Snack Food & Wholesale Bakery February 2011

6 RECYCLABLE

Kwik Lok Is The Bag Closure Of Choice When It Comes To Function, The Environment And Consumer Convenience! Environment The Kwik Lok Bag Closure is designed to be reused and RECYCLED. The closure has earned a recyclable symbol of 6, making Kwik Lok a truly recyclable closure. Other closures, such as wire surrounded by paper or plastic, or polyvinyl and polypropylene tape with paper between the two ends, cannot be recycled. Wire and tape closures are typically thrown into the garbage each and every time, seldom ever reused. During our extruding process, no processed water is used or expelled into our city’s sewer system. Kwik Lok cools its extruders within a closed loop cooling system. Our new enhanced filtration system prohibits nearly all particulates from being expelled into the air. Kwik Lok is actively seeking to reduce our electrical demands by inventing and installing new, efficient closure manufacturing machinery. No hardeners or additives are added to our plastic. Newly developed additives such as PLA (Polyactide Acid), Polystarch or others are not used. Such additives, while claiming to make plastic degradable, present a couple of problems. (1) Recycling of products made with additives is problematic. The Biodegradable Products Institute concurs, “The recycling of plastic products made with these types of additives is poor, the plastic products have to end up in the landfill ... they cannot be recycled in their original form.” (2) The use of these additives creates methane gas which is 20 times more potent than carbon dioxide emissions! Every landfill has a different content, be it wet or dry, compost, or general waste, mixed with or without moisture and oxygen. Thus the process of degrading is highly dependent upon each landfill’s composition. Should the Kwik Lok closure be tossed into the garbage, its degradation process began at the moment the closure plastic left the extruder since no inhibitors or additives were added to the Kwik Lok. When you compare the choices, Kwik Lok, wire or tape ... Kwik Lok is the logical answer to your bag closing requirements.

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Convenience Kwik Lok is easy to remove. Many consumers have health issues such as arthritis, diabetes, and degenerative eye problems. For vision impaired customers and/or those with arthritis, the Kwik Lok is easy to remove. A person with totally impaired vision can remove a Kwik Lok closure. There is no guessing which way to untwist like you have with a wire closure. Attempt to find the ends of sticky tape and have the dexterity to separate the ends! It takes three hands to remove this closure, and it certainly is not reusable. The Kwik Lok Bag Closure is one of life’s little conveniences that plays an important function in packaging. It Closes the Bag Securely. It can carry Best Before Dating, or Country of Origin Labeling. It is manufactured with a low carbon output. It is degradable. It is recyclable. It’s Resealable, it’s Reusable, it’s REMARKABLE! Kwik Lok ... the Logical Choice ... Recyclable Bag Closure ... Convenient Bag Closure ... High Quality Dependable Bag Closing Machinery ... Date Coding on the Closure ... High Quality Custom Printed Closure Labels. Kwik Lok’s 893 Automatic Bag Closing Machine closes bags at 110 per minute and permits the packager to close bags with our standard Kwik Lok Closure or Closure-Labels.

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Contents 12 | Supplier Standpoint Larry Blagg, senior vice president of marketing for the California Raisin Marketing Board, nominates Craig Ponsford to The Bread Bakers Guild of America’s “Hall of Fame.”

Cover Story 16 | Pure Perfection A strong foundation, a rich family culture, a team of better-for-you products and a laundry list of achievements allow Shearer’s Foods to rise above the same-‘ole same-‘ole and achieve “Shearer Perfection.”

Photos by Vito Palmisano

Plant Story 26 | LEED-ing the Way Shearer’s Foods portrays “Shearer Perfection,” thanks to the world’s first LEED Platinum-certified snack manufacturing plant, located in Massillon, Ohio.

Columns 10 | Editor’s Note With the dispute of genetically-modified foods becoming a more global issue, Editor-in-Chief Lauren R. Hartman advises consumers to remain vigilant and read package labels because we might never know who to trust.

46 | The Nutritional Corner February is American Heart Month, and the perfect time to think about lifestyle changes that can protect your ticker, says contributing columnist Judi Adams. Thankfully, there are so many delicious, grainy choices that do so.

62 | Engineering Management The workplace can be a very challenging environment on any given day, says contributing columnist Jeff Dearduff. That’s why workers should become highly organized with methods and tools that make the workday feel more comfortable.

86 | The Final Word Studies show that many of today’s consumers are re-learning how to grocery shop to save money, time and effort, says Executive Editor Marina Mayer.

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Snack Food & Wholesale Bakery - February 2011

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©2011 Sensient Colors LLC, all rights reserved. The FUSION PRECISE NATURAL COLORS trademark is owned and registered by Sensient Colors LLC. The SENSIENT trademark and the Sensient Technologies Corporation logo are owned and registered by Sensient Technologies Corporation. All rights in trademarks are reserved.

S a f e a n d S e c u re I n g re d i e n t s

Contents Market Trends

Production, Technology & Product Development Solutions for a Changing Industry. February 2011 Vol. 100 No. 2

34 | Healthy Snacking Snack food manufacturers are stepping up to meet consumer demand for natural and organic versions of better—but not blander—products.

Special Section 40 | SNAXPO Pre-show Coverage The snack industry still has time to register or exhibit at SNAXPO 2011, which will take place March 20-23 at the JW Marriott Grande Lakes in Orlando, Fla. Here’s a rundown of the educational sessions, list of exhibitors and more.

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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

Peter Havens Senior Group Publisher [email protected]

Tom Imbordino Group Publisher [email protected]

Jeff Heath Publisher

New Products

[email protected] 847-405-4074

44 | New Products

Editorial

Read about some of the most recently introduced products, including frozen enchiladas and pizza from Kashi Co., Pretzel Pete Pretzel Pearls from SB Global Foods, Bone Suckin’ jerky from Ford’s Gourmet Foods and Journey bars.

Lauren R. Hartman Editor-in-Chief [email protected] 847-405-4015

Marina Mayer Executive Editor [email protected] 847-405-4008

Ingredient Technology

Patty Catini Art Director

48 | Not Half, but Whole Grains

Advertising & Internet Sales

Find out what several sources are saying about whole grains, why they’re in so much demand and how they are impacting the snack food and baking industry.

Barbara Szatko Senior Sales Manager [email protected] 630-527-9927

Suzanne Sarkesian Classified Sales

Production Technology

[email protected] 248-786-1692

Jill L. DeVries Corporate Reprint Manager

68 | Banking a Deposit These days, customers are in search of depositors that are flexible, accurate and fast and can handle several new product types, textures, viscosities and configurations, without missing a beat.

Coming Next Month

[email protected] 248-244-1726

44

Support Services Gail Porter Advertising Production Manager [email protected] 847-405-4104

Liz Wright Marketing Coordinator [email protected] 248-786-1652

Join us as we meet with the folks at Gabby’s Bakery, a creative artisan bakery in Franklin Park, Ill., that bakes Ciabatta bread, pretzel bread, bagels, hearth breads, baguettes, dinner rolls, and more for restaurants and fresh-bake/frozen customers. Also, Editor-in-Chief Lauren R. Hartman will examine various food safety issues in a special report that covers the recent passing of the Food Safety Modernization Act.

Audience Development Rita M. Foumia Corporate Strategy Director Kourtney Bell Audience Development Manager Stephanie Hunt Multimedia Specialist Carolyn M. Alexander Audience Audit Coordinator

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List Rental Postal contact: Rob Liska at 800-223-2194-726 [email protected]

Email contact: Shawn Kingston at 800-409-4443-828 [email protected]

BNP Corporate

48 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].

Timothy A. Fausch Publishing John R. Schrei Publishing Rita M. Foumia Corporate Strategy Scott Kesler Information Technology Vincent M. Miconi Production Lisa L. Paulus Finance Michael T. Powell Creative Nikki Smith Directories Marlene J. Witthoft Human Resources Emily Patten Tradeshows & Conferences Beth A. Surowiec Clear Seas Research BNP Media Helps People Succeed in Business with Superior Information

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Select what you’ll enjoy tomorrow

On the Road... ...to better understanding consumer preferences in their own environment, Puratos is delighted to introduce The Sensobus. The first of its kind in our industry, on American soil, this fully equipped mobile sensory analysis lab can be driven anywhere within the contiguous United States and Canada to conduct tailor-made sensory analysis projects for our customers. The Sensobus will collect data from consumers in pre-defined locations as they are on their way to and from their daily food shopping trip. Consumer preferences are constantly evolving and often vary at a local level. Let Puratos help you take the guessing out of product launches. The Sensobus unit offers you a better understanding of today’s consumer with concrete analysis. Visit www.sensobus.us to learn more.

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New Products Online o you have a new product for the snack food and wholesale baking industry? Get it recognized in Snack Food & Wholesale Bakery’s online New Products section. Qualified new products must have been introduced recently and must be a salted snack, baked good, snack bar, frozen dessert or baked snack. We also may use these new products in our monthly Market Trends articles and feature a “Product of the Week” in Operations Weekly, our free weekly e-newsletter. New product submissions require: R Press release or product literature

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Snack Food & Wholesale Bakery - February 2011

R Company name, city, state R Website R The month the product is or will be introduced to the retail market R Geographic distribution R Suggested retail price R Weight specifications of the package in ounces and how the product is sold, such as five bars to a box R High-resolution image R Ingredients list Go to www.snackandbakery.com to flip through our online new products section. While on our website, become a fan of Snack Food & Wholesale Bakery

through Facebook, www.facebook.com/ snackandbakery, or follow us on Twitter, www.twitter.com/SFWB, to get the latest in news items, featured new products and equipment and ingredients pertaining to the snack and bakery markets. Also, log on to our website and subscribe to receive our free monthly magazine and our free weekly e-newsletter, Operations Weekly. To advertise in Snack Food & Wholesale Bakery, on our website or in Operations Weekly, please contact Jeff Heath at [email protected] or Barb Szatko at [email protected].

www.snackandbakery.com 5/22/08 3:36:59 PM

Editor’s Note

Is Frankenbread Lurking Around the Corner?

hh, the New Year, which signals new beginnings and new developments cropping up throughout the bakery and snack food markets. But some of these developments sound like they’re straight out of Mary Shelley novels. We’ve heard of so-called Frankenfood, or geneticallymodified foods, and they bring with them much controversy—a dispute over the relative advantages and disadvantages of genetically-modified (GM) food crops and other uses of genetically-modified organisms (GMO) in food production involving biotechnology companies, governmental regulators, nongovernmental organizations and scientists. The dispute is most intense in Japan and Lauren R. Hartman Europe, where public [email protected] concern about GM food is higher than in other parts of the world. In the United States, GM crops are more widely grown, and the introduction of these products has been less controversial. Still, some believe that our food supply is being redesigned more quickly than any of us realize, and that scientists have hardly begun to test the long-term safety of these new foods. According to Wikipedia, there are five key areas of political controversy related to genetically-engineered food: Food safety; The effect on natural ecosystems; Gene flow into non-genetically-engineered crops; Moral/religious concerns; and corporate

A

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control of the food supply (not to mention the food allergy issue). But so far, not a single instance of harm to human health or the environment has been documented with GM crops. Instead, several benefits have been widely accepted and are uncontested in scientific literature. This year, we’re seeing syntheticallymade chocolate, as DNA discoveries and studies by a French research agency indicate that they have unlocked the genetic code of chocolate. The findings may just lead to the bioengineering of some wonderful chocolate, and with chocolate prices soaring, this could be great news. There is also a process created by scientists to produce palatable gluten-free bread (see our Jan. 5 edition of Operations Weekly, our weekly e-newsletter for more details on both the bread and the chocolate stories). The U.S. Department of Agriculture (USDA), Washington, reports that scientists at its Agricultural Research Service (ARS) Grain Quality and Structure Research unit in Manhattan, Kan., created a process to

produce high-quality, gluten-free bread, which would be incredibly beneficial for numerous consumers who are unable to digest gluten, a protein found in flour from grains, such as wheat, barley and rye (check out the Ingredient Technology article in this month’s issue for more on whole grains). There are also developments of physically-optimized flours. With the clean label trend in food formulations across Europe, it’s a conundrum that commodities such as flour are being physically modified and heat-treated and seem to be gaining ground on modified starch solutions. A report posted on foodnavigator.com notes that Michael Gusko, managing director of leading German milling group Kampffmeyer Food Innovation, says there is clear demand in the convenience and bakery sectors for these types of products, where advantages include clean label appeal and good pH shear stability, which “simple, commodity flours” cannot match. Yet with the non-GMO movement in high gear, it will be interesting to see if these GM products take hold. Greenpeace warned the public that GM wheat could soon be widely grown in Australia for use in staples, such as bread and cereals. The group was demanding that GM wheat trials be stopped, claiming that such foods are unsafe and the wheat industry is being taken over by pro-GM interests. Genetically-modified wheat isn’t currently grown for human consumption in Australia, but GM cotton and canola is. So what can we believe or trust? The jury is still out as to how GMOs will affect us humans, but how can we avoid them and should we? Some are being developed to help, not hurt us. We must continue to be vigilant and read package labels. SF&WB

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Supplier Standpoint

Proposing Artisan Hall of Fame By Larry Blagg

n a daily basis, members of the by side with other talented bakers, you baking community recognize could say that The Guild has attained that commercial producers and its’ goal. their suppliers are on a never-ending This past fall at the IBIE show in Las path toward entrepreneurship and Vegas, The Guild, the Retail Bakers Asproduction efficiencies, which in and sociation (RBA), The American Baking off itself, is a worthwhile task. In Association (ABA) and the Bakery Equipfact, seeking ways to more efficiently ment Manufacturers Association (BEMA) Craig Ponsford produce large quantities of goodformed a show in which commercial and quality bakery products at a reasonable cost artisan bakers could share the stage and put on in a tight economy should even be viewed as a a spectacular event. Not only did these bakers, noble effort. both large and small, showcase their skills, but For those of us who are regular visitors to also the leadership of these organizations disthe American Institute of Baking International in played the synergistic effects of joining together Manhattan, Kan., we see a “Hall of Fame” disin a program whose sum effect was much larger play of engravings—dedicated to the pioneers of than the individual parts. the commercial baking world—who are credited A new annual trade event, All Things Baking, with the innovation, entrepreneurship and the was born as a direct result, and now a more production efficiencies that have taken place on complete industry showcase will allow all mema grand scale. It is indeed rewarding to see those bers to participate on relatively equal footing. folks deservedly honored for their contributions. Much of the credit for bringing The Bread BakYet interestingly, there is no “Hall of Fame” ers Guild of America into the fold goes to its’ for the pioneers of the craft or artisan baking long-serving chairman Ponsford, who witnessed industry in the United States, perhaps because and encouraged the growth from a few interits governing organization, The Bread Bakers ested parties into a 1,400-member organization. Guild of America (The Guild), is but a mere 17 For The Guild, its growth came from the selfless dedication of talented bakers like Ponsford, years old. who are willing to share the skills learned in The Guild was formed in 1993 by nowtheir shops and in competitions. These talented retired Tom McMahon and others in response bakers opened their shops to other craftsmen to a real need. That same year, Craig Ponsford and interested amateurs via Guildhall activities opened his first bakery in Sonoma, Calif., and and Camp Bread events, which drew sold-out quickly rose to a leadership position. However, crowds. it was a challenge. At that time, artisan bakers Last month, Ponsford stepped down as the didn’t have an organization that afforded an chairman of The Guild after an eight-year run, opportunity for them to learn baking-fromand will now focus his attention on creating his scratch methods from U.S. masters. There newest bakery, Ponsford’s Place, an artistic and weren’t any opportunities for artisan bakers to commercial success. This seems like the perfect experience hands-on demonstrations of artisan time to create a Guild “Hall of Fame” and elect skills or any assistance in learning how to bake Ponsford, along with a few of his fellow piofrom scratch or even how to source the best neers, into the Inaugural Class. ingredients. There wasn’t a place to learn about Hats off to Ponsford for a job well done, and innovative packaging or how to find equipment to The Guild, which is now able to be sustained to be used in making handcrafted products. Today, through the efforts of The Guild, U.S. by others of equal dedication. SF&WB artisan bakers participated with six teams and 18 master bakers in the World Cup of Baking in Editor’s Note: Larry Blagg is senior vice president of marketing for Fresno, Calif.-based California Raisin Marketing Paris, France, and even won gold medals. Since Board, which sponsors America’s Best Raisin Bread Contest. The Guild’s goal was to improve U.S. bakers’ Go to www.loveyourraisins.com to learn more about California knowledge and skills to be able to stand side raisins.

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Angela Dodd Cargill

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Business Briefs News

Registration Open for ASB’s 2011 BakingTech

R need spice? seasoning system » consistently delivers key quality and cost criteria of flavor, look and taste

egistration is now open for ASB’s 2011 BakingTech, “Nourishing for Generations,” which will be held March 6-9 at the Chicago Marriott Downtown Magnificent Mile. The 2011 BakingTech will highlight keynote addresses from high-altitude adventurer Ed Viesturs, Indy racer Brian Barnhart, and Lowell Catlett, economist and futurist. In addition, breakout sessions will focus on topics such as operations/equipment, artisan/ethnic baking, regulations/safety and ingredients/formulations. To learn more about the event and to register, go to www.asbe.org.

people Commercial Creamery Co., Spokane, Wash.

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Allison Beal has been added to the R&D group, responsible for product development and sensory analysis. Beal has a master’s degree in food science and culinary training. Also, Jeffrey White has been named the Midwest sales manager, bringing 17 years of industrial food ingredient sales and a vast knowledge of specialty dairy ingredients to the team.

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Award-winning chef Della Gossett, pastry chef instructor for Chicago’s French Pastry School, has been named a pastry consultant, responsible for developing new pastry recipes and curriculum, as well as teaching courses about California raisins in pastry to students at the FPS. She also will represent the California raisin industry at special events throughout the country, while contributing to the board’s Chef Assist program.

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D.D. Williamson, Louisville, Ky. Jason Armao has been added to the science and innovation team as an application project manager for the Global Support Center, responsible for leading the development of color solutions for each customer’s unique formulation challenges.

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.

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Congratulations to Shearer’s Foods

Snack Manufacturer of the Year SPONSORED BY

Minsa Corp.

Snack Manufacturer of the Year

(From top left to right) Scott Heldreth, senior vice president of operations; Bob Shearer, chairman, co-founder and CEO; Scott Smith, president; and Fritz Kohmann, chief financial officer.

