Mario DeBenedetti III, president, and Darin DeBenedetti, vice president, of Milano Bakery Inc.
A City Institution 2 0 11 WHOLESALE BAKER OF THE YEAR
Also Inside: UÊÊ*ÀViÃÃÊ Ý«Ê*Ài-
ÜÊÊ
ÛiÀ>}i UÊÀÜ}ʼÀii½ UÊ*ÀviÀÃÊEÊ"ÛiÃ
www.snackandbakery.com
FRESHNESS protected by KWIK LOK
®
Kwik Lok and bread are a natural combination. Bread is best when fresh and our closure will keep that just baked freshness locked inside the poly bag from the first slice to the last. Easy to Open. The Kwik Lok Closure gives the consumer a package that is easy to open - no other closure is as easy and quick to remove. No twisted wire - no sticky tape. The bag can be easily reclosed and that is critical. To keep that freshness inside the open bag, it has to be properly reclosed and that is where Kwik Lok rises to the top. A simple twist of the bag neck and the closure snaps back on! The new 893 Ultra bag closing machine outshines the competition. Proven operational dependability, superior engineering standards, high quality fabrication throughout - just a few reasons to place Kwik Lok on your bakery line. The new Ultra offers the ability to close packages with the regular all-plastic closure AND promotional and colorful high quality labels.
6
RECYCLABLE
&25325$7,21
(;(&87,9(2)),&(32%2; <$.,0$:$ 7(/(3+21( RU )$; ,QWHUQHW ZZZNZLNORNFRP
Contents
Cover Story 12 | A City Institution Celebrating 96 years in business, a recently expanded production facility and a host of fresh baked goods, Milano Bakery in Joliet, Ill., receives Snack Food & Wholesale Bakery’s Baker of the Year award.
Plant Story Photos by Vito Palmisano
20 | The ‘Best’ Buns in Town
12
Milano Bakery’s recently expanded 40,000-sq.-ft. production facility mixes skillful manual baking procedures with highly automated production.
20
Columns 6 | Editor’s Note Food safety has been a hot-button issue for some time, says Editor-in-Chief Lauren R. Hartman. But are we really meeting the goals?
36 | The Nutritional Corner Contributing columnist and president of the Grain Foods Foundation, Judi Adams, provides a preview as to what the food industry can expect in the year ahead.
58 | Engineering Management When it comes to purchasing bakery equipment, bakers must weigh their options. Contributing columnist Jeff Dearduff offers a rundown of things producers must keep in mind when making this quarter-million dollar purchase.
84 | The Final Word For the past few years, high-fructose corn syrup has received some major flack, says Executive Editor Marina Mayer. However, a recent Mintel study shows that consumers aren’t too concerned about this so-called dangerous ingredient.
2
Snack Food & Wholesale Bakery - September 2011
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].
www.snackandbakery.com
21st Century Grain Processing is a trademark of 21C Oats, Inc., a subsidiary of Viterra Inc.
Some of our best ideas come in small clusters. Creating the perfect oat cluster and coated whole grain ingredients to meet tight formula and final product specifications is only possible when your team is... creative. We work closely with our customers to ensure the perfect flavor and texture, every time. That’s unique. That’s essential. That’s how we roll. viterra.com/foodingredients
[email protected]
Contents 28
Market Trends 28 | Flipping the Chip
Production, Technology & Product Development Solutions for a Changing Industry. September 2011 Vol. 100 No. 9
Today’s consumers are sporting a more refined palate. Thankfully, potato and tortilla chip producers are responding by creating unique varieties using zesty flavors and better-for-you ingredients.
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
34
New Products 34 | New Products
John Schrei Publishing Director
Read about some of the most recently introduced products, including a bite-sized wine pairing cookie portfolio in varietypack form from Cookies & Corks, a lineup of 100% whole grain brownies and cookies from Dancing Deer Baking, Michael Season’s Black Bean Popped Crisps and Wasabi Ginger and Mesquite Barbeque Journey bars.
[email protected]
Tom Imbordino Group Publisher
[email protected]
Jeff Heath Publisher
[email protected] 224-554-9154
44
Ingredient Technology
Editorial Lauren R. Hartman Editor-in-Chief
[email protected] 847-405-4015
48 | The Real Deal
Marina Mayer Executive Editor
For years, fiber has been top of mind for many consumers in search of a healthy diet. Find out who’s taking action by developing a host of dietary fiber solutions that deliver the necessary fiber intake hidden inside a tasty item.
Patty Catini Art Director
[email protected] 847-405-4008
Advertising & Internet Sales Barbara Szatko Senior Sales Manager
[email protected] 630-527-9927
Suzanne Sarkesian Classified Sales
Production Technology
70
70 | The Heart of the Line Ovens and proofers act as the center of the production line. Therefore, manufacturers must provide flexible, efficient, sanitary options.
[email protected] 248-786-1692
Jill L. DeVries Corporate Reprint Manager
[email protected] 248-244-1726
Support Services Nann Barkiewicz Production Manager
[email protected]
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
[email protected]
Special Report 38 | Growing ‘Green’ When it comes to going “green” and growing “green,” various bakery, snack and food-related companies are changing the game. Here’s a peek at some of the latest sustainable ingredient developments and technologies that are designed to keep the industry thriving in the future.
4
Snack Food & Wholesale Bakery - September 2011
60 | Process Expo Pre-Show Coverage Where else can bakers, snack food producers and suppliers find the latest in trends, packaging equipment and technology than Process Expo 2011? Check out this pre-show guide featuring show information, session highlights and booth profiles of equipment introduced at the show.
Email contact: Michael Costantino at 800-223-2194 x748
[email protected]
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
www.snackandbakery.com
Struggling with the high cost of flour?
®
Take control of your material costs. Danisco’s POWERBake dough strengtheners help you control costs, even in the face of skyrocketing flour prices. The POWERBake range provides high tolerance for flour of varying quality, delivering the consistently high-quality end product your customers expect. At Danisco, you’ll find the baking supply resource you’re looking for with the experience, application knowledge, technical expertise and quality enzymes, emulsifiers and blends you need. Contact us. Let’s talk about how Danisco can help you take control. ®
®
Danisco USA Inc. Tel: 800.255.6837 www.danisco.com © 2011 Danisco USA Inc.
Editor’s Note
or some time now, editors of Snack Food & Wholesale Bakery, along with countless other members of the media, have been reporting on food safety and the recent Food Safety Modernization Act (FSMA), which was signed into law by President Obama on Jan. 4. The Food and Drug Administration (FDA), Washington, D.C., claims that it continues to “move forward in its efforts to protect the nation’s food supply.” But is this really happening? The revised FSMA gave FDA a mandate to implement a system based on science, and addresses food safety hazards from farm to table. The agency has already strengthened a number of protections, including providing consumers with more information Lauren R. Hartman about recalled foods
[email protected] and other specific goals, such as preventing the smuggling of food into the United States and others to ensure that all new ingredients in dietary supplements are safe for consumers. On FDA’s website, www.fda.gov, Michael Taylor, FDA’s deputy commissioner for foods, says “this new system will better leverage the resources of federal agencies, and it will make industry a major partner in safeguarding the health of U.S. consumers.” But, in your opinion, is the new system accomplishing this? Bakers and snack food producers across the country have been implementing new practices and initiating new record-keeping
F
6
procedures with regard to food safety well in advance of the new mandates, in order to stay ahead of the curve. FDA now has the authority to prevent the distribution of unsafe food by suspending the registration of processing facilities, so food producers must be registered with FDA to market their products in the United States. FDA says that registration could be suspended if the food processor not only fails to produce safe foods, but also takes no measures to keep those foods from reaching consumers. In addition to preventing their distribution, the processor of unsafe foods would be expected to investigate what went wrong and take steps to prevent a recurrence. If this is not done, FDA says it “will step in.” To prevent these things from happening, facilities must devise written preventive control plans that clearly outline potential safety problems and the steps to be taken to avoid or minimize the likelihood of these hazards from occurring. The bakery and snack associations do a great job of coordinating with FDA on various aspects of the act and assist manufacturers with concerns. On July 25, the American Bakers Association, Washington, D.C., AIB International, Manhattan, Kan., and several others met with Taylor and his team to discuss key issues related to the implementation of FSMA. As FDA develops FSMA standards and implementation strategies, it wants to tap industry expertise and establish an interactive exchange focused on preventative controls, imports and inspection and compliance. For example, ABA recently filed a citizen petition to exempt from compliance or modify requirements for facilities that are solely engaged in the storage of packaged foods not exposed to the environment. Already, FDA has had setbacks in regard
Snack Food & Wholesale Bakery - September 2011
to the FSMA, and recently estimated the cost of implementing the FSMA at $1.4 billion over five years. Last month, it stated that it plans to implement “re-examination” fees under the act, collecting a fee from importers for a re-inspection/re-examination of an imported food if there’s any identified failure to comply with a requirement materially related to food safety. This in effect changes how FDA defines “examination.” What’s next? Funding for the bill has been a sticky issue, as some legislators question whether the agency actually needs more funding, mainly to pay for greater authorities granted to it by the new legislation, such as ordering product recalls and more frequent inspections of food facilities. And some of the Republicans from the House of Representative have proposed a $285 million cut to FDA funding in fiscal 2012, 11.5% less than 2011, even though the agency is seeking additional funds to pay for new food safety legislation. FDA says its new web-based search engine makes it easier and faster to learn about product recalls, and it has also redesigned its web page dedicated to the food safety act—www.fda.gov/FSMA. Are these changes working the way they were supposed to work? Is FDA accomplishing what it set out to do? What are you noticing? We hope Taylor’s assessment about the industry becoming a major partner is happening. Contact me with your comments at
[email protected]. SF&WB
www.snackandbakery.com
Business Briefs
supplier news
News Webinar: Food Plant of the Future: Anticipating the Next Generation oin Snack Food & Wholesale Bakery and Hixson, a Cincinnati-based design and engineering firm, for a live webinar on Sept. 29 at 2 p.m. EDT. The webinar series, titled “Food Plant of the Future: Anticipating the Next Generation,” will discuss several issues shaping food plants of the future, including productivity improvement, cost reduction, sustainability and food safety. Attendees include but are not limited to senior management and operations/engineering food and beverage plant personnel, CEOs and COOs, project managers, senior engineers, vice presidents of engineering and plant engineers, senior operations managers and vice presidents of operations. A live Q&A discussion with attendee-submitted questions will follow the webinar. To register, go to www.snackandbakery.com.
J
people Caravan Ingredients, Lenexa, Kan. James Anderson is named sales manager of Trancendim Solutions, responsible for managing sales growth of the high diglyceride brand, Trancendim, and managing multiple industry channels, including retail and foodservice segments. J. Anderson Meanwhile, Bob Klima is named business development manager, food and beverage, responsible for capturing the voice of the consumer to help Caravan develop appealing products and programs specifically within food and beverage applications for commercialization. And, Brent Miller becomes product management director, responsible for identifying and managing product platforms to drive growth opportunities within Caravan’s product portfolio.
Dorner Manufacturing, Hartland, Wis. Gary Cully is the new Northwest regional manager, responsible for working with G. Cully sales channel partners and key accounts to grow the company’s industrial and sanitary conveyor business. B Bakery Equipment Manuffacturers a and Allieds ((BEMA), B Overland Park, Kan. K Matt Zielsdorf, vice presiM dent of sales for The Peerd M. Zielsdorf less Group, Sidney, Ohio, le a division of the ITW Food Equipment Group, is elected chairman, responsible for helping guide BEMA in its vision of being the premier resource in providing interactions, innovation and information for its members and the baking industry.
Editor’s Note: Go to www.snackandbakery.com to learn more about other news items relating to the snack food and wholesale bakery markets, or subscribe to Operations Weekly and receive news directly to your inbox every Wednesday.
8
Snack Food & Wholesale Bakery - September 2011
Nielsen-Massey Vanillas spices up its look with a new logo and updated labels, which rolled out in July. Both the logo and labels eature a new seal and lettering, but still maintain many familiar elements to better showcase the NielsenMassey name. The Wright Group receives FSSC 22000 certification. With more than 50,000 custom nutrient premixes to date, The Wright Group continues to adhere to the most stringent quality and safety standards in the food and beverage industries. Baketech plans to merge into AMF Bakery Systems. Baketech will continue to operate as part of AMF Bakery Systems in the Tucker, Ga., facility. SensoryEffects establishes Sensory Effects International, based in Deland, Fla. It’s led by David Lee, director of international sales, and serves as an international export arm for all divisions of SensoryEffects, including Flavor Systems, Powder Systems and Cereal Systems. With this new arm, SensoryEffects can provide products and services in Central and South America as well as Caribbean countries. Bay State Milling commissions a 2,500 hundredweight specialty mill to expand its capabilities and capacity in Winona, Wis. The mill processes assorted cereal grains into unique flour and whole grain solutions focused on delivering flavor and natural health and wellness benefits through fiber, vitamins and minerals. Sensient Flavors & Fragrances Group expanded its extraction capabilities thanks to a new state-of-the-art CO2 extraction plant in Indianapolis, Ind. The plant comprises two commercial-scale, supercritical CO2 extractors as well as several pilot units available for research and development purposes. Other technologies include counter-current extraction, molecular distillation and more traditional methods such as percolation distillation and cold solvent extraction. Continued on page 10
www.snackandbakery.com
Your customers and the future... "U1VSBUPT XFCFMJFWFQFPQMFXJMMDPOUJOVFUPBUUBDINPSFBOENPSF JNQPSUBODFUPUIFRVBMJUZPGUIFJSGPPE5IBUJTXIZXFNBLFJUPVSNJTTJPO UPEFWFMPQVOJRVFJOHSFEJFOUT UFDIOPMPHJFTBOEBQQMJDBUJPOTUPIFMQCBLFST QBUJTTJFSTDIPDPMBUJFSTBSPVOEUIFXPSMEUPCFTVDDFTTGVMXJUIUIFJSCVTJOFTT 0VSGPDVTPODPOTVNFSQSFGFSFODFTGVSUIFSSFJOGPSDFTUIJTDPNNJUUNFOUXJUI UIF1VSBUPT4FOTPCVT BNPCJMFTFOTPSZMBCPSBUPSZXIJDIDSFBUFTBDPNGPSUBCMF FOWJSPONFOUGPSDPOTVNFSTUPTIBSFUIFJSPQJOJPOTXJUIVTBCPVUUIFJSFWFSZ EBZGPPEOFFETFind out more at www.sensobus.us Contact Puratos today for your unique solution!
1VSBUPT$PSQPSBUJPOt5FMt'BYtXXXQVSBUPTVT
Business Briefs Continued from page 8
supplier news ROHA Food Colors invested $5 million to expand its St. Louis location, and is completing a $15 million expansion at the world headquarters in Mumbai, India. Construction at the St. Louis location began last month and will be wrapped up by Jan. 31, 2012. The expansion in India will be completed by the end of this year. Weldon Solutions hosted more than 200 guests from across the mid-Atlantic region to its “Open House: Automate-Innovate-Educate” on July 21. Manufacturers enjoyed interactive robotic demonstrations, educational seminars, a barbeque luncheon and a tour of the Weldon Solutions engineering and manufacturing center in York, Pa. The event was capped off with a “Save Your Factory” presentation by FANUC Robotics provided to the Manufacturer’s Association of South-Central Pennsylvania. The discussion focused on how robotic automation can help manufacturers reduce cost in their
10
Snack Food & Wholesale Bakery - September 2011
operations to remain competitive with offshore suppliers. Spraying Systems made available more than 15 case studies documenting quality improvements, operational efficiencies and cost savings achieved through the use of spray technology. Each case study uses a problem/solution format and provides detailed information about the application, products used and the results. Quantifiable results are included and range from increased production time, improved food safety, better product quality and reduced operating costs/maintenance time. The case studies are available at www.spray.com/ results. MGP Ingredients published a new booklet detailing the properties as well as functional and cost-saving benefits of its Arise line of wheat protein isolates in bakery and other flour-based food formulations.
Created under the guidance of Ody Maningat, vice president of applications technology and technical services, the booklet contains extensive data and results from functional and performance tests performed by both external and internal scientific resources. It is available at www.mgpingredients.com. Robertet Flavors selected GeoPeak Energy LLC to design, install and service a highefficiency solar energy system at their flavors manufacturing facility in Piscataway, N.J. The roof-mounted solar panels will span 115,000 square feet and will be operational by the end of 2011. Fourteen percent of the manufacturing plant’s power will be provided by this system, which will reduce the site’s annual CO2 emissions by more than 1.1 million pounds, the equivalent of planting 33,665 trees or the conservation of 1.5 million gallons of gasoline over the system’s lifetime.
www.snackandbakery.com
8dc\gVijaVi^dch id B^aVcd7V`Zgn 2 0 11 WHOLESALE BAKER OF THE YEAR
SPONSORED BY
2 0 11 WHOLESALE BAKER OF THE YEAR
A City Institution Milano Bakery is part wholesale bakery, part artisan, part pastry and cake specialist, all wrapped up in a city institution that Joliet, Ill., is proud of. Celebrating 96 years in business, Milano currently produces assorted breads, rolls, buns, cakes, desserts and more in a recently expanded 40,000-sq.-ft. production facility. For three generations and counting, the bakery has served parts of the Chicagoland area and all of northwestern Indiana with freshbaked goods using top-quality ingredients and a flair all its own. These are just some of the reasons Milano is the 2011 Baker of the Year.
Left to right: Bryce Ruiz, president and CEO; Fred Ruiz, co-founder and chairman emeritus; and Kim Ruiz Beck, chairman, along with the rest of the Ruiz team continue to drive new ideas.
Lauren R. Hartman, Editor-in-Chief
A
s you drive down the street, there’s no mistaking Milano Bakery; the facility and neighboring pastry/bake shop is decorated in red, green and white. In fact, everything Milano is decorated in the color scheme of the Italian flag. That’s
12
Snack Food & Wholesale Bakery - September 2011
because Italian tradition and a sense of family pride run deep within the company. These (and many more) are just a few reasons why Milano has been named Snack Food & Wholesale Bakery’s 2011 Wholesale Baker of the Year. “My grandfather began baking using a brick www.snackandbakery.com
Milano Bakery’s Darin DeBenedetti, vice president, left, and Mario DeBenedetti III president, right, display their 2011 Wholesale Baker of the Year award from Snack Food & Wholesale Bakery.
