Snack Food & Wholesale Bakery January 2011

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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 Cover Story 14 Happy Anniversary, Gonnella Gonnella Baking Co. celebrates 125 years in the bread baking business, mixing high technology with old world traditions.

Plant Story 24 They ‘Bake’ to Differ Gonnella Baking Co. operates sophisticated baking/manufacturing facilities, including a fresh-bread plant in Aurora, Ill., that produce breads, rolls and more at rates exceeding three million pounds a week.

Special Section 42 IBIE Editor’s Choice

Photos by Vito Palmisano

Find out what hot pieces of equipment and ingredient solutions Snack Food & Wholesale Bakery’s editors named “Editor’s Choice” while walking the halls of IBIE 2010.

Columns 8 | Editor’s Note 2010 was a big year for food issues, food safety and food policy—particularly because food became the subject of new legislation to require increased inspections, says editor-in-chief Lauren R. Hartman. Let’s hope the New Year sees some stricter reinforcements.

60 | The Nutritional Corner In light of National Birth Defects Prevention Month, the Grain Foods Foundation commemorates mandatory folic acid fortification of enriched grains and celebrates the milling and baking industry’s past contributions and continuing commitment to preventing birth defects.

70 | Engineering Management The New Year should be about finding extraordinarily talented people, says contributing columnist Jeff Dearduff, and keeping them engaged for an extended period of time

94 | The Final Word Looking back, 2010 was quite a year, says executive editor Marina Mayer. However, from the looks of how 2011 might turn out, the snack food and wholesale bakery industries should buckle their seatbelts, because they may be an über-fun ride.

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Snack Food & Wholesale Bakery - January 2011

Coming Next Month Snack Food & Wholesale Bakery is proud to announce that Shearer’s Foods Inc., headquartered in Brewster, Ohio, is our 2011 Snack Manufacturer of the Year. Since 1974, Shearer’s has been perfecting the art of snacking, and continues to flourish in a down economy, thanks to its array of quality snacks, including potato chips, pretzels, pork rinds, Tango’s tortilla chips and Shaper’s whole grain chips. Join us as we look inside this blossoming business and take a tour of its new state-of-the-art Massillon, Ohio, facility.

www.snackandbakery.com

Contents Ingredient Technology 34 Packing It In Whether it evokes a feeling of nostalgia, boasts healthful benefits or touts sustainability, many of today’s bakers and snack manufacturers continue to find innovative ways to sell their products through packaging innovations.

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Production, Technology & Product Development Solutions for a Changing Industry. January 2011 Vol. 100 No. 1

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

58 New Products Read about some of the most recently introduced products, including Michael Season’s Kettle-cooked Honey BBQ chips, Wasa Thin & Crispy flatbread crackers, Snyder of Berlin’s Jalapeño-flavored and Movie Theater popcorn and Weight Watchers Coffee Cakes.

Peter Havens Senior Group Publisher [email protected]

Tom Imbordino Group Publisher [email protected]

Jeff Heath Publisher [email protected] 847-405-4074

62 Including it All When it comes to inclusions, bakers and snack producers want it all. That’s why many of today’s ingredient suppliers are developing a host of inclusions that act as the one-stop shop for taste, mouthfeel, functionality and healthy attributes.

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

Marina Mayer Executive Editor

Production Technology

[email protected] 847-405-4008

Patty Catini Art Director

76 Conveying Outside of the Belt Many of today’s manufacturers are ramping up their portfolios with a lineup of belts and conveyors that bring more to the line than just a run-of-the-mill piece of machinery.

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

Suzanne Sarkesian Classified Sales [email protected] 248-786-1692

Jill L. DeVries Corporate Reprint Manager [email protected] 248-244-1726

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

Petra Cady Marketing Manager [email protected] 248-244-6449

Audience Development

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Rita M. Foumia Corporate Strategy Director Kourtney Bell Audience Development Manager Stephanie Hunt Multimedia Specialist Carolyn Alexander Audience Audit Specialist List Rental Postal contact: Rob Liska at 800-223-2194 x.726 [email protected]

Email contact: Shawn Kingston at 800-409-443 x.828 [email protected]

BNP Corporate

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.: $104.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $137.00 USD (includes GST & postage); all other countries: $154.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2010, 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 Bleuchip International, 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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JANUARY 2011 - Snack Food & Wholesale Bakery

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Editor’s Note

Food (Safety)

for Thought ast year—2010—was a big year for food issues, food safety and food policy—particularly because food became the subject of new legislation to require increased inspections both for domestic and foreign foods and to keep them safe from harmful and sometimes deadly pathogens like Salmonella. With recalls of foods such as eggs, romaine lettuce, butter, pet food and peanut butter, it was a very busy year for the Food and Drug Administration. Scientists say that the BP oil disaster in the Gulf of Mexico will likely cause decades of seafood testing for safety purposes. The new $1.4-billion S. 510, or Food Safety Modernization Act, gives the FDA Lauren R. Hartman enhanced [email protected] ity to ensure that the nation’s food is safe, provides the FDA with mandatory recall authority, mandates that the agency increase its frequency of inspections and enables the FDA access to food producer records. It also requires importers to verify the safety of their foreign supplies, and requires businesses that make and process food to have plans in place also designed to prevent adulteration. The legislation requires the food industry help pay for the increase inspections through additional fees. But if our nation’s food safety system was running the way it was supposed to run, this would never have had to be im-

L

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Snack Food & Wholesale Bakery - January 2011

The people in this country can’t risk the chance of someone dropping the ball again because they just don’t care. How many more innocent victims must there be? posed. Though it’s an age-old structure and desperately needed improving, the tragic incidents that have taken place in the last few years should never have occurred if everyone was doing their job. The bipartisan senators released a joint statement after the announcements were released: “With the announcement today, we aim to not just to patch and mend our fragmented food safety system, we hope to reinforce the infrastructure, close the gaps and crate a systematic, risk-based and balanced approach to food safety in the United States.” Why wasn’t this being done in the first place? The food bill will place more emphasis on preventing foodborne illness and will provide new tools to respond to food safety problems. This is all well and good, but situations like the egg scandal this summer should never have happened if the powers in place were doing their jobs. Period.

This is not to say that we in the food industry don’t take pride in our work; there are many great companies, entrepreneurs and others involved in the food industry that do a terrific job and aim to continue to do so for as long as they can. But it seems that a tragedy always has to take place before new legislation is enacted and reinforced because someone or something within the supply chain has dropped the ball. The question is, how long will food safety’s reinforcement honeymoon last? The people in this country can’t risk the chance of someone dropping the ball again because they just don’t care. How many more innocent victims must there be? You have heard all of this before and will again. I’m almost as sick of seeing it online and in print as you are, but I’d rather be sick of seeing this than read about another food safety crisis. SF&WB

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Business Briefs News

Food Companies Back Food Safety Bill any of the food companies that back the food safety bill proposed by Congress have recalled products from stores shelves earlier this year, yet support the tougher regulations proposed in the measure that headed to a vote in the Senate. Large food makers, including those that have faced recent recalls, say the bill provides clear regulations that level the playing field among competitors. When it comes to recalls, most companies will pull unsafe items whether or not the government requires them to do so. Consumer advocate groups credit the companies and others in the industry with helping to make the $1.4-billion measure one of the few bills moving quickly through Congress during the year-end, “lame duck” session that began Nov. 15, 2010. The bill would mandate Food and Drug Administration inspections of facilities with the highest risk of contaminating food once every three years. The measure would also give the government broad power to issue mandatory recalls rather than relying on private companies to act voluntarily. Encouraged by recent outbreaks of food contamination, such as last summer’s recall of 550 million eggs suspected of salmonella contamination, the legislation also includes provisions that would let officials better trace foodborne illnesses to their source. According to a USA Today report, the House of Representatives passed a more stringent bill in July 2009 that would impose registration fees on food processing plants and require more frequent inspections.

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supplier news Central States Industrial launches a new website, www.mixproofs.com, designed to answer questions about how mixproof valve technology works, what applications it’s used for and which valve is best for which application. The site also contains videos explaining how a mixproof valve works and how the valve can be cleaned. Users also can download product data sheets, instruction manuals and spare parts lists or request a quote for a valve customized for their application. LMI Packaging Solutions, Inc. purchased renewable electricity from We Energies, Energy for Tomorrow to offset 100% of the electricity used for its business operations. We Energies is providing electricity generated from renewable energy resources, such as wind, hydro and biomass. In addition, LMI joined the U.S. EPA’s Green Power Partnership, a voluntary program that encourages organizations to buy green power as a way

to reduce the environmental impact from use of electricity. LMI Packaging Solutions is the first U.S.-based heat seal die-cut lidding company to make this commitment. SunOpta Inc. signed definitive agreements to acquire 100% of the outstanding shares of Dahlgren & Co., Inc., an integrated processor and global supplier of confection sunflower seed products, including in-shell and kernel products, roasted sunflower and soy nuts, bird food, hybrid seed and other miscellaneous products, for cash consideration of $44 million, subject to normal post-closing adjustments, plus an earn-out based on pre-determined targets over the next two years. The combination is expected to be synergistic and will create one of the largest confection sunflower businesses in the world, with extensive vertically-integrated operating capabilities via operations in North America and China.

people ENRECO Appoints Director of Operations ENRECO names John Roszak the director of operations for the Newton, Wis.-based flaxseed manufacturing company. Roszak comes to ENRECO with more than 30 years manufacturing experience, including 27 years at Kohler Co., and maintains knowledge and implementation of production management and quality assurance techniques. “We are truly fortunate to have been able to acquire such a talented and experienced individual to oversee our operations,” says Sean Moriarty, president of ENRECO. “His proven ability to implement stringent control processes while fostering a ‘team’ attitude among employ-

ees is just what we were looking for.” Roszak brings expertise with Six Sigma methodology, maintaining an ASQcertified Six Sigma Black Belt and is a Wisconsin Forward Award Examiner. Additionally, he has led teams charged with developing the systems required for ISO/ QS registration.

Ross Names New National Sales Manager Charles Ross & Son appoints Bill Alhofen as national sales manager. Alhofen joined the Hauppauge, N.Y., company in 1986. Prior to

Bill Alhofen

Continued on page 12

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Snack Food & Wholesale Bakery - January 2011

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hen it comes to cocoa for foods, not just any company will do. The experts agree. ADM Cocoa’s knowledge and premium deZaan® cocoa powders exceed expectations every time. We’re devoted to supporting your innovations. For successful products made from the finest ingredients and technical support, ask the experts - ADM Cocoa. Subscriptions and updates to the most recent version of The deZaan ® Cocoa Manual are available at adm.com/cocoamanual.

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people Continued from page 10

joining Ross, he served in the U.S. Air Force, specializing in photograph and imagery interpretation. While in the military, he also pursued a bachelor’s degree in business administration and has since worked in several areas of the business, including inside and outside sales and product management positions. His time will now be spent handling varied general sales management duties as well as working with the company’s extensive network of sales representatives.

ConAgra Foods Names V.P. of Spicetec Division ConAgra Foods names Mark A. Duffy vice president and general manager of Spicetec Flavors & Seasonings, the newly rebranded business under the ConAgra Foods umbrella. Duffy will be responsible for growing the seasonings and flavors busiMark Duffy ness both with key customers and through new business opportunities. Duffy joins the Omaha, Neb., Mark A. Duffy company from Specialized Technology Resources, Inc., where he was president of the quality assurance division. Prior to that, he was president of Griffith Laboratories USA, a food ingredient and flavor systems company. He also maintains extensive consumer foods experience, having served in foodservice sales and marketing leadership roles at The Quaker Oats Co. and Nestlé.

Grain Processing Promotes Lester Grain Processing Corp., based in Muscatine, Iowa, promotes Kevin Lester to director of technical service for the food, pharmaceutical and personal care group. Lester joined the company in 1998 in the quality assurance group where he was manager of analytical services. He transferred to operations in 2006 where he held a variety of leadership roles, most recently as the MALTRIN division superintendent.

Kevin Lester

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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Gonnella Baking Co.’s board of directors are (from left to right) Thomas Mazukelli, treasurer, Nicholas Marcucci, president and Ron Lucchesi, secretary.

(From left to right) Catalino “Cuco” Quirarte, general manager; Frank Puentes, distribution center/logistics manager; Ricardo Baez, president; Evan Jaqua, national tortilla category manager; and Mark Haig, Eastern region category manager helped design and open Don Pancho’s new Halifax, N.C., facility.

