most of which resulted in future interview opportunities. Essentially, tradeshows are the most successful way to facilitate that B2B connection.
Bold looks, bold tastes. 2011 brought out the spiciness in food makers. Whether it was a zesty flavor, bold texture or just good old-fashioned innovation, grocery store shelves displayed sharp packaging, vivid colors and graphics and a host of varieties designed to make any plain Jane consumer ooh and aah.
The HFCS versus sugar debate. The controversy surrounding high-fructose corn syrup (HFCS) exploded just as quickly as Charlie Sheen turned his coveted acting career into a crazed train wreck. However, this debate forces consumers to become serious about actually reading labels and making hard-nosed decisions about the foods they bring into their homes for their families to eat. It also allows bakers and snack manufacturers to go against the norm and maintain the essence and foundation of their portfolios.
Food safety. It takes time, money and resources to bring a facility up to par in accordance with government standards, but thankfully, several bakers and snack manufacturers failed to bend the rules. In fact, some companies went above and beyond the rudimentary guidelines to achieve superior certifications, awards and ratings.
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Snack Food & Wholesale Bakery - November 2011
Tradeshows. While walking and/ or exhibiting at a tradeshow can be exhausting, grueling and let’s face it, hard on the feet, it’s also the best (and sometimes only) way to really connect with bakers and snack producers. Many times, I’ve returned from a
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Freedom. What separates our country from the rest of the world is our freedom—freedom of speech, freedom of the press and best of all, freedom to eat what we want, when we want. Thank you to the men and women behind the lines who fight so that we can maintain these and other freedoms. SF&WB
www.snackandbakery.com
FROM FORMULATION TO FINAL PRODUCT Look to ADM to increase your edge in the competitive baking segment. The ADM Bakery Platform is a network of R&D services designed to help our customers achieve maximum success. Think of us as your single point of contact for technology and resources that keep you on the cutting edge. Whether you’re looking to identify market trends, develop new products or enhance existing ones, we aim to exceed your expectations – quickly and efficiently.
For customers around the world, ADM draws on its resources — its people, products, and market perspective — to help them meet today’s consumer demands and envision tomorrow’s needs.
www.adm.com/milling © 2011 Archer Daniels Midland Company
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