Photos by Vito Palmisano
oven in Lockport, Ill., in 1915 in the Soffiantini’s grocery store. In 1926, he moved the business to our current location on Chicago Street in Joliet [Ill.],” recalls Mario DeBenedetti III, president of Milano Bakery, Inc., Joliet, Ill. www.snackandbakery.com
Today, Mario, together with his brother, Darin DeBenedetti, the bakery’s vice president, run the operation. Mario graduated in 1987 from the American Institute of Baking International (AIB), which today regularly audits the bakery. Continued on page 14 September 2011 - Snack Food & Wholesale Bakery
13
2 0 11 WHOLESALE BAKER OF THE YEAR
Continued from page 13
“Our father taught us to have a good work ethic,” DeBenedetti says. “Our father could have turned the bakery over to us [at that point], but instead, he had us buy him out in the late 1990s,” he recalls. “Before he passed away in May of 2005, he told my brother, Darin, and I that because of the fact that we had to earn the bakery, he knew we would take good care of it and would fight to make it succeed. Also, having honest, loyal employees has been a big part of who we are.” Named after the northern Italian city, Milano bakes top-selling items, including Vienna bread and 4- and 6-in. French rolls daily. Brat and sausage rolls debuted about a year ago and cinnamon raisin bread, three-layer jumbo hamburger buns and long French bread were made available about six months ago. All of the items are made with no artificial preservatives and sold fresh every day. “We want to create buns for Italian beef that absorb more juices and develop better-for-you products, such as a 4-in. wheat roll,” DeBenedetti says. From its 40,000-sq.-ft. production facility in Joliet, Milano and its 50 employees provide some 150 assorted types and sizes of fresh Italian bread, French bread, rolls, sliced breads, Ciabatta, focaccia, boules, Vienna breads, Pullman loaves in several sizes, submarine and Kaiser rolls to hundreds of commercial customers, including restaurants, hospitals, nearby riverboat casinos and various foodservice suppliers within a 35-sq.-mile radius.
AT A GLANCE
Company: Milano Bakery, Inc. Headquarters/Location: Joliet, Ill. Website: www.milanobakery.com Plant Size (in square feet): 40,000 No. of Lines: 3 No. of Employees: 50 Annual Sales Total: $5 million Products (including private label/ contract/copack manufacturing): Breads,
The pastry/coffee/bake shop, located in an adjoining building, produces delectable cakes, pies, muffins, donuts, pastries and cookies, to name a few. “We occasionally ship out of state, but mostly distribute to Southern Chicago suburbs and Southern Illinois,” DeBenedetti explains. He is the third-generation of bakers in his family, and learned much of the business from his father, Mario DeBenedetti II, who learned from his father who started it all.
‘Everybody loves a little Italian’ The bakery’s brand image centers around its logo and ad slogan, which reads, “Everybody Loves a Little Italian,” and features an illustration of a little boy and girl eating, what else? A tasty loaf of bread. “We advertise that we have, ‘The Best Buns in Town,’ and stand by our mission statement: tradition, service and quality,” DeBenedetti explains. “The image is also that the product is healthy—it has no artificial preservatives. But we go by TSQ: Tradition, Service and Quality, and we always strive to improve. If we do that, we’re moving the ship forward.” But, the family-owned bakery has seen plenty of good days and
cakes rolls, French bread, Italian bread, artisan breads, desserts, breakfast pastries, hamburger buns Brands: Milano KEY PERSONNEL President: Mario DeBenedetti III V-P: Darin DeBenedetti
bad, he admits, and has enjoyed successes and withstood bad times, yet the family gets along and keeps pressing on, which is critical to keeping the bakery in top operating form. That’s one of the reasons why Milano has established itself as one of Joliet’s business institutions. “Since the economy changed, it has forced us to tighten our belt and look at everything more closely. Our core business is grocery stores, but we’re trying to broaden our sales by advertising to the public more, and with sponsorships for the park district and donations to local events. We also participate in many parades and expos and provide samples to foodservice suppliers,” DeBenedetti says. “But this is where we want to stay,” he adds. “It’s the town I grew up in.”
Flexibility and being local counts Milano’s main advantage over its competition is its long heritage in the area, its quality, attention to detail and service, DeBenedetti says. “We’re constantly changing and reformulating recipes and are also price competitive. One major advantage is that we bake custom products and can do it within 24-48 hours of the request. We’re nimble that way. Our being located where we are is also a big advantage. We can folContinued on page 16
14
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
GrainEssentials®
Performs the way you want. Tastes the way they want. When it comes to whole grains, why settle for less than the whole package? Here, we help you satisfy the trend toward health and wellness deliciously, GrainEssentials® FLOURS: t 8IJUF8IPMF8IFBU9' t 'MPVS#MFOE t 4UPOF(SPVOE8IPMF8IFBU t $SBDLFE8IPMF8IFBU t "OENPSFy #-&/%4 t (SBJO#MFOET t $PNQMFUF1J[[B.JY t .VMUJHSBJO5PSUJMMB$PODFOUSBUF t 8IPMF(SBJO#SFBEFST#BUUFST t "OENPSFy
with quality flours and mixes, and the ability to provide custom solutions. Add in extensive resources and R&D capabilities, and you’ve got a powerful partner. Even so, it’s the performance of our products that makes us the easy choice. Take our White Whole Wheat XF Flour. A terrific substitute for refined white flour, it offers similar texture, consistency, color and flavor. For more information on all of our products, visit baystatemilling.com.
GrainEssentials®
© Copyright 2011
OrganicEssentials®
800-55-FLOUR www.baystatemilling.com
BakingEssentials®
EthnicEssentials™
2 0 11 WHOLESALE BAKER OF THE YEAR Continued from page 14
low through and take good care of customers who might not be served this way by larger or more indirect suppliers.” Some of the programs and initiatives Milano has on the plate right now include clean-label products. “We like to keep a clean label,” DeBenedetti adds. “It’s very important, just like setting new goals and making quality control improvements. We
have a vested interest in becoming more efficient, making our truck routes as efficient as possible and providing what the customers want. So we have regular team-member meetings to discuss everything that’s going on. We are implementing a new quality control system to keep product waste down, and we also introduced a program using product score sheets with images of all of our products to help with quality control. We’re looking at a new way of complying with the Health Insurance Portability and Accountability Act (HIPAA) program and want to implement some new company communication programs.” He also maintains that the bakery will deliver emergency orders to many local customers within an hour or so of ordering. The bakery
stopped delivering to private homes in 1957. “Where else can you get that kind of service?” he says. DeBenedetti adds that he’d also like to expand into fresh baked/frozen production some time in the future. “We revise our product stock-keeping units [SKUs] to accommodate customer needs, so we’re always changing things,” he says. “We also offer custom products for many of our clients.”
Automation mixes with tradition The production facility has three makeup lines—one, a nearly fully automated “string” line that produces various types of rolls and buns, while another produces bread and the third is a manual line where operators produce specialty artisan items on which the dough is hand-cut and hand-sheeted. While there’s plenty of hand craftsmanship at Milano, automation and Continued on page 19
Carometec automatic walk-through boot or sole cleaners ensure product integrity and a healthy bottom line.
Look us up at CarometecUSA.com or give us a call at 563.582.4230 and put your best foot forward.
16
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
ON E MACH I N E. M A N Y AT TAC H M E N T S.
INFINITE S O L U T I O N S.
Guillotine Attachment
Dripless Valve Attachment
Rotary Sheeter Attachment
Waterwheel Attachment
The Vemag 500 is an incredibly versatile machine that allows you to easily produce a wide variety of products. The Vemag incorporates a number of innovative attachments that provide you with the flexibility to not only expand your product line, but to react quickly to the ever-changing tastes of your customers. Attachments can be swapped out in minutes. Use a single-lane Guillotine attachment to produce individual cookie dough portions. Change over to a Dripless Valve attachment and use your Vemag 500 to fill tubs with that same cookie dough, or use it to portion fillings into pie shells and tarts, or batter into pans. Then change over to a Rotary Sheeter attachment to extrude smooth, uniform sheets of brownie batter. And when business takes off and you need higher production volumes, use that same Vemag 500 with our Waterwheel flow divider attachment for multiple-lane production. You’ll find that the versatile Vemag offers the highest levels of portioning accuracy, speed and product quality. Let us help you expand your product line and grow your business…with the one and only Vemag. Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com
E q u i p m e n t a n d Te c h n o l o g y f o r t h e B a k e r y I n d u s t r y
PRODUCT DEVELOPMENT Snack food manufacturers have come to rely on ADM Cocoa for consistency and quality. But what really sets us apart are the added extras you can’t get anywhere else. Like product development. Come to us with an idea, we’ll help you transform it into a high-performance product your customers will crave. To find out more about how ADM’s technical expertise can give you an advantage, visit us at adm.com/ambrosia.
ADM. Chocolate…and so much more.
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. © 2011 Archer Daniels Midland Company
800-558-9958 |
[email protected] | www.adm.com
2 0 11 WHOLESALE BAKER OF THE YEAR Continued from page 16
technology are continually added to the equation. “We had a major expansion about three years ago to increase production speeds and efficiencies and added updated equipment,” DeBenedetti says. “We now have automated mixing, bagging, dividing, slicing and forming on one line, but for certain customers, we also work dough by hand and create artisan products. The facility’s recently expanded production space includes a larger packaging area, the automated packaging line and a multi slicer. “We’re also looking at getting an additional food x-ray inspection system for more safety,” he points out. “We will update as necessary, in the future.” The bakery has been making artisan breads, which are growing in popularity, years before such breads were called artisan. “That’s one point of difference of ours,” he says. “We always made what’s called artisan items for restaurants.” What’s ahead for Milano? “We hope to see our sales at least double in the next five years,” says DeBenedetti. “We’d like to be baking more products for other bakeries, and as I mentioned, want to enter the baked/frozen arena nationally.” Milano also wants to provide healthier products and check out trends such as smaller, healthier meal portions. “We’re looking at introducing all-natural breads,” he says. “These trends are helping us sell healthier products, making up for some lost sales due to the bad economy. It’s easy to sell something if you believe in what you’re selling—if not, you may get customer once, but you won’t get their repeat business.” As it always has done, Milano will maintain tradition, service and quality, he says. DeBenedetti is most proud of seeing a family buying Milano products or eating
www.snackandbakery.com
them in restaurants. “Getting compliments and seeing people smile when eating our products makes us feel good. You have to stick to what you’re good at, and we do a variety of things well,” he says. “We will definitely celebrate our 100th anniversary
when it gets here. As it gets closer, we’ll start planning on what to do. As long as we make a quality product with a clean label and give the customer what they want at a reasonable price, we’ll be around for another 96 years.” SF&WB
September 2011 - Snack Food & Wholesale Bakery
19
THE ‘BEST’ BUNS IN TOWN Photos by Vito Palmisano
Surviving neighborhood declines and thriving for 96 years, Milano Bakery’s recently expanded 40,000-sq-ft. production facility mixes skillful manual baking procedures with highly automated production, blending in tradition, a strong family heritage and quality with tasty new ideas. Lauren R. Hartman, Editor-in-Chief
aking fresh, tasty Italian and French bread, dinner rolls, burger and hot dog buns, Kaiser and submarine rolls, Pullman loaves and more for restaurants, supermarkets, casinos, foodservice suppliers and others, Milano Baking Co., Joliet, Ill., known affectionately as the bakery with “the best buns in town,” has seen a lot in 96 years of doing business. An expansion to the production facility a few years ago was a welcome improvement, adding 20,000 sq. ft. of production and packaging space as well as new production equipment and a bagging line. “So we’re set for the time being,” explains Darin DeBenedetti, vice president of Milano Bakery, Inc., who oversees production and, like his brother Mario, is a third-generation of the family running the business. “But I’m always looking at new equipment that might be a big help to us.”
B
The plant’s most recent addition was the bagging line installed in the packaging area, the latter of which was made larger in the expansion process. “We’re always trying to position ourselves with larger corporations, and we’re flexible enough to provide a wide variety of things to the seasonal companies here in Joliet, such as the river boats, race tracks and baseball stadiums that need seasonal items for the summer,” he says. “We’ve put quite a lot of food safety and quality measures in place, so we’re a very clean bakery. This new line has helped us out a lot because it’s versatile. We can make several different types of products with it.” With 50 employees, the bakery churns out fresh, delectable breads, rolls, artisan items, buns and more, some 150 stock-keeping units (SKUs) altogether. Milano’s 91/2 truck routes serve the greater Joliet area, as well as Continued on page 22
20
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
Top left: dough is removed from the mixer and (top right) transferred to the automatic “string” line, which produces assorted rolls, burger and hot dog buns and specialty items. Bottom left: artisan foccacia bread is always made by hand at Milano’s. Center left: freshly baked breads are removed from one of the large brick-lined ovens.
www.snackandbakery.com
September 2011 - Snack Food & Wholesale Bakery
21
Continued from page 20
southern Chicago suburbs and occasionally, portions of Indiana. Production starts at 6 a.m. most days and 3 a.m. on Fridays, he says. “We run two shifts a day, five days a week standard and then do cleanings on
Tuesdays and come in on Sundays. We can deliver seven days a week, depending on customer requirements. We’re planning on consolidating our truck routes to make them more efficient. That way, we will eliminate a few trucks and maintenance, which will help offset the rising cost of
flour and fuel,” DeBenedetti explains. Producing about 50,000 loaves of fresh bread a week or 65,000 lb. of dough, and products from 1 oz. to 3 lb. in quantity, the baking facility is organized according to function. There are basically three production lines: An automatic “string” line for dinner rolls, bread sticks, submarine rolls, hamburger and hot dog buns, Kaiser rolls and similar items; a bread line for all different loaf sizes up to 3 lb. and a manual, custom line for artisan breads and specialty items for restaurants, Ciabatta breads, focaccia, boules and “just about anything else the customers want,” DeBenedetti says. At the time of Snack Food & Wholesale Bakery’s visit, the automatic line was producing 4- and 6-in. French rolls and the manual line was making a 4-in. Ciabatta. “With the added space and upgraded equipment, we’re able to produce more in less time,” DeBenedetti says. “It used to take about six hours to make hot dog and burger buns by hand on a bench. Today, two staff members are able to produce the same amount in 30 min. to an hour. We also no longer have to hand-stretch and cut our French rolls by hand if we don’t want to, thanks to our automatic line.”
A little in every batch Flour is stored in a large outer silo that holds 90,000 lb. The flour is mixed for almost 10 min. with water, yeast and “a certain amount of the dough starter” in one of two, 600-lb. batch metal mixers. “We keep the starter here all the time,” DeBenedetti says as he points to a large container in the corner. “We add a portion into every batch, which is one reason the flavor of our breads stays the same and the product is consistent. We add something to this starter mixture daily and feed that mixture again before we go home.” Time and temperature are critical to each batch, he says. After the dough is properly mixed and rests for a time, the mixing bowls are taken over to the new line where the dough is dropped into a hopper leading to a conveyor that moves it into separate belts of the divider, is then Continued on page 24
22
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
SINCE 1972
NEW
c I62 (Four single racks or two double racks) t$BQBDJUZVQUPQBOT t)FBWZEVUZDPOTUSVDUJPOoIFBWJFSo MCT t7BSJBCMFTQFFECMPXFSTGPSUBSHFUFECBLJOHQSPåMF t%PVCMFTUFBNJOHTZTUFNoHSFBUTUFBNRVBMJUZXJUIJNQSPWFESFDPWFSZ t%JSFDUESJWFQMBUGPSNoOPCFMUToOPDIBJOT
S Fully and par baked bread and rolls
S Multiple weigh hoppers are easily incorporated for both horizontal and spiral mixers
S0VUEPPSCJOTBSFBWBJMBCMFJO CPUIBTTFNCMFEPSQSFXFMEFE WFSTJPOT
S *OEPPSTUPSBHFCJOTDBOCF BSSBOHFEJOUJHIURVBSUFSTUP NBYJNJ[FTUPSBHFDBQBDJUZ
S $FOUSJGVHBM1SFTTVSF4JGUFS
UP MCDBQBDJUZ JOEPPSCJOTBWBJMBCMF
(&.*/*ttXXXHFNJOJCFDPN],#4:45&.4ttXXXLCTZTUFNTJODDPN
Creative Technology and Service for the Baking Industry
Kaiser rolls, left, are dumped onto the conveyor leading to the bagging line, which layers the buns in a 4x4 configuration before multipacking them in clear PVC film, right. Below, finished submarine rolls are placed in groups of four on the conveyor.
Continued from page 22
stretched, weighed, automatically formed into rolls and placed on pans, 30 per pan. The pans are placed by staffers onto racks that hold 30 pans each. The staffers then move the racks to the proofing area. “We stretch a lot of things on the string line or can do it by hand,” he adds. “But, we fold things like our focaccias by hand.” Scoring of large round loaves and rolls can also be performed by hand, as is applying toppings like cooked onions, sun-dried tomatoes, herbs and more. “We use a lot of toppings, and presentation is so critical,” DeBenedetti says. “We talk to the chefs at the riverboat casino restaurants and other restaurants that change their menus often to find out what they’d like. We use things
24
like seeds and cheeses, tomatoes, herbs and pestos. The restaurants ask for various things. We’re seeing the trend toward wheat and multigrain breads, which has been big for the last few years. We also notice more demand for brioche buns and pretzel buns and now we make a brioche/ pretzel roll combination.” New bread and roll shapes are also requested. “We get asked to make things in different shapes— sticks, twists, larger, smaller whatever we can make in a roll, they want to try as a pretzel, we try wheat flours, corn flours
Snack Food & Wholesale Bakery - September 2011
and others,” he says. The racks are placed in the proof box (or can be put into a retarder for 12 hours, depending on the product), and stay there
www.snackandbakery.com
for an hour at 80-90°F and 90% RH. Once proofed, the rolls are taken out of the proofer and placed on the racks to be baked in brick-lined revolving ovens at 350-400°F for 8, 12 or 13 min., depending on the product. The seven brick-lined rack ovens were made in Canada, DeBenedetti notes. Five of the ovens reside in the main production facility and two were installed in the bakery/coffee/pastry shop. “They save 15% on gas usage, so we’ve cut our energy use. And they bake superior artisan breads,” he says. “But they weigh twice as much as a standard rack oven. We have the capacity for two more of them if needed. The ovens bake most products at 350-400°F for 8-13 min., but it depends on the product, its size and customer specifications.” Next, the racks of rolls are moved to a holding spot near the packaging line where they rest for about 30 min., says DeBenedetti. “If you let bread rise slowly, you have more control in your plant.” Other items can rest up to an hour, depending on what they are, and then head to packaging. Once the rolls are removed from the pans, the pans are cleaned and brought back to the front of the line. In the case of the French rolls, pans of rolls are dumped on a conveyor leading to the automatic bagging line. The rolls are separated by hand on the conveyor and can be sliced, depending on specifications, either straight through or with a hinge, and are then automatically stacked (usually in a 4x4 configuration) and pass through a metal detector before they’re bagged in clear polyvinyl chloride film. The various products can be bagged in multiples depending on the order, but the eight-pack is the most prevalent. Printed with the red, green and white Milano logo and bakery information, the bags are automatically clipped closed with a bag closure, loaded onto crates (usually six to 12 bags per crate) and moved into a holding area. After the bagged rolls are inspected, the staff checks what truck route they will be placed and the crates are loaded into trucks. Long breads and specialty breads and rolls that don’t fit into the clear bags are
www.snackandbakery.com
packed by hand in white paper sacks printed with the red, white and green Milano logo. The Milano staff inspects the products and monitors each operation constantly. “We perform hourly quality control checks and weigh everything on stand-alone weigh
scales over by the divider (on this line),” DeBenedetti points out. “We have two cleanings during the week, a full washdown on Tuesdays, which is our down day and each night, we clean the heads and sanitize Continued on page 27
"""$
Your
"
")"+"' ("!%' $%& & !,&% ",$) & "'&" #$" % ! &%&!&*&'$ & 0 &$+ $ $" $ $% ! $ &"%"'#%!% $%% ! %! (!-("$)&$0 &$+ $ % ) &" $&!"$ ' &%% +$%' & ! ! & $""%& &&%& "'%
)))#$" &"$,$"
" "! "" "
! $ !&%." %'%% 1&+ /)))&&! + "
September 2011 - Snack Food & Wholesale Bakery
25
Continued from page 25
everything—the mixers, the cutter/slicers, the dividers, everything. So, we have been ahead of the new food safety regulations.” Milano is well known and has been a fixture in the community thanks to its contributions to local food pantries and shelters with donations of extra product. “We send extras to a few places so that it doesn’t go to waste. We’re helping to reduce our carbon footprint,” DeBenedetti points out. Milano also sometimes works with a feed company. Any returned bread is mixed with grain and made into animal feed while some goes into making bread crumbs.