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Snack Food & Wholesale Bakery - January 2011

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Happy Anniversary, Gonnella Gonnella Baking Co. celebrates the major milestone of 125 years in the bread baking business, mixing high technology with old world traditions. Once a small basement ‘shop,’ the now-extensive, leading U.S. baker of hearth breads, rolls and fresh-baked/frozen breads and doughs is still family-owned and operated and still takes great pride in its product. Lauren R. Hartman, Editor-in-Chief

A

lessandro Gonnella made his “dough” like many ItalianAmericans: He baked it. He founded Gonnella Baking Co. in 1886 in Chicago, and has enjoyed consistent success ever since. So successful in fact, that this year, the company is celebrating its 125th anniversary in business. And by combining traditional goodness and modern production tech-

niques, Gonnella is ensuring its success for the next 125 years. As the sole employee of his business, Alessandro Gonnella quickly learned his trade of mixing doughs, baking bread, delivering the products and keeping the books for the fledgling neighborhood enterprise. He began making fresh Italian- and French-style specialty breads, and his little bakery began to thrive, just as the large company still does today. Its meager beginnings in a Continued on page 16

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

January 2011 - Snack Food & Wholesale Bakery

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Continued from page 15

tiny basement shop on the Windy City’s De Koven Street when Gonnella churned out a few hundred loaves a week hardly compare to the multi-product, multi-plant, highspeed operations of today (there are currently six production facilities total), which produce roughly three million pounds of product a week. But even after an incredible 125 years, the breads continue to rival the quality of Gonnella’s traditional Old World Italian flair. “We’re planning to celebrate and have some parties, do some things for our employees, the city and our stockholders,” says Ron Lucchesi, company secretary and a director of Gonnella’s board. “Being in business this long is quite an accomplishment.” The event means a great deal to the company, adds Thomas Mazukelli, treasurer and another director of the board. “It is a testament to the hard work of all our employees over the years. Not many companies reach this milestone of 125 years of service.”

Too numerous to mention By 1896, Alessandro Gonnella moved to a larger building and brought his wife, Marianna Marcucci, over from the northern Italian village of Barga. In the early 1900s, his brothers-in-law, Lawrence, Nicholas and Luigi Marcucci, joined him in the United States to assist in the growing business. By 1915, the three brothers moved to a location on Erie Street, which is now the company’s corporate headquarters. Today, Gonnella is still all in the family and is owned by the family descendants, who make hundreds of types of bread—so many, that pages and pages of stockkeeping units fill the company’s catalogs, making it almost impossible for the owners to count all of the SKUs. But the families maintain tight bonds and established traditions that allow the luscious bread to emerge from the ovens with the same quality that Alessandro Gonnella produced in his small, wood-burning oven more than a century ago. “We incorporated in 1923,” notes president Nicholas Marcucci, the third of

the company’s board of directors. “There were seven company principles. Now, we have 150 stockholders, all descendants, so the base of the pyramid is getting a lot bigger, and depending on the family you’re in, you’re either fourth or fifth generation.” The families operate the bakeries much like their grandfathers and great-grandfather did all those years ago, using centuries-old methods to create rustic breads and rolls with a European hearth oven. There are approximately 33 family members who work for the company today. Their breads include Italian, Vienna, French and Tuscan, as well as soft rolls, sub rolls, Kaiser and sandwich rolls, buns and many others, and are available to grocers and restaurants in the Midwest. The company’s route distribution covers Milwaukee to Indianapolis. Gonnella also produces fresh products, including hearth items for grocers, restaurants and contract customers out of its Chicago and Aurora, Ill., locations. It makes fresh-baked frozen breads, rolls, pan breads, ryes in numerous sizes, flavors and shapes, including Traditional and Wheat “families” for distribution to Midwestern in-store bakeries and restaurants. In the 1980s, the company expanded even further, establishing a frozen dough plant in Schaumburg, Ill., which ships in-store bakery and foodservice products throughout the United States. The company also offers a variety of bread crumbs, rolls and

breadsticks for retail sales. It has a national distribution footprint in frozen products and in its contract business. Its overall business consists of one-third in frozen products, one-third in fresh and one-third in contract business. And it has expanded on both coasts over at least the last 20 years. “We started producing frozen dough [today totally some 150 different varieties] in the 1980s,” recalls Nick Marcucci. “That was really the birth of the frozen business,” he says. “We then began expanding our boundaries. Prior to that, we were geographically located in the Chicago market because the fresh product had a one-day shelf life. But the frozen market was our first foray into the national market, and that allowed us to expand our horizons and our sales.” A recently introduced Thaw ‘N Sell bakery solution gives retailers an easy, freshly baked option. “The Thaw ’N Sell program was created out of market demand for retailers who wanted more flexibility,” Tom Mazukelli points out. “The program caters to retailers who don’t have a bakery or chains that don’t have bakeries in every store. Even if they have a bakery, Thaw ‘N Sell helps them rotate stock, offer a wider variety and keep up with demand on busy days. The program also helps us expand distribution to new areas, such as convenient stores, club stores and grocery stores.” Gonnella also has opened a second, Continued on page 18

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S U C C E S S

H O W

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D O U G H

S T O R I E S

V E M AG D I V I D E R

produced a B E T T E R loaf of B R E A D A TRUE STORY: We recently helped out a successful, high-end bread producer. He discovered that his European dividers were wearing out and needed to be replaced. He tested other dividers, but none were able to duplicate the quality of his European and American breads. He was also concerned about the drawbacks of simply buying the same units again – the lack of dividing accuracy, the expense of mineral oil, and the frequent service that the units required. Still, he placed the order. During the long lead time for the new machines, he decided to try our Vemag Dough Divider on his products. Working with one of our on-staff Reiser bakers, this customer was able to equal or exceed the quality on all of his breads. He was absolutely delighted with the Vemag and cancelled his order for the “old-style” European dividers. His plant now runs five Vemag Dough Dividers – all producing the highest quality breads with excellent weight control, no mineral oil, and Reiser service and support just a phone call away.

T H E V E M AG P R E VA I L E D OV E R O L D - S T Y L E E U R O P E A N DI V I D E R S Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com

E q u i p m e n t a n d Te c h n o l o g y f o r t h e B a k e r y I n d u s t r y

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state-of-the-art, frozen products manufacturing facility in 2008, located in Hazle Township, Pa. The 100,000-sq.-ft. operation boasts highly efficient production and warehousing capabilities. “We’re very excited to have the modern Hazle Township facility online,” says Ron Lucchesi, company secretary and another board director. “It allows Gonnella Frozen Products to meet the rising demand for the highest quality frozen dough items for which we are known. We are now centrally located to customers on the Atlantic Sea Board, where Gonnella products have been very well received.” There’s also a fresh-bread production plant in Chicago that produces baguettes and French bread and artisan products, known as Plant Two.

Keeping up with demand To say that business is rising as quickly as Gonnella’s bread is an understatement. “We’re undergoing a resurgence in our brand,” Tom Mazukelli adds. For Chicago bread connoisseurs, the Gonnella name is quite familiar, conjuring up visions of freshly baked, aromatic, crisp-crusted, hearth-baked bread that could be found fresh baked every day of the year. But the six sophisticated and extensive facilities are producing bread that has quickly gained enormous popularity nationwide. “Things over the last five years have become more competitive,” admits Tom Mazukelli. “Consumers have become more health-, cost- and value-conscious, and we are baking fewer product varieties in our frozen division on the store level and see a greater demand for technical support. Demand for Hispanic items has also grown tremendously.” Despite increased demands from customers and consumers, as well as having to face increases in regulations and other issues, the company somehow manages to balance its fast-paced production with staying flexible. “We bring a lot to the table,” points out Michael Lucchesi, vice president of operations, Fresh Division, who took Snack Food & Wholesale Bakery on the tour of the

At a Glance Company: Gonnella Baking Co. Headquarters: Chicago, Ill. Website: www.gonnella.com Plant Size (Aurora location): 60,000-plus sq. ft. Annual revenue: $150-plus million Production lines: Two bread and roll/bun makeup lines feeding one oven Employees (Aurora location): 80 Years in Business: 125 Product list: Hearth-baked breads and rolls, pan-baked breads and rolls, frozen dough, frozen par-baked and fully baked breads, bread crumbs. KEY PERSONNEL: President: Nicholas Marcucci V-P./Dir., Contract Sales: Paul Gonnella V-P., Mktg.: Thomas Marcucci V-P., Prodn.: Mike Lucchesi Treasurer: Thomas Mazukelli Secretary: Ron Lucchesi Aurora facility. “We balance the needs of our customers with our production capacities and run a lot of volume each day at most of the facilities to foresee the needs of our customers. We’re at the leading edge of anything we need to be.” As the world has changed, so has Gonnella. The company is also enlarging its route distribution for fresh-baked/frozen products for both foodservice and retail customers, says Paul Gonnella, vice president of contract sales, and “the oldest” of the fourth-generation of the family. “Some of our retail customers are really taking us on in a big way. But we have been expanding nationally for some time. Our fresh breads are finding a national market, whether for restaurant chains or freshbaked/frozen retail. And we’re working with two of the biggest food distributors in the country. So our Chicagoland distribution base has spread out.” The company has been in the route business a long time, he says. “We have made sure that all of the states around Illinois know Gonnella very well. Now, we’re heading down to Kentucky, Arizona,

Arkansas and several other places. I think we’re also moving into Las Vegas, New Mexico and California. Since I started working in the family business 28 years ago, the growth in the company has been amazing. What we’re doing in terms of expanding our fresh-baked/frozen and frozen dough businesses is great.” Inspected regularly, the 60,000-plus-sq.ft. Aurora plant recently earned a superior rating from the AIB. There are several quality control points located throughout the facility and one Hazard Analysis and Critical Control Points (HACCP) validation. “We’re working toward the GFSI (Global Food Safety Initiative), and one of our plants just became certified in that area,” Mike Lucchesi points out. “Two more plants are working on this as we speak and a third will come online shortly. It’s exceptional that we’re at that level already.” Delivering product six days a week, the five facilities accommodate sustaining orders and can take orders by phone or the Internet. Orders are processed for the next day starting at 4 p.m.

A dedicated team Operating all of the plants, balancing customer demands and daily deliveries and staying competitive with the vast amount of products Gonnella makes every day could be a logistical nightmare for any company. But it works, Mike Lucchesi says. “It’s amazing how we get everything out the door everyday. And we’re in a super-competitive—crazy competitive— market. But there are a lot of foundational building blocks here that employees should have their names carved in. We have a tremendous group of dedicated, loyal employees.” Lots of family members work at the manufacturing sties in Aurora, Schaumburg and at the other plants as well as the downtown Chicago headquarters location. Some of the employees have generations of family who have worked for Gonnella, Mike Lucchesi adds. “It speaks volumes about the company that we inherited from our family. The loyalty is wonderful. Times Continued on page 20

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change and things change, but we’re still a very tight-knit group. I started working here in my teens. We have one gentleman who worked here for 70 years.” While many bakers talk about trends such as different product types hitting the market, Ron Lucchesi says Gonnella has seen many businesses consolidate. “Our customers continue to consolidate,” he says. “There are more and more demands. Now we’re dealing with customers that buy millions of dollars worth of product—that demand and rightly so—to be our partner in this situation.”

Keeping things going The company can also say that it has seen it all. “Just working in the company—it’s inbred in us how important the family business is and how important it is to continue,” Ron Lucchesi explains. “That’s the challenge we have is to grow the business

with the future generations coming up. We’re doing that by making major investments in plants here and in Pennsylvania to be able to compete in the marketplaces we’re in.” Ron Lucchesi, Tom Mazukelli and Nick Marcucci say that over the decades, the original bakery of course has gone from being a “hand operation” to a mechanized one, and then to multiple production production facilities, and that means chal-

lenges. “We face challenges, as any other baker does today, regarding financing, commodity costs and labor—it’s a much more complicated, hard-to-understand business,” says Ron Lucchesi. Sustainabilty plays a role at the company, and it hopes to save energy by changing its plant lighting. It’s also looking at harnessing wind energy at its plant in Hazle Township. Robotics for some of its packaging operations are also being considered, and updated packaging graphics unify the enormous line of items with a contemporary, consistent and unified message. “We hope to expand our frozen dough division and put a facility on the West Coast in the near future,” adds Tom Mazukelli. “We also want to expand our frozen and fresh product lines.” The current economic crisis doesn’t Continued on page 22

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exactly sway the many generations of employees. The ups and downs of the economy haven’t been as much of an issue as the gyrations of the commodity pricing, says Ron Lucchesi. “Over the last 10 years, it has gotten to the point that commodity pricing is totally unpredictable. That has

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really changed the business for us. We’re dealing with things overseas that control the commodity markets–that part of the business has changed dramatically.” Paul Gonnella says it’s sad to see how many of the little bakeries and great restaurants have closed. “But we always remember

that you’re never a big shot here. You do what you have to do for the business, even if that means delivering buns at 3 a.m. in a van to make this as successful as we can.”