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Pure Perfection A strong foundation, a rich family culture, an array of better-for-you products and a laundry list of achievements allow Shearer’s Foods to rise above the crowd and achieve ‘Shearer Perfection.’ Marina Mayer, Executive Editor

Lauren R. Hartman, Editor-in-Chief

Photo by Vito Palmisano

hen the economy spiraled downward, several manufacturers hunkered down, scaled back operations, ceased creating new products and eliminated product lines. Some producers even shut their doors completely. But for companies like Shearer’s Foods, Inc., everything is an opportunity, even in uncertain economical times. Instead of hiding underneath their bottom line, the Brewster, Ohio-based snack manufacturer rose above the fear and hesitation that forced most companies to

W

Continued on page 18

Photos and product shots by Vito Palmisano. www.snackandbakery.com

February 2011 - Snack Food & Wholesale Bakery

17

Snack Manufacturer of the Year

Continued from page 17

hold back. Instead, it forged ahead, creating a future unlike those suffering from economical woes. With two new product lines, updated packaging initiatives and the introduction of the first Leadership in Energy and Environmental Design (LEED) Platinum snack manufacturing facility in the world, located in Massillon, Ohio, Shearer’s Foods was experiencing what it calls, “Shearer Perfection.” “To get to where we are today, you have to get better in all areas,” says Bob

Shearer, chairman, co-founder and chief executive officer. “You have to keep pushing yourself every day to do better. It’s like a treadmill. If you stop, you’re going to go backward. [Shearer perfection is] quality, it’s sustainability, it’s wellness, it’s safety. It’s also all about the people.” A combination of rich culture, sustainable practices, better-for-you products and a devotion to being, well, perfect, have allowed Shearer’s Foods to garner Snack Food & Wholesale Bakery’s Snack Manufacturer of the Year award for the second

time in 10 years. Everything is an opportunity, Shearer says. That’s why Shearer’s Foods continues to perfect itself over and over again. “Within our industry, we’re trying to become a better-for-you, healthier snack [company], and we’ve put a lot of emphasis on our product offerings,” Shearer says. For instance, it rebranded its Tangos tortilla chips under the Shearer’s label, which consists of four all-natural varieties, he adds. Categorized as “Na’Cho Ordinary Tortilla Chips,” Tangos all-natural tortilla chips have no trans fat and are low in sodium. The all-natural line includes Blue Corn with Sesame Seeds, Blue Corn and Berries, Fire Roasted Veggie and Flaxseed with Sesame. Tangos’ white corn options include Restaurant Style, Margarita Lime, Cantina Style and Bite Size, whereas the yellow corn varieties are available in Cheesy Nacho, Deli Rounds and Habanero Queso. For consumers in search of whole grain chips, the Shapers brand of trans-fat-free chips is a sensible snacking alternative. The chips provide a good source of whole grains and fiber and come in Sea Salt, Cheddar, Cinnamon and Black Bean and Salsa varieties. Continued on page 20

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Snack Manufacturer of the Year

Continued from page 18

Shearer’s Foods also produces extra crunchy, kettle-cooked artisan chips in Original, Mesquite, Salt and Pepper, Salt and Vinegar, Jalapeño, Sweet Barbeque, Unsalted and Reduced Fat Original options. In addition to its lineup of chips, Shearer’s Foods produces pretzels, such as its all-natural and fat-free Thins, Minis and Sticks, and a host of potato chips, including Home-Style Classic, Wavy, KettleCooked, Original Thin and Rippled. Despite its vast number of flavors, the Shearer’s Classic Home-Style potato chip still reigns as the top-selling variety, Shearer says, followed by the Original Kettle-Style and Reduced-Fat Kettle Chips.

“It goes back to the basics,” he adds. “Our staples are the most popular, but we have a wide variety of seasonings to meet consumer tastes.” From a better-for-you snack standpoint, says Scott Smith, president, revenue stems from its whole grain Shapers, ReducedFat Kettle Chips and its award-winning, gluten-free Riceworks tortilla chips. “At the end of the day, our snacks all taste really good, but some consumers want healthier product attributes. With

our veggie tortilla [chips], you can eat one serving and get one-third of your vegetable requirements for the day,” he adds. “I think it’s more fun to eat tortilla chips than eating vegetables.”

Goodness beyond the bag Shearer’s Foods didn’t attain “Shearer Perfection” overnight. In 1974, Shearer, along with his parents, Jack and Rosemary, and brother Tom, acquired a one-truck Wise Continued on page 22

At a Glance Company: Shearer’s Foods, Inc. Headquarters (and plant): Brewster, Ohio Plant Locations: Lubbock, Texas; Canonsburg, Pa.; Massillon, Ohio; Hermiston, Ore.; Bristol, Va. Distribution: Global

Products: Kettle chips, tortilla chips, potato chips, whole grain chips, extruded snacks, pretzels and rice chips Brands: Shearer’s, Tangos, Shapers, Riceworks No. of Employees (Company-wide): 1,500

KEY PERSONNEL:

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Snack Food & Wholesale Bakery - February 2011

Chrm., CEO: Robert (Bob) Shearer

Sr. V-P., Opers.: Scott Heldreth

Vice Chrm., Pres., Shearer’s Canada: John Frostad

Sr. V-P Bus. Dev.: Tom Shearer

Pres.: Scott Smith

V-P. Hum. Res.: Walt Fink

CFO: Fritz Kohmann

V-P. Mfg.: Michael Parks

COO, Shearer’s Canada: Bob Armstrong

V-P. Mktg.: Jeff Bincyzk

Corp. Cont., V-P.: Alan Fritts

V-P. Natl. Accounts: Brian Newland

Exec. V-P: Bill McCabe

V-P. Natl. Accounts: John (Chris) Jayne

Exec. V-P: Jim Wiegmann

V-P. Sales, Shearer’s Canada: Mike Ricci

Sr. V-P., Co-Pack Opers.: Steve Surmay

V-P. Strategic Sourcing: Jim Allan

V-P. Comm.: Melissa Shearer

www.snackandbakery.com

Snack Manufacturer of the Year

Continued from page 20

potato chip distributor to complement their local grocery store, which was once owned by Shearer’s great-great grandfather, William. About five years later, the Shearers’ built one route into five routes. “When we decided to manufacture our own potato chips, we rented a 2,500-sq.-ft.

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building and bought a used kettle fryer that made 125 lb. of potato chips per hour, and started bagging them in poly bags, with a twist tie and a label and distributed them to the local market,” Shearer says. Today, Shearer’s Foods owns six plants and 70 production lines, which produce more than 40,000 lb. of product an hour.

The 200,000-sq.-ft. headquarters plant in Brewster, Ohio sits on 77 acres, which is 10 times the size of the original facility, Shearer points out. “Our next plant [purchase] was in Lubbock, Texas, and our next acquisition was a pretzel factory in Canonsburg, Pa.,” he adds. “Then we started construction on our new Millennium manufacturing facility in Massillon, which opened in April 2010 (the first platinum, LEED-certified snack food manufacturing plant in the world).” Simultaneously, Shearer’s Foods acquired the Vancouver, Canada-based Snack Alliance, Inc., which included two manufacturing facilities (Hermiston, Ore., and Bristol, Va.), and its Riceworks brand of better-for-you snacks. The Snack Alliance purchase expanded Shearer’s already broad sales reach to a total of 18 countries for its branded, co-pack and private-label products. Continued on page 24

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Snack Manufacturer of the Year Continued from page 22

Fritz Kohmann, chief financial officer, says that Shearer’s competitive advantages are its broad range of product capabilities, geographic reach and the company’s focus on quality and food safety programs. Shearer’s is unique in its ability to offer

customers a full line of innovative snacks on a national scale, he adds. Shearer’s has also made significant investments in stateof-the-art quality and food safety processes and systems to meet and exceed increased customer requirements, enabling them

to offer customers a unique value in the market. Shearer’s Foods also has been able to target all channels of distribution within each location, with sales predominantly concentrated within grocery, mass, clubstore and foodservice. While this core business remains strong, Shearer’s must continually stay in tune with leading-edge trends. “As a company, we’re seeing positive growth in organic,” Shearer says. “The better-for-you category is gaining momentum.” Therefore, Shearer’s wants to develop better-for-you snacks because as Shearer says, that’s the future. As this issue goes to press, Shearer’s Foods is redesigning its packaging to highlight better-for-you messages and call out healthy attributes. There are many health issues that are important to consumers, such as lower sodium and gluten-free, Smith says, and the packaging needs to be a careful balance of providing the right information combined with attractive graphics to drive the purchase, he adds. That’s why the folks at Shearer’s Foods conducted several online consumer panels, asking for feedback on products and packaging. Whether it’s their deep family culture, multitude of sustainable practices, numerous better-for-you snacks or their perseverance to continue forward, Shearer’s Foods defines pure excellence and prestige, and of course, that “Shearer Perfection.” SF&WB SFWB1008AC.indd 1

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Snack Manufacturer of the Year

LEED-ing the Way Shearer’s Foods portrays “Shearer Perfection,” thanks to its new LEED Platinum-certified snack manufacturing plant. Marina Mayer, Executive Editor

ince 1974, Shearer’s Foods has been epitomizing “Shearer Perfection,” which is “the art of snacking and science of product, support, merchandising and corporate culture,” according to the Brewster, Ohio, snack manufacturer. “Shearer Perfection” is also about customer loyalty, a rich family culture and “goodness beyond the bag,” says the company’s motto. That’s why the 1,500-employee snack manufacturing empire received Snack Food & Wholesale Bakery’s Snack Manufacturer of the Year award. That, and also because it developed the first Leadership in Energy and Environmental Design (LEED) Platinum snack manufacturing facility in the world, known as the Millennium Plant.

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Continued on page 28

Photos by Vito Palmisano

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www.snackandbakery.com

Photo courtesy of Shearer’s Foods, Inc.

This 110,200-sq.-ft. facility in Massillon, Ohio, is the first LEED-certified plant in the world.

Corn is soaked for nine to 11 hours in one of the 12 3,000-lb. soaking tanks before entering the washing room.

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February 2011 - Snack Food & Wholesale Bakery

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Snack Manufacturer of the Year Chips convey on an equilibrating belt, where they rest and cool before being sent into a three-well fryer.

Continued from page 28

entering a grinder. “The grinder is the first area mechanically where we can start adjusting the texture of the product depending on the opening of the gap of the grind,” Brower says. “We can make a very flaky tortilla or a really robust tortilla that will hold a bunch of salsa, depending on what the customer is asking for.” After leaving the grinder, masa, or ground corn dough, comes through a transfer tube and drops into a sheeter, which forms the masa into a specified thickness. Then the masa travels through a cutter that

forms the product into shapes, “like a little army of tortilla chips, marching into the oven,” Brower adds. Next, the chips enter a triple-pass oven, which is considered “one of the centerpieces of the energy-savings of the plant,” Brower says. “This is a one-of-akind, patent-pending oven. It has 24 infrared heating units on the inside, and has little drafting with the exception of where the chips come in and where the chips come out.” The oven also pre-heats combustion air using the infrastructure as conduits for this supply. The combination of these innovations results in gas savings of more than 47% when compared to competing technologies. Chips begin baking at the top of the oven and travel through to the bottom for about 30-40 seconds. Off of the tortilla oven is a liquid chimney. Previously wasted thermal energy from the oven stack is redirected to a skid where a combination of water, glycol and heat exchangers are used to recapture this heat. This energy then supplies more than 92% of the building heating load, as well as pre-heats water for corn cooking and sanitation, Brower says. Next, the chips convey on an equilibrating belt, where they rest and cool before being sent into a three-well fryer. “We have a continuous filtration system in the fryer with turnover of less than eight hours,” Brower says.

The chips then travel into a weigh scale, which electronically informs the seasoner how much seasoning to add into the seasoning bowl. “Historically, it’s been based on infrareds, but this actually weighs it so we’re getting a 1:1 ratio between the amount of weight we want in there and the proportion of seasoning going in,” Brower notes. After seasoning, the chips travel along a 45-ft.-long conveyor into a packaging room where they funnel into vibrational conveyors, drop into form/fill/seal baggers and the bags are then manually bundled. On the other side of the building lies the twin-screw line, which produces 800 lb. of product an hour. At the time of Snack Food & Wholesale Bakery’s visit, Shearer’s Foods was producing whole grain chips. Ingredients come in 50-lb. bags and are screened into a batch mixer on an upper level before dropping down into a batch hopper. The mixture then processes through the twin screw extruder, where temperature is controlled from 60-120°C. A speciallymade die produces a hot ribbon of product, which is then cooled and cut before entering the fryer. “All of our heat exchangers use oxygen trimming, which optimizes the ratio of gas and air for cleaner, more efficient combustion,” Brower notes. Lastly, chips exit and travel to the seasoning room upstairs where they are seasoned, conveyed, then transferred into the form/fill/seal arena where they are bagged and manually bundled.

The sustainability factor Constructing a sustainable facility was key to taking the company to the next phase of growth, says Bob Shearer, chairman, co-founder and CEO. That’s why installing state-of-the-art equipment, controls and lines was necessary to achieve the sustainability factor. For starters, all of the lines use computer-controlled touchscreens that act as surveillance systems for the lines, allowing the plant to be operated with minimal staffing. Continued on page 32

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Snack Manufacturer of the Year Steve Surmay, senior vice president of co-pack operations, inspects a package of tortilla chips to ensure that the batch meets a series of checks before being shipped out to the customer.

(Right) After seasoning, the chips travel along a 45-ft.-long conveyor into the packaging room where they funnel into vibrational conveyors (left), drop into form/fill/seal baggers for bagging and are then manually bundled.

Continued from page 30

“If I’m running this line, and I want to see what’s going on in the fryer downstairs, I just push the buttons, pull up [some information] and I can make any adjustments I need to,” Brower says. “This helps the quality of our products because we have a lot of sensors and a lot of readings on this that give us real-time feedback. They’re controlled within a certain capacity, whereas before, we didn’t have this type of feedback or controls.” The LEED-certified plant also is home to rainwater harvesting, which allows for 60% savings in water. Rainwater collects from the roof, runs through a triple filtration system, is stored in a 1,200-gallon tank and is used for the plant’s non-potable applications, such as flushing toilets. In the snack food quality lab, opera-

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tors conduct titrate tests every 45 minutes on each line. Meanwhile, in the Infinity quality system, virtual program management officers (VPMOs) perform a series of checks in which the product being tested must pass all tests in order for the batch to be shipped out. In addition, the product inspection team (PIT) conducts a PIT test every two hours. “We grab a bag off of every line, open it up in a room and look at it for appearance, taste and texture,” Brower says. “We have a cross-functional team of processors, packagers, lab people and supervisors, and we’re grading it on a scale of zero to five, zero is gold standard—the best. Anything over three, we won’t ship and we have immediate action out on the line. We’re very picky about our product.” The facility also conducts mock recalls

twice a year and maintains a 965 AIB score. It also features six docks, where product is picked up once every two hours and taken to the Shearer’s Food’s distribution center down the road. As the Millennium Plant comes online, Shearer’s Foods is opting to dial down its production shifts from six days to five, so as not to overwork our associates, Brower adds.

Shearer perfection “First and foremost, [Shearer Perfection] is about the people, no doubt,” he adds. “I don’t know of anyone who could match our workforce. We’re very open with each other. Through training programs and various meetings, we help our associates do their job perfectly every time.” That’s why the folks at Shearer’s Foods continue to LEED the way. SF&WB

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Market Trends

Healthy Snacking Snack food manufacturers are stepping up to meet consumer demand for natural and organic versions of better—but not blander—products. Romy Schafer, contributing writer

ot too many years ago, natural and organic foods were commonly associated with health-food fanatics and Birkenstock-wearing vegetarians. Healthfood stores, natural food markets and local food co-ops were the retailers of choice for these consumers. Now, natural and organic foods are more mainstream, as health issues and food-quality concerns are prompting consumers to re-evaluate the foods they’re eating and seek out healthier alternatives. More Americans are looking for ways to help address medical issues brought on, in part, by years of unhealthy eating. Parents are becoming more aware of—and concerned about—foods laden with sugar and artificial ingredients that are marketed to children. Meanwhile, others are switching to healthier diets in hopes of preventing future health problems. However, anyone who’s ever tried to eat healthier and give up a favorite “junk food” knows that good intentions can evaporate when snack time rolls around. Fortunately, snack food manufacturers are acknowledging Americans’ food concerns and desire to eat better—but not blander—by introducing more natural and organic snack products that appeal to taste buds young and old.

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Potato and tortilla chips Americans love potato chips, on their own or paired with dips. What a growing number of people don’t like about these savory treats, however, is that they typically contain a lot of fat and salt. That’s why

companies like Natural Snacks, LLC in Addison, Ill., introduced Michael Season’s Kettle Cooked potato chips, which contain 40% less fat than regular chips and less than 140 mg of sea salt per serving. “A lot more people are cutting back on sodium,” says Christine Brown, director of marketing. “As they get older, they start to watch their intake and exactly how much sodium is in products and how much they should be digesting.” Like other Michael Season’s brand snack products, Kettle Cooked potato chips are made with all-natural ingredients and contain no preservatives, artificial colors or flavors, hydrogenated or partially hydrogenated oils or MSG. They’re also wheat- and gluten-free. Plus, consumers can choose from Lightly Salted, Honey BBQ, Sea Salt & Balsamic Vinegar and Jalapeño varieties in 5-oz. bags at a suggested retail price of $2.49. The Unsalted version comes in a 2-oz. bag priced at $1.29. The Lightly Salted and Honey BBQ chips also come in a 100-calorie pack. Tortilla chips are also getting a healthy makeover from snack food manufacturers. In November 2010, Prime Choice Foods Inc., a Henderson, Nev.-based producer of organic, gluten-free and kosher snacks, introduced Savory Balance tortilla chips, which contain a

full serving of fruits and vegetables in each 10- to 12-chip serving. Savory Balance tortilla chips come in 1- and 7-oz. bags that retail for around 99 cents and $2.99, respectively. “[A company we work with] came up with a patented process of taking six fruits and vegetables, and basically encapsulating them and turning them into a powder form,” says Mauro Gomez, vice president of sales and marketing. “What they were able to do was work with us on putting this powder into a yellow tortilla chip— into the corn masa—giving us a tortilla chip where every ounce has the equivalent nutrients of a full serving of fruits and vegetables.” The powder is made from apples, oranges, tomatoes, carrots, cranberries and broccoli, all produce known for being rich in vitamins, antioxidants and lycopene, and added to other natural ingredients, such as non-genetically modified corn, sea salt and non-hydrogenated oil. “This tortilla chip is really a healthier way of eating,” Gomez says. Continued on page 36

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Market Trends Continued from page 34

But healthy snacking doesn’t always mean tasty snacking. “People feel that food should taste good, and they’re not willing to give up taste for health,” says Gomez. “People are realizing that these tortilla chips taste just as good [as regular tortilla chips].”