DeBenedetti continues. “There’s always something we have to fight for, whether the high costs of gasoline and commodities or operating costs. But we love what we do and have been with each other a long time, with good people around us. If we can stay ahead of the economy, we’ll be okay.”
Get it right the first time The bakery is making other productive efforts, such as working to improve its quality control practices with visual and online inspection processes. “There are a number of visual and online QC checks and inspection processes performed hourly throughout the production process,” DeBenedetti says. “We are training employees on visual product inspection with a new picture program that allows us to compare finished products to a standard and fill out bread scoring sheets for each product. We also use x-ray inspection systems and metal detectors. We monitor the lines by the hour to ensure that everything is going according to plan. And our maintenance crew inspects the machinery regularly to make sure it’s kept clean and running properly, and we check weights, slices and temperatures frequently.” The bread basically dictates everything that happens, he says. “We try to stay as efficient as possible. Everyone must stay on task, so if we start something, we finish it. And we take our time as much as we can. The more time we take, the better the product. We don’t want to have to bake a product over again; we want to make sure it’s done right the first time.” Being what the DeBenedettis call “a middle-of-the-road” bakery in size—not too small and not too large—the production plant is faced with challenges on a daily basis. But its strong family ties and firm work ethic keep things running smoothly. “There are few breathers,”
www.snackandbakery.com
Some of the fourth-generation children in the family now work at the bakery, including DeBenedetti’s son and daughter. “They’re carrying the torch and continuing on. If I could just pay them with bread, I’d be happy,” he laughs. SF&WB
#
" # #
! # # ! # ! # #
## ! # !
:7+ 2/ 1$&)'0 $.(' : 2&$,0' # :501$,,*.'2&10' 9 ,2%,'.*%' : ,5'410'*%' :$,1'41*.'0 :" :$12$, 1$&)'0 :,!$1' 3',,*.( 1$&) :((,-'$1'.01$.1 1$&) :*//)*,,*& 1$&) # 1$%*,*6' 501'-0
our*.('*'.107your02&&'00 ;
$1'5,'8333 1$1'$.,5,' &-80$,'0*.1$1'$.,5,' & :*0$1$'-$+&'*,21*1*.$,0
September 2011 - Snack Food & Wholesale Bakery
27
Market Trends Potato and Tortilla Chips
Flipping the Chip When it comes to potato and tortilla chips, today’s consumers have a more refined palate. Manufacturers are responding by producing their well-known products in unique varieties using zesty flavors and better-for-you ingredients. Jen Roth, Contributing Writer
f you want something salty without any guilt, chip manufacturers have you covered, providing many of their fanfavorite products with less fat. “The redefinition of health to consumers is interesting,” states Michael Joyce, vice president of marketing for Deep River Snacks. “There’s an appreciation for allnatural products and consumers’ disdain for preservatives or ingredients they’re not familiar with.” The Old Lyme, Conn., company is responding to this appreciation by providing an all-natural, gluten-free, multigrain tortilla chip made with quinoa, flaxseed and brown rice and features the Whole Grains Council seal of approval. They come in Hint of Salt, Nacho Kick, Twist of Lime and Guacamole varieties. “Flavor is the other trend we are watching on a daily basis,” says Joyce. “Consumers are demanding full flavor without any compromises on healthfulness.” Deep River Snacks’ line of kettle-cooked potato chips also aims to deliver a full bag of flavor. While bringing consumers standard options such as Original Salted, Salt and Vinegar, Cracked Pepper and Sea Salt and Lightly Salted (which contains 40% reduced fat), Deep River Snacks offers unique profiles like Rosemary and Olive Oil, Zesty Jalapeño, Asian Sweet
I
and Spicy, Sweet Maui Onion and Mesquite BBQ. Plus, all of Deep River Snacks’ products are gluten-free and produced in a nut-free facility. Meanwhile, consumers across the board are starting to look for potato chips and tortilla chips that offer more than just great taste, says Ramona Cappello, chief executive officer of Corazonas Foods. “They expect snacks to provide additional nutritional benefits and less ‘unhealthy’ ingredients, as well as taste good,” Cappello adds. That’s why the Los Angeles-based snack producer infuses its chips with plant sterols to help lower cholesterol and deliver a 40% reduction in fat for potato chips and 18 g. of whole grain and 3 g. of fiber in tortilla chips, Cappello says. “In addition, we offer unique, gourmet-inspired flavors for the foodie in every consumer with flavors like Parmesan Peppercorn, Spicy Rio Habanero, Black Bean & Cheese and Sea Salt & Vinegar, so those who
want to be more heart healthy no longer need to sacrifice on taste in their snacks,” says Cappello. Along with eating hearthealthy, consumers can also dive into a more run-of-themill option with its newly released Sea Salt and Vinegar variety. “Like our other kettle-style potato chips, our Sea Salt & Vinegar chips are be infused with plant sterols, which are proven in more than 140 clinical studies to help fight heart disease by lowering LDL cholesterol, and have 40% less fat than regular potato chips,” Cappello adds. Options such as Lightly Salted, Black Bean and Cheese and Squeeze of Lime help Corazonas prove that healthier profiles can taste just as good as every other tortilla chip on the market, if not better. “With Corazonas, we’re challenging the notion that snacks can’t provide heart health and taste at the same time,” asserts Cappello. “Our snacks show consumers that they can do something good for their hearts and still enjoy the foods they love— in fact we’re helping them become more heart-healthy by eating our snacks.” Natural Snacks, LLC, Addison, Ill., also focuses on churning up better-for-you snacks, starting with their new Michael Season’s Kettle Cooked potato chip line. Made with lower sodium and featuring 40% less fat, this line includes selecContinued on page 30
28
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
Increase product yields and Improve your bottom line.
Use Compact Grid™ conveyor belting… only from Wire Belt. t 70% open area allows for efficient heating and cooling of your product.
t Five times greater flow through than average plastic modular belt.
t Excellent product support for smaller, delicate products such as tortilla chips.
t Belt joining is simple and fast. t Low energy requirement for driving the belt. t Excellent belt tracking. t Easy to retrofit on your conveyor. Wire Belt Companyt)BSWFZ3PBE -POEPOEFSSZ /) 5&-t'"9 &NBJMTBMFT!XJSFCFMUDPNt8FCTJUFXXXXJSFCFMUDPN *403FHJTUFSFE$PNQBOZ
Market Trends Potato and Tortilla Chips Continued from page 28
WHAT MAKES THIS
CAYENNE PEPPER
A FRENCH’S
®
CAYENNE PEPPER
$## &"$( ( "#% $&$ %#$ " ! ! ! ($$ $ $ $$ ## %"%#$ "# ##$ $ ("&$#$!% $( " %$# ## $#'(' (%# " %#$"## ! %$ $ $ " ! " $ $ #$'$ # # #$" ! $ # " #$ ( " ## "#$"%#$$ &" "# %#)& "# ( ( %$("$"(" For ingredients that make products more competitive, call French’s today at (417) 521-2065 or visit www.FrenchsFlavorIngredients.com
tions such as Lightly Salted, Unsalted, Honey BBQ, Sea Salt and Balsamic Vinegar and Jalapeño, and come in 2-oz. bags for on-the-go snacking. “Our focus is to get our products into consumer hands,” says Christine Brown, director of marketing. “Once they try our products, they are very impressed with our snacks and love the taste.” Also new to the Michael Season’s family of better-foryou snacks are Baked Multigrain Cracker chips. These low-sodium, whole-grain chips come in Lightly Salted, Bruschetta and Cheddar varieties, and are scheduled to hit store shelves in September. “Michael Season’s has baked the goodness of a multi-grain cracker into a delicious little chip,” states Brown. “With 65% less fat than the leading potato chip, you can go ahead and enjoy snacking again.” Each cracker chip is light in texture, crispy and perfectly seasoned, Brown adds. Natural Snacks also developed Michael Season’s Popped Black Bean chips, a popped, gluten- and wheat-free snack made with black beans and delivers reduced fat and sodium. They come in 3-oz. bags in Original (Lightly Salted), Nacho and Roasted Red Pepper options. “Michael Season’s Popped Black Bean chips are distinctively delicious with a crispy crunch,” says Brown. Meanwhile, Kettle Brand, Salem, Ore., launched a new 40% reducedfat line, featuring just 130 calories per serving and 40% less fat. The line includes Sea Salt, Sea Salt and Vinegar and Salt and Fresh Ground Pepper varieties, along with Sea Salt & Vinegar in the Krinkle Cut arena. Kangaroo Brands, Milwaukee, Wis., also explores the benefits of producing a healthier snack through its Corn-Fusion Crisps. Made with corn and wheat and baked using a one-of-kind baking process, they come in a 4-oz. snack pack or 8-oz. option in Sea Salt and Chili Lime varieties. “It is a perfect replacement to tired and fried tortilla chips since it has half the fat and calories, yet [is] full of flavor,” says Salem Kashou, marketing manager.
AMERICA’S FAMOUS FLAVORS. QUALITY IS OUR ONLY INGREDIENT.
Innovative flavorings Another noticeable trend in the potato and tortilla chip category is innovative varieties of beloved snacks. In response to this shift, Prime Choice Foods, Bristol, Va., introduced a new Hispanic snack line called Go-Mex. Using a stone-ground process, Go-Mex tortilla chips are made with organically-grown corn and are offered in Yellow Corn, White Corn, Blue Corn, Nacho Cheese, Chili and Lime, Jalapeño and Molé Continued on page 32
“Now we can mix high viscosity emulsions 600% faster.” The Ross PreMax is the first batch rotor/stator mixer that delivers both ultra-high shear mixing quality and high-speed production. In side by side tests, the PreMax produces thickened dressings and sauces much faster than a traditional high shear mixer.
John Paterson PreMax Inventor Employee Owner
With a patented, high-flow rotor/stator design, the PreMax also handles viscosities far beyond the capacity of ordinary batch high shear mixers. In many applications, this can eliminate the need for supplemental agitation.
Contact Ross today to arrange a no-charge test in our laboratory. Call 1-800-243-ROSS Or visit mixers.com
The PreMax with a Delta generator operates with a tip speed of 5,000 fpm and handles viscosity up to 50,000 cP.
*Patent No. 6,000,840
Market Trends Potato and Tortilla Chips Continued from page 30
options in 16-, 21- and 28-oz. sizes, as well as a convenient 1.5-oz. snack size. “We see a huge shift toward chips made of masa flour containing a lot of inclusions or adding sweeter flavors and that have a unique taste that relates to a specific region or area of the country,” says Mauro Gomez, vice president of sales and marketing. “We also see more requests for chips and flavors that target a specific ethnicity.” Also tapping into exotic flavors is Pinnacle Foods Group, Mountain Lakes, N.J., with its Hawaiian Kettle Style potato chips. Bearing the tagline, “Lolo Ono,” which means “crazy
delicious,” these Hawaiian kettle-style potato chips provide an exotic twist to a familiar flavor. The potato chips come in Original, Sweet Maui Onion (seasoned with sweet Maui onion flavor), Luau BBQ and Wasabi, which combines wasabi root and horseradish on to a thickly-sliced chip. Other chip manufacturers are discovering ways to add a little zest to their already-established products. For example, Plano, Texas-based Frito-Lay is spicing things up with a new host of Tapatio hot sauce-flavored Doritos, Fritos, which is delivered on a twisty corn chip in lieu of the company’s traditional strip shape, and
Ruffles, which boast a hint of lime juice.
Sweetening up the category with sweet potatoes One ingredient making an impact is sweet potatoes. In fact, companies are discovering new and innovative ways to use this tuber to create lively, innovative chip offerings. For instance, Seneca Farms, Yakima, Wash., debuted a new gluten-free line of Sweet Potato chips in Sea Salt and Cinnamon varieties. The Bachman Co., Wyomissing, Pa., fuses sweet potatoes into its tortilla chip portfolio with Toasted Sweet Potato tortilla chips, which offer 18 g. of whole grains per serving and are made with stone-ground white corn and, of course,
Gluten-free | Omega-3's | Whole Grains | Trans-fat free IdenƟty Preserved
Let us be your Best Value - Quality, Service, Price supplier for: sŝƐŝƚǁǁǁ͘ƐŬĨŽŽĚ͘ĐŽŵĨŽƌŽƵƌĐŽŵƉůĞƚĞƉƌŽĚƵĐƚůŝƐƚŝŶŐ͊ ϰϲϲϲŵďĞƌsĂůůĞLJWĂƌŬǁĂLJͻ&ĂƌŐŽ͕EϱϴϭϬϰh^ ƐŬĨŽŽĚΛƐŬĨŽŽĚ͘ĐŽŵͻϳϬϭ͘ϯϱϲ͘ϰϭϬϲd >ͻϳϬϭ͘ϯϱϲ͘ϰϭϬϮ&y
CerƟĮed Organic
Non-GMO Project VeriĮed
ͻ^ŽLJďĞĂŶƐ ͻ'ƌĂŝŶƐ ͻ^ĞĞĚƐ ͻƌLJ ĚŝďůĞĞĂŶƐ ͻ&ůŽƵƌƐͬDĞĂůƐ ͻZŝĐĞWƌŽĚƵĐƚƐ ͻsĞŐĞƚĂďůĞKŝůƐ ͻsŝŶĞŐĂƌƐ ͻƌĂŶƐͬ'ĞƌŵƐͬ&ŝďĞƌƐ ͻ/ŶƐƚĂŶƚWŽǁĚĞƌƐͬ&ůĂŬĞƐ ͻ^ƉůŝƚͬĞŚƵůůĞĚ^ŽLJďĞĂŶƐ ͻ^ǁĞĞƚĞŶĞƌƐ Product of USA
32
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
Market Trends Potato and Tortilla Chips sweet potatoes. Laura Unger, marketing communications coordinator, noticed the greatest opportunity for growth in this category is by developing unique products that consumers love. “Consumers don’t want to spend their money on ‘new’ products that are already available in five other brands,” says Unger. “The product development and research process is very important before launching a new product. When consumers find a product they love, they will share it with friends. Personal recommendations are the best advertising you can receive on a new product.”
In addition to its sweet potato craze, the Bachman Co. has a new on-the-go line. “We have taken some of Bachman’s classic, loved products, including our MultiGrain tortilla chips and Black Bean tortilla chips, and packaged them in a convenient twoserving size,” says Unger. Rhythm Superfoods, Austin, Texas, also discovered the versatility of the sweet potato. Rhythm Superfoods prides itself on providing healthy snacks made from “superfoods,” but recently introduced a line of fat-free Sweet Potato chips. Made with wholesome, organic sweet potatoes and fresh ingredients and just 115 calories per serving, these raw and vegan sweet potato chips offer a nutri-
tious fat-free snacking option. They’re high in fiber, potassium and vitamins A and C. Available in Honey BBQ and Sea Salt flavors, these chips can be found in 1-oz. bags, great for on-the-go snacking. “Our products are unique,” says Scott Jensen, chief executive officer. Using vegetable superfoods such as kale, carrots and sweet potatoes as the base for all the products and not frying the snacks helps Rhythm Superfoods fuel new trends in this category, he adds. Certainly, consumers can expect more varieties of ingredients and flavors as their favorite brands continue to produce unique and healthier products, perfect for that 3 p.m. snack. SF&WB
FREE COATING TEST Find Out If There Is a Better Way to Apply Your Coatings U( &! ) )
UÊ% * % ** #" !+$ ' '
UÊ
" ! # % *
New Products
3
2
1
4
4
2
Wasabi Ginger and Mesquite Barbeque Journey Bars
1
Michael Season’s Black Bean Popped Crisps
Company: Natural Snacks, LLC, Addison, Ill. Website: www.naturalsnacksllc.com Introduced: September Distribution: National Suggested Retail: $2.99 for a 3-oz. bag Product Snapshot: New to the Michael Season’s family of better-foryou snacks are Black Bean Popped Crisps. Made with black beans, this gluten- and wheat-free snack comes in Sea Salt, Nacho and Roasted Red Pepper varieties. Ingredients (Nacho): Black beans, rice flour, sunflower oil, salt, maltodextrin, Cheddar and Romano cheeses (pasteurized milk, cheese cultures, salt, enzymes), onion powder, buttermilk powder, yeast extract, tomato powder, garlic powder, sugar, paprika, spices, natural flavors, lactic acid, paprika extract (color), citric acid. Contains: milk.
Company: Journey Bar, Chicago Website: www.journeybar.com Introduced: July Distribution: Midwest, New York Suggested Retail: $1.99-2.19 for a 1.93-oz. bar
3
Dancing Deer’s Whole Grain Collection
Company: Dancing Deer Baking Co., Boston
Website: www.dancingdeer.com Introduced: July Distribution: National Suggested Retail: $5.99 for an 8-oz.
package of brownies or a 9-oz. package of cookies collection now includes two new variet- Product Snapshot: Dancing Deer’s ies that, like the rest of the lineup, are new Whole Grain Collection consists of made with 100% natural ingredients and 100% whole grains. The lineup includes combine organic whole grains with real Chocolate Chunk brownies (accented flavors. Inspired by Japanese cuisine, with semi-sweet chunks), Peanut Butter Wasabi Ginger boasts flavors such as & Jelly squares, Fruit & Nut squares with soy sauce, ginger and wasabi, whereas Rolled Oats (featuring peanuts, almonds, Mesquite Barbeque provides a smoky, oats, apricots and cranberries), Cransweet, yet slightly tangy taste mixed with berry Orange with White Chocolate Chip healthy whole grains. cookies, Chocolate Chip cookies and Totally Nuts cookies (containing peanuts, Ingredients (Mesquite Barbeque): almonds, pecans and walnuts). Grain blend (organic oat flour, de-hulled buckwheat, organic brown flaxseeds, Ingredients (Fruit & Nut Squares): organic amaranth, organic oats, organic Brown sugar, whole grain organic barley millet seed), molasses, almonds, apple flour, cage-free eggs, cane sugar, butter cider vinegar, tapioca syrup (tapioca (milk), canola oil, whole grain white starch, water), tomato paste, canola oil, wheat flour, rolled oats, honey, peanuts spices, salt, garlic powder, onion powder, (peanuts, salt), raisins, dried cranberries, baking soda, natural smoke flavor, ascor- dried apricots, almonds, water, baking bic acid (vitamin C), vitamin E acetate. powder, pure vanilla, kosher salt.