The trends The core consumers the company targets have also changed, which is why Gonnella continues to develop a variety of products that appeal to them, such as different types of rolls and breads. “It’s what has taken us nationally,” says Nick Marcucci. “We see a greater demand for quality products and are targeting different ethnic groups with bolito rolls, telera rolls, ciabiatta bread and artisan-type breads,” adds Tom Mazukelli. “Our goal is to make good quality products at a reasonable price. We’re trying to broaden our sales base by giving the consumers what they want. Families are smaller, so they’re looking for smaller package sizes. They’re also looking for healthy-conscious products, so we bake more whole grain loaves of bread. Our top sellers in the fresh group are baguettes and rolls but in the frozen division it’s French and Italian breads, mini French bread and ethnic-style rolls.” What is the family’s secret to keeping it all together? Ron Lucchesi says that each individual has an expertise. “As a whole, all of this bolsters the company to move forward. We’re in this boat together and we succeed together.” Nothing comes easy, adds Tom Mazukelli. Success comes only from hard work and sacrifice. “You get out of the business what you put into it. We have good people and have to invest in the business with updated equipment to become a better manufacturer.” But as the world changes, so do we, says Nick Marcucci. “It’s not our grandfathers’ company. But it has been a gift handed down, and we’re kind of like the stewards now. We’d like to keep it going, and I would love to see it last at least another 50 years.” Paul Gonnella smiles, adding, “My son is 10 years old and recently asked me if he could work in the bakery someday. So we hope things keep on going.” SF&WB

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They ‘Bake’ to Differ Celebrating 125 years in business, Gonnella Baking Co. operates sophisticated baking/ manufacturing facilities that produce breads, rolls and more at rates exceeding three million pounds a week. Join us on a tour of the 80,000-plus-sq.-ft. Aurora, Ill., facility that includes high-tech equipment, superior operating standards and two makeup lines that provide plenty of product to major U.S. companies. Lauren R. Hartman, Editor-in-Chief

hen Gonnella acquired a plant in Aurora, Ill., more than six years ago, it installed new production equipment and overhauled much of the facility, which now produces eight luscious bread varieties—four consistently each day —and assorted bread and bun products. Eight is really a drop in the bucket considering Gonnella’s massive stock-keeping units list. According to Michael Lucchesi, vice president of operations, fresh

W

Continued on page 26

Gonnella’s Aurora plant produces assorted fresh bread and bun products for some of the largest, most popular food companies in the United States. These small loaves were being made for nationally distributed childrens’ meal kits. Photos by Vito Palmisano

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division, the total product list for the entire company is about 14 pages long. “We make close to a thousand SKUs total, but we produce them at the various locations,” he says. Employing 80 people, the Aurora freshproduct plant supplies contract customers, including two of the largest “soup” companies in the country. The plant starts its baking shift at 11 p.m. There are two makeup lines—one for bread and another for buns—that feed a 125-ft.-long tunnel oven. Production starts off with bread-baking and then migrates to producing buns, then back to bread and back to buns. “We change over the product on the lines on a daily basis,” Lucchesi explains. “We have a significant national presence in frozen dough and achieve the same type of presence in fresh-baked items.” Equipment efficiencies and reliability are critical to this large-volume plant, he adds, which can output as much as 12,000 lb. of product an hour. Safety is also of utmost importance, and the company aims to achieve the highest standards in customer safety, including top inspection scores. Inspected regularly, the 80,000-plus-sq.-ft. Aurora plant recently earned a superior rating from AIB. Programmable logic line controls are

Top left, dough is mixed at the front of the line on one of two mixers that accommodate the bread and the bun line. Top right, the formed meal kit buns are automatically scored on the tops after being proofed. Above, dough balls are dusted with flour and are deposited directly into pans.

in place “and the lines can talk to each other,” notes Lucchesi. “The plant was laid out very effectively. It’s very spacious here, compared to some of our smaller, landlocked facilities in the city [of Chicago], so we have a lot of room to operate here.” There are several quality control points located throughout the facility and one Hazardous Analysis Critical Control Point (HACCP). Each line receives daily maintenance and inspection, the latter from a

quality control inspection operator. Delivering product six days a week, the Aurora plant, like the other Gonnella facilities, accommodates sustaining orders and can take orders by phone or the Internet. Orders are processed for the next day starting at 4 p.m. On the morning of Snack Food & Wholesale Bakery’s visit, the bun line was producing aromatic, buttery sandwich rolls for childrens’ meal kits. Continued on page 28

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Mixing, rounding, dusting At the head of the line is a mixing area, equipped with two mixers that accommodate the bread line and the bun line, with one mixer used for each line. In full production, both mixers are used for each line. Located on the outside of the plant are three flour silos that each hold about 100,000 lb. for production of the fresh products, which carry a three-day shelf life but last for as long as 14 days, depending on the item. Minor ingredients are scaled and manually dumped into one of the mixers. Flour and other ingredients are conveyed directly into a scaling (weigh) hopper located above each mixer. The hopper, which can hold 1,200 to 1,300 lb. of dry ingredients, opens directly into the mixers. Water and other liquid ingredients are pumped into the mixers and the dough is then mixed for several minutes. The mixed dough then drops through a “slide” and into a dough pump. The dough then conveys on a long belt to the roll makeup line and heads to a bun divider system. At this point, the line turns at a 90-degree angle and progresses in a long continuous flow into two hoppers leading to the divider. The dough then moves under a set of rounding bars to a flour duster chute that prevents the dough from sticking (the flour dust is re-circulated into the system). Each divider creates four portioned balls of dough at a rate of about 400 pieces per minute. The dough balls are dusted with flour using the zig-zag dusting chute. At this point, if the product is to become a round bun, it’s deposited directly onto a pan. If it’s molded, the dough balls are immediately conveyed to an intermediate (pocket) proofer. After a short resting time, the dough pieces drop out of the proofer pockets and onto a molding board and are then indexed into pans that hold 40 buns each (the amount varies, depending on the size and shape of the bun or other item being made). The large pans continue conveying downstream to the final proofer, which proofs the dough at temperatures of 96-

The buns are baked in a large oven at 400-410ºF for 30 minutes. Times and temperatures vary with the many different fresh products produced at the facility.

98ºF (this also varies with the product being made) for an hour. “This line can produce hamburger, hot dog, sub buns and several other items,” Lucchesi notes. Just prior to proofing, line operators check the rolls for proper pan placement. “If the bun is overlapping or not centered properly in the pan, it’s unacceptable and it’s removed,” he says. After the buns are proofed, they are automatically scored on the top and are conveyed to a staging area. “This gives the buns some time to skin over on a circulating conveyor before they go to the oven,” says Lucchesi. Then, the scored buns make their way into the large oven, which bakes at 400410ºF, for nine to 30 minutes, again depending on the product. “We’re equipped here to use pans or peel boards for certain types of hearth breads,” he continues. In the first stage of the oven, the scores open on the tops of the rolls while a golden-brown crust sets in the second stage of baking and the rolls achieve a warm golden color, or bloom, Lucchesi explains.

Quality control checks After baking, the buns are then automatically de-panned and placed on spiral cooling conveyors where they cool at ambient temperatures for approximately an hour. Meanwhile, the empty pans convey back to the front of the line to be re-circulated into the system. Before the pans are reintroduced into the line, they are tilted and blown off with air to remove any residuals. After cooling, the buns move through

a metal detector system and are bagged in the packaging area. The clear bags are automatically clipped closed with a bread bag clip that incorporates a production code. “A quality control test is performed every hour of production,” says Lucchesi. The buns can also move through a set of indexers and rotary or band slicers as well as orienters if they are to be sliced, Lucchesi says. A quality check is also made at this stage to inspect for any rolls with imperfections. Measurements of the products are also taken to ensure they’re the proper height, weight and size. “This is done every 15 minutes to make sure each product fits into the packaging properly and is made to our and our customers’ requirements to ensure that the customer gets the best possible product,” Lucchesi points out. Just before bagging, a bun stacker groups the buns into multiples. During Snack Food & Wholesale Bakery’s visit, the system placed six buns on top of another six buns for a 12-pack. A final quality control check is made in this area. The clear film bags are then loaded in counts of five into the shipping trays while sensors help control bag pattern feeders that orient the bags of buns for placement into the trays. The trays convey to the shipping area where they’re stacked and loaded onto trucks ready for shipment. The closed-loop system requires that the trays returned from customers be washed in an automatic tray washer before being reused. “The bread line operates almost the same way, and we can place six bags of bread on a tray,” he says. The plant runs Continued on page 30

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Continued from page 28

two shifts, eight hours a day, five days a week. Even though it’s very well established, Gonnella isn’t set in its ways. “We are innovative,” Lucchesi continues. “In terms of our production, there is a lot of innovation in this world-class plant. We’re dealing with some of the biggest food manufacturers in the world and we’re competitive. We win their business because we’re dedicated, compassionate, innovative and high-capacity. A lot of blood, sweat and tears end up culminating at this plant.”

What’s ahead? Aside from adding two new indexers on the bun lines to pick up 1-2% percent of additional throughput, and some packing pattern conveyors, the Aurora facility is still new enough that major equipment changes or additions are not necessary for the foreseeable future. “We upgrade equipment on a continuous basis,” Lucchesi says. “We

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have various new things on the drawing board, and have customers who we’re talking to right now on things that could take us into new levels of production. But at this plant, we’re most concerned with maximizing product throughput, one efficiency at a time. As we expand into different markets, our next big investment could be on the packaging end, in terms of robotic palletizing and getting things ready for shipment without missing a stroke.” As far as the packaging itself goes, the retail packaging recently got a graphic revise, and Gonnella as a company is investigating ‘green’ or sustainable packaging. Other environmental initiatives include adopting more energy-efficient lighting systems and upgrading to more environmentally-friendly motors, Lucchesi says. “We recycle plastics, paperboard, food and other materials. Food that doesn’t make it to end users is reprocessed into animal feed and other things. Used motor oil and oils

used in the systems are sent to recyclers. “We’re a pretty light footprint of an industry. We use a lot of power, but only at optimal times,” he continues. “We don’t operate in the high-energy-use hours and we wind down production at mid-day, so our power profile is ideal. At our other plants, it’s also ideal and our frozen dough plants try to balance out their energy power needs with respect to the community.”

The beat goes on The lines at this facility hum along every day (and night), without missing a beat. That’s the whole idea, says Lucchesi. “If our customer wakes up and doesn’t see his bags of bread delivered to his shop or store, he’s in trouble,” Lucchesi says. “We can’t allow that to happen. We’ve gone through a lot over the years and survived all sorts of circumstances—we even ran out of flour once —but the bread gets out. We have always maintained the operation.” SF&WB

www.snackandbakery.com

Market Trends

Packing It In Form and function both come into play when packaging snack food and bakery products. Now, more than ever, manufacturers are finding ways to reinvent their packaging for multiple purposes beyond just advertising the product within. Jen Roth, contributing writer

or years, that crinkly cupcake wrapper or the familiar pop top on those potato crisp tubes has been the best ways to get a fresh product from the store shelves to consumers’ mouths. But as consumers’ taste buds change, so do packaging initiatives. That’s why manufacturers are now finding new ways to use packaging to not only keep their products fresh, but also deliver them to consumers in innovative fashions. Single-serving size packaging has been present in many snack and bakery categories for years. As consumers look to companies to provide portion control and a portable bite, Boulder County, Colo.based cracker manufacturer 34° has met that need with flair. “We recently introduced a ‘snack-pack’ version of our crackers,” says Craig Lieberman, president. “We received a lot of feed-

F

back from consumers who wanted a smaller size pack of our crackers that they could use for picnics, school lunches, hiking, etc.” The company ensures that all the varieties of its Crispbread crackers are perfectly packaged for maximum enjoyment anytime, anywhere. “We use a moisture-resistant film that allows the product to be refrigerated and used for cheese and deli trays [along with] boxed lunches,” says Lieberman. “We also provide full-color caddies in each case that allows retailers to merchandise the snack-packs at store level, but also encourages them to refill the caddies to cut down on waste.”