Dried veggies and fruits Another vegetable renown for its exceptional nutritional value, but typically not thought of as a snack food, is the primary ingredient in Earth Chips’ Kale Chips, launched last summer by Blue Mountain Organics, LLC, Floyd, Va. Raw kale is dipped in spices and dehydrated at a low temperature to produce crunchy chips that are rich in manganese, cal-

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cium, iron and vitamins A, C and K, and contain no artificial ingredients, preservatives, fillers, additives, oils, trans fats or genetically-modified organisms (GMOs). In fall 2010, the company added three varieties to its original Cheezy flavor: Cheezy Spicy; Nutty Cheezy; and Chocolate. “We’re the first company to make chocolate-covered kale,” says Blue Mountain Organics founder Jared Mizrahi, who also formulates the flavors. “It’s a very unique product.” Organic cacao butter and cacao powder give Earth Chips’ Chocolate Kale its chocolaty flavor, while ingredients such as chia seed provide high levels of

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Snack Food & Wholesale Bakery - February 2011

Omega-3 and Omega-6 fatty acids. In late November 2010, Vanilla, Cinnamon and Spirulina options joined Earth Chips’ lineup. All seven varieties are packaged in 3-oz. bags that retail for $7.50 each. “People are trying to get more connected with their food,” Mizrahi says, citing growing consumer interest in slow and locally grown food. “They’re becoming more aware of what’s in their food, and they’re switching their diets. That’s why the raw food market is growing.” Consumers looking for a more traditional, non-crunchy raw snack will find it in Peeled Snacks’ new Peeled Organic line of gently dried fruit, expected to be available early this year. “This new line is certified organic, so there’s nothing added at all,” says Cassie Abrahms, director of finance at the Brooklyn, N.Y., company. “A lot of dried fruit has added sugars, oils and preservatives. We don’t add anything.” The line contains several of the same flavors currently available in Peeled Snacks’ single-serving Fruit Picks line: apple; apricot; mango; and banana, as well as seedless raisins and three dried fruit mixes. “We’re very excited about the mixes,” Abrahms says. “We’re launching a mix called Paradise Found, which has dried mango, pineapple and banana. Farmer’s Market Trio contains dried apple, cherries and raisins. We have another one called GoFigure, which is more of a Mediterranean mix with apricots, dates and figs.” The company tries to purchase as many of its ingredients as it can domestically. Peeled Organic fruits and mixes come in standup pouches that hold two to six servings and retail for $3.99. On the other hand, tasty, dried fruits are just some of the ingredients found in Bear Naked 100% Pure & Natural Trail Mix, introduced by La Jolla, Calif.-based Bear Naked last August. It comes in three

www.snackandbakery.com

blends: Cranberry Almond, which contains cranberries, raisins, walnuts, almonds and Bear Naked Peak Protein granola clusters; Pecan Apple Flax, with raisins, sunflower seeds, pecans, pepitas, apple slices, flaxseeds and Bear Naked Peak Flax granola clusters; and Chocolate Cherry, which combines cherries, cocoa-covered almonds and Heavenly Chocolate whole-grain granola clusters. Bear Naked 100% Pure & Natural Trail Mix comes in a resealable, 4.5-oz. package with a $2.99 suggested retail price.

Organic pretzels Baked snacks are taking up more retail shelf space, as more consumers shy away from fried snacks and snack food manufacturers introduce better-tasting, baked alternatives. Even pretzel producers are rolling out new versions of a snack that’s considered to be one of the more better-for-you products on the market. Snyder’s of Hanover in Hanover, Pa., introduced a pretzel product that’s certified organic by the U.S. Department of Agriculture. Snyder’s of Hanover Organic Whole Wheat Nibblers are made with organic whole wheat flour, organic blue agave syrup, organic expeller-pressed sunflower oil and organic rosemary. “The organic pretzel market is relatively less developed than the traditional grocery pretzel channel,” says Bryan Dobson, marContinued on page 38

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Market Trends

A Flavorful Foundation

B

read often serves as the foundation for betweenmeal creations for many consumers, especially teenage boys, peanut-butter-and-jelly sandwich fans and Dagwood Bumstead, the main character in the cartoon Blondie. That’s why, last August, Boulder, Colo.-based Rudi’s Gluten-Free Bakery, a sister company to Rudi’s Organic Bakery Inc., introduced three certified-gluten-free sandwich breads that are made with all-natural ingredients. Consumers can choose from Original, Multigrain or Cinnamon Raisin at about $5 for an 18-oz. loaf. “We historically have been a wheat baker, but over the years, the No. 1 request we’ve had has been for a glutenfree bread that tastes as good as regular bread,” says Doug Radi, vice president of marketing. “We’re pretty wellknown for making organic bread for mainstream, so retailers were coming to us and asking us to try to do the same thing with gluten-free [bread]. We spent about 18 months

developing the formula and getting it ready for launch.” Radi contends that what makes Rudi’s gluten-free breads different from other such products is their taste. “We would never have launched a gluten-free bread that didn’t taste like real bread,” he says. “So far, consumer response has been phenomenal.” Continued on page 39

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Market Trends Continued from page 38

keting manager. “The nibbler will offer a completely new snacking item versus what is currently available in the natural pretzel category. The bite-sized nibbler shape has proven to be a very popular item in our traditional line of pretzels.” An 8-oz. bag of Organic Whole Wheat Nibblers retails for $3.49.

how their customers shop can use this knowledge to more effectively market their merchandise. Even though more Americans are committed to eating healthier, they still want foods that are flavorful and fun to eat, es-

pecially when snacking. That’s why snack food manufacturers are making it easy for retailers to give their customers what they want and improve their sales by continuously introducing better-for-you natural and organic products. SF&WB

Overcoming obstacles All-natural and organic snack foods still can be challenging for retailers to sell. First, there’s the matter of taste. Some people think, without even trying them, that all-natural and organic foods taste bland. Others shun them due to a previous, bad-tasting purchase. Regardless of how nutritious and healthy a snack is, if it doesn’t taste good, people won’t buy it. Offering in-store samples is a great way for retailers to acquaint customers with natural and organic snacks. “It’s the best way of having someone try, or start liking, your product,” Brown says. “We make sure Michael Season’s products taste good. Taste is No. 1.” Then, there’s the matter of cost. Natural and organic snack products often cost more than regular snack foods because manufacturers typically pay more for high-quality, natural and organic ingredients. Educating people about a product’s contents and why they make an item a healthier snack choice helps them understand what they’re paying for. Shelf talkers, signage and printed materials that highlight or expand on the information on a product’s packaging are all good ways to enlighten potential customers. Finding the right in-store location for natural and organic snack products is important, too. Some retailers devote an entire section of their store to all types of natural and organic products, including consumables and household items. Others group natural and organic snack products together within the snack section. “Now, a lot of [grocery stores] are going in line with their natural and organic products, and just indicating that these are natural, these are organic and these are glutenfree,” Brown says. Retailers who know

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SNAXPO 2011

Snack Attack Time he snack industry still has time to register or exhibit at SNAXPO 2011, March 20-23 at the JW Marriott Grande Lakes in Orlando, Fla. According to the Snack Food Association, the sponsor of the show, SNAXPO exhibitors and attendees will be part of more than 2,000 industry professionals, including buyers, decision makers and industry leaders from the United States, Latin America, Europe and the Pacific Rim. Whether you’re a small startup or a multinational corporation, SNAXPO offers educational sessions, speakers and a multitude of networking opportunities for everyone. The show will kick off on Sunday, with registration from 8 a.m. to 5 p.m., committee and board meetings, a Latin American educational track and a welcome reception dinner. Monday will include keynote speaker Jeb Bush, former governor of Florida. In his speech titled “America’s Promise in Uncertain Times,” Bush will share his visionary understanding of the issues about the country’s future. What are the enduring American values that can provide a strong defense against tough economic times? Do today’s current policies—from healthcare to the economy to immigration—reflect those values? And how will these policies shape the Obama administration’s agenda? In the State of the Snack Food Industry Report, Sally Lyons Wyatt, senior vice president of Chicago-based SymphonyIRI Group, will discuss how consumers and market demands for new products,

Photo courtesy of the Snack Food Association

Monday, March 21 1:30 a.m.–7:00 p.m.

T

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Exhibit Show Hours

Tuesday, March 22 11:30 a.m.–5:00 p.m. Wednesday, March 23 9:30 a.m.–11:30 p.m.

flavors and packaging are reshaping and transforming the snack food industry. She also will discuss the snack food industry’s performance in 2010 and present the latest industry trends, up-to-date snack food sales data and consumer insights for the major snack food categories. Also on the agenda are four general sessions designed to outline major trends and issues faced in the snack food industry. For instance, “Sustainability in the Snack Food Industry” will discuss the ins and outs of sustainability, what it means and how to achieve it. This session will focus on the practical tools available to perform sustainability for profit and how manufacturing practices and other operations can make products and the industry more sustainable. The panel also will share real-world experiences on ways to add millions to the bottom line and better serve your customers. “Food Law & Regulation Update” will uncover the food safety provisions that are destined to impact the snack food industry. Food law and regulation experts from Hogan Lovells US, LLP will discuss the latest food safety laws, regulations and issues affecting the snack food industry and share how many of today’s manufacturers can prepare for these new requirements.

In “Successfully Implementing a Continuous Improvement Culture,” attendees will find out how continuous improvement fits into the mainstream of how team members should be thinking, how to begin developing continuous improvement culture and what it takes to make it work and sustain it over the long term. In “Developing & Maintaining Food Safety & Product Quality,” attendees will discuss planning, tools and methods needed to develop and maintain programs to help meet the challenges of maintaining safe manufacturing practices and product quality as well as how to find more effective, efficient and cost-saving ways to stay on track. Also, hear from snack food industry leaders on the Global Food Safety Initiative (GSFI) and various audit and inspection programs such as Safe Quality Food (SQF). Finally, “Innovations in Ingredients” is made up of a panel of ingredient experts who develop innovative solutions needed to meet consumer needs. Find out how food manufacturers are improving the nutritional profile and of their products, as well as lengthening shelf life. For exhibitor and attendee information, travel arrangements, airfare discounts, registration links, and more, visit www.snaxpo.com.

Continued on page 42

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Company*

E X H I B I TO R S L I S T Booth Number

Company*

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Company*

Booth Number

A&B Process Systems Corp . . . . . . . . . . . . . . . . 113

American Extrusion International . . . . . . . . . . . . 603

Buhler Aeroglide . . . . . . . . . . . . . . . . . . . . . . . . 314

A.C. Horn & Co. . . . . . . . . . . . . . . . . . . . . . . . . . 501

Baking & Snack Magazine . . . . . . . . . . . . . . . . . 801

Bunge Milling . . . . . . . . . . . . . . . . . . . . . . . . . . 610

Abraxis LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Blue Print Automation Inc. . . . . . . . . . . . . . . . . . 507

ADI Systems Inc . . . . . . . . . . . . . . . . . . . . . . . . 214

BMA Nederland BV . . . . . . . . . . . . . . . . . . . . . . 617

Alliedflex Technologies, Inc. . . . . . . . . . . . . . . . . 404

Bruker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

Allstate Business Insurance . . . . . . . . . . . . . . . . 103

Bryce Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

C-P Flexible Packaging . . . . . . . . . . . . . . . . . . . 517 C. Cretors and Co. . . . . . . . . . . . . . . . . . . . . . . . 100 Cablevey Conveyors . . . . . . . . . . . . . . . . . . . . . . 318 Carolina Ingredients . . . . . . . . . . . . . . . . . . . . . 407 Casa Herrera, Inc. . . . . . . . . . . . . . . . . . . . . . . . 301

9L 61 VLW %R $ XV RW ;3 DW K 2   

Clextral Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Colorcon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814 Commercial Creamery Co. . . . . . . . . . . . . . . . . . 316 Continental Ingredients . . . . . . . . . . . . . . . . . . . 106 CPM Wolverine Proctor . . . . . . . . . . . . . . . . . . . 311 Dallas Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 611 DAO Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816 Douglas Machines Corp. . . . . . . . . . . . . . . . . . . 703

Things our competition can’t say #91

“...our 24-hour online ordering system.”

Dow AgroSciences . . . . . . . . . . . . . . . . . . . . . . . 109 DSM Food Specialties . . . . . . . . . . . . . . . . . . . . 613 Ellison Bakery, Inc. . . . . . . . . . . . . . . . . . . . . . . 711 Emsland Group . . . . . . . . . . . . . . . . . . . . . . . . . 101 European Snacks Assn. . . . . . . . . . . . . . . . . . . . 813 Evans Food Group Ltd. . . . . . . . . . . . . . . . . . . . . 504 ExtenData . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811 Filtercorp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Focke & Co.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 Food Service Specialties . . . . . . . . . . . . . . . . . . 704 Formers By Ernie, Inc. . . . . . . . . . . . . . . . . . . . . 505 Formers International . . . . . . . . . . . . . . . . . . . . 405 Fuchs North America, Inc. . . . . . . . . . . . . . . . . . 200

www.formers.com/theshop

Gamay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Build, order, re-order and track your formers online.

GENPAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Heat and Control . . . . . . . . . . . . . . . . . . . . . . . . 513 Iconotech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812 Incalfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702 J.R. Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 J.C. Ford Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . 614 K-Tron Process Group. . . . . . . . . . . . . . . . . . . . . 612 Kerry Ingredients & Flavors . . . . . . . . . . . . . . . . 400 Kliklok-Woodman. . . . . . . . . . . . . . . . . . . . . . . . 307 Kraft Food Ingredients . . . . . . . . . . . . . . . . . . . . 509 Land O’Lakes Ingredient Solutions . . . . . . . . . . . 706

Durable, high-quality bag forming assemblies.

The Lanly Co.. . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Leng D’or Snack Foods . . . . . . . . . . . . . . . . . . . 601

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E X H I B I TO R S L I S T Company*

Booth Number

Company*

Booth Number

Company*

Booth Number

Life Spice Ingredients . . . . . . . . . . . . . . . . . . . . 808

Ovivo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Sigmaplast/Sigma Trading USA . . . . . . . . . . . . . 300

Loar & Young, Inc. . . . . . . . . . . . . . . . . . . . . . . . 809

Palmex Alimentos . . . . . . . . . . . . . . . . . . . . . . . 608

SK Food International . . . . . . . . . . . . . . . . . . . . 616

Maddox Metal Works . . . . . . . . . . . . . . . . . . . . . 303

Parker domnick hunter . . . . . . . . . . . . . . . . . . . 717

Snack Food & Wholesale Bakery . . . . . . . . . . . . 721

Mafin S.P.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Pioneer Hi-Bred . . . . . . . . . . . . . . . . . . . . . . . . . 209

Spray Dynamics Ltd . . . . . . . . . . . . . . . . . . . . . . 312

Mane, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615

Polymer Logistics . . . . . . . . . . . . . . . . . . . . . . . 201

Symrise, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Masipack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

Nu-Con Equipment/Powder-Solutions, Inc. . . . . . 715

Tate & Lyle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707

Mettler-Toledo Hi-Speed . . . . . . . . . . . . . . . . . . 806

PPM Technologies LLC . . . . . . . . . . . . . . . . . . . . 606

TNA North America, Inc. . . . . . . . . . . . . . . . . . . . 401

Mettler-Toledo Safeline . . . . . . . . . . . . . . . . . . . 802

Printpack Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 600

Tru-Vision Plastics, Inc. . . . . . . . . . . . . . . . . . . . 714

Meyer Industries . . . . . . . . . . . . . . . . . . . . . . . . 114

Process Sensors Corp. . . . . . . . . . . . . . . . . . . . . 111

Urschel Laboratories, Inc. . . . . . . . . . . . . . . . . . 710

Michigan Potato Industry Commission . . . . . . . . 107

Quality Fabrication & Design, LP . . . . . . . . . . . . 412

UVA Packaging . . . . . . . . . . . . . . . . . . . . . . . . . 315

Minsa Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

Quickdraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Wenger Manufacturing, Inc. . . . . . . . . . . . . . . . . 203

Moist Tech. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Reading Bakery Systems . . . . . . . . . . . . . . . . . . 411

Wire Belt Company of America . . . . . . . . . . . . . . 713

National Starch Food Innovation . . . . . . . . . . . . 700

Red-Ray Manufacturing Co. Inc. . . . . . . . . . . . . . 309

Wixon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810

NDC Infrared Engineering . . . . . . . . . . . . . . . . . 705

Ross Computer Systems . . . . . . . . . . . . . . . . . . 604

Wyandot, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . 503

Novozymes N.A. . . . . . . . . . . . . . . . . . . . . . . . . . 313

Rudolph Foods Co. Inc. . . . . . . . . . . . . . . . . . . . 408

Xpedium(Numeric Computer Systems, Inc.) . . . . 709

O’Malley Grain . . . . . . . . . . . . . . . . . . . . . . . . . 716

Sani-Matic, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . 206

Yamato Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Oilseeds International Ltd.. . . . . . . . . . . . . . . . . 207

Schenck AccuRate. . . . . . . . . . . . . . . . . . . . . . . 102

*As of Jan. 25, 2011

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February 2011 - Snack Food & Wholesale Bakery

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New Products

1

Bone Suckin’ Jerky

Company: Ford’s Gourmet Foods, Raleigh, N.C. Website: www.bonesuckin.com Introduced: January Distribution: International Suggested Retail: $7.99 to $8.99 for a 2-oz. package Product Snapshot: Bone Suckin’ Jerky is handmade by the Cow Creek Band Indians in Oregon and contains apple cider vinegar, black pepper and garlic. Plus, it is all-natural, gluten-free and contains no preservatives or nitrates. Ingredients: Beef, water, brown sugar, vegetable protein from soybeans and water, apple cider vinegar (apple cider vinegar, water), sea salt (magnesium carbonate), black pepper, celery powder (celery juice, sea salt, raw sugar, spices), garlic.

2

Pretzel Pete Pearls Pretzel Balls

Company: SB Global Foods, Inc., Lansdale, Pa. Website: www.sbglobalfoods.com Introduced: January Distribution: National Suggested Retail: $1.99 to $2.99 for a 4.5-oz. bag Product Snapshot: New to the Pretzel

Pete snack line are Pretzel Pearls, or small, round-shaped pretzel balls that are accented with exotic spices. They come in Szechuan, Wasabi and Coconut Curry varieties. Ingredients (Szechuan): Wheat flour, vegetable oil (may contain corn, canola, soybean oil), salt, sugar, spices, vinegar powder, corn syrup, soy sauce, garlic powder, tomato powder, onion powder, caramel powder, soda, yeast, citric acid, paprika, silicon dioxide.