Product Snapshot: The Journey bar
Cookies & Corks’ SingleVariety Packs
Company: Cookies & Corks, Falls Church, Va. Website: www.cookiesandcorks.com Introduced: July Distribution: National Suggested Retail: $3.00 for a 2.47-oz. single-flavor pack; $7.95 for a 6.92-oz. full-size box Product Snapshot: Cookies & Corks expanded its bite-sized wine-pairing cookie portfolio to now include singlevariety packs, available in Apricot Sage, Ginger Molasses, Zesty Lemon, Sea Salt Chocolate Oatmeal, Espresso Chocolate Peanut Butter and White Cheddar Rosemary. Each carton maintains a six-month shelf life and comes equipped with a wine-pairing guide that expertly suggests certain varieties with red, white or sparkling wine. Ingredients (Sea Salt Chocolate Oatmeal): Chocolate chips (sugar, chocolate liquor, cocoa butter, soy lecithin), sugar, butter (cream), oat flour, whole grain rolled oats, wheat flour (wheat flour, malted barley flour, niacin, reduced iron, thiamine mononitrate, riboflavin, folic acid), brown sugar, eggs, water, vanilla extract, baking powder (corn starch, sodium aluminum sulfate, calcium sulfate, monocalcium phosphate), sodium bicarbonate, salt.
E d i to r ’s N o te : G o to w w w. s n a cka n d b a ke r y. c o m to re a d a b o u t m o re n e w p ro d u c t s .
34
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
In 1959, twenty-two St. Mary's College students set a world record by cramming into a phone booth.
22 is Still The Record The Industry’s Original CB5 Baking Band® is Still Inspected with 22 Quality Checkpoints to Guarantee True Tracking and a Long Operating Life. Ashworth introduced and patented the CB5 Baking Band ® in 1963 and after 46 years, it remains the industry leader. Ashworth’s CB5 is hand woven by expert craftsmen and inspected with 22 different checkpoints to ensure the highest quality belt. Each CB5 is tested for true tracking prior to leaving the factory. The dense breathable weave provides even heating and outstanding relief of cooking gases. For perfectly baked products, rely on the performance of Ashworth’s Original CB5 Baking Band ®
Contact Ashworth Today - We’re Just a Phone Call Away! +1-800-682-4594
|
[email protected]
|
www.ashworth.com
The Nutritional Corner
Influencing the Influencers: A Preview of the Year Ahead
J
ust as children are shopping for new backpacks and sharpening pencils to head back to school, we at the Grain Foods Foundation (GFF), Ridgway, Colo., have been busy preparing for the upcoming year. Because our year starts on Sept. 1, we spend our summers preparing for the year ahead. The upcoming year will strike a balance between reaching both influencers and consumers. The foundation’s mission is to advance the public’s understanding of the important role grainbased foods play in a healthful diet. Therefore, part of our job at GFF is asking what resonates with consumers when it comes to nutrition and health information—there is no single answer to this complicated question and our programs must reflect this complexity. Since GFF formed in 2004, a number of programs have been executed to fulfill our mission, but as nutrition, media and consumer trends change, so does our outreach. According to the International Food Information Council Foundation 2011 Food & Health Survey, Americans obtain nutrition and health information from a variety of sources. When asked, “what three sources of information do you use most often to guide your food and nutrition practices,” more than two-thirds of participants revealed they turn to at least one media source (ranging from traditional to online media). Other top sources include the food label and the advice of friends and family members. The implications of these findings have certainly played a role in shaping our programming for this next fiscal year. Based on the explosive growth and adoption of
36
social media, how we define influencers has changed. While the term influencer once meant health professionals, it now encompasses consumer influencers, including bloggers and social media influencers. As a result, engaging with this group will be critical throughout the coming year. In particular, we’ll be enhancing the foundation’s social media presence. On Twitter, we currently engage with consumers using the account @GoWiththeGrain. However,
the addition of @GrainsRD this month will enable us to better reach nutrition and media influencers in this space. Because a registered dietitian is running the new handle, it establishes GFF as a credible resource for all things related to grains nutrition. And because grains nutrition can encompass a wide range of topics, we’ve refined our focus from an efficiency and impact standpoint. Two trends we’ve identified that most affect the industry are the gluten-free movement and Hispanic nutrition. In the coming months, we will have webinars planned for health practitioners in each of these areas that can later be shared through our social media channels. When it comes to gluten-free, our objectives are to clarify when a gluten-free diet
Snack Food & Wholesale Bakery - September 2011
Judi Adams, president, Grain Foods Foundation and the Wheat Foods Council
is medically necessary and help mitigate the promotion of it for weight loss. With the help of advisory board member and glutenfree expert, Shelley Case, we are working to position GFF as a leading voice in the gluten-free conversation. The Hispanic population is disproportionately affected by birth defects, with Hispanic women nearly twice as likely as non-Hispanic women to have a baby born with a neural tube defect. As such, our Hispanic nutrition messages are focused on the prevention of birth defects. Given enriched grains’ fortification with folic acid, we are educating those who work with this population about the importance of enriched grains for prevention, especially since they are the single largest source of folic acid in the American diet. Advisory board member Sylvia MelendezKlinger will be integral in our efforts. Finally, GFF will showcase its programs to traditional health professional influencers at tradeshows throughout the fall. This month, we will exhibit at the American Dietetic Association’s Food & Nutrition Conference & Expo (FNCE), Sept. 24-27 in San Diego. While we’re there, we’ll have the opportunity to attend events with both the gluten-free and Hispanic nutrition communities. Following FNCE, we’ll host the panel, “Grains Nutrition Update: The Issues Affecting Our Industry” at Chicago’s All Things Baking, Oct. 2 at 11 a.m. Please join us to hear from the experts about gluten-free, the Dietary Guidelines for Americans, folic acid and more. This is a small snapshot of what lies ahead, and we’re very excited to start our new year. I look forward to seeing many of you at upcoming events. SF&WB
www.snackandbakery.com
Quality Assurance Sifters Protect Your Products & Reputation Our precision sifters are custom designed to match your stringent requirements. We have an exceptional line of BISSC certified sifters to meet your food production and quality assurance applications. Gentle gyratory action, an unparalleled focus on sanitation, easy access for inspection and maintenance, dependable, safe, quiet, vibration free designs to protect your products, people, reputation and plant. Let us show you the right unit for your application, with quality assurance second to none.
www.gwmfg.com 913-682-2291
Product Protection & Production Sifters Since 1858
Special Report: Sustainable Ingredients
Growing ‘Green’ Protecting the world we live in through ‘green’ ingredient solutions can help make food more sustainable. Here’s a peek at some of the latest sustainable ingredient developments and technologies that are designed to keep the industry thriving in the future. Lauren R. Hartman, Editor-in-Chief
W
hen it comes to going “green” and growing “green,” various bakery, snack and food-related companies are changing the game. However, improving the sustainability of products and ingredients just may start with farming and crop production. Representing U.S. farmers, the United Soybean Board (USB), St. Louis, a farmerled organization consisting of 68 farmer/directors who oversee the investments of the soybean checkoff on behalf of U.S. soybean farmers, seeks to boost agricultural productivity to help feed the world, improve human health through good nutrition, be stewards of the environment and improve social and economic well-being of agriculture communities. Soybean farmers are using science-based mechanisms to help assess sustainability in the soy value chain. Production systems are increasingly environmentally sustainable and organic. Biotech varieties account for the vast majority of U.S. soybean acres. Biotech crops are able to produce more food than conventional agriculture with less environmental impact. In 2010, the USB commissioned a quantitative study to measure Americans’ perceptions and awareness of sustainable farming, and it proved to be a somewhat unfamiliar term, with more than 63% of the participants re-
38
porting that they “didn’t know” what the term sustainable farming meant. However, once a definition was provided and participants were asked how they perceived U.S. soybean farming practices, 72% agreed that U.S. soybean farming is sustainable. The study further indicates that 70% of Americans consider sustainability when choosing food products at the grocery store. And, when consumers think about sustainable farming, they most often refer to a way of raising food that’s healthy for consumers and animals without harming the environment. U.S. farmers rank as the
Snack Food & Wholesale Bakery - September 2011
global leader in sustainable farming, the USB study states.
Palm oil progress Cargill, Inc., Minneapolis, and its joint venture, Horizon Milling, LLC, enacted several sustainable programs, such as boosting the sustainable stakes in palm oil, with a move that all palm oil products (excluding palm kernel oil products) that Cargill supplies to the United States, Canada, Europe, Australia and New Zealand will be certified by the Roundtable on Sustainable Palm Oil (RSPO) and/or originated
“It’s important to understand where each customer is with regards to executing initiatives around sustainability. Sustainability is still an emerging area, and the food industry is working to identify products with meaningful value to the consumer.” Jennifer McLenighan, food ingredients marketing manager at Cargill, Minneapolis
www.snackandbakery.com
Special Report: Sustainable Ingredients
Photo courtesy of Dansico
from small-holder growers by 2015. This commitment will then be extended to cover all of the company’s palm oil products and customers worldwide, including China and India, by 2020, says vice chairman Paul Conway. Cargill is also working to develop other solutions that can aid in developing more sustainable food production, states Jennifer McLenighan, food ingredients marketing
manager at Cargill. The company sets fiveyear environmental goals for improving energy efficiency, greenhouse gas (GHG) intensity, renewable energy and freshwater efficiency. Its current set of environmental goals extends through May 2015. “Eleven percent of our energy comes from renewables with the goal of increasing use of renewables to 12.5% of the energy portfolio by 2015,” reports Pete
Stoddard, director of corporate affairs at Cargill. “In 2010, we expanded the Behavior-Based Energy Management (BBEM) program, which engages employees to reduce energy consumption.” A new business with a carbon or energy reduction focus called Cargill Process Optimizers (CPO) offers services that work with food manufacturers to reduce energy and water consumption, optimize yields Continued on page 40
www.snackandbakery.com
September 2011 - Snack Food & Wholesale Bakery
39
Special Report: Sustainable Ingredients Continued from page 39
and enhance capacity. CPO also helps food manufacturers grow leaner through operational and sustainability efficiencies, thus improving the bottom line. “Whether a bakery needs to squeeze more capacity from existing assets or tackle sustainability goals, CPO delivers pragmatic, actionable solutions with a quick return on investment, usually within two years,” says Dave Ward, general manager, Cargill Process Optimizers. EcoFlour from Horizon Milling, Minneapolis, uses technology combining satellite imagery and soil samples. EcoFlour growers apply nutrients to crops only where they’re needed, resulting in more efficient fertilizer and energy use, fewer emissions and higher yields per acre. The customizable program links precision agriculture technology through the supply chain from the farmer to the bakery. Partnering with Horizon Milling allows customers to
Photo courtesy of Caravan Ingredients
each customer is with regards to executing initiatives around sustainability. Sustainability is still an emerging area, and the food industry is working to identify products with meaningful value to the consumer. In many cases, sustainability is a driver in a consumer’s purchasing behavior, but not likely the only driver,” she adds.
Extending shelf life
develop new products that reach a “green” audience, make improvements in reducing their carbon footprint and source responsibly to protect their reputation, according to Jim Jarman, marketing manager at Horizon Milling. However, Cargill does face challenges with regard to sustainability, McLenighan says. “It’s important to understand where
Guohua Feng, manager of bakery ingredients IC at Caravan Ingredients, Lenexa, Kan., sees two trends: “Ingredients that promote ‘all natural’ and minimally processed products and those that extend the shelf life, which in turn reduces waste and increases production and distribution efficiencies.” “We dedicate a significant amount of time finding ways to help customers reduce waste and keep product on the shelves lonContinued on page 43
FREE
October 5, 2011
Virtual EXPO Event Sponsor )"(
# )" ) ) % )!% )!% )$ '& ) ' %
Media Co-Sponsors
Register @ www.PreparedFoodsVirtualExpo.com
www.PreparedFoodsVirtualExpo.com
*HW\RXUEDNHU\ RQWKHIDVWWUDFN ([- :,UNYH]PUNV\Y)HRLY`:LY]PJLZ +P]PZPVURLLWZ`V\HSHWHOLHK
^^^MHUKZLUNYH]PUNJVT
@V\JHU»[HMMVYKKV^U[PTL^OPSL`V\^HP[MVYYLWSHJLTLU[ J\[[LYZVYYV[HY`TVSKLYZ)LJH\ZL^LKVP[HSSPUOV\ZL`V\ NL[^OH[`V\ULLK^OLU`V\ULLKP[^P[OSLZZKV^U[PTL OPNOLYWYVK\J[P]P[`HUKIL[[LYX\HSP[`
9LJLP]LV\YUL^S`W\ISPZOLK YLWVY[¸;OL2L`[V9VSSPUNPU[OL +V\NOPU@V\Y)HRLY`)\ZPULZZ¹ *HSS+HU-YVTTH[ VYLTHPSOPTH[ KHUMYVTT'MHUKZLUNYH]PUNJVTHUK[`WL-YLL9LWVY[PU[OLZ\IQLJ[SPUL
-,97,69,; 9
Special Report: Sustainable Ingredients
Continued from page 40
ger,” Feng says. “Our enzyme technology helps ensure freshness and extended shelf life of bakery products and reduces waste of the products being returned as ‘stales’ from the display shelf. The technology also allows for greater flexibility throughout the supply chain.” Enzymes in baked goods also allow for a cleaner label, Feng explains, because the enzyme technology takes over the roles traditionally filled by chemical-sounding ingredients. “Our Trancendim products can stabilize liquid oils without palm or hydrogenation on the label,” Feng adds. Caravan’s new Pristine 500, an addition in the Pristine line of clean-label bases and functional ingredients, is a natural dough strengthener and conditioner designed to remove undesirable additives while still maintaining dough strength, explains Feng. “The line allows bakeries to produce products from all-natural or minimally processed ingredients.” The company’s Invisible Goodness
Natural Base offers many health and wellness benefits by invisibly adding betterfor-you ingredients such as whole grains, vitamins and fiber without compromising on taste, Feng says. “Consumers can enjoy bakery products in a new experience, and
manufacturers can produce, distribute and sell this type of product more efficiently.” However, Feng says, “The benefit of increased sustainability can sometimes be hidden. Also, new technology often Continued on page 44
Good to the Core!
Visit Shurtape.com/GoodToTheCore for a free sample and start seeing the difference.
!
"
Pack Expo 2011 | Booth 2624 | 888-442-TAPE
Photo courtesy of United Soybean Board
www.snackandbakery.com
September 2011 - Snack Food & Wholesale Bakery
43
Special Report: Sustainable Ingredients
Photo courtesy of Sensient Food Colors, LLC
Continued from page 43
involves a new way of thinking and doing things. For example, increasing shelf life will change how customers and consumers view the shelf life and quality of bakery products and how those bakery products will be manufactured, transported, distributed, marketed and ultimately consumed. And often, new technology costs more, especially on the earlier stages of commercialization.”
Color me green Sensient Food Colors, LLC, St. Louis, Mo., provides new aseptic packaging capabilities that establish best practices for natural color production and minimize the carbon footprint. The company creates color for food applications, and is known for proprietary technologies, including Fusion Precise Natural Colors. The aseptic packaging offers customers preservative-free colors that
“The benefit of increased sustainability can sometimes be hidden. Also, new technology often involves a new way of thinking and doing things.” Guohua Feng, manager of bakery ingredients IC at Caravan Ingredients, Lenexa, Kan.
deliver maximum shelf life and enhanced sustainability. “Our customers want preservativefree, natural colors to align with wholesome, clean-label declarations,” explains Steve Morris, commercial director, U.S.
Continued on page 46
The food industry needs to slice, stack, apply, portion, count and arrange. Check. We’ve used the last four decades to improve ways to do each one. Think what you can do going forward - with that kind of experience behind you.
Innovating Automation…Past. Present. Future. SEE US AT PROCESS EXPO, BOOTH 1406.
44
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
Special Report: Sustainable Ingredients Continued from page 44
Food Group. “Eliminating preservatives from natural color systems significantly reduces shelf life. Our new aseptic packaging system [allows us] to offer customers preservative-free natural colors with enhanced shelf life. Our aseptic packaging also aligns with our sustainability policy, as well as those of many of our customers. It reduces waste and is completely recyclable, minimizing the carbon footprint.” Sensient’s new product line extension in microfines technology also uses “natural” ingredients that can be applied to powdered food and beverage applications, providing a visual appearance not achieved in the industry until now, according to the company. An evolution in “natural” colors for applications such as topical seasonings and powdered food applications, the microfine powders can enhance Sensient’s leading natural color portfolio, marked by an extensive color spectrum, consistency and superior product stability.
New operating procedures Sustainability has become part of everyday life at Briess Malt & Ingredients Co., Clinton, Wis. “Our program, called ‘Green With Briess’ started in 2005, when our application to the U.S. Department of Energy’s ‘Save Energy Now’ program was accepted,” says Gordon Lane, president and COO. “In 2009, we received an ‘Energy Saver’ award from the [U.S.] Department of Energy for acting on audit recommendations and reducing overall energy usage more than 7.5%.” Briess’ sustainability efforts include re-
Photo courtesy of Briess Malt & Ingredients Co.
ducing energy consumption and emissions, he says. “By reusing heat in our extraction plant, we reduced natural gas consumption by 20%. We realized similar savings in malting and roasting operations through a combination of new heat exchange systems and new operating procedures.” New procedures or products undergo extensive reviews so that they’re produced in the most efficient manner possible and are constantly reviewed, Lane says. “We feel a great responsibility to operate in an environmentally conscious manner,” he says.