Another company getting in on portable-portions packaging is Ralcorp Frozen Bakery Products of Downers Grove, Ill. The manufacturer’s new Krusteaz Mini Pancakes and Waffle Sticks are individually wrapped in microwavable bags, ensuring that the consumer gets a hot breakfast on-the-go. Ralcorp also uses its packaging to boast that each serving of its mini pancakes and

waffle sticks offer 0 g. of trans fat and 16 g. of whole grains. The bags even include the official seal from the Whole Grains Council, making it an easy breakfast choice for busy moms. While packaging a product in a portable structure is one must, American Pop Corn Co. found a way to make its packaging do double duty — literally. The Sioux City, Iowa-based company recently introduced the Insta-Bowl for its Jolly Time popcorn line. “Jolly Time’s new Insta-Bowl is the most innovative item to be introduced to the microwave popcorn category since the 100-calorie and single-serving popping bags,” says Garrett Smith, president. “This popping bag goes from bag to bowl with a simple pull of the string,” Consumers can enjoy the Homemade variety of Jolly Time without getting butter on their knuckles or having to wash a bowl. Likewise, American Pop Corn Co. uses its Jolly Time packaging to evoke a feeling of nostalgia. “The retro image prominently displayed on the front of the Homemade package accurately conveys the flavor profile,” says Garrett. “The image is of a 1950s era, Continued on page 36

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apron-wearing mom holding a big bowl of popcorn and lovingly giving her daughter a smaller bowl.” Garrett also asserts that the photo on the 3- and 6-pack cartons is square with a white border, which is similar to photos of that generation. For other companies such as Rudolph Foods, the resurgence of nostalgic packaging is not lost either. “For decades, not only pork rinds but potato chips and other snack foods, including popcorn, were sold in gift tins or home-delivered tins,” states Mark Singleton, vice president of sales and marketing for the Lima, Ohio-based company. “That went away with the advent of [flexible] film, but over the last several years, we have [seen] a real insurgence in our big pork rind barrels.” The company is also finding that not only does the new packaging look great; it also holds a dual purpose. “Consumers react well to the fact that it is reusable. Consumers can reuse it for something else in their everyday lives,” Singleton says. “They can eat the greattasting pork rinds at a great value and then use the barrel for sprinkler parts [or] dog biscuits. That really appeals to a lot of people.” The company is not ignoring its other packaging for pork rinds. For example, Rudolph Foods’ smaller-portioned bags are always made with clear film, which is a critical component to the company’s packaging design. “[Our consumers] know what they

are looking for, they are very loyal to our product and they know what it looks like, so that’s the reason we want to show consumers what they are buying in the bag,” asserts Singleton. Rudolph Foods also uses packaging to convey the health benefits and unique attributes of its snack product. “Since we do have a surprising health story to tell, we focus on making sure to communicate to our consumers that there are zero carbs in our products,” Singleton says. “Also, you have to communicate the flavor and flavor impact, like we did for our Southern Recipe line. We enhanced the bags and brought them in[to] the 21st century, but still remains true to the Southern heritage and its roots.” Rudolph Foods also calls out to its target market in the design and labeling of its packaging. “Our Pepe’s bag is a great example of that,” says Singleton. “We’ve got Hispanic ingredient statements, we’ve got a Hispanic/Spanish/English back story, and we always make sure and mention chicharrones, which is the Spanish word for pork rinds.” On the other hand, sometimes the introduction of a new product will prompt a manufacturer to redesign its packaging. This holds true for Hostess-owned Merita of Irving, Texas. “In November [2010], Merita made its first major packaging update in more

than three decades when the brand added two more nutritious bread choices to the Merita family of breads,” says Ann Oades, director of premium bread marketing for Hostess Brands. The new Merita Smartwhite and Merita Made With Whole Grain White varieties inspired the company to make such changes. “Our first goal was to create a consistent brand architecture that would allow consumers to more easily see the breadth of product offerings the Merita brand brings to Southern families,” states Oades. “This new brand architecture features a new logo, richer colors and design of the Merita ‘Quality Guarantee.’” As part of the “Quality Guarantee,” Merita included taglines on the front of its packaging to call out the benefits provided by its line of breads. Oades adds that the Merita Smartwhite package totes the tagline, “The Fiber of 100% Whole Wheat,” while the Merita Made With Whole Grain White’s packaging boasts that it contains 8 g. of whole grains per serving. Oades says that this reminds consumers of the added nutrients at-a-glance. Of course, Merita had to keep in mind that many of its loyal consumers might be apprehensive about the changes made to the packaging of their favorite bread. Oades states that in the case of the Merita Old Fashioned and Merita Autumn Grain lines, modifications had to be made with care. As a result, design changes were more tempered. While some companies initiate packaging changes to display health benefits, other companies such as Mars Chocolate North America focus solely on altering packaging to garner more impact on supermarket shelves. “There’s been a trend toward cleaning up packaging graphics and focusing on singular communication,” says Steve Ginsburg, director of strategic brand design for the Hackettstown, N.J.-based company. Ginsburg attributes the less-is-more design trend to the influx of media images presented to the average person on a daily basis, adding to what he calls the “visual noise” consumers are exposed to. Mars Continued on page 38

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Market Trends Continued from page 36

redesigned the packaging thusly, so that its Combos snack can compete on store shelves. “The new packaging features brighter colors and a black arch design at the top, which helps the product stand out on the

shelf,” says Ginsburg. “The description ‘Baked Snacks’ appears just below the Combos brand logo, so consumers will immediately know the origins of the hearty snacks.” The Combos bags also feature large

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photos of the food representing the snack variety contained within, such as a large pizza slice for the Pizzeria Pretzel selection or a Cheddar cheese wedge for the Cheddar Cheese Cracker variety. Keeping in mind the consumer demand for on-the-go packaging, Mars will also be producing the Cheddar Cheese Pretzel, Cheddar Cheese Cracker, Pizzeria Pretzel and variety mix selections in 0.93-oz. snack-size portions starting in May. In addition to its Combos redesign, Mars enhanced the packaging for its Marathon energy and protein bars. “The new packaging clearly identifies nutritional benefits, including callouts for protein, vitamins and minerals, as well as appetizing product photos,” states Ginsburg. He adds that due to the impulsive nature of snack purchases, the package must be seen and understood within seconds in order to be considered for purchase. “The brand’s promise should be instantly recognizable and resonate emotionally without consumers having to read the pack,” Ginsburg says. “This is true whether it’s premium, taste, fun, efficacy or any other value.” Furthermore, Jack Link’s Beef Jerky of Minong, Wis., recognizes the importance of package design for its snack products. “We call out the protein, fat and carbohydrate information on the front of the package, allowing consumers to see product benefit[s] at a glance,” says Jeff LeFever, marketing director. “We recently Continued on page 40

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SAVVY SNACKING

6 grams of protein power

Crave-worthy crunch

Energy that lasts

© 2010 Almond Board of California. All rights reserved.

A natural complement to sweet and savory tastes

A variety of flavor possibilities

3.5 grams of satiating fiber

AND YOU THOUGHT YOU WERE JUST ADDING ALMONDS.

A lot goes in with a little almond. We’re talking 13 essential nutrients to give health-conscious consumers a snack they can feel good about, and feel fulfilled after eating. Then there’s the tasty, satisfying crunch that keeps everyone reaching for handful after heart-healthy handful. Not to mention the natural, lasting energy, global appeal, and unmatched versatility. A snacking success story? We think so. Good news about good fat: U.S. Dietary Guidelines recommend that the majority of your fat intake be unsaturated. One serving of almonds (28g) has 13g of unsaturated fat and only 1g of saturated fat. Scientific evidence suggests, but does not prove, that eating 1.5 ounces per day of most nuts, such as almonds, as part of a diet low in saturated fat and cholesterol may reduce the risk of heart disease.

Market Trends Continued from page 38

updated our back panel to highlight three of the most important pillars of our products: Taste; quality; and nutrition.” These pillars are not the only things consumers want to see when looking at the Jack Link’s snacks; they have also demanded a peek inside the bag. That’s why Jack Link’s added a window to the back of its Nuggets variety foil bags so consumers can view the product they are purchasing, as well as an easypeel film, making the package easier to open. “We’ve innovated a way to maintain the barrier properties, yet now consumers can actually see the

40

Snack Food & Wholesale Bakery - January 2011

premium quality of the Nugget product inside the package,” says LeFever. “A window on our Nugget package was one of our number-one consumer requests, and we were able to make that happen.” The jerky and meat snack producer is also going “green,” by reducing the size and amount of film for its main jerky bags by 25%, LeFever says. “Sustainability emerged several years ago, but continues to be on the top of the minds of customers and consumers,” he adds. “We are constantly searching for ways to reduce our overall packaging material and carbon footprint.” Meanwhile, Inventure Foods of Phoenix, Ariz., is following the sustainability path, evidenced in its new line of packaging for the Boulder Canyon Kettle Chips. “We introduced the first-ever compostable package for the natural food channel last spring when we unveiled a bag made from forestry-certified wood pulp,” states

Steven Sklar, senior vice president of marketing. “The benefit is the obvious direct impact on lightening the amount of trash in landfills throughout the U.S.” Not only will the bag compost quickly, it also alleviates the risk of jeopardizing existing food supplies, unlike bags made from corn- and starch-based contents. This “natural” bag further promotes the ideals of Inventure Foods and the Boulder Canyon line. “As it relates to Boulder Canyon snacks, we feel our packaging fits the brand. It speaks to our customers—consumers who value healthier foods and better-for-you food and lifestyle choices,” says Sklar. Additionally, Pepsico-owned Walkers Potato Crisps of Leicester, England, is making strides in sustainable bag trends. The company uses potato skins, which they already have on hand, and extracts the starch to create its packaging. Walkers plans to launch the bags within the next 18 months and says the new packaging will not rustle quite as much as other biodegradable bags have in the past. From redesign to redevelopment, snacks’ and baked goods’ packaging has experienced an overhaul. Whether it evokes a feeling of nostalgia, boasts healthful benefits or touts sustainability, manufacturers will continue to find innovative ways to sell their products with packaging. SF&WB

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Special Report

IBIE Editor’s Choice Exhibitors at the International Baking Industry Exposition (IBIE) showcased an array of new equipment and ingredient solutions. Check out our picks as Snack Food & Wholesale Bakery’s Editor’s Choice hot items for 2011. Lauren R. Hartman, editor-in-chief, and Marina Mayer, executive editor

You could spend weeks at a show like the International Baking Industry Exposition (IBIE) 2010, held at the Las Vegas Convention Center Sept. 26-29, 2010, and never see it all. No doubt, the show was an unprecedented success. Nearly 20,000 attendees gathered, ready to take their baking businesses to the next level. A variety of companies baked products in live competitions or demonstrated new ingredients and equipment on the show floor, some with an added focus on sustainability and environmental friendliness. The show also experienced a more retail influence, courtesy of the partnership of the Retail Bakers Association (RBA) with BEMA and the American Bakers Association (ABA). That’s why the editors at Snack Food & Wholesale Bakery are sharing their choices of hot, new items from IBIE 2010, ranging from wholesome, fresh, better-for-you ingredients to compact, flexible and efficient equipment. To learn more about these and other exhibiting companies, go to www.bakingexpo. org.

INGREDIENTS Just ‘Nosh ‘em’

Caravan Ingredients introduced a new bakery base to make Nosh’ems, an innovative bakery snack that allows consumers to get wholesome goodness on the run in a portable and tasty way. “The Nosh’em hits on a number of key consumer trends: Portability; convenience;

health; and wellness and allows our customers to offer the consumer a product that fits their changing lifestyle,” says Kerrie Medlicott, vice president of marketing for the Lenexa, Kan.-based company. Hand-held and convenient, Nosh’ems are single-serve, yeast-raised bakery snacks that contain a chewy, moist texture and are an excellent source of Vitamin D, calcium and fiber. Nosh’ems can be created by using Invisible Goodness Natural Base, a 35% base. “The Nosh’em is a new way to snack so it needed a new name,” Medlicott says. “It’s not quite a bar, not quite a muffin, not quite a scone. It’s a tasty, better-for-you snack. You don’t need to feel guilty about enjoying them, so just ‘Nosh’em.’”

Squeezably fresh 10 days after baking Danisco USA launched a new line of bakery enzyme products in the North American market. The enzymes with G+ technology maintain oven-fresh softness, taste and texture in bread for at least 10 days after baking, says the company (which has a corporate location in Copenhagen). Unlike one-type-fits-all enzymes, new POWERFresh bread and POWERFresh Special with G+ technology can be tailored to specific bread applications, including regional specialties, such as ovals, Panettone and brioche “POWERFresh bread with G+ makes good on the promise of bakery enzymes like never before,” says Simon Walley, regional director for Danisco Food Enzymes. “Bread manufacturers can have the best-ever combination of longer-lasting product freshness, resiliency, consistency and cost-effectiveness. POWERFresh is raising the bar.” The longer, fresher shelf life means less waste, fewer product returns, broader distribution opportunities and an enhanced brand image. The patented also eliminates the need to compro-

mise resilience when making bread as soft as possible, Walley explains. Commercial-scale production trials are underway, following an impressive performance of the products in pilot tests. POWERFresh is available in powder and easy-to-dose tablet formats.

Sustainable wheat solutions EcoFlour is more of a “program” or a “system” than just flour alone, relates Niki Larson, publics relations manager at Cargill Food Ingredients and Systems, Wayzata, Minn. Launched by Horizon Milling, a joint venture between Cargill, Inc. and CHS Inc., the flour program is part of the company’s emphasis on growing leaner, greener and healthier. “[The] EcoFlour program combines unique ingredients, origination and supply chain capabilities,” Larson says. “It’s basically a customizable program to grow wheat more sustainably utilizing precision agriculture, thereby producing a more sustainable end product.” The sustainability ingredient program is designed to appeal to eco-conscious bakery consumers with ways precision agriculture can help use fertilizer more efficiently, reducing energy inputs and improving yields. “This [precision agriculture] combines satellite imagery and soil samples to identify the best use of fertilizer on the farmer’s field,” Larson says. “The farmer uses this information to apply nutrients to the crop with precision and only where it is needed. Studies show precision agriculture uses less fertilizer than conventional agriculture, uses less energy and reduces emissions while increasing the amount of wheat grown on the land.” Horizon Milling develops sustainable ingredients to boost product sales, distinguish brands and preserve a brand’s identity by linking the technology to the brand. “We help customers innovate around sustainability,” notes Kyle Marinkovich, marketing manager at Horizon Milling. “With new EcoFlour Continued on page 44

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sustainability solutions, we design customize programs that link the technology and the supply chain from the farmer to the bakery to help customers execute against their sustainability focus areas.” The system was recognized at IBIE 2010 with a B.E.S.T. in Baking award for its contribution to environmental sustainability (check out Snack Food & Wholesale Bakery’s August 2010 IBIE show supplement).