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Snack Food & Wholesale Bakery - February 2011

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New Products

3

Frozen Enchiladas and Pizza

Company: Kashi Co., La Jolla, Calif. Website: www.kashi.com Introduced: January Distribution: National Suggested Retail: $4.09 for a 9-oz. box of enchiladas or a 12.45-oz. box of pizza Product Snapshot: New to the freezer aisle is Spicy Black Bean Enchiladas. Made with Kashi’s signature Seven Whole Grain and corn tortillas and seasoned with tomatillo, tomato, cilantro and jalapeno salsa, these all-natural enchiladas can be served with red skinned potatoes, roasted corn, red pepper and spinach. Meanwhile, the Basil Pesto Pizza brings an Italian pizzeria right to the consumer’s living room. This all-natural,

vegetarian pizza is made with Kashi’s signature whole grain crust, is packed with fiber and protein and topped with Mozzarella and feta cheese, roma tomatoes, caramelized onions and nut-free basil pesto sauce. Ingredients (Basil Pesto Pizza): Crust (crust mix with Kashi Seven Whole Grains & Sesame blend [wheat gluten, whole oat flour, oat fiber, oat syrup solids, barley malt extract, whole triticale flour, brown rice flour, whole hard red wheat flour, whole rye flour, salt, whole barley flour, whole buckwheat flour, sesame seeds], water, wheat flour, white whole wheat flour, ground flaxseed, extra virgin olive oil, barley fiber, yeast, wheat starch, garlic powder), sauce (basil pesto [basil, water, expeller-pressed canola oil, Parmesan cheese [pasteurized part-skim milk, cheese cultures, salt, enzymes], dried garlic, sea salt, acacia gum, xanthan gum), Mozzarella cheese (pasteurized part-skim cow’s milk, cheese cultures, salt, enzymes), diced tomatoes (tomato, calcium chloride), caramelized onions (onions), feta cheese (pasteurized cow’s milk, cheese culture, salt, enzymes), basil. Contains: wheat, milk.

4

Journey Bars

Company: Journey Bar, Chicago Website: www.journeybar.com Introduced: January Distribution: Midwest Suggested Retail: $2.19 for a 1.8-oz. bar Product Snapshot: Journey bars are 100% natural savory-flavored “travel” bars that combine the nutrition of organic whole grains with real-food flavors. For instance, the Italy-inspired Parmesan Romano variety contains oats, flaxseed, amaranth and millet mixed with Parmesan and Romano cheese and Italian spices. The Thailand-inspired Coconut Curry variety blends a host of curry flavors to deliver a soft, but firm texture. Ingredients (Parmesan Romano): Organic whole grains (oats, flaxseed, amaranth, millet), tapioca syrup, almonds, canola oil, Parmesan cheese (part skim cow’s milk, cheese cultures, enzymes), Romano cheese (cultured milk, enzymes). Contains less than 2% of the following: sea salt, dehydrated garlic, spices, water, vitamin C, vitamin E.

Gluten-free | Omega-3's | Whole Grains | Trans-fat free IdenƟty Preserved

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February 2011 - Snack Food & Wholesale Bakery

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The Nutritional Corner

Let Grains Love You Back ccording to the Centers for Disease Control and Prevention, Atlanta, one person in America has a stroke or heart attack every 25 seconds. That totals a whopping 1.26 million people affected by these coronary events each year, which doesn’t include the millions living with heart disease and high blood pressure every day. February is American Heart Month and the perfect time to think about lifestyle changes that can protect your ticker. On the whole, heart disease is a “lifestyle disease,” meaning there are steps we can all take to reduce our risk for developing it. These include smoking cessation and increasing physical activity as well as a number of dietary improvements such as decreasing saturated fat intake, consuming alcohol in moderation and eating lots of fruits, vegetables and grain foods, especially whole grains, which is another important component of a heart-healthy diet. Whole grains are composed of the entire kernel—the bran, germ and endosperm—and are an important source of antioxidants, fiber, B vitamins, vitamin E, magnesium, iron and numerous other vitamins, minerals and phytonutrients, all of which play an important role in disease prevention. Whole grains may be eaten whole, cracked, split or ground and can also be milled into flour used to make breads, cereals and other foods. There are many whole grain choices to suit anyone’s tastes—popular options include barley, brown rice, quinoa, bulgur, millet, wheat berry, whole rye, whole wheat and oatmeal. If a food label states that the package contains whole grain, the “whole grain” part of the food inside the package is required to have virtually the same proportions of bran, germ and endosperm as the harvested kernel does before it is processed. (For more on whole grains,

A

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Snack Food & Wholesale Bakery - February 2011

Whole grains really do love you back. Unfortunately, Americans are consuming far too few of them. check out the Ingredient Technology article in this issue). Findings from a number of scientific studies illustrate the beneficial role whole grains play in heart health. A recent study published in the October issue of American Journal of Clinical Nutrition show that consuming three servings of whole grain foods daily led to a significant decrease in blood pressure among middle-aged adults. Because high blood pressure is a significant risk factor for heart disease, reducing blood pressure with the help of whole grains can lead to a longer, healthier life. Further evidence of the protective effect of whole grain consumption came through via findings published in the research journal Circulation in May 2010. Researchers found that a diet rich in whole grains and bran may lower the risk of overall death and death from heart disease in women with diabetes. Bran intake was specifically associated with a lower risk of death from heart disease, even after accounting for known risk factors such as physical activity and tobacco use. While this is just a small sampling of the wealth of research out there, it’s clear that whole grains really do love you back. Unfortunately, Americans are consuming far too few of them. While the United States Department of Agriculture’s (USDA)

Judi Adams, president, Grain Foods Foundation and the Wheat Foods Council

MyPyramid recommends that people consume three 1-oz. servings of whole grains daily for a healthy diet, several surveys, including data from the Journal of the American Dietetic Association, indicate that most American adults and children are only including one serving or less of whole grains in their daily diets. In fact, the Dietary Guidelines for Americans Committee found that 95% of Americans are not getting their recommended three daily servings of whole grains. Even though much of the research about grains and heart health focuses on whole grains, enriched grains are now getting their due as well. Enriched grains are fortified with the nutrient folic acid, which is popularly known for the prevention of some birth defects, but recent research published in the January 2011 issue of American Journal of Clinical Nutrition links the folic acid found in enriched grains to a healthy heart. Compared to much larger amounts, the amount of folic acid currently added to enriched grains such as white bread, pasta, cereal and tortillas was found to be optimal for lowering homocysteine levels. Homocysteine is an amino acid found in your body and some research suggests that higher homocysteine levels can actually increase the risk of heart disease, meaning enriched grains may also play a role in taking care of your heart. So, what are you waiting for? This is American Heart Month: Share the love! With so many delicious grainy choices, start thinking of the ways you can incorporate more whole grains into loved ones’ daily diets (as well as your own!). Your healthy, happy heart will thank you for it. SF&WB www.snackandbakery.com

Ingredient Technology Whole Grains

Not Half, but Whole Grains What exactly are whole grains? Why are they dubbed ‘healthy’ and which foods incorporate them? Here’s what several sources say about whole grains, why they’re in so much demand and how they are impacting the food industry. Lauren R. Hartman, Editor-in-Chief

hole grains are cereal grains that contain germ, endosperm and bran, in contrast to refined grains, which retain only the endosperm. Whole grains can generally be sprouted while refined grains generally will not sprout. They are a natural source of protein as well as a source of carbohydrates and are made into many different kinds of foods. The difference between whole grains and processed flours is that whole grains are made from the whole kernels of grain, both the inside part of the grain and the outer covering. Processed flours remove this outer covering, which affords a lighter texture and taste to baked goods but removes a lot of the nutrition and fiber. Whole grains are also in big demand from consumers, mainly because the new proposed U.S. Dietary Guidelines recommend eating more of them. Study data reported in the American Journal of Clinical Nutrition shows that eating three servings of whole grain foods daily might reduce the risk of cardiovascular disease in healthy, middle-aged adults, mainly by lowering blood pressure. The report also says the blood pressure reductions could lower the incidence of coronary artery disease and stroke by about 15% and 25%, respectively.

W

The fiber is key Consumers are searching for healthier food options and that’s not gone unnoticed by food makers. What do food manufacturers have to say about consumers going whole hog on whole grains? Plenty. For example, SK Food International, Fargo, N.D., which markets precooked amaranth and quinoa flakes, crimson red

Photo courtesy of SK Food International

corn whole and flour, organic brown and white rice whole grain and flour, organic rye and barley grains and flour, millet, sorghum grains and organic flour versions, says that there can be some challenges bakers and snack producers face when formulating and working with whole grains. But these can be beat with SK Food’s help in determining the percentage/ratio of the whole grain and type to be added. “We work with research and development on formulations based on desired finished product,” says Jennifer Tesch, sales and marketing director at SK Food. “For example, instead of a whole amaranth seed, perhaps a precooked amaranth flake may be better suited for a particular application,” she says. SK Food’s products can be used to make tortillas, flatbreads, crackers, tortilla chips, granola bars, cereals and breads. They can be easily incorporated into formulation in form of the grain, flour, flake and more. Its new certified-organic rice products in its line of identity-preserved ingredients come in brown and white versions of grain, meal or flour and in short, medium and long varieties. Specialty types such as basmati, red and black are also available. The strong demand for organic products as well as gluten-free products prompted SK Food to add rice products

to its diversified ingredient line. “We have been better able to serve our customers by offering more organic products that are gluten-free; rice was just a natural fit for that niche,” notes Tesch. With an expected 25% annual growth rate over the next four years for gluten-free products, she says SK Food was pleased to add another glutenfree ingredient to its already established gluten-free line of beans, grains, seeds, flours and meals. The company’s identity-preserved, certified-organic and conventional nonGMO Crimson Red Corn is a hybrid with two unique qualities; one of which is the colored alerone. Other varieties’ color is in the seed coat, which causes the corn to lose its color during food processing. This Crimson Red Corn has a clear seed coat with the color in the alerone, allowing the red color to remain in tact through processing. The other special feature is the corn’s gametophyte gene, which prevents cross contamination of other types of corn. This is very beneficial to prevent GMO contamination, SK Food explains. The gametophyte gene within the corn does not allow other types, or species, of corn to pollinate it. Product applications include, but are not limited to, snack foods, tortilla chips, soft tortillas, flours and meals. Tesch says SK Food’s quinoa and amaranth flakes are custom milled from heirloom grains and are gluten-free and kosher. Amaranth and quinoa are both commonly known as “supergrains,” each touting high levels of protein, in addition to many other health benefits. “Our precooked flakes are very healthy, whole grain products that easily incorporate into many food applications,” she notes. Applications include, but are not Continued on page 50

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Ingredient Technology Continued from page 48

limited to, cereals, tortillas, snack foods, baby food, flatbreads, baking mixes and energy bars.

Must taste good and look familiar Dave Kovacic, director of technical service at Bay State Milling, Quincy, Mass., says that many people are embracing healthy lifestyle habits, particularly with regards to food. “Whole grain baked goods are viewed as healthy and have found a place in our daily meals,” he says. The whole grain wheat and rye products offered by his company work in many applications, but typically find wider use in yeast-leavened products, such as pan and variety breads, hard and soft rolls, bagels, pizza and crackers. “The biggest challenge bakers face when incorporating whole grains into baked goods is maintaining products that not only taste good but look and feel familiar to the consumer, all at a price point that doesn’t discourage consumption,” Kovacic says. “We understand the challenges of incorporating current trends through continuous improvement and innovation. Customers rely on our extensive technical knowledge to optimize their formulas and manufacturing processes, utilizing the best principles and practices of the industry.” Bay State Milling offers whole grain solutions for bakers in both wheat and rye, traditional whole wheat flour, milled from high-protein Hard Red Spring wheat or fine, medium and coarse granulations. All of them offer whole grain nutrition. Whole wheat flour can also be milled from soft red or white wheat, or graham flour. Both of these flours are now available in an extra fine granulation and are milled from white wheat. Whole grain wheat is also available in various crushed, flaked and cracked varieties. Whole grain rye, often referred to as rye meal, also comes in fine, medium and coarse granulations. “Although wheat and whole wheat flours have been around forever, they have

been getting much more attention with the recommendation to consume more whole grains under the new proposed U.S. Dietary Guidelines,” Kovacic adds. “Literally, hundreds of whole grain products have been introduced this year alone.” In the past few years, bakers have been taking things out of breads, buns and other yeast-leavened products, he reports. “We have reduced or removed fats, particularly saturated and trans fats, cholesterol and sugar. Where possible, dough conditioners and additives have been removed or replaced to provide cleaner labels.” Despite recommendations to consume at least three servings of whole grains per day though, he points out that most consumers in this nation eat far less, according to studies. “One approach is to introduce whole grains in small increments,” he says.

Sorghum for gluten-free foods Lesser known though very important sorghum, a grain, forage or sugar crop, is a high-energy, drought-tolerant crop and is among the most efficient in the conversion of solar energy and use of water. Because of its wide uses and adaptation, “sorghum is one of the really indispensable crops” required for the survival of humankind because sorghum grain is used primarily for livestock feed and in a growing number of ethanol plants.

Photo courtesy of United Sorghum

Sorghum produces the same amount of ethanol per bushel as comparable feedstocks but uses one-third less water. In the livestock market, sorghum is used in the poultry, beef and pork industries. Stems and foliage are used for green chop, hay, silage and pasture.

But it has recently appeared in food products in the United States for use in gluten-free food products. Sorghum is an excellent substitute for wheat for those who cannot tolerate gluten, according to the United Sorghum Checkoff Program (USCP), Lubbock, Texas, a national organization that collects funds and promotes and researches sorghum. USCP is working to overcome the decline in sorghum acres and production, and works to improve the profitability of the sorghum industry through research, promotion and information. It says that sorghum is used to make both leavened and unleavened breads. In Sahelian, Africa, it’s also primarily used in couscous. It can be steamed or popped and is consumed as a fresh vegetable in some areas of the world. “ADM recently announced the availability of a whole grain white sorghum flour for use in the commercial baking industry,” reports Virgil Small, executive director of the USCP. “Numerous new products with sorghum as a gluten-free alternative whole grain flour are available via the Internet, while few wholesale products are currently available in supermarkets.” Small says that work at Texas A&M University, the U.S. Department of Agriculture/ARS and Kansas State University has shown that whole grain white sorghum flour works well in many applications, including pancakes, snack cakes, crackers, pasta and whole grain baked products. “Sorghum flour is cost-effective and has a very mellow neutral flavor and color,” he says. “The trend toward eating whole grain products is increasing. Consumers with celiac are forced to eat a glutenfree diet, and there are very few whole grain options for these consumers. Sorghum offers a very cost-effective whole grain solution to the glutenfree market.” Small says one challenge with sorghum is that it works well as a flour in most baked products, except leavened breads. “Like all non-wheat flour, a foaming agent is needed to formulate good breads and cakes,” he explains. “The flavor and texture of propContinued on page 52

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Ingredient Technology Continued from page 50

Photo courtesy of SunOpta Grains and Foods Group

erly milled sorghum flour is very similar to wheat flour. The Sorghum Checkoff is funding research at TAMU, KSU, UNL and USDA/ARS to prove the health benefits of sorghum flour and to develop a formula for commercial applications.”

Corn and whole wheat products For snacks, cereals and baked goods, Cargill’s MaizeWise whole grain corn products can help customers deliver whole grain nutrition in their products, says Christine Cerkvenik, commercial manager for Cargill Corn Milling, Wayzata, Minn. MaizeWise products include whole grain corn meal, whole grain corn flour and whole grain masa flour. These solutions work best with extruded cereals and snacks because they are easy to incorporate into existing or new formulations due to a proprietary production process that results in an ingredient with very consistent quality, Cervenik says. Cargill’s Horizon Milling and Cargill Photo courtesy of Cargill Corn Milling

Bakery Category’s WheatSelect white spring whole wheat is made from select wheat varieties that optimize key baking characteristics such as volume and mixing and processing tolerances to deliver superior baking performance in a wide variety of applications. “The product performs well in bread, buns, bagels, tortillas, pizza crust, pasta, cookies, crackers, brownies, breakfast breads, pancakes and waffles, snacks and cereal bars—all while maintaining great taste and without the bitter off-notes of traditional whole wheat,” says Kimberly Keller, marketing manager at Horizon Milling and Cargill Bakery Category, Wayzata, Minn.

Like other companies, Cargill sees that consumers are increasingly asking for benefits like whole grain, as well as increased fiber and other wholesome food solutions related to digestive health, Cerkvenik points out. “With heightened awareness around healthy diets, regulatory bodies globally are beginning to mandate certain nutritional standards for foods sold to children,” she says. “Food manufacturers are responding by reformulating their products to make them healthier. Whole grain is one solution.” She agrees that there are key challenges that bakers and snack producers face when working with whole grains, such as a short shelf life, the potential for operational issues if the ingredient is variable or inconsistent going into their food production processes and reformulation efforts and the dollars spent if the product isn’t a drop-in direct replacement in an existing formula. “Through a proprietary technology, we are able to extend the shelf life of our whole grain products significantly,” she adds. “Through our corn origination program, we have a consistent supply of corn that allows us in turn to produce a consistent product. MaizeWise whole grain corn products can be a direct replacement for existing ingredients, which allows producers to easily reformulate in pursuit of meeting Dietary Guidelines for whole grain.” Horizon’s technical service experts work side-by-side with bakers to help ensure formulation changes meet product performance expectations, says Keller. “WheatSelect white spring whole wheat flour features an optimal granulation size for versatile baking performance while preserving whole grain nutrients and taste.”