Natural food protection Consumers don’t seem to focus on ingredients and food when it comes to sustainability, and look more at packaging, says Rebecca Bingman, marketing manager for Dansico USA, New Century, Kan. “You can see that reflected in the way most food companies incorporate the idea of ‘green’ in marketing—it’s most often about the packaging.” “Consumers tend to not be aware of
how important ingredients can be when it comes to lowering the carbon footprint of food,” she adds. “But the most significant means of lowering a food product’s environmental impact is extending its shelf life through ingredient solutions. Studies estimate that about 30% of all food is thrown away. When you extend its shelf life, you reduce impacts along its entire life cycle, reducing consumption of raw materials, water and energy in production and lowering waste and emissions from manufacturing, transportation and packaging.” Danisco developed a solid line of solutions to help customers extend shelf life, such as the Care4U range of natural food protection solutions, which includes MicroGARD fermentates, NovaGARD antimicrobial blends, Nisaplin and Natamax natural antimicrobials, HOLDBAC protective cultures and GUARDIAN natural extracts. “We are coming out with the next generation of the Natamax B antimicrobial product, an effective mold inhibitor sprayed on the surface of bakery products (where mold would grow),” Bingman says. Natamax B was recognized among the “Best in Baking” at IBIE 2010 last September, promoting greater sustainability in the baking industry. “With Xivia, Danisco’s sustainable xylitol product, we completely redesigned the manufacturing process to achieve dramatic improvements in environmental performance,” she says. “Our new xylitol process now uses the wastestream from a
Photo courtesy of Shearer’s Foods, Inc.
product life cycle to find the best place to realize sustainable growth. We’ve achieved a lot, but continue to push ourselves to improve across the entire business.” However, raw material costs sometimes present a challenge, Smith says. “Many
traditional ingredient technologies may offer a lower up-front cost. At Shearer’s, we take a holistic, value-add approach to our costing. Sustainability is an important core value and thus is always considered at our company.” SF&WB
neighboring pulp and paper mill as a raw material source and has slashed the product’s carbon footprint by 90%.” Danisco sees many challenges as opportunities to use sustainability as a driver of innovation, Bingman says. “Sustainability isn’t a destination; it’s a mindset and a way of life, about continually asking ourselves what we can do better and working to find the answer.” Shearer’s Foods, Inc., Brewster, Ohio, boasts the first Platinum LEED-certified (Leadership in Energy and Environmental Design) snack food production facility. Located in Massillon, Ohio, it was named Snack Food Plant of the Year by Snack Food & Wholesale Bakery in the February 2011 issue. “Company wide, sustainability is at the very core of Shearer’s values,” says Paul Smith, director of product solutions at Shearer’s. “We have many key initiatives, including a zero landfill program, resource conservation and scorecard tracking, recycling, health and wellness programs and many more.” Smith sees organic and all-natural, minimally processed ingredients as big trends. “Our organic business has grown significantly over the last year,” he notes. “We have continued to grow our all-natural seasoning solutions and have many seasoning options that contain no artificial colors, preservatives or flavorings.” Shearers’ wild riceworks product, launched in March, epitomizes the allnatural, minimally processed trend. “This great-tasting product features whole grain brown rice, wild rice, black sesame seeds and more in a delicious all-natural, glutenfree, vegan-friendly [form with] no preservatives or MSG, 0 mg. cholesterol and 0 g. trans fat,” Smith says. “We look across the
www.snackandbakery.com
%+#0*+&) **+" '%* %+ ) *. + &%- %+ &%#&))&&+ *+" % (, '$ %+ * ) , %&+ / * % %,#+ - #*0*+ $*- ## +)& ++& / *+ % " )0# % *
) * % %+# %# % /+ %*'%# # , + *' &' )+ &% ,+&$+ ##0!,*+*+& '%# +0' + # 1 * * %,*+)0# % '## + 1 % )&&+ +"'%*,'* &.% %+ )$&*+*+# %*% +)0&) %++ &%
"
# %'%*. # + 0) ,'* &.% $')&- *'%*% ++ &%,) % &%- 0 % %*+" % & % &- ) +. %) %,%'%* *0.0% ).0&' )+ &% '%*' )$ %,+
!
,#+ - #*0*+ $*- * #&&)*' &+)&, & *+*) (, ) ,##0')& )$$# )$ %++ &%% *+ $ * **%0&, +%0+ $ %+ ) *. + %0$ / )&)$" ,' (, '$ %+
Think speed. Think flexibility. Think Weldon. See it in action at weldonsolutions.com
September 2011 - Snack Food & Wholesale Bakery
47
Ingredient Technology Digestive Health & Fiber Fortification
The Real Deal Today’s ingredient suppliers provide a host of fiber solutions that deliver on taste, functionality and ease of use. Marina Mayer, Executive Editor
or years, fiber has been top of mind for many consumers in search of a healthy diet. However, confusion arises when it comes down to actually deciphering what fiber really is and how much is needed to reach and maintain that healthy diet. Earlier this year, the U.S. Department of Health and Human Services and the U.S. Department of Agriculture jointly published the revised Dietary Guidelines for Americans (DGA), which indicated that consumers should consume 14 g. of fiber for every 1,000 calories per day (Americans greatly under-consume with a usual intake of just 15 g. per day, according to the revised study). As a result, many of today’s ingredient suppliers are taking action by developing a host of dietary fiber solutions that deliver the necessary fiber intake hidden inside a tasty item. The latest trends in digestive health focus around fiber addition, says Käti Ledbetter, product development scientist for Matsutani America Inc., Decatur, Ill., a subsidiary of Matsutani Chemical Industry Co., Ltd. in Japan. “Fiber can be used to increase the total dietary fiber content of a product while possibly providing a reduction in fat and sugar,” Ledbetter adds. That’s why Matsutani released Fibersol-2, a 90% digestion resistant maltodextrin that is 1.6 kcal per gram. Due to customer demand for a liquid form of fiber, says Ledbetter, Matsutani also created Fibersol-LQ corn syrup, a soluble corn fiber containing approximately 75% fiber and 2.05 kcal on a dry solids basis. “[Fibersol-LQ corn syrup] is used to
F
Photo courtesy of Cargill Food Ingredients & Systems
increase the fiber content of many foods while adding sweetness and humectancy as additional benefits,” Ledbetter says. “Fiber fortification is simplified because FibersolLQ is water-soluble, making fiber enhancements feasible in products such as snack and bakery applications.” Cargill helps its customers address new regulatory initiatives, guidelines and laws by providing an extensive portfolio of ingredients. “For instance, Oliggo-Fiber inulin improves the nutritional value of food by
increasing the dietary fiber content,” says Laura Daly, marketing manager, snacks for Cargill Food Ingredients & Systems, Minneapolis. “Another Cargill ingredient, Barliv barley betafiber, has been clinically shown to reduce cholesterol when consumed as part of a low saturated fat, low cholesterol diet and is authorized for an FDA health claim. WheatSelect white spring whole wheat flour and MaizeWise whole grain products make it easier for bakers to create great-tasting products with more whole grains. GrainWise wheat aleuContinued on page 51
48
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
BEANS MAKE GOOD THINGS EVEN BETTER. From fiber and protein to antioxidants and iron, beans are loaded with big nutrition. And now, you can add that nutrition quickly and easily to almost any application with VegeFull™ cooked ground bean ingredients from ADM. To learn mo more about how VegeFull can ca make your products ev even better, call 1-800-637-5843 or visit 1-800-637-5 adm.com/vegefull. adm.com/ve
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. © 2011 Archer Daniels Midland Company | 800-637-5843 | www.adm.com/vegefull
6 grams of protein power
Crave-worthy crunch
Energy that lasts
A natural complement to sweet and savory tastes
A variety of flavor possibilities
3.5 grams of satiating fiber
Ingredient Technology Digestive Health & Fiber Fortification
Photo courtesy of Archer Daniels Midland Co. (ADM)
Continued from page 48
rone provides the fiber and vitamin/mineral nutrition of whole grain.” Meanwhile, Archer Daniels Midland Co. (ADM) urges consumers to increase fiber intake with VegeFull, a line of cooked ground bean powders that contain a greater amount of fiber and protein compared to some major cereal grains, according to Cheryl Borders, manager, soy foods applications for the Decatur, Ill.-based company. “VegeFull cooked ground bean powders can be used in various food items to
Confusion arises when it comes down to actually deciphering what fiber really is and how much is needed to reach and maintain that healthy diet.
increase protein and fiber,” Borders says. “Popular applications include extruded and sheeted snacks, extruded cereals, crackers and cookies, nutritional bars, tortillas and baked goods. VegeFull cooked ground bean powders are also gluten-free, making them suitable for use in products developed for individuals with celiac or a gluten sensitivity. Examples of these products include gluten-free pastas and various baking mixes.”
Overcoming challenges Bakers and snack producers can face many obstacles such as texture issues when looking into adding a source of fiber into products, Ledbetter says. “Fibers are classified as either insoluble or soluble, with insoluble fibers adding additional texture attributes,” Ledbetter adds. “Fibersol-2 and Fibersol-LQ are soluble fibers and can minimize the textural effect on a finished product. Fibersol-2 and Fibersol-LQ can be used as the main source of fiber in a product as well as can be used in combination with other insoluble and soluble fibers in the market for multiple needs.” Consumers are increasingly seeking heart-healthy products, Daly says, but Continued on page 52
Ingredient Technology Digestive Health & Fiber Fortification Continued from page 51
HIGH
FOOD FOCUS
adding ingredients that offer digestive health benefits can force certain snacks and baked goods to suffer from a dry texture, a cardboard-like taste, viscosity, density and even heat. Cargill suggests combining fiber and Omega 3s to formulate a heart-healthy granola bar, for example. “Concentrated sources of fiber and Omega 3s allow for a heart-health claim even in these challenging applications,” she adds. “A blend of canola and flaxseed oils provide a solution that is shelf-stable and flavor neutral. [It’s also recommended to work] with barley beta-glucan, a nearly invisible soluble fiber has been developed for use in a variety of applications without affecting taste or texture.” Additionally, depending upon the nutritional targets and the desired finished product, VegeFull bean powders can be used in quantities up to 100% for extruded snacks and up to 50% for sheeted
" "!& !&"!
% "& ! % % )$ (+
' # *
“The latest trends in digestive health focus around fiber addition.” —Käti Ledbetter, product development scientist for Matsutani America Inc., Decatur, Ill.
snacks, Borders notes. “In baking applications, the flour percentage can be replaced 1:1 with VegeFull bean powder,” she adds. “We recommend starting with a 10-30% replacement and adjusting the water as necessary.” While the DGAs may showcase how consumers should be maintaining a hearthealthy diet, today’s ingredient providers deliver the real deal of solutions that enable Americans to do so without even knowing it. SF&WB
!#% !
'%& &
%)" !
$&
""" %
" $## "( $
""% #%
$ && $)
REGISTER TODAY
,!$
877-BFM-FLEX POWDER-SOLUTIONS.com
Enhanced soybean oils offer plenty to celebrate.
Ingredient Briefs
J.R. Short develops a selection of pellets designed to provide healthier alternatives for schools. The rice/potato/corn-based ripple fries come in plain, spinach and tomato and provide a credible calcium claim. Its vitamin A content meets up to 45% of the daily allowance. In addition to flexible formulations, the ripple fry pellets can be air popped or fried for expanded product development possibilities. J.R. Short Kankakee, Ill. 800-544-8734 www.shortmill.com
IOI-Loders Croklaan introduces Freedom IC500 dairy fat replacer. Freedom IC500 is a drop-in replacement that provides frozen dessert manufacturers with the ability to reduce and control costs while maintaining the desired quality of the end-product. Freedom IC500 is based on palm oil, which provides a less volatile raw material base relative to dairy fat, while providing the unique functionality and eating qualities needed in the frozen dessert segment. Loders Croklaan North America Channahon, Ill. 800-621-4710 www.croklaan.com
Drum-dried apples from Van Drunen Farms (VDF) offer the fresh flavor and nutrition of real apples but in an easy-tohandle flake or powder form. Drum-dried apples can be used in fillings, bakery mixes, cobblers, tarts and pies, and with instant solubility, it is easy to blend and add sweetness and texture to frozen desserts. VDF sources its apples from Canada and U.S. orchards, assuring that they have been picked at the peak of ripeness. The apples are then drum-dried at carefully controlled temperatures to keep them fresh. Van Drunen Farms Momence, Ill. 815-472-3100 www.vandrunenfarms.com
Viterra’s non-GMO expeller-pressed canola oil is an all-natural refined, bleached and deodorized oil manufactured using a double expeller-pressed process to maintain natural nutritional value. Its nonGMO Omega-9 expeller-pressed canola oil is a high-oleic canola oil that also is all-natural, refined, bleached and deodorized and manufactured using a double expeller-pressed process to maintain natural nutritional value. Both oils boast a six-month shelf life. Viterra Canola Processing Ste. Agathe, Manitoba, Canada 877-882-2565 www.viterra.com
Clabber Girl’s Rumford brand now offers a reduced-sodium baking powder to produce light and fluffy cakes, breads and more. It is said to contain 52% less sodium than leading brands and can reduce sodium in baked goods by more than 40%. This gluten-free powder comes in 4- and 8.1-oz. resealable, recyclable canisters. Clabber Girl Corp. Terre Haute, Ind. 812-232-9446 www.clabbergirl.com
For more than 100 years, snack food manufacturers have relied on ADM Cocoa’s Ambrosia brand of quality chocolates for their custom confectionery formulations. But, Ambrosia offers more than just first-class chocolate. What truly sets ADM Cocoa apart is its ability to work with customers and create one-of-a-kind, craveworthy products. ADM Cocoa also provides market information, production troubleshooting and ongoing customer service to help ensure the success of any creation. ADM Cocoa Decatur, Ill. 800-558-9958 www.adm.com/cocoa Continued on page 56
SF&WBtv 54
View videos demonstrating the newest bakery & snack food ingredients by visiting
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
www.snackandbakery.com
There’s only one Alberger brand salt. ®
© 2009 Cargill, Incorporated
It’s the shape that makes it great. Alberger® brand salt, exclusively from Cargill, is created from a process that starts with a hollow pyramid shape to form multi-faceted crystals. These unique crystals with a large surface area and low bulk density provide superior adherence, blendability and solubility compared to regular cube-shaped granulated salt. The rapid solubility also gives Alberger® salt its flavor burst when used in topical applications. To find out what else we can bring to the table, call 1-888-385-SALT or visit cargillsalt.com. collaborate
www.cargillsalt.com
>
create
>
succeed™
Ingredient Briefs Continued from page 54
The new SafeGuard treatment and delivery system from ConAgra Mills is a state-ofthe-art integrated production and distribution process for SafeGuard ready-to-eat flour. This patent-pending flour extends the safety assurance of the flour from ConAgra’s plant to the customer’s facility. The system delivers a five-log validated pathogen reduction, provides third-party validation studies and maintains the flour’s natural flavor, color, absorption, appearance and gluten functionality. ConAgra Mills Omaha, Neb. 800-851-9618 www.conagramills.com
Perfect Grain White from Watson is a blend of wheat bran and germ from white wheat that can be used in conjunction with existing flour. Perfect Grain White is derived from white wheat, providing minimal color impact. It also has an average particle size of under 1.5 microns, resulting in low water retention and virtually no organoleptic perception of the bran particles, thus producing smooth textured baked goods. Applications include bread, rolls, croissants, muffins, cakes, donuts, pizza crusts and batter, among others. Watson, Inc. West Haven, Conn. 800-388-3481 www.watson-inc.com
Ocean Spray’s Ingredient Technology Group debuts cranberry powders designed for snack, bakery and confectionery applications. Produced from superior-grade cranberries, these powders lend fruit appeal, deliver heart-health benefits and offer a superior replacement for artificial colors and flavors. Cranberry’s nutrient profile includes vitamin C, quercetin and fiber. Ocean Spray Ingredient Technology Group Lakeville-Middleboro, Mass. 800-662-3263 www.oceansprayitg.com
Continuous Seasoning and Coating Systems We provide fully integrated systems and individual machines to fit your application. If you need a versatile system that offers consistent and accurate control when applying your dry and LIQUID COATINGS THE 1UIK #OAT SYSTEM IS THE ONE FOR THE JOB For drum coating applications TO OVER BELT TOPPING APPLICATIONS &//$ESIGN PROVIDES QAULITY integrated coating systems for your application. #ALL TODAY OUR APPLICATION AND equipment specialists can provide YOU WITH A 1UIK #OAT SOLUTION FOR your seasoning and coating application.
56
Snack Food & Wholesale Bakery - September 2011
s (EAVY DUTY DURABLE DESIGN FOR continuous operation s %ASY TO CLEAN SANITARY UNITS THAT MEET FDA and USDA requirements s "ACKED BY &//$ESIGNS PROVEN experience and innovation
www.snackandbakery.com
. ®
Lubriplate com
IT’S TIME TO CHANGE YOUR LUBRICANTS... TO SOMETHING
SAFER!
If you are still using conventional H-2 lubricants anywhere in your food processing plant, you’re missing out on the many advantages of using 100% Lubriplate NSF H-1 Registered Lubricants. Designed speciÀcally for food processing operations, these high quality lubricants do more than keep machinery running at its best. They free you from the potential chemical hazard risks posed by H-2 lubricants. Clean, Safe, Non-Toxic lubrication for all of your machinery. Using 100% Lubriplate H-1 Lubricants throughout your plant can signiÀcantly simplify your HACCP program by completely eliminating lubrication as a potential chemical hazard. NSF H-1 Registered, Food Machinery Grade. Manufactured in compliance with ISO 21469 guidelines. Formulated with ingredients that comply with FDA Regulations 21 CFR 178.3570, 21 CFR 178.3620, 21 CFR 172.878, 21 CFR 172.882 and 21 CFR 182 for lubricants with incidental food contact. They meet USDA H-1 safety standards and are authorized for use in federally inspected meat and poultry plants.
ISO
ISO
21469
9001
Compliant
Registered
Lubricants You Can Use With Confidence!