Topping glaze

a successful partial replacer for black cocoa. The two ingredients function at the same replacement rates, up to 25% of the black cocoa in devil’s food cake products, and offer options in label declarations: malted wheat or malted barley. Briess Malt’s caramel-flavored malt extract, for instance, not only helps improve fermentation and browning in raised doughs, but it also offers a special boost of caramel flavor and a hint of color to enhance breads even more. The CBW Sparkling Amber is 100% pure malt extract blends specialty bakery malts, such as Caramel Malt and Munich Malt. Caramel Malt has a sweet, caramel/toffee flavor and Munich Malt has what Briess describes as an intense, malty flavor. Available in liquid and powder forms, the resulting extract delivers all of the functionality of a standard malt extract and is recommended for use at low percentages, from 1-2%, in yeast-raised dough systems. CBW Sparkling Amber benefits breads and dinner rolls as well as pizza crusts, so fewer toppings are needed for flavor enhancement.

natural vanilla bean seeds in a convenient paste form that adds a gourmet touch to various recipes. The powder can be used in dry mixes and liquid or color-sensitive products and as a flavoring for baked goods. Adding a rich, mellow flavor and essence to recipes, Madagasacar Bourbon Pure Vanilla Sugar can be included in products where a hint of vanilla and sweetness are desired. Mexican Pure Vanilla Extract is a creamy, spicy flavor that carries a special affinity for dishes containing chocolate, cinnamon and other warm flavors. Mexican Vanilla Beans are of prime gourmet quality, which bring a deep, tangy character that complements chocolate, cloves and other warm spices. Talking about all of the extracts, which are easy to use in a variety of applications, Nielsen says, “First, it’s purity. Second, it’s user-friendly, as opposed to using essential oil that can be volatile and inconsistent. Third, it comes with our guarantee that it is the best pure flavor on the market today.”

Gluten-free flour International Foods & Ingredients developed Jelfix, a high-quality topping glaze created for fast, high-quality glazing of jams, pastries and fruit fillings. Jelfix glazes dry instantly, are fully air-tight and do not penetrate the pastry confection. Plus, they maintain a soft structure, making them ideal for machine or manual application. “Jelfix is a high-quality, pectin-based topping glaze,” says Shelly Kreml, director of marketing for the Gurnee, Ill.-based company. “Our customers choose Jelfix because it’s fast, easy to use and has a nice, clean taste. When applying Jelfix to a fruit tart, it never masks the taste of the fruit, instead it helps bring out the sweetness of them.”

Natural cocoa replacers, malt extract Briess Malt & Ingredients’ expanded line of natural cocoa replacements include one that can replace up to 25% of the natural cocoa in cakes and brownie products. A new black cocoa replacer called Briess Black Wheat Flour joins a portfolio of the Chilton, Wis.-based company’s Black Cocoa Replacers, which is currently in a variety of foods as

Not just plain, old vanilla

Pure vanilla extracts, such as Madagascar Bourbon and Madagascar Bourbon Pure Vanilla Bean Paste, Powder, Beans and Sugar were showcased by Nielsen-Massey Vanillas International, Waukegan, Ill. Producing the world’s best vanilla is an intricate task, according to Craig Nielsen, chief executive officer. It means extracting the true flavor, aroma and functionality of what nature intended. Nielsen-Massey captures the flavors of nature through its cold-extraction process, which takes three to five weeks to perform. The process gently draws delicate and distinctive flavor from the vanilla beans instead of speeding up the process using heat or pressure. The creamy, sweet, velvety flavor of the Madagascar Bourbon Pure Vanilla Extract is suitable for a wide range of foods ranging from baked goods to sauces and dressings. The bean paste is pure vanilla with

American Key Food Products rolled out its gluten-free King Lion Premium Cassava Flour, which yields a unique natural ingredient that’s an effective, simple replacement for wheat flour in pastries, cakes, cookies, pizza crust, tortillas, foccaccia, burger buns and bread. Derived from cassava root, which is naturally gluten-free, the flour contains superior moisture-retention properties with baking performance characteristics that closely mimic wheat flour in structure, texture and taste of the finished baked goods. Because the flour is the only ingredient needed to replace wheat flour, it greatly simplifies the formulations, production processes, ingredient inventories and ingredient lists. “Bakers can now create high-quality, gluten-free baked goods without complex combinations of flours, starches and hydrocolloids, while presenting a greatly simplified, consumer-friendly ingredient statement on Continued on page 46

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their label,” says Mel Festejo, chief operating officer for the Closter, N.J., company. “This versatile flour delivers excellent taste, texture and moistness in a wide range of mainstream baked products. AKFP also announced the application for a patent for King Lion Premium Cassava Flour and the proprietary manufacturing process developed by the company.”

More gluten-free flour

The skinny on shortenings Reducing saturated fats is on many consumers’ minds. That’s why SansTrans RS39, a reducedsaturated fat shortening from the IOI Group of Loders Croklaan, Channnahon, Ill., offers bakeries the same functionality as traditional shortening, with 30% less saturated fat compared with typical trans-free shortenings, the company reports. Based on its performance, SansTrans RS39 all-purpose shortening avoids problems such as oil migration, excessive spread and weak cookie structure. Available in quantities including 50-lb. cartons and 1,945-lb. bulk totes, the shortening boasts superior eating qualities and can allow for an improved Nutritional Facts label panel and a clean label. “SansTrans RS39 helps reduce saturated fat in baked goods and snack foods,” explains Gerald McNeill, vice president of R&D. “It is blend of palm oil and canola oil and is approximately 35% lower saturated fat that typical palm oil shortenings. It acts as a drop-in solution for saturated fat reduction, retaining all the functionality of regular shortening.” The SansTrans DF Select Series is another new trans-free donut frying shortening that McNeill says is non-hydrogenated and highly stable with a long shelf life. “SansTrans DF Select donut frying fat is also a palm oil-based shortening that’s designed to prevent oil migration and to improve mouthfeel in donuts,” he says. A similar product, SansTrans DF Select 55, contains added soybean oil, and was developed to give the palm oil shortening an odor similar to traditional hydrogenated soybean oil fat, while maintaining high quality and avoiding damage to chocolate and sugar coatings.

ConAgra Mills, Omaha, Neb., introduced Eagle Mills gluten-free, all-purpose multigrain flour. “Eagle Mills sets a new standard for gluten-free ingredients, combining outstanding nutrition, all-purpose functionality and mainstream appeal,” says Mike Veal, vice president of marketing. “Made with a proprietary blend of seven different whole grains, including rice and tapioca flours and corn starch, one serving of this flour provides 24% of the daily recommended value of fiber and whole grain nutrition while delivering the functionality that manufacturers need and the finished product taste, texture and appearance that gluten-sensitive consumers crave.” This flour also is made with a blend of whole ancient grains, including amaranth, quinoa, sorghum, millet and teff, this whole grain, and is designed for sandwich breads, pizza, tortillas, muffins, snacks and coatings. In addition, Eagle Mills flour is certified by the Gluten-free Certification Organization. “A 32 g. slice of bread made with Eagle Mills gluten-free, all-purpose multigrain flour blend has the same fiber as a slice of 100% whole wheat bread, which is 12% of the recommended daily value of fiber,” says Elizabeth Arndt, director of research and development. “This means that product developers can fill the need for better-tasting gluten-free foods with the nutritional benefits and label claims consumers are looking for.”

Grain-based line

Bay State Milling created an extensive array of solutions, developed to satisfy a wide variety of grain-based food ingredients. For example, BakingEssentials includes Bay State Milling’s traditional flour brands and classic mixes, bases and concentrates to support customers’ conventional grain-based and gluten-free food

needs, while its GrainEssentials line offers a host of flours, mixes, bases and concentrates to help customers develop whole grain products. OrganicEssentials provides customers with organically certified flours, mixes, bases and concentrates, and EthnicEssentials consists of flour, mixes, bases and concentrates that help customers develop grain-based food products for a variety of ethnic markets. “There are 112 years of quality and experience behind our products,” says Donna Reiser, marketing specialist for the Quincy, Mass., company. “Our BakingEssentials line includes not only the flour brands that are the core of our business, but also our latest gluten-free offerings. GrainEssentials products address the growing demand for whole grains, including white whole wheat extra fine flour. Customers trust that our OrganicEssentials products are the result of strict adherence to organic standards and close farmer relationships, and we embrace the demand of changing demographics and taste trends with EthnicEssentials. This is a very passionate group, dedicated to helping our partners prosper through our flour and grain blend Essentials offerings.”

Simplifying the baker’s process

Bakers’ Best Vital-G from Chesterfield, Mo.based AB Mauri Fleischmann’s is a unique blend of wheat gluten and enzymes designed to provide strength to bread, rolls, buns and other yeast-raised goods. It reduces total wheat gluten use in bread and roll formulas, providing significant cost savings, ensuring processing tolerance and increasing finished volume of bakery products. Vital-G is formulated for ease of scaling and to ensure consistent delivery of active ingredients. Bakers’ Best Vital-G should be added to the dough side in a sponge and dough or liquid sponge process, the company says. “The Bakers’ Best portfolio from AB Mauri Fleischmann’s is a line of functional ingredients designed to simplify the baker’s process through an efficient and economical single source,” says Greg Strauss, vice president of sales and marketing. “Vital-G is an example of how Bakers’ Best is a true solution for all bakers, especially retail bakers. Vital-G is an Continued on page 48

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all-natural, advanced enzyme-enhanced gluten for bread and bun applications. It reduces gluten usage by up to 50% and its concentrated usage reduces scaling time.”

EQUIPMENT In-line sifter Great Western Manufacturing’s QA36 In-Line sifter is an HACCP solution for operations with moderateto high-production volumes. Designed with a high net screening area, the QA36 is manufactured with a high level of sanitation in mind and provides easy maintenance using light weight components and form-fitting, snap-on neoprene gaskets. “The QA Series represents our latest thinking in sanitary sifters for process sifting (removal of oversize, particle grading or fines

removal) as well as final product quality control sifting. Although we initially developed the QA series sifters for In-Line applications (direct insertion in a pressure or vacuum conveying system), the many sanitary features that were incorporated in the design like all stainless-steel contact parts with fewer weldments, lighter weight components and the use of snap-on neoprene gaskets, made the concept ideal for gravity flow sifters as well,” says Bob Ricklefs, sales manager for the Leavenworth, Kan., manufacturer. The sifter may be inserted directly into a vacuum or pressure dilute phase pneumatic conveying system.

Tying bread bags Bedford’s new PolyTwist offers a re-engineered wireless solution to closing up bread bags. These twist ties come in 8- and 10-in. precisionwound spools and pre-cut lengths for hand

application, are biodegradable and microwavable and come in a variety of colors. “We’re excited at the market interest we have received since the new PolyTwist debuted at the IBIE show in September,” says Robert Tims, product development and outside sales manager. “PolyTwist material incorporates Bedford’s new PolyWire technology and works on both Burford and Plas-Ties HD equipment; no wireless conversion kits are required. Market interest has been strong for applications currently using non-twist tie closures. Bedford [based in Worthington, Minn.] is willing to visit bakery locations that have interest in converting their current closure method to the new PolyTwist product.”

Data logger for ovens

Controlling the internal temperature of food products is key to obtaining the degree of safety required in today’s marketplace. Regardless what oven or thermal system you use, the Scorpion 2 Data Logger profiling system from Reading Thermal Systems, coupled with a temperature array, provides a precise picture of applied temperatures. The Scorpion 2 gathers critical line information and analyzes specific situations to spot problems, maximize quality and jumpstart line and oven efficiencies. Employing advanced, proprietary SV7 software, the service measures thermal process parameters, air velocity, heat flux, humidity and temperature under full product load, using fixed sensors located at the actual product level. It then profiles, analyzes and compares data collected to maximize performance and solve production problems. The Robesonia, Pa., manufacturer explains that the system is the second iteration (with upgrades) of the original Scorpion developed in the United Kingdom, and brings with it more than two years of R&D effort. Physically sent through an oven on a conveyor belt, just alike a pan of bread or rolls, the portable system features Smart Sensor Technology, which the company defines as easy-to-use advancements to increase the resolution of the baking profile. The unit also Continued on page 50

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issues a comprehensive, detailed performance/ inspection report with a duplicate backup copy kept at Reading Thermal Systems, and maps out solutions to problems, such as uneven bakers, low production capacity, moisture retention and inconsistent quality. Able to perform benchmark profiles of an oven, the system can be used with both sold and open-mesh conveyors.

Conveying powders The newly redesigned K-Tron Premier P30 sanitary receiver conveys difficult powders in applications that require a high level of sanitary design and frequent cleaning. A modular design accommodates various discharge options, quick disassembly for cleaning, volume extensions and jet filter cleaning. The modular P30 now includes extension modules to increase the receiving volume of bulk materials. The new design also allows ease of disassembly and cleaning, offers a new sealing and earthing feature and is more user-friendly. “The sanitary design of the K-Tron Premier P series receivers make them ideal conveying solutions for difficult flowing snack food ingredients, such as spices, cheese powders and high-fat coatings,” says Sharon Nowak, global business development manager, foods and pharmaceuticals for K-Tron America, headquartered in Pitman, N.J. “When combining the use of these conveying systems with the added expertise of the K-Tron Process Group, the overall material handling solution for your snack food and bakery process is sure to include cost-effective design with an emphasis on improvement of overall product quality.”