Must be functional and high-quality SunOpta Grains and Foods Group, Hope, Minn., supplies a variety of organic and non-GMO corn ingredients, including corn flour, corn bran, corn cones, corn meal, polenta, pre-gelled corn flour and corn grit. They can be made into flaking grits for the production of cereals, popcorn meals for extruded cereals, snacks and puffed

products; corn flours for baking, pasta and confectionery purposes; and pre-gelled corn flour for thickening characteristics. For extruding, baking and flaking applications, they have a consistent and specific particle size and are a natural fiber choice for cereal and bakery products, says Kristy Johnson, marketing coordinator. “Specific corn varietals can be selected for specific product needs. SunOpta’s senior food scientist Ilan Weiss says that consumer trends are impacting these products in terms of value. “The economic crisis of the past two years has made consumers focus on where their dollars are being spent,” Weiss says. “Consumers are demanding the same quality with more functionality or benefits for all of their food choices. We see consumers willing to pay more for products they perceive and believe will give them more benefits that regular food items.” Weiss says organic and natural product categories show no signs of slowing down. “The growth curve has slowed from the breakneck speed of the past 10 years, but growth still remains strong. The rise of the ‘green’ movement has added to the growth in this category too. Additionally, consumers are being more cognizant of the foods they are putting into their bodies.” Fiber also remains a strong trend, Weiss says. “As consumers continue to try to lose weight while not sacrificing the feeling of being full, fiber use will grow. The health benefits of fiber continue to be highlighted by food manufacturers but lack of a clear, consistent message has added to consumer confusion. Specifically, marketing messages need to be clarified for the differences between soluble and insoluble fiber, purContinued on page 54

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Ingredient Technology Continued from page 52

ported health benefits for cardiovascular health, diabetes, weight management and others.” But the broad functional/added health benefits category covers several items, including whole grains. “Similar to fiber, whole grains continue to grow as an ingredient and marketing tool for food manufacturers,” Weiss says. “Most breakfast cereal manufacturers have completely switched to using whole grains. Advances in flour milling technologies have allowed for whole grain flours to approach the same functionality that white flour once could only provide.” Consumer confusion regarding whole grain usage and benefits is similar to that of fiber. “This leaves the responsibility on the food manufacturer for conveying a positive message for both of these ingredients,” says Weiss. But thankfully, consumers are more informed on everything from “good” fats versus “bad” fats, botanical

extracts, nutraceutical supplements and superfruits to name a few, according to Weiss. “Foods are being viewed as part of the entire health picture rather than strictly an energy source. This is challenging food manufacturers to respond to new trends and ingredients at an increasingly faster pace. R&D cycles have been cut to get products to market sooner than the competition.” Functional challenges in adding fiber and whole grains to products can be substantial. “The key is to maintain sensory acceptability while incorporating these ingredients,” Weiss adds. “The products made with whole grains or added fiber must look appealing and taste good, too. Newer fiber products and advances in whole grain milling technology have made formulating these products much easier. Working with suppliers of these ingredients is now the norm as collaboration allows for products to get to market faster.”

But with consumers demanding that industries across the board become more sustainable, there are more challenges. “Couple these demands with the new age of Facebook, Twitter and all the other online content, and you have the need to ‘talk-the-talk’ and ‘walk-the-walk,’” admits Weiss. “Sophisticated consumers today will be able to figure out what is really going on over the ‘official’ company press releases.”

Cocoa copiers Whole grains aren’t new to Briess Malt & Ingredients Co., Chilton, Wis. Twenty years ago, Briess introduced a line of whole grain, pregelatinized ingredients for use in snacks and baked goods. Since then, Briess has since added lines of malt and roasted grain ingredients. Most of them are whole grain. Its new line of CocoaPlus cocoa replacers are whole grain ingredients made from Continued on page 56

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Ingredient Technology Continued from page 54

darkly roasted grains that mimic the flavor, color and functionality of cocoa. The ingredients are made from the whole kernel and milled without streaming off any shaft. As a result, they maintain natural fiber, reduced fat and caffeine-free benefits. They are used to partially replace cocoa particu-

larly in snacks and baked goods. Launched at IBIE 2010, CocoaPlus is said to be an economical alternative to cocoa, which is beneficial now considering the current state of the cocoa market, notes Judie Giebel, technical services representative. Giebel says the line includes substitutes

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Photo courtesy of Briess Malt & Ingredients Co.

for both natural and black cocoa. “We’re finding that the natural cocoa replacers work very well in light-colored brownies and cake products,” she says. “The dark cocoa replacer works well in devil’s food cake and cookie products. That means manufacturers of dark-colored brownies, cakes and cake mixes, breakfast pastries and black wafer cookies could realize cost savings by substituting 25-50% of the cocoa with CocoaPlus. We work very closely with manufacturers to help determine the amount of cocoa replacer to use for maximum cost effectiveness.”

Corn flour with high fiber

G i sorghum Grain h originated i i t d iin AAfrica f i centuries t i ago andd iis known as one of the world’s oldest grains. It can be used to make breads, cookies, muffins, tortillas and much more. Sorghum has numerous nutritional benefits including high levels of antioxidants and polyphenols. American sorghum flour is tannin-free and has a light color and neutral flavor, making it ideal for use in many foods. For more information about sorghum flour suppliers and applications visit www.sorghumcheckoff.com

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National Starch Food Innovation provides Hi-maize whole grain corn flour, which offers functional nutritional benefits, such as high fiber, vitamin A antioxidant and folic acid levels and a long shelf life. Described by the Bridgewater, N.J.-based company as having the highest dietary fiber content of any whole grain flour on the market, Hi-maize whole grain corn flour is made from a specialty hybrid high-amylose corn that provides a dietary fiber content of 30-33% per 100 g., nearly triple the level delivered by whole grain wheat flour and whole grain oats. Hi-maize whole grain flour contains resistant starch, a naturally occurring form of fiber found in legumes, seeds and partially milled grains that in recent studies, has been shown to have a significant impact on satiety. A proprietary dry milling process extends the shelf life of the product to twice the shelf life found in a typical whole grain, the company says, and it also contains

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Ingredient Technology

North Dakota Excellence Organically

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Photo courtesy of National Starch Food Innovation

antioxidants comparable to levels provided in blueberries, nearly three times the vitamin A and one-and-a-half times the folic acid available in traditional whole grain sources while delivering fewer calories. The corn flour can boost the functional benefits for baked goods, cereals and snacks by adding crunch to flaked and extruded cereals, adding a crusty texture to hard rolls and artisan breads, high fiber and great eating qualities to whole grain cookies and cakes and a golden color and extra crunch to battered and breaded foods. “Hi-maize whole grain makes it easier to formulate high fiber and whole grains into most low-moisture foods,” says Mike Klacik, senior director of nutrition at National Starch. “It is especially valuable in the formulation of white- or light-colored foods because it is a white, bland cornstarch that easily replaces flour. It contains 60% dietary fiber and is being utilized to boost the fiber content of whole grain foods. Adds Rhonda Witwer, senior business development manager, nutrition, food manufacturers who incorporate Hi-maize whole grain corn flour into their formulations have an opportunity to make a range of label claims, including 100% whole grain, a “good source” or “excellent source” of fiber, high levels of antioxidants, vitamin A and folic acid, as well as lower calorie label statements. “New and proprietary HealthFocus International/National Starch consumer research indicates that 55% of American primary grocery shoppers think that whole grain is an extremely or very important label claim on food packages (approximately the same level as two years ago),” she says. “Bakers and producers are focusing on incorporating whole grain, dietary fiber and resistant-starch ingredients that differentiate their healthier products from their standard (refined) foods.”

• outstanding mixing characteristics • high absorption • consistent quality Organic Flours: • Dakota Maid Organic Spring Wheat Flours • Dakota Maid Organic Whole Wheat Flours The North Dakota Mill’s organic flours are the premium quality flours for today’s discriminating bakers. With exceptional mixing and baking characteristics, North Dakota Mill’s organic flours will tolerate almost any baking demand. Our organic flours deliver for a variety of breads and are available in bulk or 50- and 100- pound bags.

Adding grains as accents Today, many customers want to see whole grains not only inside the bread but also use it as a topping, observes Trey Muller-Thym, vice president of Thymly Products, Inc., Colora, Md. “After many of our bread bakers started to release their products, it seemed to spark interest with the snack industries,” he adds. Thymly found that within the chip market, many customers liked to use grains not only visually but also to add taste and a rich, toasted flavor. “Lately, the trend is turning to adding accent Continued on page 58

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Call 1-800-538-7721 to discover the difference. www.ndmill.com

Ingredient Technology Continued from page 57

grains to help make the grains stand out more in finished products and add a natural taste.” “The one seed we feel really compliments the whole grain initiative is the heart-healthy Chia seed, which allows the body to better process Omega-3.”

Photo courtesy of Thymly Products, Inc.

Muller-Thym says that his firm finds that whole grains can work well in baked goods as long as the right technology is behind the product. “The industry in which we have seen the biggest growth would be hearth-baked bread and the snack industry,” he says.

New at Thymly is a mix of whole grains that gives a hearty grain look and taste. “We are currently doing this through grind size and toasting or malting of whole grains,” he adds. One obstacle he notices that bakers face is that the U.S. Food and Drug Administration is reluctant to give a clear definition to the term whole grain. “This makes it hard for the baker to design a product that truly embraces the term whole grain,” he says. “Our R&D team often solves the protein problem through the addition protein through vital wheat gluten, but we have also seen problems solved through the introduction of enzyme. In regards to a clear definition, we hope that our request along with unified organizations from groups like the grain console will force the FDA into giving us a better understanding.”

Could be for snacks, too At ADM Milling, whole wheat flours are available in course, medium and fine granulations, all with different protein levels. The company’s Kansas Diamond white whole wheat flour has a mild flavor and smooth texture similar to white refined flours, but provides the nutritional benefits of whole grains. Nick Weigel, director of technical services at the Overland Park, Kan.-based company says that in 2010, ADM Milling introduced its whole grain white sorghum flour for gluten-free and multigrain applications. Weigel observes that different companies have positioned whole grains based on the type of application, target market and overall marketing strategy. “Some applications are better suited for a ‘made with whole grains’ approach, while others are able to be formulated as 100% whole grain

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Ingredient Technology Photo courtesy of ADM

products,” he points out. “Certain target markets (i.e. kids) may only embrace a gradual transition to whole grains. Whole grain flours like Kansas Diamond have made it possible to introduce higher levels of whole grains into mainstream product segments that have traditionally used refined white flours.” Kansas Diamond extra-fine white whole wheat flour helps food manufacturers introduce whole grains into products such as breads, buns and bagels, as well as “unexpected” products such as pizza crusts, tortillas and sweet goods, he says. “Going forward, we see the snack segment as a high potential market for the inclusion of whole grains. Consumers are looking for healthier snacks that are convenient and deliver value.” ADM addresses challenges such whole wheat flours’ coarser, denser product result. Products made with such flour can exhibit a different mouthfeel than those made from

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refined white flour. “This texture issue can be resolved by grinding the white whole wheat flour into an extra fine granulation that is very similar to the particle size of white refined flour,” Weigel says. “And some products may target a coarse, dense profile, some do not. It’s important to remember that other ingredients may need to be incorporated or adjusted.” When it comes to nutrient density and satiety and how they relate to a snack item’s perceived value, whole grains can have an important role to play in product development, he adds. He, too, considers that despite the current emphasis on cost savings, the future of whole grains is bright. “It appears that the whole grain trend will remain at the forefront as consumer awareness regarding health and nutrition

continues to increase. People are starting to understand that balance, moderation and healthy lifestyle habits are the keys to long-term success. Whole grains will be viewed as a key component of a healthy diet.”

And more snacks In addition to providing premium multi-use flours and traditional whole grains, ConAgra Mills furnishes three pillars of innovation in its whole grain portfolio: Ultragrain, Sustagrain and a line of ancient grain flours and blends. Each of the flours brings unique attributes to products and can be used in blends to achieve the optimal flavor, texture and labeling claims for any snack or baked good, says Mike Veal, ConAgra Mills’ vice president of marketing. Continued on page 60

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Ingredient Technology Continued from page 59

Ultragrain is an all-natural whole wheat flour with the taste, texture and appearance of refined white flour, while the ancient grain flour blends, aimed at the snack category, add culinary adventure and an interesting story for the label. New Eagle Mills gluten-free, all-purpose multigrain flour blend is made with a blend of ancient grains for optimum functionality, taste and whole grain nutrition. Sustagrain’s ultrahigh fiber and versatile formats make it a great addition to naturally boost nutrition in a variety of applications. “The snack category is particularly great for innovation because of its size and because consumers already expect, and crave, new flavors and formats in their snacks,” notes Veal. “The key for developers is to understand the needs of their customers and then use ingredients that can deliver appropriately appealing products.” Veal says that some snack categories have been declining recently because of

may need to increase the moisture content to compensate for the moisture absorbed by the additional fiber found in whole grain flours. “They may need to add gluten or alter their dough conditioner profile to carry the additional fiber and maximize volume and be careful not to over mix, which can result in damage to the gluten structure of a dough as well as leading to lower volumes.”

Perfectly grained Photo courtesy of ConAgra Mills

negative consumer perceptions about their healthfulness. Adding whole grains to them can help reverse those trends by giving consumers a certain amount of permission to eat snacks again. “But bakers and food manufacturers know that consumers’ preference for familiar tasting products can’t be ignored,” he points out. He finds that in terms of formulating products using whole grain flours, bakers

New Perfect Grain from West Haven, Conn.-based Watson, Inc., Bakery Ingredients Division, is a blend of micronized, wheat bran and full-fat germ with the same ratio of bran and germ found in whole grain wheat flour. It was developed for use in reconstructed whole wheat doughs to provide a soft, fine-grained whole wheat baked product. Watson uses proprietary processing to convert coarse bran and germ into colloidal particle dimensions. The Perfect Grain blend is then combined with mill-grade flour to mimic the composition of whole wheat flour. The use of reconstructed whole grain wheat flour can result in increased absorption, lighter color and improved volume.

Photo courtesy of Watson, Inc.

Perfect Grain was developed with consumers, nutritionists, dieticians and wellness professionals in mind, with refocused attention on the health benefits of whole grains, says Bill Vertolli, vice president of sales. “We introduced Perfect Grain to help meet these new interests.” Perfect Grain can be added to products that use patent flour, such as breads, rolls, cakes, muffins, pizza crusts, crackers and pretzels—marvirtually any product where a whole grain claim is desired, he says. SF&WB

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Engineering Management

Why Make it Simple? o you ever start your day by causing something to become very complicated when it didn’t need to be? It could be anything from how you go about your morning routine before leaving the house to adjusting the route you take on your drive into work to greeting co-workers when you walk into the office, shop or plant. It’s almost like we wake up some days and say to ourselves, “why make it simple?” The great thing is that if you make any one of these things complicated, it makes everything else around you more complicated. Life is difficult enough—why add to its inherent challenges? The workplace can be a very challenging environment on any given day. Adding our own complications is like mixing a dough with too much salt; it will still somewhat machine, proof and bake and is actually food-safe and edible, but it leaves a really bad taste in your mouth. How do we recognize when we are actually making something more difficult or complicated than it needs to be? This in itself is difficult to answer because our minds are trained to follow through on habits, even bad ones, that some of us don’t even know we are creating. We just get used to scrambling. We are creatures of habit. In the workplace, we are faced with many routine and mundane tasks, exciting and challenging research projects and critical decision points every day. What can we do to improve our thoughts, actions and results as we mull through what is supposed to be another ho-hum day? The answer for me is to become highly organized with methods and tools that make the workday feel more comfortable than it really is.

D

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We are in the electronic age, and there are systems available that can help organize our workload, time schedules and even relationships. Starting with calendars. Whether you’re a PC or Mac fan, your computer has some sort of calendar program. So many people that I know do not utilize this feature. Keeping track of your work life in an electronic calendar format can organize your priority list, keep your appointments, give you notices and point out conflicts where you might have over-committed yourself. Many of these calendar programs will beam right to your mobile phone, so when you make a change in your computer, that change is also recorded in your pocket. When you remember to use this tool, you will not have to remember as much, thus making things simple. Another method is to simplify your todo lists. Again, these can be found in many computer programs, but they can also be managed in a more manual process. The bottom line is that when you remember to write something down, you identify your commitment to that something and set your own deadline so you won’t have to remember all of that data in your brain. So many people think they have memories like steel traps, but in reality, they are rusty. Our brains are not working like they use to because we are distracted and often times overworked. Because of the electronic capabilities, our dependency has caused us to forget even our parents’ phone number, since we haven’t actually dialed it since the invention of the contact list in the cell phone. So write it down; make it simple. If you have an iPhone or one of those Droidy things, there are tools on these devices that when utilized, can make your life simpler. Let’s say you’re out for a walk

Jeff Dearduff [email protected]

on a quiet evening with someone special, thinking about work (because we do), and you have a thought, but nothing to write it down on, try the voice memo. Nobody goes out of the house without their phone, no matter what they’re doing. Learn to use this voice memo feature to record those one/off thoughts. Then you can reach back the next time you are near your calendar or to-do list and document it. This works well for dates you remember or things you need to do. This can also be a huge help in remembering those great inventions that you think about at odd times of the day and night. Also, listening to your own voice is really weird and you might have some fun with it. You can even email your voice message to someone else. Finally, the other function on our phones that’s beneficial is the camera. When you’re working on something that you will need to put back together, or investigating a machine or system problem, or have that component that you can’t quite describe, take a picture and use it in your next steps. You might be saying, why mention this; everybody uses the camera? The fact that everybody has a camera doesn’t mean they receive the full benefits out of it. Sometimes people just don’t think about it. I have found a way to simplify meeting notes in that when I use a white board in a discussion, I take a picture of the notes, sketches and thoughts on the board and then email the pictures to the group. As a result, no one needs to capture the notes on paper. This saves everybody time and provides everyone with consistent, thorough information. These are a few of my favorite things that make my work life simple. Why make it complicated? SF&WB

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Equipment Briefs Heat and Control introduces the CEIA THS 21e metal detector, designed to continuously test and calibrate itself to maintain peak inspection performance. Its one-button sensitivity preview provides an estimate of the size of contaminant material and its easy-to-use auto-learn system accurately scans products in one pass, reducing setup time and inspection errors. It also features an electronic platform for superior stability, a stainless-steel casing and keyboard and conformal coated circuit boards for IP65K washdown. Heat and Control, Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com

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Hinds-Bock’s ring, layer and sheet cake line is a fully automatic, high-volume depositing line designed to increase productivity, decrease labor costs and improve the bottom line. Optional automation modules include a pan oiler, a primary batter depositor or a secondary depositor for swirled, layered batters or fillings, such as fruit, cream cheese, mousse or chocolate. The line is also designed to operate with individual or strapped pans, and is available in single or multiple lanes to meet the production speed requirements of even the largest wholesale bakery. Additional options include positive shutoff spouts, automatic swirling stations, dry ingredient depositors for nuts, chocolate chips, sugar, sprinkles or flakes, or streusel depositors for high-

fat streusel. It also comes with automatic spreading systems for ring cake pans. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com Fritsch presents a new single-strand braiding module derived from its signature pretzel twister, the Multitwist. Similar to hand production, the starting point is a 45-mm-long cylindrical dough string with gripper arms that twist one braid after the other from 90- to 110-g. dough pieces. The single-string braiding features a new tool kit with additional components in the lower machine area. The Continued on page 66

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Snack Food & Wholesale Bakery - February 2011

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If leading edge manufacturing and automation technologies are your priorities, save the date for the food industry’s PREMIER CONFERENCE in 2011.