Lubriplate®H-1 Class Lubricants Newark, NJ 07105 / Toledo, OH 43605 / 1-800-733-4755 www.lubriplate.com /
[email protected]
Engineering Management
You Can Git with Dis or You Can Git with Dat can’t help but get a kick out of those rodents dressed in gangsta garb, trying to sell cars that look like rolling toasters (check out the Kia Motors “Hamster Rap” commercial on YouTube). What they are seemingly trying to do is show us the huge advantage of buying one company’s shoebox on wheels over the competition’s. Whether you buy the Kia Soul or the Scion xB, when all is said and done, they both stack nicely in the junkyard. The point of the commercial is that when you are looking to buy something new, there are always choices, and often, the choices look alike and act similar. In the baking industry, we face the same dilemma. When it comes time to purchase a new oven or a mixer, there are several options, and while they look nearly the same from a distance and may deliver similar results, the supplier always believes that theirs is better than the others. When faced with decisions on how to choose which machine or system you are going with, there are a lot of factors to consider that aren’t visible to the naked eye. For starters, when considering the purchase of a major capital item, you need to get a feel from peers in the industry as to how the supplier has performed in the past. Although this is important, it is not a tell-all to how your experience will be. Ask around to get the pros and cons. Reputation goes a long way, so make sure you take every opportunity to learn as much as you can before making that first call for a quote. Next, find out how long the supplier has been serving the specific industry. Longevity doesn’t always lead to the best
I
58
fit, but it does provide assurance on how the provider services its customers and applications. The supplier may have been around selling machinery for the mixing room forever and suddenly, they come up with something for packaging. Their top reputation in mixing might not carry them in the new selling space right away. Additionally, you need to consider your own personal experience with the company. Your experience may have been in a past season of your career, but reach into your own memory and weigh your own set of pros and cons, all before making that first call. If you are considering a brand new supplier to the marketplace, you have your work cut out for you. I’m not suggesting that you stay away from new providers, but evaluating them may be more difficult to accomplish before making the call. Once you are ready to deal with the supplier, make a point to meet their people. I have a lot of industry friends that sell equipment, but when I start the conversation, I like to dig a little deeper into the organization. Chats with the engineers, the parts peope and the service folks can
Snack Food & Wholesale Bakery - September 2011
Jeff Dearduff
[email protected]
be some of the most beneficial time spent when considering their wares. The sales people will provide the outline and the specifications and even help apply the right machine to the task, but the guys behind the scenes will say what they deal with and how they feel about the key features of the machine. They say that most successful design modifications to equipment come from the field, so why not get some feedback from the folks “behind the scenes” before moving forward? Finally, discuss the features of the machine or system in detail so that both parties know what you need and what they can deliver. Clear expectations are the key to figuring out the correct price. Car dealers talk about the “service after the sale.” In our business, we need to be conscientious of the service before the sale, especially when dealing with a quartermillion-dollar order. Timely responses to questions, quick turnarounds on quote adjustments and providing answers before you ask the questions are all signs of good things to come. And, if the supplier is willing to get you out to other customer’s facilities so you can see their gear in action and talk to the user, and they can service you with qualified technicians, readily available repair parts and a quick reaction to warranty claims, you can’t ask for much more than that. The final frontier in a deal like this is the delivery schedule and terms. If delivery is promised to be timely and payment terms are fair to you, the end of the conversation becomes the negotiated price. If you use this process to evaluate your deal, you’ll never have to worry about getting shanked by a giant rat. SF&WB
www.snackandbakery.com
Process Expo 2011
The Global Food Technology Show
W
60
here else can bakers, snack food producers and suppliers find the latest in trends, packaging equipment and technology besides Process Expo 2011? Otherwise known as “the global food and technology show,” Process Expo is the place to be when it comes to everything new going on in the food industry. Hosted by the Food Processing Sup-
critical issues in the food and beverage industry, the educational sessions provide a wide array of manufacturing solutions for participants from some of the industry’s top experts. Sessions start each day of the show and are free. “This is by far is the most comprehensive educational program we have ever offered at Process Expo,” says David Seckman, president and CEO of FPSA. “We are grateful for the support of our food
pliers Association (FPSA), McLean, Va., Process Expo 2011 will take place Nov. 1-4 at Chicago’s McCormick Place. This 100%-food-focused event attracts more than 10,000 attendees from the world’s leading food companies that are looking for developments that will help them more rapidly, efficiently, safely and successfully create and bring food products to market. The educational program features three main areas of interest. Designed to address
processor educational sub-committee that chose the submissions that will best appeal to Process Expo attendees. We are confident that the strength of this program gives food processors yet one more reason to come to Chicago this fall to a show that is on track to double in size compared to the 2010 show. By combining this high-level educational content with the unmatched technical expertise that attendees will find on the show floor, Process Expo has
Snack Food & Wholesale Bakery - September 2011
Exhibit Show Hours Tuesday, Nov. 1 9 a.m. – 5 p.m. Wednesday, Nov. 2 9 a.m. – 5 p.m. Thursday, Nov. 3 9 a.m. – 5 p.m. Friday, Nov. 4 9 a.m. – 2 p.m. *Exhibit show hours are subject to change.
become an integral resource for the food and beverage processing industry and a must-attend event.” Attendees can look forward to visiting the Siemens Exhibitor Spotlight Theater, which will deliver a series of short technical workshops throughout the day on the show floor, covering a wide variety of topics. Visitors can listen to experts discuss manufacturing solutions. Dedicated entirely to Process Expo’s attendees from Latin America is Seminario de Innovaciones, which runs throughout the day on Oct. 31. These sessions are presented in Spanish and sponsored by the show’s international partners—Canainca, Canilec, Comecarne and Chilealimentos. FPSA also launched a Spanish language version of its website to inform Latin American food processing professionals about the benefits of participating in Process Expo. While still in development, the Spanish language educational sessions will feature topics such as food safety and sanitation, employee training and maintaining standards for food and beverages being exported into the United States. In addition, FPSA councils will develop industry-specific sessions for meat/poultry/seafood, dairy, bakery, beverage and fruit and vegetables. For exhibitor and attendee information, travel arrangements, airfare discounts, registration links and more, go to www.myprocessexpo.com.
www.snackandbakery.com
Process Expo 2011 Exhibitors EXHIBITOR NAME
BOOTH(S)
3-A Sanitary Standards A M King A1 Webcams, Inc. Accuform Signs ADI Systems Inc. Admix, Inc. Advantec MFS Inc. Air Products Alchemy Systems Alfa Laval Inc. Alkar American Process Systems
5614 108 2740 1628 349 423 2452 123 2754 1415 2019 4612
EXHIBITOR NAME
As of Aug. 29, 2011
BOOTH(S) TH(S) TH(S) H(S (S S)
Amerivap Systems Ampco Pumps Co., Inc. AmTrade Systems Anderson Instrument Co., Inc. Anhydro, an SPX brand Anritsu Industrial Solutions USA Anton Paar Anzu Technology/ Fenco API Heat Transfer Inc APV - an SPX brand Arizona Instrument LLC ARPAC Food Group
150 3614 4812 2156 1002 1960 4733 4636 440 1002 1952 616
Tap into our baking talent. >L»SS>VYR>P[O@V\ >OH[L]LY`V\YMVYT\SH[PVUULLKZJOVVZLMYVT[OL
MHTPS`VM`LHZ[HUKIHRLY` PUNYLKPLU[Z·HUK[HWPU[V[OL HUK VMV\Y[HSLU[LK[LHT
-,94,5;(;065
6?0+(;065
8<(30;@°,5/(5*,4,5;
:/,3-°30-,°,?;,5:065
*/,40*(3°3,(=,505.
HITMJVT
( )4 (< 9 0-6 6 + 05 *
>L»YLJVTTP[[LK[VHYLSH[PVUZOPWVYPLU[LKWHY[ULYZOPW· ZLY]PUNHZ MVYWYVJLZZVW[PTPaH[PVU HUKJ\Z[VTMVYT\SHZVS\[PVUZ
EXHIBITOR EX EXHIBIT EXH HI IT NAME HIBI HIB
BOOTH(S)
Ashworth Bros., Inc. Atlas Copco Compressors LLC BASF Corp. - Building Systems Beckhoff Automation LLC Beehive BELL-MARK Corp. Bemis Co., Inc. BEST USA Bioni USA and Americas LLC Bizerba USA, Inc. Blentech Corp./BPS BLUCHER Blumer USA, Inc BNP Media Bran+Luebbe - an SPX brand Bredel Bühler Group Bunting Magnetics Co. Burns & McDonnell C M Process Solutions Carometec Inc. Carruthers CES / Foodlogistik USA Cesco Magnetics/Q-Controls Chad Equipment, LLC Charlottetown Metal Products ChemStation International, Inc. Chester-Jensen Co., Inc. CHL Systems Choice-Pac Cipriani Harrison Valves Corp. Clarion Lubricants Clayton Industries, Inc. Clextral CMC America Corp. Cole-Tech Industries Colormasters LLC Comark Corp. Combicut Inc. Comtec Industries Ltd Corenco, Inc. Cozzini, LLC. CPM Wolverine Proctor, LLC CSB-System International, Inc. Custom Metalcraft Inc. CVP Systems, Inc. DCS Sanitation Management, Inc. Delkor Systems, Inc. Donaldson Co. Inc. Douglas Machines Corp. Drake Co. Drying Technology, Inc. Dupont / Liqui-Box Corporation DuPont Teijin Films Dur-A-Flex, Inc. Dynamic Flow Solutions Eagle Product Inspection Ecolo Odor Control Technologies, Inc. Edlund Co. Electro-Steam Generator Corp. Emery Winslow Scale Co. Epstein Eurotek Ltd. Evergreen Packaging Filtration Automation, Inc. Flowtech Div./ Unibloc-Pump Inc. Fluke Electronics Focus Works, Inc.
1016 1422 2054 415 3723 1843 343 4216 664 4544 1831 348 3250 1554 1002 226 4236 3640 4631 4231, 5625 419 4219 133 1602 1443 109 1751 1626 1950 660 1851 1740 1356 140 1703 554 3414 2451 106 3548 112 2019 1727 2449 1455 2240 3643 1426 1615, 1616 4208 3819 141 3607 4736 2954 2956 643 764 1819 150 233 3416 3403 2448 850 4523 1424 160
Continued on page 64
62
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
Process Expo 2011 Exhibitors
As of Aug. 29, 2011
Continued from page 62 EXHIBITOR NAME
BOOTH(S)
FOMACO Food Manufacturing Magazine Formax Fortress Technology, Inc. FOSS North America FPEC Corp. Franz Haas Machinery of America FRC Systems International, LLC FRICK by Johnson Controls Fristam Pumps USA G&F Systems, Inc.
2602 3444 3723 2012 3615 1026 1445 1354 3255 2116 3549
EXHIBITOR NAME
BOOTH(S) TH(S H((S) (S S)
G. J. Olney, Inc. Gainco, Inc. Gamajet Cleaning Systems, Inc. GEA Convenience-Food Technologies GEA Freezing GEA Group GEA Niro Soavi GEA Process Engineering GEA Tuchenhagen GEA Westfalia Separator Graco Inc.
Convey For Profit. Line efficiency, seasoning quality, breakage, stale product complaints, sales attainment, processing uptime, sanitation downtime, warehouse capacity, weigher accuracy: Are these issues reducing your profits? We understand and we can help! As the conveying technology leader, Heat and Control will work with you and create the product handling system that brings the profit back!
800 227 5980 / 510 259 0500
[email protected] www.heatandcontrol.com
1619 2035 2040 431 3403 3403 3403 3403 3403 3403 2048
EXHIBITOR EX EXHI HIB HI HIBIT BIT NAME
BOOTH(S)
Great Western Mfg Co, Inc Greydon Grote Co. Handtmann Inc. Hanna Instruments Harpak-ULMA Packaging, LLC Haynes Manufacturing Co. Heatec, Inc. Hinds-Bock Corp. Hitachi America, Ltd. Hitec Food Equipment, Inc. Hoegger Food Technology Inc Hosokawa Bepex Hovus HRS Heat Exchangers HydroCal, Inc. I J White Systems Ingersoll Rand Inline Industries, Inc. Intec LLC Intralox LLC JanTec Jarvis Products Corp. JAX INC./ Xact Fluid Solutions JBT FoodTech JLS Automation Johnson Pump - an SPX brand K&G K L Products Kaak Group Kamflex Corp. Karl Schnell Inc. Key Technology, Inc. KNOLL America Koch Equipment LLC Koppens K-Tron Kuhl Corporation Lee Industries, Inc. Leviton Mfg. Co. LMI Packaging Solutions Lubriplate Lubricants Luceo Inspection Worldwide Lyco Manufacturing, Inc. MadgeTech, Inc. Magna Products Corp. Magna Systems Magnuson Corp. Marel Marlen International MasoSine Meltric Corp. MEPACO Mesa Laboratories Mettler-Toledo CI-Vision Mettler-Toledo Hi-Speed Mettler-Toledo Safeline Meyer Industries, Inc. Midas Printing International Limited Middough Inc. Midwestern Industries, Inc. Multisorb Technologies Multivac, Inc. Murzan, Inc. Naegele, Inc. Nelson-Jameson, Inc. New Age Industrial
125 1654 1406 1802 1456 602 1614 765 4635 2249 627 2231 234 1743 354 5612 1448 3808 1627 3403 2243 956, 957 1160 3417 615 4227 1002 431 2748 3048 1651 5019 1402 848 1248 431 3707 4819 816 4735 1606 1609 3449 2031 661 1062 2950 1603 4808 4219 226 4713 1031 127 202 202 202 3319 662 5219 1621 1054 4640 1617 3252 4619 335
Continued on page 66
64
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
Mega
When Mega Means More Than Simply Great THE MEGA 52 & TWIN IN-LINE OP/AL SYSTEMS
TIA Las Vegas
The Lawrence Mega 52 OP/AL System
Come visit us at booth #119 September 12 - 13
Automatic production of quality Wraps, Flour Tortillas and other Flat Breads • Patent pending vacuum
head technology • Three station temperature control plates
• Digital pulse air discharge
Time and time again, Lawrence Equipment has proven that their Mega 52 OP/AL system is more than just big… it’s the seamless integration of the best baking machinery manufactured today.
integrated with recipes • Highest speed at the lowest waste in the world • Fully automatic from mixer to sealed bag
The new Hartmann Servo Bagger and Sealer is a fully automated bagger which features improved stack infeed staging, 50% wider seal band and handles 5" to 14" diameter wraps with ease.
Hartmann Servo Bagger & Sealer
Accuview III Inspection & Rejection System
2034 North Peck Road • S. El Monte, CA 91733 • USA Tel 626/442-2894 • 800/423-4500 • Fax 626/350-5181 www.lawrenceequipment.com
The new Lawrence Accuview III features an easy to follow press shim report to allow perfect sizing for each product diameter.
Process Expo 2011 Exhibitors
As of Aug. 29, 2011
Continued from page 64 EXHIBITOR NAME
BOOTH(S)
Nicholl Food Packaging Nilfisk Industrial Vacuums NiMCO Corp. noax Technologies Corp. Noren Products, Inc. Thermal Solutions NuTEC Manufacturing Oncor optek-Danulat, Inc. Osgood Industries Inc. OYSTAR North America Pacific Ozone Technology, Inc. Packaging Progressions, Inc. Palmer Wahl Instrumentation Group Pappas, Inc. Parker domnick hunter Parker Hannifin Corp - Balston Patty Paper, Inc. Paul Mueller Co. Peco Controls Corporation/ InspX Petro-Canada Lubricants Pick Heaters, Inc. Plex Systems Poly-clip System Potato Processing International and Potato Storage International POWER Engineers, Inc. Promarks/Biro Protective Industrial Polymers Provisur Technologies Inc. PSG Wilden Pump Quantum Quickdraft QuickLabel Systems QuikWater, Inc.
1948 1623 223 965 1454 2840-1 1706 313 2640 619 3645 1336 1620 3445 232 1042 3354 1612 1419 1440 1605 3642 4140 2852 5212 4823 761 3723 3608 4616 3715 2248 314
EXHIBITOR NAME
Radiant Industrial Solutions RapidPak RathGibson LLC Reiser Remco Products Corp. Rigidized Metals Corp. Risco USA Corp. Rollstock, Inc. Ross Industries Ross Technology Corp. Ruitenberg Ingredients, Inc. Russell Finex Sani-Matic, Inc. Sanitube Scan American Corp. Schenck AccuRate Semi-Bulk Systems, Inc. Separators, Inc. Sharpe Mixers Sherwin-Williams Siemens Industry, Inc. Sigma Industrial Automation Silikal America Silverson Machines, Inc. Sipromac Inc. Solbern Sosland Spray Dynamics, Ltd. SPX Flow Technology Stellar Steriflow Valve Sterling, Inc Sudmo North America SWECO, a business unit of M-I L.L.C.
BOOTH(S) TH(S H((S) (S S)
1862 2019 954 2602 2848 1749 4214 2840-3 2602-5 1268 3816 2142 1323 2056 216 4715 4506 3714 5123 4613 868 241 3256 3617 219 4607 2168 1723 1002 240 4525 2854 3419 2014
EXHIBITOR EX EXHI HIB HI HIBIT BIT NAME
BOOTH(S)
TAWI USA TEGAM, Inc. Tel-Tru Manufacturing Co. Terlet USA Tetra Pak Inc. Thermal Care, Inc. Tiger-Vac Inc. (USA) Tiromat Top Line Process Equipment Company Toyo Millennium Company Limited Traker Systems Tufco Flooring Unifiller System Inc. Urschel Laboratories, Inc. USDA, Agricultural Marketing Service VANMARK VC999 Packaging Systems Videojet Technologies Inc. Vincent Corporation Visys Sorting VNE Corp. Vogelsang USA Voss Belting & Specialty Co Warner Bodies Wastecorp Pumps LLC Watson-Marlow Waukesha Cherry-Burrell - an SPX brand Waukesha Foundry, Inc. Weiler Wild Flavors, Inc. Wilevco Inc. Wire Belt Company of America WRH Industries, Ltd. ZM Technologies, Inc.
96 8*&1 3+ *<4*687 -*04 7*0*(8 8-* 6.,-8 *59.41*28 +36 =396 463)9(8.32 '98 ;* )32 8 7834 8-*6* $* ;.00 ;36/ ;.8- =39 83 .1463:* 463)9(8 59&0.8= &2) 1&<.1.>* =396 463+.8&'.0.8= 96 -396 (97831*6 7*6:.(* -380.2* &2) +900= 783(/*) " 4&687 ;&6*-397*7 &)) 83 8-* 437.8.:* 3*2., *<4*6.*2(*
63;.2, %396 97.2*77 8-639,- "94*6.36 9831&8.32 ? " ? !" ? "!# <(097.:* &78 3&78 .786.'9836
;;; '&/* 6.8* (31
!.(- 6**7;.2* *2*6&0 &2&,*6 3*2., &/*6= "=78*17 "*880*6 !3&) !.(-132) # 6.(-&6) '6**7;.2*/3*2., 6*< (31 ;;; /3*2.,97& (31
2551 1457 2850 138 1814 333 323 431 413 252 5623 2654 2436 1412 762 1406 5631 4623 332 4816 3603 4734 4637 2656 2643 226 1002 564 3723 3514 3440 337 1312 556
Process Expo Booth Profiles
[Editors’ Note: booth numbers, if made available, are current as of April 21, 2011.]