Powder on-demand Powder On Demand (POD) from Hayward, Calif.-based Heat and Control is a compact system that transfers powders and granules to seasoning applicators, mixers, storage bins and elevated equipment, eliminating the need for ladders, heavy lifting and potential

physical injury. POD uses energy-efficient dense phase conveying to transfer products, and powders are transferred without spills, cross contamination or dust pollution. Plus, there are no moving parts or expensive, highmaintenance augers, dust socks or vacuum pumps. “Hazardous lifting of heavy bags, operators standing on small footstools, reaching to fill seasoning hoppers, messy spills and dust--unacceptable as they are, these issues have always seemed to be tolerated as part of the seasoning application process,” says Blake Svejkovsky, manager of product handling systems. “Heat and Control developed POD to eliminate the risk and mess and to elevate powder transfer to the efficiency level of modern seasoning applicators.”

Belt tracking

Berndorf Band Engineering introduced the bernmatic BTRV belt-tracking roller, designed to improve product quality and provide precise belt tracking for precision right down the line. An inductive sensor checks belt speed while an optical or mechanical belt edge sensor checks the actual belt edge position. The belt-tracking roller comes with a touch panel that controls the functions while displaying the tracking history of the belt. It also includes leading automation components, which ensure that the bernmatic system can be linked to a super-ordinate control and visualization system within the plant. Recorded data and messages are displayed on the monitor and integrated into the system. “The new bernmatic BTRV Belt Tracking Roller, from Berndorf Band Engineering GmbH, offers precise belt tracking due to continuous belt monitoring. Some advantages of the new bernmatic BTRV Belt Tracking Roller include: easy integration into existing systems, a compact design, belt tracking independent of speed and reduced downtime from optimal belt guidance. The bernmatic BTRV Belt Tracking Roller increases the overall

life of your belt and allows your belt to run perfectly for perfect product quality,” says Daniela Weiszhar, marketing manager for Berndorf Belt Technology USA in Elgin, Ill.

A world of washing systems Located in Byron, Ill., JEROS USA has more than 40 year’s experience in the manufacture of service washers. The JEROS line of tray cleaners, utensil and tunnel washers feature smart, compact yet high-performance designs and efficient operation. Three sizes of tunnel washers were exhibited at IBIE, including the 6015 tray cleaner. Handling trays with up to two edges, the machine can be used for flat and perforated trays and can be set up to clean two different tray sizes as long as the thicknesses are the same. The inlet and output driving rollers are a large diameter, so they apply even pressure to all of the trays. The labor-saving unit can cut hours of cleaning time and the system also greases 100 trays within 6-8 min. JEROS says that the cleaning brushes can last as long as 6-8 years while the machine itself has an average lifetime of 15-20 years. The system helps keep trays moving through production, as fewer trays are needed due to clean trays always being available. The stacked trays require a minimum of storage space. The company’s 200XL tunnel washer includes four rotating arms in the wash zone, a tunnel width and height of 25.5 x 18.5 inches, a stainless steel conveyor, a 31.5-in. washing section and a 57-gal wash tank capacity.

Robotic wrapping goes with the flow

Formost Fuji Corp., Woodinville, Wash., and FANUC Robotics, Lake Forest, Calif., Continued on page 52

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A top priority in every bakery operation is proper maintenance and inspection of all equipment. Every Great Western sifter is designed with ease of operation, maintenance, and optimum sanitation in mind.

The use of sifting equipment to maintain food safety and quality management is more important today than ever. Sifters make it possible to control and monitor internal plant sanitation conditions; provide an indication of changing process conditions; ensure that incoming ingredients have been manufactured, stored and transported under sanitary conditions and are unadulterated and on spec; and remove filth to prevent products from being branded as adulterated. Great Western designed their QA24 sifter as a compact, space-saving, pneumatic In-Line sifter specifically developed for the quality assurance and HACCP needs of food operations with small to moderate production requirements. The Model QA36 handles moderate to large production volumes and is available in versions for In-Line or Gravity Flow systems. The QA Series sifters have received Third Party Verified compliance to BISSC standards for the design and construction of equipment used in the baking industry.

Great Western pioneered the pneumatic sieve compression system that allows for easy and quick access and the nest together sieve frame design enables the machine to be quickly and completely dismantled in minutes. The QA Series sifters in particular feature snap-on neoprene gaskets that require no adhesives for attachment. The increased popularity of whole grain products has led to the use of more sifters, and since the bran flakes in whole wheat flour require a coarser mesh than other white flours, it is crucial that accurate product testing be done to ensure the use of the proper mesh size. Great Western maintains a complete testing laboratory to evaluate product samples and make equipment recommendations to meet the user's needs.

800-682-3121 gwmfg.com [email protected]

Special Report Continued from page 50

collaborated on some of their IBIE packaging machinery introductions. Formost Fuji showcased its latest horizontal form/fill/seal flow wrapper, the Alpha VI, which provides tight, neat packages and strong seals, in combination with FANUC’s food-grade M-3iA/6S intelligent, parallel-link robot, designed to maximize speed and flexibility for picking

applications. The food-grade, four-axis robot is equipped with iRVision visual tracking, which picks randomly-placed product from an infeed conveyor, orients the products and places them into the infeed of the Alpha VI’s conveyor to be wrapped. Also equipped with a servo motor, a

cantilevered frame, positive product control and a touchscreen user interface, the Alpha VI features as an adjustable forming box that can be accessed for calibration of repeatable settings and fast changeovers. The controller stores product data to assure exact machine settings for easily repeatable product setup. Rotary and end-seal machine models or a box-motion end-seal configuration are available, and depending on the model, reach speeds from 10 to 300 packages/minute.

Slicing and slabbing FoodTools introduced a single-blade, top-drive slabbing machine, built to precisely and efficiently cut cakes, biscuits, muffins and other bread products into horizontal slabs from 0.3- to 3.5-in. thick. The top drive allows for high-speed slicing by holding the tops and bottoms in place as buns and rounds are sliced top and bottom halves. This machine removes cutting knives and blades from human hands and perfectly portions each layer every time. “The CS-8AW-1 had been a valuable tool in make cake production lines for years, and now it can also be used in bread production,” says Chris Clemens, marketing manager for the Santa Barbara, Calif., company. “The 18in. wide conveyor allows bakers to cut up to 18 in. of product at a time. Products can be stacked across the width of the conveyor and can also be continuously placed in rows to increase the slicing capacity of the machine.”

Dough lines Automating artisan production is the name of the game at Fritsch USA, Cedar Grove, N.J. The Multitwist for twisted baked goods has an expanding range of tool sets and innovative upgrades. With production cord lengths from 250 to 600 mm, the machine moves beyond classic brined pretzel making and produces sweet dough pretzels and ring-shaped products. Changeovers from one product to another take a matter of minutes without special tools, the company says. An intelligent toolcontrol system is constantly on alert to ensure the system is operating with the right combiContinued on page 54

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CHRISTY

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• 360˚ Coaters • Flex-Top® Coaters • Roll-Top® Dispensers • Round-Top Dispensers • Icing Dispensers

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CHRISTY ® MACHINE COMPANY

Machines made and patented in the U.S.A.

P.O. Box 32 • 118 Birchard Ave • Fremont, OH 43420 • 419 332-6451 • Fax: 419 332-8800

Special Report Continued from page 52

nation of tools. A single module manages as many as 2,000 dough pieces per hour. With the help of a Fritsch dough sheeting unit, the Multitwist can operate around the clock for as long as six days without interruption for cleaning, the company says. Another significant system is the Multiline dough line, suitable for a high-performance,

pre-stage dough sheeter, a monocline or a sheeting system that permits bakers to work uninterrupted with dough sheets on a single line. Easy to clean, the Multiline is considered a jack-of-all trades for any bakery, and handles a variety of doughs, such as laminated puff pastry that must be processed at low temperatures to artisan breads that consist of

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soft, sticky, high-water content recipe types. The Multiline also handles dough sheet lines of up to 600 mm and has a production capacity of 800 kg per hour.

Divide and conquer Reiser’s Vemag line of dough makeup and depositing equipment uses double-screw technology to provide versatility, flexibility and accuracy. Not exactly new to the industry, the Vemag technology is all about the customer, says company president Roger Reiser. Based in Canton, Mass., the family-owned company’s first bakery applications came in the late 1970s when a customer bought several of its cookie double chub fillers. At the heart of the systems lies a patented double-screw pumping system. With positive displacement, it assures gentle and consistent product handling without overworking the product and exact weight portions. “Our Vemag equipment offers a broad range of solutions to produce cookies, scones, breads, rolls (soft and hard), English muffins, bagels, pretzels, batters for brownies and cakes, pie shells and coextruded items, among many others,” says John McIsaac, vice president. The new ProcessCheck checkweigher in the line is for bakery lines, pizza dough production and more. Changing product over the course of a batch or batches can result in weight variations. ProcesCheck automatically monitors weights and adjusts the divider without operator intervention. Add a simple-to-operate, compact design and automatic monitoring and you get uniform weights, reduced giveaway and full control of the product. An optional rejection system that gets rid of off-weights is available. The system is adjustable from 10 to 300 portions per minute, depending on the product and portion sizes being run and has a weight range from 1 to 3,000 g. Also new at Reiser is its customer center in Canton. The 6,600-sq.-ft. addition to its headquarters includes an 800-sq.-ft. conference center, several types of mixers, dry storage, a walk-in cooler and freezer areas and a rack oven to produce products and test dough processing capabilities. Continued on page 56

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Innovative extrusion processes without limits. With our extensive extrusion know-how and passion for customized solutions, Buhler strives to generate added value and success for any product concept. With the addition of Aeroglide® to the Buhler family, we now offer one of the most complete lines of process technology available anywhere. From raw material handling, cooking and shaping through extrusion to drying of finished products - from breakfast cereals and snack foods to modified flours and starches and texturized proteins. In short: extrusion processes without limits.

Buhler Inc., 13105 12th Ave N., Plymouth, MN 55441, T 763-847-9900 [email protected],

Innovations for a better world.

Special Report Continued from page 54

A steaming we will go AmeriVap Systems, Dawsonville, Ga., showcased Xtreme Steam, a vapor system that uses electricity to heat the water in the tank, creating steam under pressure. When the temperature of the steam reaches 365°F and the pressure reaches about 150 psi, the moisture content drops to about 5%. In addition, the eco-friendly, economical and easy-to-use machine comes with a variety of brushes and other accessories that allow the steam to reach dirty surfaces while the brushing action releases and removes dirt and stain particles. “Xtreme Steam produces culinary grade, super heated, saturated dry steam vapor, which cleans and sanitizes most any surface even in the hardest-to-reach area,” says Dolly Diercks, vice president of marketing and sales. “AmeriVap Systems introduced dry steam vapor cleaning to the United States in 1990 and we continue to develop products and applications that save time and money for our customers, combined with a deep respect for the environment.”

flour processing capacities (used in craft and industrial applications) of 75, 100, 125, 150, 200 and 250 kg. The systems process in three shift operations and are designed to be highly durable modules. The mixers also feature easily movable and dockable constructions for light bowl handling, easily maneuverable bowls, stainless steel flour dust protection covers with plastic slip rings, automatic operating cycles and a “hydraulic” head lifting/ lowering unit. The Titan mixer features a double-withdouble three-zone mixing principle for up to 240 kg of dough for high quality at high capacity, short batch-cycle times, a programmable controlled touch panel, stainless-steel panels and mixing tools and a stainless-steel bowl and bowl carriage. It also has a flour capacity of approximately 150 kg and can handle four to six batches per hour. The Magicline is a new laminating plant concept from Werner & Pfleiderer that makes it possible to assemble a production line for a multitude of dough types and recipes. With a new modular structure, the user can assemble the desired individual configuration from a range of functional modules. The user also defines the requirements.

mance manager software suite can maximize productivity by tracking performance in real time across the warehouse by period, shift, section or individual versus standards that should be met. Distrib Bakery WMS (warehouse management system) helps provide the transparency bakers need to cope with balancing control costs and the need to increase service levels and higher expectations. The company reports that the application can be integrated into the entire supply chain through multiple inventory and equipment tracking and shipment data captured at the enterprise level, finished goods confirmation, bulk and route dispatch and automatic tray picking and truck load validation at the plant level, pick-and-put to light, dynamic floor allocation, cross docking and order dispatch at the distribution center level and custom picking, shortage handling, small-volume handling and consolidation at the depot/warehouse level.