SAVE the DATE APRIL 3-6, 2011 The Ritz-Carlton, Palm Beach, Florida

WHO SHOULD ATTEND:  O Vice Presidents of Operations  O Plant Managers  O Vice Presidents of Engineering  O Plant Maintenance Managers  O Plant Engineers  O Directors of Engineering  O Owners and Presidents

FEATURED SPEAKERS INCLUDE: Peter Hock, Senior Director of Continuous Improvement, ConAgra Foods; Al Koch, Director of Engineering—Global Biscuit, Kraft Foods Nabisco; Peter Monkeiwicz, Vice President of Operations, Kayem Foods, Inc.; Bob Palczewski, Engineering Director, Celebration Foods; Alex Posada, Project Engineer, Campbell Soup; Diane Wolf, Global Vice President, Safety and Environmental Sustainability, Kraft Foods; Ed Delate, Vice President Global Engineering and Corporate Social Responsibility, Keystone Foods, Peter Takacs, Manager, Quality Assurance. Spoetzl Brewery

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Equipment Briefs Continued from page 64

braider’s capacity at this time amounts to approximately 1,000 pieces per hour. Fritsch USA Cedar Grove, N.J. 973-857-7272 www.fritsch-usa.us Clextral offers a new technology for creating extruded snacks that combines style and crunch with generous dip-handling capacity. Clextral’s processing technology and expertise can craft snacks with specific attributes such as texture, mouthfeel and cell structure to make dipping chips with ridged designs that add structural strength for heavy dipping, or open-celled snacks with a broad shape and light crunch for soft dips. Clextral, Inc. Tampa, Fla. 813-854-4434 www.clextral.com

SF&WBtv

Charles Ross & Son introduces a new bench-top model of its popular line of high-shear rotor/stator mixers. The LCI-V comes with a bevy of standard features, such as a 1 HP variable-speed drive for operation up to 10,000 rpm, 316 stainless-steel wetted parts, four-stator heads, a temperature probe to monitor batch temperatures, a vacuum and jacketed mix vessel, raw material addition ports in cover and controls, including tachometer, timer, speed, power draw and automated raising/lowering. Charles Ross & Son Co. Hauppauge, N.Y. 800-243-7677 www.mixers.com Spiroflow Systems launches a line of CABLEflow tubular cable drag convey-

ors, designed for gentle handling applications installations requiring conveying in multiple planes. They can transfer friable bulk products from single or multiple infeed points to single or multiple discharge points with little or no damage and operate with reduced clearances and running speeds. Meanwhile, the range of DYNAFLOW tubular chain drag conveyors is a mechanical drag conveyor system that operates within the confines of a pipe. The heavy-duty discs are connected by articulated metal links (chains) that equip for heavy-duty applications. The discs can be made from a variety of materials, including steel and cast iron, which enables them to operate at temperatures up to 482oF. Spiroflow Systems, Inc. Monroe, N.C. 704-291-9595 www.spiroflowsystems.com

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Production Technology Depositors

Banking a Deposit Depositors must be dependable, precise and versatile, and bakers demand all of this plus high speeds and few changeovers, without breaking the bank. Lauren R. Hartman, Editor-in-Chief

ven in these uncertain economic times, bakers are searching for equipment they can count on, and they won’t make an investment until they are absolutely convinced it will be worth it. They seek equipment that’s flexible, accurate and fast, and can handle several new product types, textures, viscosities and configurations, without missing a beat.

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Five primary considerations According to Eric Riggle, vice president of Rademaker USA, Inc., Hudson, Ohio, his company must constantly pay attention to five areas when making improvements and advances to its depositing disciplines: fast, flexible, accurate, easy to clean and easy to maintain. “But not every depositor can address each of these areas,” he points out. For this reason, Rademaker produces three different types of depositors, each with its own set of options to provide the right solution for the particular depositing challenge. These five areas are important to customers for a variety of reasons, he explains. “Fillings are generally expensive to purchase and expensive to clean up and wash down the drain. Therefore, the more accurate we can deposit means less product giveaway due to inaccuracies. For example, 500 products per minute at 5 g., excess deposit is 330 lb. per hour. Clients are looking for speed in order to be a low-cost producer.” Typically, a client doesn’t want the depositor to be a bottleneck on a speedy production line. “Time is money,” Riggle adds. “The less time a client spends cleaning and maintaining [equipment], the more time the depositor is in production making sellable product.” To do that, Rademaker matches an

Photo courtesy of Rademaker USA, Inc.

application and requirement to one of its depositing solutions from a “product-first” approach. The company’s three basic depositor designs include a piston depositor, which addresses the budget-minded customer looking for a flexible and accurate system with a reduced initial investment. Piston depositors are generally slower in speed and have more moving parts to clean and maintain than its other equipment offerings. Rademaker’s gearwheel depositor—its top seller—addresses the need for speed and accuracy. “The design of the gearwheel depositor allows for flexibility in depositing spots, strips or continuous ribbons of filling, either onto a dough product or into a container,” he explains. “However, due to the design of the pumps, it’s not suitable for particulates larger than a ¼-in. sq.” He adds that this model is the easiest to clean and maintain in the company’s depositor line with very few moving parts. The gearwheel depositor can also be designed to automatically hinge open for easier access to its entire inner workings, which boosts cleaning and maintenance. The Mohno pump depositor is for those in search of speed, accuracy and flexibility when it comes to a wide range of fillings, he says. “Each lane of a Mohno pump

depositor is individually driven and can be shut off or adjusted per lane. We tie many of these depositors into a no-product/ no-fill system, so that the client doesn’t waste expensive filling or time cleaning up. This machine is extremely gentle on fillings with particulates in it.” Rademaker notices many customers (and manufacturers for that matter) neglect an important part of the depositing equation: nozzles. They work hand in hand with a depositor, which is why Rademaker offers a wide range of nozzles that complement the entire depositing process. These include nozzles with positive rotary or air-assisted shutoff and blow-off capabilities, rise-andfall nozzles and those on travelling depositing bridges. “Each of these is carefully designed based on the depositing requirement and filling type,” Riggle continues. Rademaker’s customers often want to be the low-cost supplier with the highest quality possible. That means the lowestcost supplier generally runs its products faster and more accurately and has the flexibility to go between a variety of products offered. Riggle says a sanitary design is an absolute must and is a feature customers ask for more now than they did a few years back. “Clients specify more sanitation and easier changeovers along with high performance,” he says, “however, a sanitary design is generally not an option to be specified—it’s a must.” Depending on the company size, customers consider the primary cost factor in an equipment purchase to be the return on their investment (ROI), or the long-term cost of ownership, factoring in efficiencies and downtime into the equation. “We Continued on page 70

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Production Technology Continued from page 68

work with these on a case-by-case basis because the application and deposited material has a big impact on what sort of efficiencies, tolerances and weight variances can be achieved.” Riggle says. “Smaller clients or upstart bakeries are generally focusing on the lowest initial investment.” But there haven’t been any purchasing shifts from one machine to another since the economy declined.

‘Thinking outside of the bun’ For Randy Fielding, president of Christy Machine Co., a Freemont, Ohio, custom designer of automatic dispensing, metering and feeding equipment for dry, moist and wet materials, it’s difficult to say what emerging trends are appearing regarding depositors. He doesn’t see too many trends. That’s because Christy’s spot depositing equipment is completely custom-designed using CAD capabilities, says Fielding. “In most cases, our customers come to us with special or proprietary needs that vary with the application and the customer,” Fielding explains. “We solve problems with custom machinery using thinking that’s outside of the bun, if you will. All of our systems are new designs.” He does notice that conveyor speed and application rate requirements are changing. “Companies want machinery to move so fast [online]. One example is about a company that needed a wider deposit than everyone initially determined. We spot deposit and we had to stretch an 18-in. machine into a 19.5-in. machine, which solved cost problems and was shipped out on time.” Christy also designs cohesive material dispensing machines for things from donut sugar to confectionery sugar, as well as oil, powders and food toppings. “We come up with material-dispensing requirements for thousands of applications, such as compound applicators, extrusion coaters, salt dispensing, moist material and dry material—and they’re all custom applications,” he says. “Nearly every machine we ship is customized to fit the user’s specific dispensing or coating situation. So they’re not getting a machine off the shelf that we

must adapt to their needs. Rather, they’re getting a machine configuration specifically designed to fit your dispensing requirements. Engineering is focused on devising and combining the perfect combination of components to meet the exact dispensing needs of our customers,” he says. The company’s mounting options, infeed/outfeed conveyor/depositor systems, fill and/ or recovery systems, special motors and controls all can be applied as a package to fulfill processing specifications. Do customers specify more sanitation features or easier changeovers? Yes, he says. “With regard to sanitation features and the salmonella and food safety issues lately, customers are requesting the USDA specifications. That escalates the cost of machinery and can complicate delivery time and we don’t want to do that; we only do it as it’s requested.”

Sanitation ranks high From where Lance Aasness sits, hygienic designs are an emerging trend in depositing equipment. The company produces servopump fillers designed with sanitation in mind, says Aasness, vice president of sales and marketing at Hinds-Bock Corp. All flat surfaces are angled. Round tubing replaces square, and all overlapping or recessed surfaces have been redesigned, eliminating the pooling of water. “Our sanitary pumps are clean-in-place (CIP) and sanitize themselves,” he points out. “There are fewer parts to clean, and the front cover plates are hinged for rapid sanitation swab testing. The servo-pump fillers are the only machines on the market that offers CIP with hinged front cover plates.” The Bothwell, Wash., company’s equipment can be customized to meet specific hygienic and CIP needs. Its top-selling machines produce mini or portion-controlled products, such as mini-muffins and cupcakes, snack cakes and brownies. The 10-piston Hinds-Bock 10P-01 high-speed mini-products depositor has a compact construction and runs up to 1,000 units per minute. The Hinds-Bock 12P-06 highspeed depositor allows bakers to produce products for the portion-control and mini

Photo courtesty of Hinds-Bock Corp.

markets, while achieving yields typically associated with producing standard-size products. The machines can reduce costs with accurate filling and portion control and can improve payback with versatility, ease of maintenance and operation, easy sanitation and rapid flavor changeover, says Aasness. “It’s important to consider speed, accuracy and machines that are easy to clean,” he says. “They improve payback with versatility, ease of maintenance and operation and rapid flavor changeover. Yet some of the challenges in this market are to design in versatility that’s user-friendly. The versatility to run different products with the same machine and the ability to change the flow and size of the deposit from product to product is important.” Aasness agrees that another critical factor is ROI. “How quickly the return is of the customer’s investment is achieved through labor savings and increased yield,” he says. “The equipment produces product quicker and with features like CIP and rapid changeovers, customers are on to the next product. Accuracy also yields a savings by reducing ingredient waste.” Hinds-Bock also witnessed a shift in what customers purchase. “They are interested in automation to reduce waste and costs associated with labor.” Aasness says. “Automation reduces costs and waste, yielding higher profits. Our customers are result-focused, so they leave the design and technology to us.”

Low- maintenance and precise Fritsch launched the Multifiller, a new depositing/filling unit for the processContinued on page 72

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ing of pasty, flowing filling masses. The continuous-motion system-fills, stripe-fills, spot-fills and surface-fills precise amounts at up to 80 strokes per minute. Every filling nozzle is supplied with product filling by its own pump, with its own drive to improve the range of use, hygiene and efficiency, says Ken Schwenger at Fritsch USA, Cedar Grove, N.J. With integral digital control, a touch panel and an operating terminal, the filling unit is easy to program, and there are 50

Photo courtesy of Fritsch USA

programs for automatic adjustment of the machine. Individual light barriers per row checks the presence of a dough piece. The filling unit receives a potentially free-starting signal from the control of a makeup line. Individual light barriers check the presence of a dough piece. A counter starts the filling pumps according to the distance set. Similar to other companies, Fritsch observes that customers want precise, hygienic systems as well as a moistureresistant, washdown execution. They also want tool-less changeovers and easy-to-clean machine features, which have been incorporated into the Multifiller, says the company. It’s indicating that the new system is maintenance-free, has a hygienic, waterproof, washdown construction and an 85-, 120- or 150-liter-capacity hopper that can be swiveled away for cleaning. Its worm gears and pumps can be removed without tools and all interior spaces can be cleaned with water. Depositing product in six, eight or 10 rows, the system’s filling pump size is approximately 30 mm and spot weight of 20-200 g./filling spot.

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Customers definitely watch the trends Customers don’t want to have to alter recipes to make their depositors work. Reiser noticed a trend of products with large chunks and inclusions, says John McIsaac, vice president of strategic business development at the Canton, Mass.-based company. “Just when we think people have found the biggest chocolate piece or nut, someone comes along with something bigger. We have made design changes to allow these big chunks to flow more easily and maintain their integrity,” he says. Reiser, which offers the Vemag line of equipment, including its top-selling depositor, the Vemag 500, notices that customers not only follow the trends, but in many cases, also start them. “This is especially true among our smaller customers,” observes McIsaac. “A new introduction for us is our ball-forming dripless valve. Our cookie customers told us they wanted the look of an ice cream scoop for the products they sell frozen and refrigerated. We developed a Vemag attachment to allow them to do this. They can produce at a high rate with minimal labor, but the product looks like it was done by hand.” The attachment range shifts to devices that can produce smaller portions at higher rates. This applies to doughs as well as batters and other liquid deposits, McIsaac says. “Hand-held, trigger-actuated depositors are popular. These are often used in appetizer applications where companies need to fill small portions quickly with frequent changeovers. We are also seeing more applications for batter and loose fillings. Formerly the domain of gravity piston fillers, exact-weight depositing is filling a need in order to maintain consistent portioning and margins. For these applications, we have a myriad of dripless valves on the shelf. We also have the capability to customize attachments and machines to the product.” According to McIsaac, no one wants a single machine for a single job, so versatility is king. “Depositors that can run today’s multiple products and easily adapt to tomorrow’s are critical. Another critical factor is sanitation and ease of cleaning. We have always designed for the ready-to-eat world

Photo courtesy of Reiser

with the highest levels of hygiene. Customers recognize this in our machines.” For Reiser, the greatest opportunities for growth in the depositor market lie in toppings. It has designed equipment for slices and icing-type toppings, but is also gearing up capacity for cheese shreds and garnish-type toppings. McIsaac finds that the ability to run multiple products on the same machine is a challenge, but it’s also a great opportunity. “Our customers need to be ready to produce for the changing needs of their customers. We need to be able to supply equipment that can adapt to these needs. It keeps our in-house application engineers jumping.” Customers are also looking for features in forming different and unique shapes with help from quick changeout dies. The Vemag systems are able to make everything from Christmas tree shapes to shamrocks.

The mini market Unifiller Systems Inc., Delta, B.C., also notices the emergence of more single-serving size cupcakes, muffins, mousse cakes and other desserts. These mini products require a different type of depositor. “Consumers also expect to see valueadded and healthier products than ever before,” states Stewart MacPherson, Unifiller’s vice president of sales and marketing. “Some bakers have taken existing products such as muffins, cupcakes and dessert cakes and downsized them to avoid increasing the selling price. But that only saves a portion of the ingredient costs, where labor costs stay the same.” With the extremely rapid increases in ingredient costs in the last year, Unifiller’s

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Production Technology

Photo courtesy of Unifiller Systems Inc.

MacPherson says his firm sees that precise portion control is more critical that ever before. “Whereas plus or minus 1-2% may have been acceptable before, our technology now performs closer to the 1% accuracy target.” Customer support goes hand in hand with these critical factors when purchasing depositing equipment for such applications, he says. “Customer support and customer service is what our world wants and expects, and we offer customer support worldwide 24/7.” The company usually ships emergency spare parts and accessories in the same day, and makes deliveries within

24 hours in most cases. Another primary factor, one of cost, production speed, versatility and precise portion control are mostly what its customers expect. “The greatest growth opportunity in the depositor market for us today is being able to offer working solutions through expertise and knowledge and a fast order turnaround to meet urgent needs,” he adds. “We have introduced computer-controlled depositors in which all adjustments for things like deposit speed, product volume and other information can be selected from a PLC screen. On fully automated depositing lines where multiple depositors are installed, all adjustments can be selected for from one master control panel by product name.”

Testing and support Testing is also something customers now want more of. “They want us to prove what we can do,” says McIsaac. “Seeing is believing. We are averaging more than a

customer per day at our new customer center. Reiser’s bakers and engineers work with our customers to deliver the products that their customers want. The state-of-the-art [customer] facility boasts multiples types of mixers, ovens and all of our machines and attachments. We can demonstrate a certain setup, or customers can work with us to develop new products.” And lest not we forget, customers want depositors that are reliable with service support. Machines should last. “We are always on call if there is an issue,” he adds. “We have technicians stationed around the country if the need arises and have full stock of spare parts for everything we sell.” McIsaac also notices that depositors are being integrated with the rest of a production line. “This means competitors are working together on larger projects. We embrace the trend because it is to the customer’s benefit, and we expect this trend to continue.” SF&WB

COMBI LINE THE BREAD ROLL PLANT THAT GROWS WITH YOUR SUCCESS

With our bread roll plant Combi Line you have the perfect modular assembly system for all kinds of products - round, rounded stamped, flattened, long rolled and folded, etc. Additional components can be easily expanded later on. We look forward to your visit at IBIE! Hall C, Booth 6140 Koenig Bakery Systems Rich Breeswine, National Sales Manager, +1-804-564-3997, [email protected], www.koenig-rex.com

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Corporate Profiles Heat and Control Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com SNAXPO Booth # 513 One call to Heat and Control delivers complete processing, inspection and packaging machinery systems for all types of chips and salty snacks, french fries, bakery products, nuts, taco shells, tostadas and corn tortillas. Heat and Control provides the following: • Raw product unloading, storage, cleaning and sizing • Peelers and inspection conveyors • Washers and blanchers • Sheeters and extruders • Fryer systems and ovens • Heat recovery and pollution controls • Seasoning applicators • Conveyors, accumulation and product distribution • Ishida weighers, snack bagmakers, tray sealers, checkweighers and X-ray inspection • CEIA metal detectors • Control systems and real-time line monitoring • Sales, service, parts and training • Equipment demonstrations • Expertise and customer support since 1950

Arizona Instrument LLC Chandler, Ariz. 800-528-7411 www.azic.com Arizona Instrument LLC develops rapid loss on drying instrumentation to provide reliable moisture measurement results in minutes instead of hours. These versatile instruments improve process efficiency, allowing for an increase in production, as well as provide vital information, which can be used to make adjustments and optimize the quality of baked goods. Rapid loss on drying instrumentation has proven to provide a more desirable method of moisture measurement when compared to traditional loss on drying techniques. It addresses the drawbacks associated with conventional loss on drying while maintaining the ease of application. The reduction in test times increases manufacturing efficiency while reducing energy costs. Additionally, this instrumentation provides real-time moisture measurements to help users optimize moisture measurement methods.