Continued from page 42
68
Remco Products Booth # 2848
Reiser Booth # 2602
A family-owned business since 1985, Remco Products has been developing its presence as a trusted supplier to the food processing, pharmaceutical, janitorial/sanitation, safety and material handling industries by providing a range of color-coded quality plastic products. With today’s increasing focus on hygiene and crosscontamination issues, Remco has taken a proactive approach toward product development to help companies comply with stringent HACCP regulations and guidelines. That’s why Remco’s color-coded tools are made from FDA-compliant materials and are ISO-certified, providing the ultimate step in quality assurance and safety. Remco’s product line includes polypropylene shovels, scoops, scrapers, kart tubs, and mixing paddles in addition to a team of color-coded metal detectable products. Remco also offers Vikan brooms, brushes, squeegees, pails and handles. Remco Products Zionsville, Ind. 317-876-9856 www.remcoproducts.com
Reiser will feature live demonstrations of its Vemag bakery equipment. The Vemag is a versatile machine that combines the highest levels of portioning accuracy, speed and product quality. The Vemag is used as a dough divider to produce breads, rolls, buns and English muffins, and is easily adaptable to all ranges of dough absorptions and crumb structures. The Vemag is also used as a depositor to accurately portion fillings and batters onto moving or stationary lines. It is ideal for any depositing task where placement and weight control is needed. Reiser will also demonstrate the Vemag dough divider in various sizes and configurations from singlelane to high-speed multilane output. A Vemag cookie dough depositor will be on display. This depositor is an ideal solution for producing pre-formed, ready-tobake frozen cookie dough portions. Reiser Canton, Mass. 781-821-1290 www.reiser.com
Unifiller Systems, Inc. Booth # 2436
Great Western Manufacturing Co., Inc. Booth # 125
Unifiller is a leading global supplier providing portion control, pumping, decorating, filling and depositing systems to bakeries worldwide. Unifiller can help companies streamline their production operations by providing solutions to achieve higher output, greater weight accuracy and better product integrity. Its highly reliable and versatile machines are great for bakery applications such as cookies, pies, cake batters, cheesecake production and various other pastries. And, it provides solutions for precise portion control with an extensive range of single-piston depositors, transfer pumps, multiple head units and fully and semi-automated production systems. Unifiller has a dedicated team of professionals who have the knowledge and expertise of the baking and food production industry. Unifiller Systems, Inc. Delta, British Columbia, Canada 800-370-8947 www.unifiller.com
Great Western’s series of in-line pneumatic and gravity-flow sifters is designed to answer the quality assurance and HACCP needs of food operations. These sifters make it possible to control and monitor internal plant sanitation conditions, provide an indication of changing process conditions, ensure that incoming ingredients have been manufactured, stored and transported under sanitary conditions, are unadulterated and on spec and remove filth. Every Great Western sifter is designed with ease of operation, maintenance and optimum sanitation in mind. For instance, the pneumatic sieve compression system allows for easy and quick access. The nesttogether sieve frame design enables the machine to be quickly and completely dismantled in minutes and the QA series snap-on neoprene gaskets require no adhesives for attachment. Great Western Manufacturing Co., Inc. Leavenworth, Kan. 800-682-3121 www.gwmfg.com
Snack Food & Wholesale Bakery - September 2011
ADVERTORIAL
www.snackandbakery.com
Process Expo Booth Profiles Wire Belt Co. of America Booth #337
Grote Co. Booth # 1406
Wire Belt Co. is a leading manufacturer of open-mesh, stainless-steel conveyor belts, keeping lines running for more than 60 years. Wire Belt is a fourth-generation, family-owned company offering the latest in conveying solutions perfect for processes where product coating, drainage and air circulation are factors. Made of high-quality, stainless steel, Wire Belt’s latest conveyor belt innovation, the CompactGrid, can take the heat when transferring a product out of an oven and onto a cooling line. The belt won’t sweat, slip, droop, sag or catch fire like many plastic conveyor belts can. CompactGrid’s 70% open area makes it the perfect solution for cooling freshly baked or freshly fried products in high-volume, high-throughput processes. Wire Belt Co. of America Londonderry, N.H. 603-644-2500 www.wirebelt.com
Celebrating 40 years in business, Grote will display its latest developments in slicing and depositing technology. Grote’s industry leading slicer/applicator 530E features numerous design improvements that greatly enhance both sanitation and performance. Notable changes include a remote enclosure for placement of all electronics outside the main slicer body, sloped and hermetically sealed framing, stainless-steel bearings, sanitary leveling feet and full 6-in. stroke capability. The waterfall topping applicator was recently redesigned to meet today’s highest standards in sanitation and cleanliness, while retaining several unique design features that deliver optimal product distribution over a wide range of individually quick frozen toppings. The 2-lane horizontal bread cutter is Grote’s newest slicer. It’s suitable for cutting a wide variety of fresh breads and breakfast rolls, and easily integrates into existing sandwich assembly operations. Grote Co. Columbus, Ohio 614-868-8414 www.grotecompany.com
Hinds-Bock Corp. Booth # 4635
Carometec Inc. Booth # 419
Hinds-Bock is your source for producing a wide variety of snack foods. From thin sauces or marinades to viscous puddings, sauces, fillings, soups and value-added entrées, Hinds-Bock’s equipment deposits accurate, clean, reliable, liquid or wet, viscous products for use over vertical and horizontal form/fill/seal machines. Positive shutoff spouts are used to maintain a clean seal zone and fills from fractions of an ounce up to 32 oz. per piston. Unique PLC controls make this machine versatile enough to run over a 1-6-up package configuration. Moving or diving spouts are used for spreading of product or to prevent mounding. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com
Carometec offers quality boot cleaners, sole washers and hand sanitizers, provides superior bacteria-fighting equipment for food operations and develops food safety designs. It’s affiliated with Europe’s ITEC/ATTEC—one of the world’s largest manufacturers of sanitation equipment for the food industry. Make bakery sanitation a cakewalk with Carometec. Carometec Inc. Peosta, Iowa 563-582-4230 www.carometecusa.com
www.snackandbakery.com
ADVERTORIAL
September 2011 - Snack Food & Wholesale Bakery
69
Production Technology Ovens & Proofers
The Heart of the Line Ovens and proofers act as the center of the production line. Therefore, manufacturers must provide flexible, efficient, sanitary options. Marina Mayer, Executive Editor
hen it comes to baking, the oven is the heart of the production line. It receives product coming in, heats it up accordingly and then sends it on its way. Without an oven, many of today’s products wouldn’t be up to par to place on grocery store shelves. But, while the simple push of a button may sound easy, the intricacies of how ovens and proofers actually operate open the door to some costly and often highvolume problems. That’s why many of today’s ovens are designed to offer efficiency, cleanliness, flexibility and other user-friendly features that help eliminate operator headaches on the back end. For starters, ovens today must be energy efficient, says Keith Dietz, thermal equipment product manager for Stewart Systems. As a result, the Plano, Texas-based manufacturer enhanced several features, including a transport chain that requires no lubrication, humidity control inside the oven, burner gas valves that are equipped with proof-of-closure switches and visual
W
indicators, rare earth magnets to increase grip of the pans, a welded track design, improved guarding and modular steam tunnels that supply an inside entrance into the oven, to name a few. Additionally, Stewart Systems uses chevron-style ribbon burners, which induce more efficient heat transfer to the pans. Dietz adds that the walls, roof and floor panels use No. 8-density mineral wool insulation to minimize heat transfer, and the recirculation system takes the hot air off the top of the oven and blows it on to the pans in the corners. Stewart Systems also breaks up the burners into three to five zones, depending on the number of burners. “Four zones are typical, says Dietz. “The heat input from each zone can be proportionally varied relative to each of the other zones for each and every product code. This allows fine-tuning of the baking profile for each product.”
Many of today’s ovens are designed to offer efficiency, cleanliness, flexibility and other user-friendly features that help eliminate operator headaches on the back end.
Photo courtesy of Moline Machinery, LLC
Enhanced proofers minimize baking challenges Likewise, proofers offer a handful of flexible options for the everyday baker. For example, Moline Machinery, LLC manufactures tray-style proofers that are typically used to produce donuts, sweet goods, buns, rolls and specialty breads. These tray-style proofers are equipped with newly developed technology that discharges product from trays to an oven or fryer. Moline also presents a belt-style proofer that contains multiple tiers of conveyors within a temperature- and humidity-controlled environment. It’s traditionally used for production of flatbread, pizza crust, pita bread, pita chips and wraps, says Eric Van Hees, director of engineering for the Duluth, Minn., company. “Today’s proofers must be easy to clean, provide uniform temperature and humidity Continued on page 72
70
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
EFFICIENT EQUIPMENT FOR BISCUIT PRODUCTION
MORE IDEAS MORE VALUE MORE FLEXIBILITY
Depositing, Extruding and Wire-Cutting System V60 The new V60 system is designed for single, twin or triple depositing as well as for wire cutting and extruding. modified extrusion head allows to process both semi-liquid batters, soft deposited dough, very stiff dough, chocolate fillings for pralines and even low fat products very short distances between feed roller and pumps ensure gentle dough handling and improved weight accuracy across the entire working width brand new pneumatic fixing system for easier operation and shorter downtimes www.haas-meincke.com
Production Technology Ovens & Proofers Photo courtesy of AutoBake Americas
Continued from page 70
control, allow easy product changeover for multiple product types, provide operating efficiency and robust cooling and heat/humidity recovery systems,” Van Hees says. Stewart Systems enhanced its portfolio of proofers to provide high-volume throughput, high-performance lubrication, variable-speed recirculation, higher volumetric airflow rate, increase in chain/grid sanitation and cool misting spray nozzles for humidity control. “We have recently completed a proofer job where the design focus was on the ability to clean the inside of the proofer (using clean-in-place features),” says Rick Rodarte, director of engineering for Stewart Systems. “We followed several food safety design specifications and improved the overall support structure, drive mechanisms and conditioner. We worked with the customer to develop a custom conditioning system that utilized fresh air intakes as part
of the environmental control for the proofer. This is unique because the fresh air is utilized directly as a control feature as opposed to using cooling coils or water misters.” Meanwhile, AutoBake Americas, Woodridge, Ill., supplies Serpentine proofers for high-volume pasty production with output of more than 5,000 lb. per hour, according to Amanda Hicks, marketing director for AutoBake, which is represented by Dunbar Systems Inc., Lemont, Ill. “Modern proofers must be efficient in respect to energy and factory floorspace,” she adds. “Their controls and design must ensure even and accurate control of the
conditions of both heat and humidity. They need to be easy to clean and maintain, and of course, meet all modern safety standards.” Baking is strenuous as it is. But, for many of today’s manufacturers, it doesn’t have to be, thanks to a host of state-of-theart proofers and ovens that are designed to do the job right the first time. SF&WB
FREE Mobile App New for 2011, PROCESS EXPO attendees have access to a FREE show directory mobile app. Exhibitors, conference schedules, show Áoor maps and local area resources at attendees’ Àngertips! Take a picture of the mobile tag to the right with your smartphone or go to www.myprocessexpo.com/ mobileapp and download the PROCESS EXPO show directory mobile app today! 127( )LUVWWLPHPRELOHWDJXVHUVZLOOQHHGWRGRZQORDGWKHIUHH PRELOHWDJDSSDWKWWS JHWWDJPREL
72
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
Equipment Briefs CPM Wolverine Proctor presents a pizza infrared fuser, designed to produce the most uniform and enhanced product possible. This USDA-approved design features an all-stainless-steel construction, a 304 stainless-steel wire belt conveyor, an internal gas-fired infrared heating system and large doors for easy cleaning and maintenance. There are virtually no ingredient losses during the fusing process, is easily adaptable to existing pizza lines and cuts ingredient losses during freezing by up to 90%. CPM Wolverine Proctor LLC Horsham, Pa. 215-443-5200 www.wolverineproctor.com Unifiller’s Hopper Topper transfer pumps keep production simple and clean with gentle pumping technology that ensures the product is quickly transferred without sacrificing quality. The Hopper Topper also transfers product directly from the bowl, fills hoppers directly from the mixing bowl, comes equipped with an automatic level sensor that maintains product level in hopper, pumps everything from smooth to chunky to thick and operates according to gentle pumping technology similar to hand scooping. Unifiller Systems, Inc. Delta, British Columbia, Canada 604-940-2233 www.unifiller.com Hinds-Bock’s SP-16T tabletop filler/depositor offers accurate and precise filling of 2- to 12-oz. fill size for a wide variety of flowable or semi-flowable products such as cake and muffin batter, jams and jellies, dips and spreads, caramel, cream topping, salsa, chili, baked beans and more. This easy-to-operate machine can be disassembled in minutes for cleaning, without tools, and increases production while decreasing labor costs. Other features include accurate piston filling, positive shutoff spouts for clean filling, automatic cycling control options and a small footprint. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com
www.snackandbakery.com
Heat and Control’s ITMPlant iT combines the real-time control of plant equipment with essential manufacturing execution system (MES) capabilities to maximize efficiency in both startup and ongoing operations. ITM-Plant iT uses an “object-oriented” model for controls, which contains the equipment control, equipment visualization and all the information required to feed integrated MES solutions. ITM-Plant iT also allows process controls to be aligned with “best-in-class” MES functions to achieve better uptime while reducing costs by improving overall production efficiencies. Heat and Control, Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com Charles Ross introduces the Planetary Dual Disperser (PDDM) for powerful mixing of high-viscosity products requiring ultra-fine dispersion quality. The PDDM features four agitators—two planetary stirrers and two high-speed shafts—all rotating on their own Continued on page 74
#"''& #) + $ + #'2$%-+ '% ... #'2$% '% '
(% #%' # ## #$( ') !&" ( ' / , $$#1 "#, ( )'$$ $ $ #& $ *#!" **# * /' !* $ '$'!* ("# " "# # ' #%!& #!" **# * , $$#1 #$%+ $ *#!" **# *#$%+ &" & $#&! "&'$'!0
September 2011 - Snack Food & Wholesale Bakery
73
Equipment Briefs Continued from page 73
axes while orbiting the mix vessel on a common axis. The two saw-tooth blades on each shaft provide an intensive shearing action, promoting solids dispersion and particle size reduction. The planetary stirrers continually turn over batch material, helping feed fresh product to the blades and facilitate uniform temperature throughout the mix zone. Sidewall and bottom scrapers can also be installed to further ensure superior heat transfer between the vessel jacket and batch material. Charles Ross & Son Co. Hauppauge, N.Y. 800-243-7677 www.mixers.com
sections and complete belt replacements. As a drop-in replacement, the belt needs no system drive modifications. It also comes equipped with a turnkey install, in addition to optimizing the stacker system, to ensure maximum throughput and capacity. Ashworth Bros., Inc. Winchester, Va. 800-682-4594 www.ashworth.com
Ashworth’s ExactaStack self-stacking spiral belt is a drop-in replacement for standard and wide belt stackers. ExactaStack is available in many widths, tier heights and mesh configurations for both spliced-in
Akro-Mils introduces new sizes to its ShelfMax product line. New sizes include 11 5/8 x 8 3/8x6, 17 7/8 x 8 3/8 x 6 and 23 5/8 x 6 5/8 x 6 in. These heavy-duty bins are available in five colors, and feature
SF SF&&WB WBtv tv
greater storage options for end users, including up to 85% more holding capacity than traditional 4-in. shelf bins, and up to 25% more holding capacity than 6-in. storage bins. The bin’s rolled ridge provides added strength and durability when filled to maximum capacity. Plus, they are easy to label for quick inventory identification and come with optional width dividers to expand sorting options and efficiencies. Akro-Mils, a division of Myers Industries, Inc. Akron, Ohio 800-253-2467 www.akro-mils.com
View videos demonstrating the newest bakery & snack food equipment by visiting www.snackandbakery.com
Snack Food Today Snyder’s-Lance Acquires George Greer Co. Snyder’s-Lance, Inc., Charlotte, N.C., acquires all of the issued and outstanding shares of George Greer Co., Inc., a snack food distributor serving Rhode Island, eastern Massachusetts and New Hampshire markets. This strategic partnership is part of Snyder’sLance’s plans to continue growing and strengthening its distribution network. Greer operates a direct-store-
distribution system encompassing 120 independent operators with distribution centers in Salem, N.H., and at its headquarters location in Providence, R.I., as well as Cape Cod, Lakeville and Boston, Mass. Greer primarily distributes the Cape Cod, Lance, Archway and Stella D’oro brands, as well as other leading brands and private label products.
Festida Foods Moves Tortilla Chip Operation Festida Foods, Cedar Springs, Mich., purchased a 155,000-sq.-ft. building in the Union Station Industrial Park in Grand Rapids, Mich., for installation of a tortilla chip manufacturing line that will effectively double its chipmaking capacity. Festida bought the building, located at 219 Canton St. SW, for $2.1 million from Voordelig Ventures LLC through a transaction overseen by Amicus Management Inc.,
also located in Grand Rapids, Mich. Amicus was acting as court-appointed receiver for the property that formerly housed warehousing for Grand Rapids Sash & Door, which has been winding down its operation after 86 years of business. Festida employs about 30 people in the Cedar Springs facility, where it manufactures private label snacks, says president Kyle Curtiss, but the company will
Frito-Lay Shifts Agencies on Three Brands PepsiCo’s Frito-Lay North America, Dallas, moves marketing duties for its SunChips brand to EnergyBBDO, Chicago, and its subsidiary, Juniper Park, the agency responsible for managing the compostable SunChips bag release. Juniper Park will continue to do work for PepsiCo’s global nutrition group and the Quaker portfolio, despite its hunt for a new chief marketing officer after Kirsten Lynch left the company earlier this year.
www.snackandbakery.com
move to Grand Rapids when it becomes operational some time before the end of the year. At that time, Festida expects to add between 10-20 employees to handle the expansion. Festida makes tortilla chips for its own label and 50 other accounts, including MexAmerica Foods LLC in St. Mary’s, Penn.
Zapp’s, Dirty Chip Maker Moves into Former Kraft Plant Zappe Endeavors LLC, the Gramercy, La.-based chip maker of Zapp’s and Dirty potato chips, is moving into a former Kraft Foods building in Hanover Township, Pa. The 40,000-sq.-ft. building along Stewart Road in the Hanover Industrial Estates began production in November 2010. With 15 employees, the plant churns out 11 varieties of Zapp’s chips and 12 of the Dirty brand. In May 2011, Utz, Hanover, Pa., purchased Zappe Endeavors LLC, and will continue to operate the plants as a division of Utz, according to the company.
September 2011 - Snack Food & Wholesale Bakery
75
Make your opinions
COUNT myCLEARopinion™ members are a diverse community of industry professionals who earn CLEARcash™ for sharing their opinions, reactions and insights with leading national and global organizations. Their insights help make better products, advertising and messaging decisions. Joining myCLEARopinion™ ensures that your opinions are worth something. Begin making your opinions count today and earn CLEARcash™ rewards for your insights and views.
Visit www.myclearopinion.com to join now!
my CLEARopinion
™
2401 W. Big Beaver Rd. Suite 700 | Troy, MI 48084 |
[email protected]
CLEARcash
™
To advertise, contact Suzanne Sarkesian 248-786-1692 •
[email protected] EQUIPMENT FOR SALE
EQUIPMENT FOR SALE
$"--'3"*/-"45 'SBJOIBTNPSF1SF0XOFE 1BDLBHJOH1SPDFTTJOH NBDIJOFSZUIBOBOZ DPNQFUJUPSBUUIF
-08&45 13*$& (6"3"/5&&%
CUSTOM TANKS & PRESSURE VESSELS Vessels, reactors and storage tanks designed to meet your special requirements! • 2 ASME Certified plants in the USA • USFDA, BISSC, ABS, API and UL code requirements • 316 and 304 stainless steel, and many alloys Call Ross today!
$"--'3"*/(3061
1-800-524-ROSS
www.storagevessels.com
TUMBLE BLENDERS IN STOCK “V”AND DOUBLE CONE DESIGNS • Sanitary construction • Many sizes available
LOWEST PRICES!