Tray, case packing

Distribution and warehouse management

Baking on the show floor WP Bakery, Shelton, Conn., showcased live baking demonstrations at their exhibit in combination with King Arthur Flour Co., Norwich Vt., which provided high-quality flour and additional baking expertise. WP featured several of its newest machines and systems. For example, the Quadro Filius produces a wide variety of rolls in a short amount of time and can be integrated into many production environments. The machine operates at rates of 4,000 pieces per hour and is easy to clean. The Eco spiral mixer operates with 30 to 125 kg of flour and is based on the Kemper three-zone mixing principle. The President spiral mixer line includes six mixers with

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Paperless order dispatching, order fulfillment and picking solutions for the baking industry were the focus for Pcdata, Inc., East Granby, Conn. Among the company’s many software and system specialties especially designed for supply chains are customizable order prioritization solutions that work with light or voice technology and shipping and warehouse services designed to improve warehouse manpower efficiency and productivity by up to 50%. Pcdata says the software and solutions can dramatically reduce order fulfillment errors, reduce “unaccounted for” items, significantly reduce administration needs and provide track-and-trace abilities and real time inventory visibility. The easy-to-use systems include the modular concept, Distrib. The perfor-

Delkor Systems presents the Trayfecta R Series retail-ready case and tray packer. Operating at production rates up to 40 trays per minute, the new Trayfecta R Series model forms display trays in a continuous flow, producing precisely-formed trays that are properly aligned and oriented for automated product loading. Trays are ejected from the former with cup cavities pointing upwards, thereby eliminating the need for additional handling in preparation for downstream loading. “A common problem facing many of our customers today is the need to have a case packer that is able to adapt to a variety of shipper formats, from standard cases to a range of retail-ready formats,” says Dale Anderson, president of the Circle Pines, Minn., company. “This is primarily due to the larger role the mass merchandiser is playing in defining how a product will be packaged.” Other features include tool-less removable changeparts for easy cleaning, sanitary stainless-steel ball-end leveling feet to minimize surface contact, washdown duty motors and gear boxes with stainless-steel hardware,

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Special Report mating parts are mounted to welded bosses to minimize surface contact and a design that minimizes horizontal surfaces.

Palletizing proficiency Schneider Packaging Equipment introduced the multi-line palletizer, designed for combining two or more lines into one centralized palletizing location. “Schneider multi-line robotic palletizing cells are designed for larger projects requiring multiple product lines and palletizing stations,” says Terry Zarnowksi, director of sales and marketing for the Brewerton, N.Y.-based manufacturer. “Several product lines are conveyed to one central location for palletizing prior to distribution or warehouse storage. Schneider’s palletizing equipment is programmed for simple trouble-free installation and operation that easily integrates with other equipment, such as labelers, bar code readers, elevators and lowerators, shuttle cars and stretch wrappers.” This machine can be combined with up to 30 picks per minute to provide high throughput and works with single or multiple lines to accommodate floor space and ergonomic requirements. Plus, it features an optional over/ under conveyor, which allows pallet exchange while operating for continuous product, and comes with end-of-arm tooling options, such as vacuum, mechanical or fork or with or without pallet hooks and slipsheet handling.

Tamper-evident closing Burford, headquartered in Maysville, Okla., developed a tamper-evident closure system, designed to improve the safety and security of snack and bakery products. “This unique closure system provides a one-time tamper-evident seal that gives confidence to the consumer that their product has not been previously handled,” says Clay Miller, sales engineer. “The tamper-evident closure system is generally followed by a twist tie machine, which allows the consumer to

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easily remove the perforated seal and then reclose the package using the twist tie.” It also features a non-contact sealing method and a patent-pending hot airflow system and works with existing packaging lines and materials, Miller says. The bag tail flattener aligns open bag tails, which are then perforated for easy opening. “With its ability to handle a wide range of bag types and thickness as well as working with speeds in excess of 100 feet per minute, the TEC100 is ready to provide your product with the added security and safety that comes with the Burford tamper-evident closure system.”

Multi-level basket Canadabased Drader Bakery Logistics is helping bakers reduce costs with its Eliminator, a dual-height basket that’s compatible with existing singleheight basket inventory. “The Eliminator basket has a unique feature; it is a multi-level basket that is also compatible with a bakery’s single-height inventory,” says Alisha Leveille, account representative. “This allows bakeries to get the benefits of a multi-level basket such as shipping more product per stack and reducing basket inventory and costs without the usual setback of an expensive and complicated mass replacement. This means a bakery orders baskets as they normally would, and the Eliminator would replace the single-height basket over time.” The Eliminator is designed to eliminate hard changeovers, storage space, wasted shipping capacity and the need for multiple baskets. It also captures more product per stack and can save on shipping because it holds various bread and bun heights, all in one basket. “We called it the Eliminator because it eliminates a lot of the headaches associated [with] baskets and trying to optimize a system,” Leveille adds. “It eliminates the need for multiple baskets and managing the associated inventory, eliminates hard changeovers and eliminates wasted shipping capacity. A multi-level basket that can also stack with existing single-height inventory allows a user to pick and choose when to use bread height versus bun height, to mix with existing or not, or do it all at once.” SF&WB

New Products 1

4

3

1

Weight Watchers Coffee Cakes

Company: Dawn Foods, Inc., Jackson, Mich. Website: www.weightwatchers.com Introduced: January Distribution: National Suggested Retail: $3.49 for a four-cake, 5.5-oz. box Product Snapshot: New to the sweet baked goods family of Weight Watchers products are Weight Watchers Coffee Cakes. These better-for-you treats consist of moist cake, crumbly streusel topping and rich cinnamon filling and contain 5 g. of fiber and just 120 calories, a PointsPlus value of three. Ingredients: Sugar, whole eggs, enriched wheat flour bleached (flour, niacin, reduced iron, thiamine mononitrate, riboflavin, folic acid), polydextrose, glycerin, invert sugar, corn syrup, modified food starch, water, partially hydrogenated vegetable oil (soybean, cottonseed and/or canola oil), pea fiber, corn cereal, canola oil, soybean oil, mono- and diglycerides, leavening (baking soda, sodium aluminum phosphate, monocalcium phosphate, aluminum sulfate), cream cheese (pasteurized milk and cream, cheese culture, salt, carob bean gum), butter (pasteurized cream, natural flavors), cinnamon, artificial flavor, salt, dextrose, propylene glycol mono and diesters of fatty acids, soy lecithin, corn starch, potassium sorbate, sodium propionate, sorbic acid, propylparaben (as preservatives), calcium carbonate, xanthan gum, guar gum, caramel color, polysorbate 60, citric acid, propylene glycol, corn oil, beta carotene as color, alpha tocopherols as preservative. Contains: eggs, wheat, milk, soy. May contain peanuts, tree nuts.

2

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Wasa Thin & Crispy Flatbread Crackers

Company: Wasa North America LLC, Wyckoff, N.J. Website: www.us.wasa.com Introduced: November 2010 Distribution: National Suggested Retail: $2.99 for a 6.7-oz. box Product Snapshot: Wasa Thin & Crispy flatbread crackers are made with just a few simple, all-natural ingredients, are delicately seasoned and oven-baked for a one-of-a-kind taste and texture. They come in “Stay Fresh” packs, in Original, Sesame and Rosemary varieties and are located in the specialty cracker aisle. Ingredients (Rosemary): Whole wheat flour, wheat flour, palm oil, salt, barley malt extract, yeast, rosemary extract.

4

Jalapeño and Movie Theater Popcorn

Company: Snyder of Berlin, Berlin, Pa. Website: www.snyderofberlin.com Introduced: November 2010 Distribution: Regional Suggested Retail: 99 cents for a 2.75-oz. bag of Jalapeño; $1.99 for a 6.5-oz. bag of Company: Natural Snacks, LLC, Movie Theater Addison, Ill. Product Snapshot: Snyder of Berlin’s Website: www.naturalsnacksllc.com Jalapeño-flavored popcorn blends the Introduced: January familiar taste of popcorn with an added Distribution: National Mexican flair. Meanwhile, the Movie Suggested Retail: $2.99 for a 5-oz. bag Theater popcorn variety captures the Product Snapshot: New to the Michael buttery flavor of movie-style popcorn Season’s family of better-for-you snacks with Snyder’s signature popcorn taste. are varieties of its kettle-cooked potato Ingredients (Jalapeño): Popcorn, vegechips. Each 5-oz. bag is made with alltable oil (contains one or more of the folnatural ingredients, contains low sodium lowing: corn, soybean, cottonseed and/ and 40% reduced fat and now comes in or sunflower oil), salt, dextrose maltodexHoney BBQ, Sea Salt & Balsamic Vinegar trin, jalapeño pepper, dehydrated onion, and Jalapeño. monosodium glutamate, torula yeast, Ingredients (Honey BBQ): Potatoes, dehydrated garlic, soy oil, extractives of sunflower oil and/or corn oil, salt. paprika, artificial and natural flavors.

3

Michael Season’s KettleCooked Varieties

Edi tor ’s N ote: G o to w w w. s n a cka n d b a ke ry. c o m to re a d a b o u t mo re n e w p ro d u c ts .

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CHRISTY

®

Look to an Industry LEADER in MATERIAL DISPENSING Christy applies vast experience to dispensing problems: engineering, design, and manufacturing

Moist Material Dispensing Machines

Salt Dispensing Machines

For five decades, Christy has solved material dispensing requirements in thousands of applications. As a result, Christy has earned a worldwide reputation for quality machines that work with reliability. Along with this recognition, we have become experts in the top and surface coating fields.

Also available: Extrusion Coaters

• 360˚ Coaters • Flex-Top® Coaters • Roll-Top® Dispensers • Round-Top Dispensers • Icing Dispensers

Cohesive Material Dispensing Machines

• Bottom Coaters

Toll Free: 888 332-6451 The material dispensing experts

Dry Material Dispensing Machines

CMC

CHRISTY ® MACHINE COMPANY

Machines made and patented in the U.S.A.

P.O. Box 32 • 118 Birchard Ave • Fremont, OH 43420 • 419 332-6451 • Fax: 419 332-8800

The Nutritional Corner This Month, Support the Health of Mothers, Babies anuary is National Birth Defects Prevention Month. Given the ongoing partnership between the Grain Foods Foundation and the March of Dimes, January is the perfect time to remind consumers about the steps we can take to support maternal health. According to the Centers for Disease Control and Prevention, the two most common birth defects, spina bifida and anencephaly development affect one in 1,000 pregnancies in the United States. Many of these can be prevented through a healthy diet and lifestyle. One particularly important lifestyle step that women of childbearing age can take is consuming a folic acid-rich diet. Folic acid, a B vitamin, is crucial for the development of a baby’s spinal cord, which begins forming in the weeks following

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conception (before most women even know they’re pregnant). Because of the timing of spinal cord development, women must understand that their pre-pregnancy diet plays an equally important role in their future baby’s health. The most recent March of Dimes survey examining women’s knowledge and use of folic acid indicated that most women had a general awareness of folic acid, yet the majority were unaware of its role in preventing birth defects. The Grain Foods Foundation continues to work to educate all women of childbearing age to consume 400 micrograms of folic acid daily, beginning at pre-conception and continuing into the early months of pregnancy. Enriched grains, such as white bread, tortillas, pasta and cereal, are important sources of folic acid.

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

In light of National Birth Defects Prevention Month, the Grain Foods Foundation commemorates mandatory folic acid fortification of enriched grains and celebrates the milling and baking industry’s past contribution and continuing commitment to preventing birth defects. Our industry’s products have already made a difference in reducing the rate of birth defects, and I’m confident that our continued efforts will further improve the health of mothers and babies everywhere. SF&WB

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Premium Quality Ingredients 60

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Ingredient Technology Inclusions

Including it All When it comes to inclusions, bakers and snack producers want it all. Thankfully, many of today’s suppliers are ahead of the game. Marina Mayer, executive editor Photos courtesy of Quali Tech Inc.

hen it comes to inclusions, bakers and snack producers want it all — the besttasting add-in that’s filled with better-for-you characteristics and comes with a perfect price point and a laundry list of applications. Sometimes, however, customers can’t have it all, so they’re forced to rely on a variety of ingredients to achieve that one taste function they’re looking for. That’s why many of today’s inclusion suppliers are developing a host of inclusions that act as a one-stop shop for taste, mouthfeel, functionality and healthy attributes. For example, SensoryEffects Flavor Systems created a line of “gooey” inclusions, designed to deliver a melted and

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sticky-type texture for muffins, says Dennis Reid, vice president, marketing and business development. Cakes, cookies and other finished products can be served right out of the oven. “We introduced the most popular flavor first — cinnamon — and then followed it with maple, marshmallow and caramel,” Reid adds. “Unlike other inclusions that are hard and have very little textural impact, these inclusions deliver flavor, color and the gooey texture to a muffin. If you heat them before eating, you will get even more enhanced gooey texture from these products.” The Bridgeton, Mo., solutions provider also developed a line of inclusions geared specifically toward ice cream. This line requires an 80°F melt point to maintain a creaminess and proper mouthfeel, Reid says.