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SK Food International Fargo, N.D. 701-356-4106 www.skfood.com SK Food International supplies a full line of premium quality ingredients, including identitypreserved, certified-organic and conventional non-GMO dry edible beans, grains, seeds, soybeans, brans/germs/fibers, flours/meals, vegetable oils, vinegars, sweeteners, rice products, split/dehulled soybeans and instant powders/flakes. SK Food services its customers’ needs with specialized commodities and processed ingredients. Its organic products are USDAcertified by Quality Assurance International, Inc., and are non-GMO project verified. Through a concentrated effort and determined purpose, SK Food is confident in providing its customers with the best value— quality, service and price—for their ingredient needs with better service, higher-quality products and faster response time.

BluePrint Automation Colonial Heights, Va. 804-520-5400 www.bpa-flexolutions.com BluePrint Automation was founded to provide fully automatic case packers for flexible bags. Since then, it has become a worldwide leader in packaging automation. With 30-plus years in the snack food industry, BPA is a multinational packaging automation company focused on three areas of expertise: • Primary packaging: Sophisticated vision-guided robotics picking individual packaged and unpackaged items for loading into containers or horizontal form/fill/seal machines. • Secondary packaging: Case-and-tray packing solutions for flexible and other toughto-handle packages (i.e. snack bags). Ask about retail-ready packaging. • Complete packaging automation systems: Turnkey packaging solutions taking total control of packaging lines from the end of processing through palletizing. Backed by thousands of successful installations in more than 30 countries, BluePrint systems are constructed for aroundthe-clock operation and known worldwide for their quick changeover, flexibility, speed and simple design.

ADVERTORIAL

Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com Hinds-Bock Corp. is dedicated to meeting the needs of the baking industry with high-quality piston depositing equipment, pumps, icers/ glazers and cake slicers. The company’s equipment ranges from small tabletop muffin depositing to high-volume industrial lines, including tray and paper cup denesters, pan oilers, large intermediate hoppers, dry ingredient depositors for toppings, servodriven conveyors and PLC controls. In addition, Hinds-Bock manufactures servo-driven pump fillers for high-speed depositing and spreading of product, servopiston depositors for automatic depositing and spreading of icings, fruits, batters and sauces, standardized and custom piston filling and depositing machines and systems, piston transfer pumps, heated or cooled machines, hopper agitation, diving, traveling or orbital spout movement and pressure-fed machines for extremely viscous products.

Archer Daniels Midland Co. Decatur, Ill. 800-637-5843 www.adm.com Archer Daniels Midland Company (ADM) connects the harvest to the home and transforms crops into products that serve customers’ vital needs for food and energy. Today, ADM is one of the leading agricultural processors in the world. ADM prides itself on sourcing the highestquality commodity goods available. Its global workforce of 29,000 employees and more than 240 processing plants worldwide convert corn, oil seeds, cocoa, wheat and other crops into food, fuel and industrial materials that are used by consumers and businesses around the world every day. In addition, its customers benefit from ADM’s unrivaled logistical network. Its premier crop origination and transportation network connects crops and markets in more than 60 countries. This logistical infrastructure allows ADM to efficiently and profitably serve thousands of customers.

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Corporate Profiles North Dakota Mill & Elevator Grand Forks, N.D. 800-538-7721 www.ndmill.com Moen Industries Samta Fe Springs, Calif. 800-423-4747 www.moenindustries.com For more than 40 years, Moen Industries has been and continues to be a leader in the design and manufacture of quality corrugated box formers, tray formers and sealing equipment, specializing in Bliss box designs. Moen equipment is ruggedly built and proven to withstand the rigors of high-volume, multishift operations. Its history in the design and quality of corrugated packaging equipment is recognized in numerous industries by major corporations including, Colgate-Palmolive, ConAgra Foods, Procter & Gamble, The Quaker Oats Co., Ocean Spray Cranberries, H.J. Heinz, Nestlé Waters North America, Burlington Coat Factory, Daisy Brand, Baxter Healthcare, Unilever Corp., Ashland-Valvoline, BP Lubricants, The Scotts Co., PrestoneHoneywell, The Dial Corp., Tropicana, U.S. Gypsum, Macy’s and more.

Caravan Ingredients Lenexa, Kan. 800-669-4092 www.caravaningredients.com Caravan Ingredients is a leader in the finest quality bakery and food ingredients. For more than 100 years, it has consistently offered the baking and food ingredient industry fresh thinking, quality and innovative products in combination with an unparalleled level of technical support. Caravan Ingredients provides an extensive product portfolio, including food ingredients, fortification such as vitamin and mineral premixes, bakery emulsifiers, polymer additives, flour additives and specialty blending equipment. Caravan Ingredients also strives to provide its customers with new ideas, breakthrough products and an unprecedented level of service. Caravan Ingredients has an international network through its parent company, CSM, which is the largest supplier of bakery ingredients and products worldwide and the global market leader in lactic acid and lactic acid derivatives. Also, Caravan Ingredients is the largest supplier of folic-acid enrichments worldwide.

The North Dakota Mill and Elevator Association started on Oct. 22, 1922 as a value-added market for wheat produced in North Dakota. Today, there are seven milling units, a terminal elevator and a packing warehouse designed to prepare bagged products for shipment, all located in Grand Forks, N.D., and paid for by operating profits. Together, these units produce and ship out 36,000 cwt of milled products a day and more than 13,500 cwt of food-grade brad and wheat middlings a day. In addition, the mill cleans, processes and mills more than 80,000 bushels of top-quality North Dakota wheat a day. Plus, the Mill adds value to 23 million bushels of spring and durum wheat on an annual basis. The Mill has an organic certification for processing organic wheat products. The terminal elevator maintains a capacity of 4.3 bushels of wheat. It also blends, cleans and transfers wheat to six milling units and provides wheat storage to farmers, country elevators and government agencies.

Blue Diamond Growers Sacramento, Calif. 916-446-8500 www.bluediamond.com Blue Diamond Growers, established in 1910, is the world’s largest processor and marketer of almonds. One-hundred years of working together has created valuable partnerships and cultivated strong customer relationships, enhancing its capability to work with its customers to create successful new products using Blue Diamond almonds. Blue Diamond is known for quality and service in more than 90 countries. Its versatile almonds add nutritional benefits, texture and flavor to a variety of food products, and are available in many forms, including sliced, diced, slivered, pasted, powdered or buttered for confectionery, bakery, dairy and snacking applications. In addition, its manufacturing facility is peanut-free.

AIB International Manhattan, Kan. 785-537-4750 www.aibonline.org

Ashworth Bros., Inc. Winchester, Va. 800-682-4594 www.ashworth.com

AIB International provides food safety audit and education services worldwide to the food manufacturing and distribution industry and its suppliers, including finished foods and beverages products, ingredients, fresh produce, packaging production and distribution facilities. Audit services include AIB’s GMP inspection, accredited certification body for BRC, SQF 2000 and FSSC 2000, HACCP accreditation, OSHA, AIB Gold Standard, customer and quality system audits. AIB International’s School of Baking offers a full array of education products in baking science and technology, including its renowned 16-week residential program. School of Baking education and food safety education are offered through public seminars, consulting, training audits, webinars and distance learning. Research and technical services include ongoing and contracted bakery research, product evaluation, ingredient testing, audits and food-labeling services.

Ashworth Bros., Inc. is the only conveyor belt company that manufactures both metal and plastic belting for low-tension and stacker spirals, offering customers the best solution for their specific requirements. Ashworth also offers a comprehensive line of straight running and turn curve belts. With more than 60 years of creating the future of conveyor belts, Ashworth continues to lead the market with the most conveyor belt patents in the food processing and material handling industries. The Spiral Conveyor System, used in freezers, coolers, proofers and ovens, is one of Ashworth’s many inventions that is a global industry standard. Other inventions include the Metal Turn-Curve conveyor belt, the Spiral Grid Belt and the CB5 Baking Band and Cleatrac, which provides extremely tight transfers. Companies around the world depend on Ashworth’s quality products, reliable customer service and innovative solutions to maximize throughput and minimize lifecycle costs. Continued on page 76

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Corporate Profiles

California Raisin Marketing Board Fresno, Calif. 559-248-0287 www.loveyourraisins.com The California Raisin Marketing Board (CRMB) represents the nearly 3,500 raisin farmers in California. The Board’s mission is to conduct marketing activities, crop and nutrition research and conduct events designed to increase overall raisin consumption. A key part of that mission is directly related to the baking industry, as grain-based foods are the single largest user of California raisins. The CRMB initiated and now manages the annual America’s Best Raisin Bread Contest, which is open to all student, artisan and commercial bakers nationwide. Students interested in participating in this year’s America’s Best Raisin Bread Contest are to submit entries by May 14; entries from professional bakers are due Aug. 1. The preliminary judging will occur in September and the final bake-off will take place Oct. 13-15.

Formers International Houston, Texas 800-468-5224 www.formers.com/info SNAXPO Booth # 400 For more than 35 years, Formers International has been the packaging industry leader in patented form/fill/seal engineering and manufacturing. Manufactured with lightweight materials, the SteelLyte and UltraLyte assemblies weigh 25-50% less than conventional bag forming assemblies, and when coupled with the patented EZ Align engineering, make for safe, easy, no-tool assemble. All formers are designed to meet or exceed your machine manufacturer’s specifications and are guaranteed to produce flawless bags and maintain superior tracking. Formers’ highly experienced sales and engineering staff ensures that your former fits your machine every time. Formers International is the FFS experts, and knows that perfect bags move products. That’s why it has earned a reputation of innovation and integrity since 1975.

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Remco Products Zionsville, Ind. 317-876-9856 www.remcoproducts.com A family-owned business since 1985, Remco Products developed 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 cross-contamination issues, Remco has taken the approach of proactive product development to help companies comply with stringent HACCP regulations and guidelines. Remco’s color-coded tools are made from FDA-compliant materials and are ISO-certified, providing the ultimate step in quality assurance and safety for the various industries. Remco’s wide selection of products includes polypropylene shovels, scoops, scrapers, kart tubs and mixing paddles, in addition to a line of color-coded metal detectable products. Remco also offers the Vikan hygiene system of brooms, brushes, squeegees, pails and handles.

Commercial Creamery Co. Spokane, Wash. 800-541-0850 www.cheesepowder.com SNAXPO Booth # 316 Commercial Creamery is well-known for the lengthy steps it takes to deliver delicious, consistent flavor in its dairy-based snack seasonings. After all, it has been doing it for decades. But did you know it also makes non-dairy snack seasonings? If you can think of it, Commercial Creamery can make it. Imagine Thai sweet chili, balsamic vinegar and caramelized onion, or even twisted lime jalapeño. Anything is possible. Once you have selected a flavor, Commercial Creamery goes to great lengths to ensure consistency every time. Commercial Creamery also makes Cheese Crumbettes, which have the appearance of cheese crumbs, contain the flavor and aroma of toasted cheese and are designed to withstand high baking temperatures. These shelf-stable cheese pieces are made from cheese and designed with your baked goods in mind. Call today for a sample.

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Sensient Colors Inc. St. Louis, Mo. 800-325-8110 www.sensientfoodcolors.com As a leading worldwide color supplier, Sensient Food Colors continues to define the future of the food and beverage industry through superior capabilities, creative formulations and extraordinary insight into what strengthens and protects brands. Sensient combines color expertise and advanced science with secure sourcing to deliver customized, healthy and safe solutions for the baking and snack markets, as well as beverage, dairy, confection, processed food and pet food. Sensient’s natural color solution, Fusion Precise Natural Colors, is at the forefront of the natural, label-friendly ingredient trend. With preservative-free and GMO-free options available, this unique, fully customizable natural color line is characterized by proven consistency and stability while delivering an extensive color spectrum and ultimate flexibility. Sensient Food Colors–The bold difference in your brand.

Unifiller Systems Inc. Vancouver, Canada 888-733-8444 www.unifiller.com Unifiller is considered to be one of the world leaders and manufacturers of depositors, pumps, cake finishing and custom bakery production lines. The design philosophy is “simple yet elegant” and “perfection is finally attained when there is nothing left that can be taken away. An example of this might be to find a better solution of reducing the number of adjustment controls from say two or three down to only one,” says Stewart Macpherson, vice president of sales and marketing. “As equipment designers and manufacturers, we at Unifiller are in a privileged position in the baking industry, and are very aware of consumer trends as they are evolving. By becoming a partner with our customers in the earliest stages of new product development enables us to provide better solutions using machines with proven technology that is both practical and versatile,” Macpherson says.

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Corporate Profiles Cablevey Conveyors Oskaloosa, Iowa 641-673-8451 www.cablevey.com SNAXPO Booth # 318-B Cablevey Conveyors, a family-owned company founded in 1971, was primarily created to convey grain and seed for the agriculture industry. Today, Cablevey engineers and builds high-quality industrial conveying systems for food processing, coffee, pet food, cereal, tea, chemical, plastic, paper, wastewater, petrochemical, wood, soap, paper, pulp and wood industries. In fact, the Cablevey industrial division conveys approximately 500 different products for the top-tier food processors globally and other Fortune 500 companies. All systems utilize cable and disc technology that gently moves products through an enclosed tube without the use of air at convey speeds averaging 100 ft. per minute. This means that coffee, nuts, snack foods, cereal, flakes, powders, pellets, shavings, crumbles, granules, fluff and dust can all be handled with ease. Numerous layouts are available using multiple inlets and discharge points that can be customized to your specifications.

Pcdata East Granby, Conn. 860-844-1086 www.pcdatainc.com Pcdata is a global leader in logistics automation for industrial bakeries. With more than 400 systems installed in more than 30 countries, including more than 75 in the United States, pcdata is second to none in its ability to service the industrial baking industry. Its mission statement is clear: To be the global leader of distribution optimization solutions and services for the industrial baking industry. The company was founded in 1988 with global headquarters located in The Netherlands. Pcdata prides on its ability to review, evaluate and invent flexible, effective solutions to improve the distribution side of your bakery. Its field-proven products allow bakers to eliminate delivery errors, track and trace products from production to delivery, reduce “unaccounted for” situations, eliminate paper, administration and human errors from the distribution process and reduce overall distribution costs by as much as 30%.

Key Technology Walla Walla, WA 509-529-2161 www.key.net Key Technology is a leading designer and manufacturer of electro-optical inspection and sorting systems, specialized conveying systems and processing equipment for snack food manufacturers and wholesale bakeries. Based on the principles of innovation, reliability and superior customer service, Key develops next-generation solutions that help producers improve food safety and product quality while increasing yields and reducing operating costs. Key’s newest product–Horizon–is a horizontal motion conveyor that features a unique maintenance-free mechanical drive. Offering gentle, quiet and sanitary horizontal motion conveying, Horizon is designed for fragile and seasoned products. Its drive is powerful and efficient and is capable of moving product at speeds up to 42 ft. per minute on a single continuous conveyor up to 100 ft. long.

United Sorghum Checkoff Program Lubbock, Texas 877-643-8727 www.sorghumcheckoff.com The Sorghum Checkoff is a farmer-funded organization dedicated to the improvement of the sorghum industry through research, promotion and information. Sorghum is a healthy, gluten-free, whole grain that provides many nutritional benefits. The sorghum plant is very high in fiber, iron and protein. Some sorghum is high in antioxidants, which are believed to help lower the risk of cancer, diabetes, heart disease and some neurological diseases. In addition, the wax surrounding the sorghum grain contains compounds called policosanols that may have an impact on human cardiac health. A non-transgenic grain, sorghum is grown from traditional hybrid seeds and does not contain traits gained through biotechnology. There are many opportunities for sorghum as a healthy, gluten-free food option.

Reiser Canton, Mass. 781-821-1290 www.reiser.com Reiser supplies a variety of Vemag dough dividing, portioning, depositing and sheeting equipment for all types of bakery applications and production requirements. The Vemag is an incredibly versatile machine that provides the highest levels of portioning accuracy, speed and product quality. The Vemag dough divider adds versatility to every production line and is perfect for all types of breads, buns, rolls and English muffins. The Vemag produces uniformly spaced dough portions onto the conveyor, eliminating doubles and downtime. And because it does not require mineral oil, bakers can save thousands of dollars annually. The Vemag also is easily adjustable to consistently and accurately produce a range of exactweight portions, dough absorptions and crumb structures. In addition, the Vemag can be 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 are needed. The Vemag is also the perfect solution for extruding smooth sheets of fats, doughs and batters.

Klüber Lubrication North America L.P. Londonderry, N.H. 603-647-4104 www.klubersolutions.com/baking Klüber Lubrication, a worldwide manufacturer of specialty lubricants, has long been on the cutting edge of lubricant technology. For more than 75 years, Klüber has been committed to providing tribological solutions for its customers by manufacturing and supplying specialty lubricants for extreme applications. With hundreds of specialty lubricants in its lineup, Klüber can provide a solution that works specifically for you. All Klüber H1 food-grade lubricants conform to National Science Foundation, U.S. Department of Agriculture and U.S. Food and Drug Administration requirements so taste and quality are never compromised. Whether it’s for chains and gears, rolling bearings, hydraulic systems or others, your equipment will have greater protection from wear, corrosion and friction. Continued on page 78

www.snackandbakery.com

ADVERTORIAL

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Continued from page 77 78

Corporate Profiles Christy Machine Co. Fremont, Ohio 888-332-6451 www.christymachine.com For five decades, Christy has solved material dispensing requirements in thousands of applications. As a result, it has earned a worldwide reputation for quality machines that work with reliability. Along with this recognition, Christy has become experts in the top and surface coating fields, and can solve your coating process problems, too. Nearly every machine shipped from the Christy factory is customized to fit the user’s specific dispensing or coating situation. Thus, when you order a Christy machine, you’re not getting a machine off the shelf that you must adapt to your needs. Rather, you are getting a machine configuration specifically designed to fit your dispensing requirements. Mounting options, in-feed/out-feed conveyor/depositor systems, fill and/ or recovery systems, special motors and controls, and more all can be applied in package form to fulfill processing specifications. Interchangeable dispensing shafts are available for each machine to accommodate various uses. Christy also uses a videotape-equipped laboratory for sample dispensing runs.