1-800-243-ROSS www.tumbleblenders.com
XXXVTFEQBDLBHJOHDPN USED WALK-IN-COOLER-FREEZERS REFRIGERATION SYSTEMS – EQUIPMENT HUGE INVENTORY, ALL SIZES Buy Sell - Nationwide - Wholesale Prices
Tel. 216-426-8882 www.awrco.com
[email protected] www.snackandbakery.com
September 2011 - Snack Food & Wholesale Bakery
77
EQUIPMENT FOR SALE
S PREVENT PRODUCT RECALL 3 P PRODUCTS, R O D U CTS, 1 SOLUTION Switching to Plastic Pallets ·
Improved hygiene, cleaning and sanitizing for WIP areas
·
Chemical & blood resistant
·
Non-porous
·
Substantially longer life compared to wood pallets
·
Improves efficiency in handling
·
Transfer raw ingredients and packaging materials to a hygienic pallet for in house use.
PlasticPallet.com
Pallet Inverter ·
Simple 180 degree inversion to recover damaged bags for Good Housekeeping and GNP.
·
Straighten poorly stacked or tilted loads which can become a safety hazard.
·
Exchange finished product from in-house pallets to rental pallets or slip sheets.
·
Cleans wood, plastic & aluminum pallets, totes, containers and freezer spacers
·
Minimizes the risk of introducing Salmonella, E-coli, Listeria, Allergens, dust, dirt and other contaminants
PalletInverter.com
Pallet Washing System
#HERRYgS )NDUSTRIAL %QUIPMENT #ORP s 600 Morse Ave., Elk Grove Village, IL 60007
800.350.0011 s www.Material-Handling.com
PalletWasher.com
NEW AND USED PROCESS AND PACKAGING EQUIPMENT s !BACUS 7RAPAROUND ,ABELER "!'2
s *ACKSON (EAVY $UTY 33 $ISHWASHER 4EMPSTAR
s $OTT "ONAPACE "LISTER 0ACKAGER )N 0ACK
s #USTOM -ADE #HOCOLATE #OOLING 4UNNEL
s ,IQUID 6ERTICAL &ORM &ILL 3EALER $8$'
s 2EDIPAX (EAD )NLINE 0RESSURE ,IQUID &ILLER
s .EW 5SED .ET 7EIGH&ILLERSCUSTOMIZABLE
s 3KIN 0ACKAGING -ACHINE -ODEL 4"
s .EW 5SED ,ONG 3TAINLESS 3TEEL #ONVEYORS
s 3EMI !UTO 33 !UGER &ILLER &,' !
s .EW 5SED v v 33 &EED !CCUMULATE 4ABLES
s *ET (EAT 4UNNEL -ODEL "3 ,!
3140*8* '(/'+-2+ -2*7 for Tablets, Capsules, Liquids, and Powders 63(*7759-41*28 Mixers, Tanks/ Kettles, Granulators, & Coated Pans ;;;).7*28(31=*1'-07'0*7).7*28(31 MOST EQUIPMENT CAN BE INSPECTED IN TORONTO!!!
78
SnackandBakery
Snack Food & Wholesale Bakery - September 2011
.com
www
2700 - 14th Avenue, Unit 6 - Markham, Ontario L3R 0J1 ,32*
=$3006**## ='<
www.snackandbakery.com
CONSULTING
completely remanufactured tunnel ovens
after photos
Experienced in Rebuilding, Upgrading, Relocation the following Brand Name Equipment: "!+).' /6%.3 s !06 "AKING 2EADCO s 4, 'REEN !-& 7ENER 0LEIDERER 3POONER 6ICAR s 7ERNER ,EHARA s -IDLE "Y -ARSHALL &-%7ELBUILT s &ISH s 4HERMOTRON 5NIVERSAL7ILCO s 7INKLER#HUBCO 4URN +EY !UTOMATION s )NCLUDING #OMPLETE !IR 0OLLUTION #ONTROL s %QUIPMENT 3ALES AND )NSTALLATIONS s !54/-!4%$ 02//&%23 #/.6%9/2 3934%-3 s 3ASIB s "AKE 4ECH 3TUART )* 7HITE s ,ANHAM s 0FENING .ORTHlELD s &(3 #APWAY s 0ULVER 3YSTEMS
We rebuild baking ovens from the ground up. Direct and indirect fired from the small revolving type to 100ft. or longer. For all types of baking performance problems let T&T provide the solutions. If you need to upgrade capacity of an existing tunnel oven, T&T can build and install extensions which might be less expensive than to purchase a new or replacement oven. An older oven, upgraded by T&T with today’s technology can deliver highly competitive baking performance against a new one for less than 50% of cost. We have a current list of ovens on inventory. Contact us for more information, company brochures and photos by phone or the web site.
T&T also offers Factory Mutual and OSHA compliance upgrade work on older baking ovens. WANTED TO BUY
Phone: Fax: 847-288-9709 Website: WWW4AND4#%COM E-mail: CONTACT 4AND4#%COM INGREDIENTS
subscribeforfree.com
www.snackandbakery.com
September 2011 - Snack Food & Wholesale Bakery
79
OVEN RACKS
Superior Commitment to Excellence Save up to 60% of your valuable work space with Magna Nesting Rack Designs! Magna Industries is a US manufacturer specializing in stainless steel and aluminum equipment solutions for storage, proofing, baking, freezing and transporting products.
Contact the rack company that saves you money and space.
Call 732.905.0957 or visit online at www.magnaindustries.com
Your One Stop Shop For... RACKS R RA A
PANS
RACK & PAN WASHERS
Oven Racks Racks, Tray Racks, Pan Racks ANY RACK YOU SLIDE PANS ONTO
SHEET PANS, STAY FLAT PANS, BREAD PAN SETS, BAGUETTE SCREENS
THE RIGHT SIZE WASHER FOR YOUR WASHING NEEDS
9230 Chestnut Ave | Franklin Park IL 60131 | www.ShopCraftRacks.com | (800) 834-8125
80
Snack Food & Wholesale Bakery - September 2011
www.snackandbakery.com
OVEN RACKS
TAKE YOUR COMPANY Southern Perfection Fabrication
TO THE TOP Place a classified ad in next months issue of SFWB contact Suzanne Sarkesian P: 248.786.1692 F: 248.283.6596 E:
[email protected]
Quality Bakery Racks, Dollies, Baskets & Trays Advantages: s Competitively Priced s Quality Guaranteed s Small Quantity Orders No Problem
l
*Specia
ie with Free Doll skets 0 ba every 20 t. bough
1-800-237- 4726
www.southernperfection.com
SMALL INGREDIENT DISPENSING SYSTEMS
www.snackandbakery.com
September 2011 - Snack Food & Wholesale Bakery
81
EQUIPMENT FOR SALE
3URFHVVVWDELOL]LQJJXPVHPXOVLILHUVIORXUVFRFRDV \HDVWSRZGHUHGHJJVVWDUFKHVFRQGLPHQWV FDVHLQDWHVMXLFHFRQFHQWUDWHVIRRGSXUHHVZKH\ VROLGVIUR]HQSURGXFWVFKHHVHVOXUULHVDQGPRUHLQ MXVWDIHZPLQXWHVHYHQDWKLJKFRQFHQWUDWLRQV
7DQH\ 1RUWK.DQVDV&LW\02 LQIR#EUHGGRFRPZZZEUHGGRFRP
DGLYLVLRQRI
Snackandbakery.com
Gear up for This Year’s Buyer’s Guide ett year-round d exposure for f your company in Snack Food & Wholesale Bakery’s 2012 Buyer’s Guide, an exclusive reference tool for equipment, ingredient and service suppliers to the snack food and wholesale bakery industries. The publication reaches 14,000 subscribers and includes a calendar of events, a list of associations and a supplier and product directory. To be listed, contact Linda Zdun at
[email protected] or 248-244-6489. To search in Snack Food & Wholesale Bakery’s online Buyer’s Guide, go to www.snackandbakery.com/buyersguide. While on our website, become a fan of Snack Food & Wholesale Bakery through Facebook, or follow us on Twit-
G
82
Snack Food & Wholesale Bakery - September 2011
ter t and/or d/ gett connected t d via i LinkedIn Li k dI att www.snackandbakery.com/connect to get the latest in news items. Get involved with discussions from fellow industry leaders and learn more about new products, equipment and ingredients pertaining to the snack and bakery markets. Also log onto our site and subscribe to receive our free monthly magazine and our free weekly e-newsletter, Operations Weekly. To advertise in Snack Food & Wholesale Bakery, on its website or in Operations Weekly, please contact Jeff Heath at
[email protected] or Barb Szatko at
[email protected].
www.snackandbakery.com
Ad Index Company Website
Company Website
Page
AB Mauri Fleischmann’s . . . . . . . . . . . . . . 62 www.abmf.com
French’s Flavor Ingredients . . . . . . . . . . . . 30 www.FrenchsFlavorIngredients.com
ADM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 www.adm.com
Gemini KB Systems . . . . . . . . . . . . . . . . . . 23 www.geminibe.com
ADM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 www.adm.com/vegefull
Gertrude Hawk Ingredients . . . . . . . . . . . . . 7 www.gertrudehawkchocolates.com
ALIT SRL . . . . . . . . . . . . . . . . . . . . . . . . . .OBC www.alit.com Almond Board of California . . . . . . . . . . . 50 www.AlmondBoard.com Ashworth Bros., Inc. . . . . . . . . . . . . . . . . . 35 www.ashworth.com Bay State Milling . . . . . . . . . . . . . . . . . . . . 15 www.baystatemilling.com Biofilm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 www.biofilm.com.co BluePrint Automation . . . . . . . . . . . . . . . . 40 www.bpa-flexolutions.com Buhler Inc. . . . . . . . . . . . . . . . . . . . . . . IBC www.buhlergroup.com Cargill/Horizon Milling. . . . . . . . . . . . . . . . 41 www.HorizonMilling.com Cargill Salt Division . . . . . . . . . . . . . . . . . . 55 www.cargillsalt.com
Company Website
Page
Page
Prepared Foods’ Weight Management Virtual Expo . . . . . . . . . . . . . . . . . . . . . . . . 42 www.preparedfoodsvirtualexpo.com PROCESS EXPO . . . . . . . . . . . . . . . . . . . . . 72 www.myprocessexpo.com Puratos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 www.puratos.us
Grain Millers, Inc. . . . . . . . . . . . . . . . . . . . 67 www.grainmillers.com
QualiTech . . . . . . . . . . . . . . . . . cover outsert www.qualitechco.com
Great Western Manufacturing. . . . . . . . . . 37 www.gwmfg.com
Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 www.reiser.com
Grote Company . . . . . . . . . . . . . . . . . . . . . 44 www.grotecompany.com
Remco Products . . . . . . . . . . . . . . . . . . . . . 26 www.remcoproducts.com
Gum Technology . . . . . . . . . . . . . . . . . . . . 22 www.gumtech.com
Roquette America, Inc. . . . . . . . . . . . . . . . 45 www.pea-protein.com
Haas-Meincke . . . . . . . . . . . . . . . . . . . . . . . 71 www.haas-meincke.com
Ross, Charles & Son Company . . . . . . . . . 31 www.mixers.com
Heat and Control . . . . . . . . . . . . . . . . . . . . 64 www.heatandcontrol.com
Shurtape . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 www.Shurtape.com/GoodToTheCore
Hinds-Bock Corporation . . . . . . . . . . . . . . . 1 www.hinds-bock.com
Siemer Specialty Ingredients . . . . . . . . . . 74 www.siemersi.com
International Bakers Services, Inc. . . . . . . 51 www.internationalbakers.com
SK Food International . . . . . . . . . . . . . . . . 32 www.skfood.com
Koenig Bakery Systems . . . . . . . . . . . . . . 66 www.koenigusa.com
Spraying Systems Co. . . . . . . . . . . . . . . . . 33 www.spray.com/freecoatingtest
Kwik Lok . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC www.kwiklok.com
Tate & Lyle . . . . . . . . . . . . . . . . . . . . . . 25, 27 www.tateandlyle.com
Lawrence Equipment. . . . . . . . . . . . . . . . . 65 www.lawrenceequipment.com
Unifiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 www.unifiller.com
Danisco USA Inc. . . . . . . . . . . . . . . . . . . . . . 5 www.danisco.com
Lockwood Manufacturing Inc. . . . . . . . . . 19 www.lockwoodmfg.ca
United Soybean Board . . . . . . . . . . . . . . . 53 www.SoyConnection.com/QUALISOY
F&S Engraving . . . . . . . . . . . . . . . . . . . . . . 42 www.fandsengraving.com
Lubriplate . . . . . . . . . . . . . . . . . . . . . . . . . . 57 www.lubriplate.com
Viterra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 www.viterra.com/foodingredients
FooDesign . . . . . . . . . . . . . . . . . . . . . . . . . 56 www.foodesign.com
MINSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 www.minsa.com
Weldon Solutions . . . . . . . . . . . . . . . . . . . 47 www.weldonsolutions.com
FPSA/Process Expo . . . . . . . . . . . . . . . . . . 52 www.myprocessexpo.com
Powder Solutions. . . . . . . . . . . . . . . . . . . . 52 www.powder-solutions.com
Wire Belt Company . . . . . . . . . . . . . . . . . . 29 www.wirebelt.com
Carometec Food Technology . . . . . . . . . . . 16 www.CarometecUSA.com CMC America Corporation . . . . . . . . . . . . 10 www.doughmixer.com Commercial Creamery . . . . . . . . . . . . . . . 63 www.cheesepowder.com
Reader & Marketing Services 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] CUSTOM MEDIA Chris Wilson E-mail:
[email protected] T: (248) 244-8264
www.snackandbakery.com
REPRINTS Jill DeVries E-mail: devriesj@ bnpmedia.com T: (248) 244-1726
PRINT & INTERNET ADVERTISING Jeff Heath E-mail: heathj@ bnpmedia.com T: (224) 554-9154
LIST RENTAL Postal contact: Kevin Collopy 800-223-2194 x684;
[email protected]
Barbara Szatko E-mail:
[email protected] T: (630) 527-9927
Email contact: Michael Costantino at 800-223-2194 x748;
[email protected]
CLASSIFIED ADVERTISING Suzanne Sarkesian E-mail: sarkesians@ bnpmedia.com T: (248) 786-1692
BNP Media 155 Pfingsten Road, Suite 205, Deerfield, IL 60015 Phone: (847) 405-4000 Fax: (847) 405-4100
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, Refrigerated & Frozen Foods Retailer, The Deli Advisor, The National Provisioner
September 2011 - Snack Food & Wholesale Bakery
83
The Final Word
Mintel Study Shows HFCS Isn’t a Consumer Concern
Marina Mayer, executive editor
[email protected]
Photo courtesy of Corn Refiners Association
or the past couple years, all we’ve been hearing about in the food industry is more whole grains, more fiber, less fat, and making sure it has zero high-fructose corn syrup (HFCS). In fact, several bakers and snack manufacturers have gone to great lengths to reformulate their recipes so that this “dangerous” ingredient doesn’t sneak into their products. As a result, the Corn Refiners Association (CRA), Washington, D.C., took action to set the record straight by launching a national media campaign touting HFCS as simply just sugar. Yet several new product developments continue to come through the pipelines promoting their elimination of HFCS. While some consumers may think HFCS is the end-all be-all to maintaining a healthy diet, a recent Mintel study confirms that most consumers really aren’t avoiding the ingredient, and in fact, don’t even consider it to be a so-called threat. The study, conducted by the Mintel Research Consultancy in April, consisting of 30 questions, half aided, half un-aided, surveyed a sample of 2,005 primary household grocery shoppers on their eating and purchasing behaviors. According to the results, only 3% of the shoppers polled indicated that they were looking for HFCS on the ingredients label. In the same question, 25% are looking at the sugar/added sugar content, 26% are reviewing salt/sodium, 37% seek the calorie count and 38% read the labels for fats and oils. In addition, the study showed that 17% of consumers were trying to avoid “sugar
F
84
or added sugar,” as opposed to only 4% who indicated they were looking to avoid just HFCS. Meanwhile, 17% seek to avoid sugar/added sugar, 20% looked to avoid fats and oils and 37% aimed to avoid calories. If consumers aren’t really concerned about HFCS, then what’s all the fuss about? “Most of the research that has been done on HFCS has simply been done incorrectly,” says David Lockwood, director of research consultancy for Chicago-based Mintel. “People are responding to the news and how dangerous [HFCS] is and how people are avoiding it, and that’s simply not true. This study shows that there’s a difference between what consumers say they do and then actually do.” Those 17% aiming to avoid sugar/ added sugar may not necessarily be looking to avoid HFCS, per se. “Many consumers know that HFCS is
Snack Food & Wholesale Bakery - September 2011
an added sugar in the diet, and it’s safe to assume that the 4% [of those who are avoiding HFCS] are trying to reduce sugar overall,” says Audrae Erickson, president of CRA, who commissioned the study with Mintel. This being said, CRA urges bakers and snack manufacturers to continue incorporating HFCS into their recipes and portfolios. “High-fructose corn syrup not only provides a cost advantage from a formulation perspective, but also offers other attributes such as functionality,” Erickson says. “[HFCS] retains moisture, enhances rather than masks fruit fillings and spices in baked goods, performs moisture control and retards spoilage, among others.” And, unlike other ingredients that have been scrutinized by the government as being not healthy enough for consumers, HFCS fails to remain on that list. “The science is very clear now that metabolically and nutritionally, HFCS is the same as sugar,” Lockwood says. “There’s not going to be a big push from science or government like there was with trans-fat, and there’s no reason there should be as it turns out.” So go on bakers and snack producers, keep those HFCS-laden products coming. SF&WB
www.snackandbakery.com
Innovative extrusion processes without limits. With our extensive extrusion know-how and passion for customized solutions, Buhler strives to generate added value and success for any product concept — breakfast cereals, snack foods, modified flours and starches, and texturized proteins. We offer one of the most complete lines of process technology available anywhere: from raw material handling, cooking and shaping, through extrusion to drying. In short, extrusion processes without limits. Visit Us at Process Expo. Booth 1572. November 1st - 4th, 2011, Chicago, IL.
Buhler Inc., 13105 12th Ave N., Plymouth, MN 55441, T 763-847-9900,
[email protected], www.buhlergroup.com
Innovations for a better world.
6LPSO\EHWWHUPDFKLQHU\
spinflex spinflex
usa
™
®
SRL
Food Processing Equipment
Conveyors & Food Processing
309 S. McKenzie - P.O. BOX 778 56156 Luverne (MN) USA Phone +1 507 449 0270 Fax +1 507 449 0271
[email protected] - www.alit.com
Via Venezia, 30 35010 Marsango (Padova) ITALY Tel. + 39 049 55 22 97 Fax + 39 049 963 92 24
[email protected] - www.alit.com