Moline Machinery LLC Duluth, Minn. 800-767-5734 www.moline.com Moline Machinery LLC is a leading manufacturer of industrial baking equipment based in the United States since 1945. From sheeting lines to donut production systems, rotary cutters to make-up tooling, Moline has the answer to your specific production needs. Its commitment to quality and service is well known in the industry. The new LIBRA sheeters and fryers provide high-volume production in efficient, easy-to-maintain platforms. Rotary cutters designed to customer specifications are precision-machined for quality cutting with fast turnaround times. Moline also offers a wide range of make-up tooling such as cutter-pickers for donuts and bagels, curling attachments for sweet rolls and flavored breads and plows and depositors for enrobed, hand-held sandwiches or appetizers. For flexible, efficient equipment and excellent service, look no further. Moline—profit from our experience.

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Wire Belt Company of America Londonderry, N.H. 603-644-2500 www.wirebelt.com 21st Century Grain Processing Kansas City, Mo. 816-994-7600 www.21stcenturygrain.com 21st Century Grain Processing provides grainbased ingredient solutions and innovative ideas that are custom designed to meet consumer and market needs. Already a leader in wheat, oats and corn, the company now offers unique capabilities in custom-designed coated whole grains and granola clusters with enhanced texture, flavor bursts and fortification to build a targeted nutritional profile. Whole grain-based ingredients form the basis for the next new leading market product. 21st Century Grain Processing also provides integrated milling and processing techniques to help exceed expectations, delivering what you need precisely when you need it—whole grains, wheat, corn, oats, custom-coated grains and clusters. Custom ingredients—innovative ideas. It’s our promise to you and we make good on it everyday.

Evans Food Group, Ltd. Chicago, Ill. 866-254-7400 www.evansfood.com SNAXPO Booth # 504 Founded in 1947, Evans Food Group has grown to be the largest producer of pork rinds and cracklins in the world, operating facilities in Illinois, Texas, Ohio, California and Mexico. Part of what makes Evans unique is that it is one of the few producers in the industry to manufacture its own pellets and produce the finest quality pork rinds and cracklins. Evans pellets are created using a unique one-step process that guarantees the product freshness is maintained throughout the entire process. Evans utilizes the years of staff experience to help its customers create programs that guarantee success in the market. From innovative package design, unique marketing and promotional activities and innovative merchandising tools to logistics management, Evans has the experience and dedication needed to help your business flourish. Evans is your choice for the highestquality, best-tasting products provided with unprecedented service and reliability.

ADVERTORIAL

Wire Belt Company of America is a leading manufacturer of open-mesh stainless steel conveyor belts, keeping lines running for more than 60 years. A fourth-generation familyowned company, Wire Belt continues to raise the bar on customer support, satisfaction and on-time delivery. In 2010, Wire Belt’s on-timeto-promised ship date was 99.77%. Wire Belt offers many styles and specifications of conveyor belts to suit specific applications, including processes where product coating, drainage and liquid or air circulation are factors. Made of high-quality stainless steel, Wire Belt’s latest conveyor belt innovation, 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 on your system. CompactGrid’s 70% open area makes it the perfect solution for cooling freshly baked or freshly fried products in high-volume, highthroughput processes. Wire Belt’s entire line of Flat-Flex belting products and CompactGrid are accepted by the USDA NSF/ANSI/3-A hygiene standards.

TNA North America Inc. Coppell, Texas 972-462-6500 www.tnasolutions.com SNAXPO Booth # 401 tna is a supplier of integrated processing and packaging solutions, which deliver simplicity, flexibility and optimum performance to the world’s leading food manufacturers. tna can offer solutions in numerous sectors, including snacks and baking, such as: • tna roflo 3 series of transfer and distribution solutions minimize breakages or loss of flavors and eliminate the risk of cross contamination. • tna intelli-flav OMS 2 on-machine seasoning solutions ensure optimum flavor dispersion and consistent coverage. • tna’s robag 3c vertical form/fill/seal (VFFS) baggers pack at speeds up to 150 bags per minute, reducing waste and minimizing environmental impact. Headquartered in Sydney, Australia, tna boasts a 200-strong team of employees, operating from 24 offices around the world.

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Snack Food Today Herr’s Wheat Pretzels Named 125 Best Foods for Men Herr’s Whole Grain Honey Wheat Pretzels were named one of “The 125 Best Foods for Men” by Men’s Health Magazine in its November 2010 issue. “The 125 Best Foods for Men” is a list of brand-name all-stars that men can add to their grocery list. Men’s Health Magazine rated hundreds of products to find the healthiest, tastiest foods for men. This low-fat snack is made with healthful whole grain wheat, contains 0 g. of trans fat and comes in a 3- or 10-oz. bag. These and other heart-healthy snacks are produced by regional snack food manufacturer, Herr Foods Inc., based in Nottingham, Pa.

Krunchers! Recalls Jays Original Potato Chips Krunchers! Inc. recalled all of its Jays Original potato chips that were produced out of its Jeffersonville, Ind., headquarters plant. The recall is the result of seasoning containing a milk allergen in an Original potato chip bag; the 12-oz. bags do not display a milk allergen warning. Consumers who purchased Jays Original potato chips are urged to return them to the place of purchase for a full refund. Consumers with questions may contact Krunchers! Inc. at 800233-7125 between 8 a.m. and 5 p.m. EST. The product can be identified by a code in the upper right-hand corner of the bag reading: JAN16CA542011. Krunchers! Inc. notified customers and is in the process of pulling products from retail stores. Nonetheless, 18 cases of Jays Original potato chips were affected. The company is working with the Food & Drug Administration to conduct the recall. No illnesses have been reported. Jays Original potato chips are distributed throughout the Midwest in Ohio, Indiana, Michigan, Wisconsin and Illinois. Krunchers! Inc. is a division of Snyder’s of Hanover, based in Hanover, Pa.

Jack Link’s CEO Named 2010 Entrepreneur of the Year Jack Link, chief executive officer of Jack Link’s Beef Jerky, was named Ernst & Young Entrepreneur Of The Year 2010 Winner in the retail and consumer products category. The award encourages entrepreneurial activity and recognizes leaders and visionaries who demonstrate innovation, financial success and personal commitment as they create and build world-class businesses. Link was recognized for growing Jack Link’s Beef Jerky from a small beef operation in 1986 to the number-one U.S. meat snack brand. Link

www.snackandbakery.com

Super Puffs Hit Up Kids Corner Plum Organics is urging babies to “eat your colors,” with Super Puffs, baby-friendly snacks made with real organic fruits and vegetables and fortified with vitamins and minerals. These wheat-free puffs come in Super Yellows (Banana and Peach), Super Purples (Blueberry and Purple Sweet Potato), Super Reds (Strawberry and Beet), Super Oranges (Mango and Sweet Potato) and Super Greens (Spinach and Apple) varieties. Touted as “super yummy,” these USDA-certified organic snacks come in 100% BPAfree containers that can be recycled or repurposed for storage, arts and crafts and more. They are sold nationwide in Babies “R” Us and Toys “R” Us.

was honored at the Entrepreneur Of The Year gala, which took place on Nov. 13, 2010 in Palm Springs, Calif. The awards show was hosted by talk show host Jay Leno. All Ernst & Young Entrepreneur Of The Year winners were selected by an independent panel of judges from approximately 300 regional award recipients. “This is an amazing experience, and I share it with the entire company,” says Link, who is also chairman of the board of the Minong, Wis.-based jerky and meat snack producer. “Truly, Ernst & Young’s Entrepreneur Of The Year award is the world’s most prestigious business award for entrepreneurs. I am so proud to share this recognition. I feel like I am living the American Dream.”

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EMPLOYMENT

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Snack Food & Wholesale Bakery - February 2011

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EQUIPMENT FOR SALE

S PREVENT PRODUCT RECALL 3 P PRODUCTS, R O D U CTS, 1 SOLUTION Switching to Plastic Pallets ·

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Straighten poorly stacked or tilted loads which can become a safety hazard.

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Exchange finished product from in-house pallets to rental pallets or slip sheets.

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Minimizes the risk of introducing Salmonella, E-coli, Listeria, Allergens, dust, dirt and other contaminants

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BFM® IT! Direct & Indirect fire Tunnel & traveling ovens * Baker Perkins 960 & 970 series * Thermotron * Werner Pleiderer * Peterson * Winkler & more * Grates, Hard plate, Wire Mesh, Band ovens

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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

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EQUIPMENT FOR SALE

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EQUIPMENT FOR SALE

CONSULTING

completely remanufactured tunnel ovens

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Experienced in Rebuilding, Upgrading, Relocation the following Brand Name Equipment: "!+).'/6%.3s!06"AKING2EADCO s4,'REEN!-&7ENER0LEIDERER3POONER6ICAR s7ERNER,EHARAs-IDLE"Y-ARSHALL&-%7ELBUILT s&ISHs4HERMOTRON5NIVERSAL7ILCO s7INKLER#HUBCO4URN+EY!UTOMATION s)NCLUDING#OMPLETE!IR0OLLUTION#ONTROL s%QUIPMENT3ALESAND)NSTALLATIONS s!54/-!4%$02//&%23#/.6%9/23934%-3 s3ASIBs"AKE4ECH3TUART)*7HITEs,ANHAM s0FENING.ORTHlELDs&(3#APWAYs0ULVER3YSTEMS

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. www.snackandbakery.com

Phone:   Fax: 847-288-9709 Website: WWW4AND4#%COM E-mail: CONTACT 4AND4#%COM February 2011 - Snack Food & Wholesale Bakery

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EQUIPMENT FOR SALE

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Snack Food & Wholesale Bakery - February 2011

Out of code / Discounted / Off Grade Overproductions / Retail / Food Service Jon at Wham Foods

954-649-7857 [email protected] www.whamfoods.com

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Ad Index Company Website

Page

Company Website

Page

Company Website

Page

21st Century Grain Processing . . . . . . . . . . 37 www.AllAboutClusters.com

Food Automation & Manufacturing . . . . . . . 65 www.foodautomationconference.com

Package Design & Development Summit . . 41 www.PackageDesignAndDevelopment.com

AC Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 www.achornco.com

FooDesign . . . . . . . . . . . . . . . . . . . . . . . . . . 54 www.foodesign.con

pcdata, inc. . . . . . . . . . . . . . . . . . . . . . . . . . 22 www.pcdatainc.com

ADM Milling . . . . . . . . . . . . . . . . . . . . . . . . . 23 www.adm.com/vegefull

Formers International . . . . . . . . . . . . . . . . . 42 www.formers.com

Powder Solutions. . . . . . . . . . . . . . . . . . . . . 36 www.powder-solutions.com

AIB International . . . . . . . . . . . . . . . . . . . . . 39 www.aibonline.org/schoolofbaking

Grain Millers . . . . . . . . . . . . . . . . . . . . . . . . 51 www.grainmillers.com

Puratos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 www.sensobus.us www.puratos.us

American Bakers . . . . . . . . . . . . . . . . . . . . . 67 www.americanbakers.org American Pie Council . . . . . . . . . . . . . . . . . 49 www.PieCouncil.org Arizona Instrument LLC . . . . . . . . . . . . . . . . 60 www.azic.com Ashworth Bros., Inc. . . . . . . . . . . . . . . . . . IBC www.ashworth.com BEMA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 www.bema.org Blue Diamond Almonds . . . . . . . . . . . . . . . . 35 www.bluediamond.com/industrial BluePrint Automation . . . . . . . . . . . . . . . . . . 43 www.blueprintautomation.com

Heat and Control Inc.. . . . . . . . . . . . . . . . . . 29 www.heatandcontrol.com/s2 Hinds-Bock Corporation . . . . . . . . . . . . . . . 71 www.hinds-bock.com Hixson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 webinars.snackandbakery.com JR Short Milling . . . . . . . . . . . . . . . . . . . . . . 58 www.shortmill.com Key Technology . . . . . . . . . . . . . . . . . . . . . . 66 www.key.net Koenig Bakery Systems . . . . . . . . . . . . . . . 73 www.koenigusa.com

Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC www.reiser.com Remco Products . . . . . . . . . . . . . . . . . . . . . 21 www.remcoproducts.com Rivland Partnership . . . . . . . . . . . . . . . . . . . 25 www.rivland.com Schaaf Technologie GmbH . . . . . . . . . . . . . 44 www.foodextrusion.com Sensient Food Colors . . . . . . . . . . . . . . . . . . 5 www.sensientfoodcolors.com SK Food International . . . . . . . . . . . . . . . . . 45 www.skfood.com

Kwik-Lok . . . . . . . . . . . . . . . . . . . . . . . . . IFC-3 www.kwiklok.com

Spray Dynamics . . . . . . . . . . . . . . . . . . . . . . 8 www.spraydynamics.com

Minsa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 www.minsa.com

Symphony IRI Group . . . . . . . . . . . . . . . . . . 53 www.sigsummit.com

Moen Industries . . . . . . . . . . . . . . . . . . . . . . 38 www.moenindustries.com

TNA North America . . . . . . . . . . . . . . . . . . . 14 www.tnasolutions.com

Christy Machine Company . . . . . . . . . . . . . 63

Moline Machinery LLC . . . . . . . . . . . . . . . . . 59 www.moline.com

UniÀller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 www.uniÀller.com

Commercial Creamery. . . . . . . . . . . . . . . . . 55 www.cheesepowder.com

National Confectioners Association . . . . . . . 61 www.sweetsandsnacks.com

United Sorgham Checkoff Program. . . . . . . 56 www.sorghumcheckoff.com

Evans Food Group, Ltd. . . . . . . . . . . . . . . . . 9 www.evansfood.com

North Dakota Mill . . . . . . . . . . . . . . . . . . . . . 57 www.ndmill.com

Wire Belt Company of America . . . . . . . . . . 11 www.wirebelt.com

Cablevey Conveyors . . . . . . . . . . . . . . . . . . 64 www.cablevey.com California Raisins Marketing Board . . . . . 12-13 www.LoveYourRaisins.com Caravan Ingredients . . . . . . . . . . . . . . . . . . 47 www.caravaningredients.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]

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REPRINTS Jill DeVries E-mail: devriesj@ bnpmedia.com T: (248) 244-1726 CUSTOM MEDIA Jeff Heath E-mail:[email protected] T: (847) 405-4074 LIST RENTAL Postal information contact: Rob Liska at 800-223-2194 x726 [email protected]

PRINT & INTERNET ADVERTISING Jeff Heath E-mail: heathj@ bnpmedia.com T: (847) 405-4074 Barbara Szatko E-mail: [email protected] T: (630) 527-9927 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 Reaching a total qualified circulation of 14,000 copies. Source: Dec 2009 BPA publishers statement.

Also publishers of: Beverage Industry, BrandPackaging, Candy Industry, Dairy Foods, Flexible Packaging, Food & Beverage Packaging, Food Engineering, Food Master, Industria Alimenticia, Meat & Deli Retailer, The National Provisioner, Prepared Foods, Private Label Buyer, Refrigerated & Frozen Foods, Refrigerated & Frozen Foods Retailer

Canada Post Publications Mail Agreement Number 40813549. Canada Postmaster: Send address changes to: Ascend Media, PO Box 456, Niagara Falls, ON L2E 6S8.

February 2011 - Snack Food & Wholesale Bakery

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The Final Word

Re-Learning How to Grocery Shop rocery shopping can be quite a tedious task. First, you have to, what we call in my house, “take inventory,” then create that never-ending grocery list, then clip coupons and then compare prices once you’re inside the store. I almost need a nap just thinking about it. However, grocery shopping doesn’t have to be this long drawn-out process or even one that requires a minimum of two hours’ prep time. According to a study produced by Chicago-based SymphonyIRI Group, many shoppers have already accrued the get-inand-get-out method of grocery shopping. Presented in SymphonyIRI’s Times & Trends report, “The New Path to Purchase: An Escalation of Channel & Consumption Migration,” the study indicates that consumers are re-learning how to grocery shop by visiting a smaller number of stores in fewer trips and spending less money during each trip. “Shoppers won’t enjoy the same financial success as corporations this spring and summer, and their continued search for lower-cost retail channels reflects this,” says John McIndoe, senior vice president of marketing for SymphonyIRI. “In addition to potential pressure on retailer revenues and margins, these trends point to managers having fewer chances to ‘get it right’ with shoppers. If a shopper visits a store and is unhappy with the experience, [he or]

G

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Snack Food & Wholesale Bakery - February 2011

she will quickly go elsewhere.” Grocery remains the dominant channel, with a 98.4% penetration rate, ending June 27, 2010, the study says. However, other channels experienced a decline in penetration points, such as mass merchandise (2.3), convenience (1.9) and drug (0.5). Meanwhile, trip frequency consistently declined nearly 2% in the second quarter of 2010, resulting from a decrease in trips to other channels, such as convenience stores (9%) and mass merchandise (7%) outlets. The exception to this rule is quick trips, or “need-it-now” excursions, which dramatically jumped in the second quarter of 2010. On the other hand, convenience, dollar and drug stores enjoyed significant increases in sales, the report shows, proving that when today’s shoppers want something, they want it now. As a result, retailers are instituting aggressive pricing, merchandising and promotion strategies, while many mass merchandisers are shifting to a super-center format, the study says. Similarly, channels known for their low prices, such as dollar stores, are showing consistent performance improvement. In a study conducted by Harrison Group for Deloitte titled, “The 2010 American Pantry Study: the New Rules of The Shopping Game,” consumers are changing the rules of the game when it comes to grocery shopping, but it’s not

Marina Mayer, executive editor [email protected]

necessarily always about saving money. For instance, 65% of those surveyed don’t feel like they are sacrificing much from switching from brands to private label. In addition, 79% reported feeling smarter about the way they shop, while 93% will remain cautious about their spending, even once the economy improves. “What we continue to witness are consumers creating a whole new rule book and skill set for shopping that’s based on value, not boasting of brands,” says Pat Conroy, vice chairman and U.S. consumer products practice leader for Deloitte LLP, based in New York. “Our analysis has found that personal gratification and a desire to feel smart about what’s going in their carts are trumping brand satisfaction, and that price-consciousness, value orientation and price hunting will remain prevalent for years to come.” To play in the new grocery-shopping game, shoppers are taking advantage of super-saving options, such as coupons or in-store specials, as well as sacrificing by making definitive changes in their buying behavior, switching brands and shopping on a more need-to-shop basis rather than for convenience. In addition, consumers are “taking inventory,” by planning out meals in advance and buying in bulk. Furthermore, 84% of shoppers own and use at least one loyalty card, while 67% of those surveyed have increased their coupon usage through various outlets, such as newspapers (59%), mail (54%), store (53%) and online (41%). When it comes to grocery shopping, it can be as cumbersome as you make it, but re-learning how to shop can be key in saving some time and money and may even allow you to sneak in a nap or two. SF&WB

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