Photos courtesy of SensoryEffects Flavor Systems

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“However, after some applications testing in baked goods, we have found that these products do provide a very different and novel functionality and texture to baked goods, due to the lower melt point,” he adds. “They can be added to a batter and will provide a lot more melt-out and spread than a standard chocolate chip, and they will remain softer and creamier even once the finished product equilibrates and reaches room temperature.” For its part, ADM Cocoa introduced chocolate- and compound-based inclusions made with its proprietary Fibersol-2 dietary soluble fiber, says Neil Widlak, director of product services and development. “Inclusions made with Fibersol-2 can be used in snacks and foods such as protein bars, snack bars, granola, cereals and muffins without compromising flavor Continued on page 64

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Ingredient Technology Continued from page 62

or textural properties,” Widlak adds. “The addition of Fibersol-2 in an inclusion can help deliver a good or excellent source of fiber, depending on the customer’s finished product. Adding fiber via an inclusion provides customers with the option of adding less fiber to their base product, which can alleviate issues related to reformulating baked goods or snack products to accommodate the additional ingredients that may be required when including fiber in the formula.” Likewise, Quali Tech Inc., Chaska, Minn., offers several solutions for snacks and baked goods. “In general, we supply products that function the way people perceive they should or wish they would function,” says Kye Ploen, vice president, sales - food division. “In most cases, we mimic what either comes from nature or is a manufactured product that needs to have significantly different functional characteristics than the industry standard.” For instance, individually quick frozen (IQF) blueberries are suitable for bagels because the bagel dough is “strong” and has a tendency to break down blueberries over a period of time, Ploen says. “Also, the physical degradation of the blueberry leaves little eye appeal other than some very small ‘flecks’ of blueberry skin that is mixed throughout the bagel,” Ploen adds. “The consumers’ expectation is generally to see a large ‘piece’ of fruit in their bagel. This is where we come in. We

Photos courtesy of of SensoryEffects Flavor Systems

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Photo courtesy of ADM Cocoa

can manufacture a piece that can contain blueberry powder (or apple powder or no fruit content if costs need to be minimized), which will be strongly and consistently flavored and will survive the bagel process to yield the desired outcome of high flavor and piece identity in the finished product.” Quali Tech’s particulates are typically perceived as an “artificial” alternative, Ploen says, when in fact they can be formulated to be allergen free, non-GMO and all-natural. “[They] also can be used as a delivery system for getting unique ingredients (fiber, protein, fruit content, nutraceuticals, flavor, etc.) into a system while masking or minimizing some of the inherent issues that particular ingredient may have in the finished application,” he says.

Formulating for all Because consumers want it all, many of today’s snacks and baked goods must

provide it all, and all at once for that matter. That’s why many of today’s inclusions can be deemed as the one-stop solution. “I think that bakers and snack producers are looking for the right size, shape and form that meets their processing setup and targeted functionality in the end-use product,” Reid says. “In the consumer’s hands, the product must always look, smell and taste good to meet their demands.” When it comes to including chocolate, Widlak says that bakers and snack manufacturers are on the lookout for the cost advantages of using premium ingredients without compromising quality. “Inclusions made with compound coatings must deliver the same flavor, solidification properties, melting properties, appearance and stability as chocolate-based inclusions,” he adds. However, when formulating for a niche or customized product, sometimes it’s challenging for bakers and snack manufacturers to achieve all of the on-demand qualities without sacrificing something else. “Let’s face it, when formulating or designing a better-for-you or gluten-free product, it is tough to get the appearance, texture and flavor right, and similar to the traditional counterpart that sets the standard,” Reid says. “The consumer knows that they are eating something that is different, yet healthier for them. Inclusions are key, because they help to deliver and support these critical attributes of appear-

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From sourcing cocoa beans in various origins, to processing and manufacturing chocolate, to delivering top-quality Ambrosia® chocolate to you, ADM Cocoa monitors each step of the process. To work with a supplier that understands the complete chocolate cycle, call ADM Cocoa at 800-558-9958.

®

The Chocolate Resource

COCOA

SNACK FOODS

CANDY & CONFECTIONERY

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BEVERAGES

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For customers around the world, ADM draws on its resources — its people, products, and market perspective — to help them meet today’s consumer demands and envision tomorrow’s needs. www.adm.com © Archer Daniels Midland Company

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Ingredient Technology Continued from page 64

ance, texture and taste. If it doesn’t look and taste good, it’s very difficult to get a repeat purchase.” Another challenge is the inability for bakers and snack producers to envision the end product.

“To alleviate this, at least in certain applications, we are presenting a finished product-concept prototype prior to showing a sample of the inclusions themselves,” Ploen says. “This has proven to be very effective in bridging the misconceptions of

how the particulates might function to how they actually function.” Whatever the challenge may be, today’s inclusion providers are in position to overcome nearly any obstacle. “Flavor and texture drive both marketing and product development, and the future for inclusions is in continuing to evolve to help deliver new and novel functionality that drives the ability for formulators to deliver new tastes and textures,”

Many of today’s inclusion suppliers are developing a host of inclusions that act as a one-stop shop for taste, mouthfeel, functionality and healthy attributes. Reid says. “Inclusions are easy solutions in that they allow formulators to innovate and add a new flavor and texture by adding just one or a few new ingredients.” There also is an increasing interest in formulating with chocolate-laden inclusions. “We see increasing interest in chocolate products that contain inclusions made with better-for-you ingredients, such as sterols, healthy oils, tocopherols or vitamin enrichments,” Widlak says. “Also, savory flavors not commonly associated with chocolate may be added to inclusions to supplement the chocolate flavor. The slow melt properties of inclusions allow for even flavor release and maximize flavor life by protecting flavors from oxidation or evaporation. Fortunately, the market is filled with a host of inclusions that act as the one-stop shop for taste, mouthfeel, functionality and healthy attributes, allowing consumers to have it all, and then some. SF&WB

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COMMAND DEMAND Enhance your nutritional appeal

Boost your healthy profile

Encourage a natural attraction

Appeal to the hearts of millions

© 2011 Almond Board of California. All rights reserved.

Connect with healthy consumers

Tap into a demand that’s going nuts

AND YOU THOUGHT YOU WERE JUST ADDING ALMONDS.

A lot goes in with a little almond. Start with 13 essential nutrients and a reputation for helping people maintain healthy cholesterol levels. Add in the fact that almonds are the number one nut introduced globally.* And finish with a tastier, crunchier creation that’s sure to appeal to millions in search of healthier products. Blend it all together and you’ve got the recipe for success. Good news about good fat: U.S. Dietary Guidelines recommend that the majority of your fat intake be unsaturated. One serving of almonds (28g) has 13g of unsaturated fat and only 1g of saturated fat. Scientific evidence suggests, but does not prove, that eating 1.5 ounces per day of most nuts, such as almonds, as part of a diet low in saturated fat and cholesterol may reduce the risk of heart disease. *Mintel Global New Products Database and Sterling-Rice Group, Global New Product Introductions Report, 2008.

Ingredient Briefs

Van Drunen Farms’ freeze-dried and drum-dried cranberry ingredients bear a tart and tangy fruit taste and are high in proanthocyanins, anthocyanins, polyphenols, organic acids, vitamins and minerals. Freeze-dried cranberries are a 100% natural ingredient with no preservatives and are available in whole, sliced, diced and powder format, whereas drum-dried cranberries are offered in a flake or powder form. Van Drunen Farms Momence, Ill. 815-472-3100 www.vandrunenfarms.com

ActivK MK-7 from Danisco is a fermented and purified Vitamin K2 ingredient using bacteria naturally occurring in natto. Stable under most processing conditions, ActivK MK-7 is suitable for a wide range of products, including fats and oils, baked goods and bars. Danisco USA Inc. New Century, Kan. 913-764-8100 www.danisco.com

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Plugrá European-style butter is the official butter of The French Pastry School in Chicago. Plugrá butter features greater plasticity, higher sheen and superior flavorcarrying qualities. It also is slow-churned for less moisture with the optimal 82% butterfat for flakier pastries and cakes. Plugrá butter comes in 16-oz. salted and unsalted solids and clarified butter. Marketed by Global Dairy Products Group, a division of Dairy Farmers of America, Inc. Kansas City, Mo. 800-535-5371 www.plugra.com

Almonds bring the perfect balance to any product and people are eating them right up. In fact, research shows that about 80% of consumers believe a product with almonds is more interesting and is better nutritionally, too. And when you formulate with almonds, you’re in good company — in 2009, almonds were the #1 nut introduced globally. So go ahead and serve up some extra appeal, just make sure almonds are in. Almond Board of California Modesto, Calif. 209-549-8262 www.almondboard.com

Softbran Don Minus by Kampffmeyer Food Innovation is a milled product made from germinable, healthy wheat and can be used in combination with mild whole grain flour. Softbran Don Minus can easily replace conventional bran in formulations without further modifications, and is suitable for baked goods, such as bread for toasting. Studies show breads formulated with 5% Softbran Don Minus were described as aromatic, slightly nutty and containing a fresh whole grain taste. KAMPFFMEYER Food Innovation GmbH Hamburg, Germany 0049 (0) 40 75 109-632 www.kampfmeyer.com

Barry Callebaut introduces Van Leer Gold line of premium chocolate for North American confection, bakery and pastry professionals. Made with unsweetened Belgian chocolate liquor and natural Madagascan bourbon vanilla, this line comes in wafer form and is available in Bel Noir (dark chocolate) and Bel Lactée (milk chocolate) couvertures. The Bel Noir couverture is available in varying cacao contents, ranging from 53-73% cacao, while the Gold Bel Lactée couverture comes in 31% and 33% cacao. Barry Callebaut USA LLC Chicago, Ill. 866-443-0460 www.barry-callebaut.com

View videos demonstrating the newest bakery & snack food ingredients by visiting

Snack Food & Wholesale Bakery - January 2011

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We offer sodium reduction solutions to satisfy any taste.

© 2010 Cargill, Incorporated

When you choose Cargill Salt to help you in sodium reduction, you get more than just quality ingredients. Not only do we offer products like Alberger® brand salt, Premier™ potassium chloride and SaltWise® sodium reduction system, we also have the food application expertise to help develop the right options for your food and beverage products. To learn more about how Cargill can help you reduce sodium without compromising taste, call 1-888-385-SALT or visit www.cargillsalt.com. collaborate

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Engineering Management

All My X’s…of Recruiting elcome to 2011! Things have been looking up over the past 12 months, and we in the industry should be excited about the next 12 ahead. The stock exchange seems to be bouncing back, unemployment numbers are exhibiting a slight decline and Americans are showing that bread products and baked goods are still important to their family’s well being. Except for the onslaught on our wallets from the new “healthcare” bill, our future is looking pretty good. With that said, it’s time to examine what lies ahead. One of the biggest challenges we will continue to face in the industry for a number of years is finding extraordinarily talented people and keeping them engaged for an extended period of time. You might feel like you have exhausted every avenue when it comes to your searches for the people that will help you keep your ship righted, but I would like to offer a few examples and ideas for recruiting from which you might extract a thing or two that will help. Going forward, it will take a little extra effort on your part to find exceptional candidates to fill your openings, so let’s get started. Presentation is everything. Way back in the old days, you could post an ad in the local paper and say, “bakery maintenance man needed,” and the mailbox and phone lines would fill up with exuberant candidates wanting to exit their present job at the dealership, gas station or farm to come work in a bakery. They heard that the pay was always good for this type of job and the work was steady. The problem back then was that no one expanded the recruiting conversations to include the Saturdays, Sundays and holidays that they would have

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to work, but the money and old-time work ethic made up for that. In order to excel in attracting today’s “bakery maintenance person,” we have to present the offer in a totally different way. Today, maintenance personnel is thought to be those who clean the pool down at the local motel or look after an apartment building. In the bakery world, our automated facilities require people with a bit more experience and expertise than ever before. Just a change in the name or “title” of the job gets things started on a different track. By referring to our folks as “technicians,” we will exude a different level of candidate from the crowd. When you are exploring the idea of recruiting some new talent, take an extremely close look at what you name the role you are trying to fill. The next place to tackle is the pay for the job. Yesterday’s pay will not attract today’s technician. We first must take a close look at what we are expecting from the new recruit needed for today’s challenges. Identify how this new role exceeds the requirements of the old role. Then exercise some common sense in setting a new pay scale, and finally, find a way to express to upper management that the current pay may not be competitive. Determining the expectations for this new “technician” role may require you to become an extrovert and reach out for some help from experts who may have already dealt with this issue. Don’t try to do this in a vacuum as there is no way that you, by yourself, can come up with the perfect job description that will satisfy the needs of the position. Your execution in this area will provide for the absolute best results possible.

Jeff Dearduff [email protected]

The next area of concern that you may want to work on to excite the next wave of employees is “quality of life.” The fastest way to have a mass exodus of employees is to treat them as if they don’t matter. People today want to be scheduled fairly and given good benefits, and they expect you to extend a courtesy that makes them feel a part of the bigger picture. They want to be included in everything, not excluded. They want to be free of stress, not exasperated. You as their manager are in complete control of how involved they can be in their job. When it comes to improving the quality of life for your employees, there is some room for experimentation. Since this is not an exact science at this point in time and is part of the new workplace culture shift, you can try some things one day. If they don’t quite work out, you can try something else. As you are creating something to make them feel better about where they stand in the company, consider exporting some ideas from them so that they have some skin in the game. The other part of this quality of life piece has to do with their working conditions. When they are in the workplace, they expect excellent training, tools and materials that allow them to execute their tasks with confidence. Spare no expense to make sure they have what they need. Their success on the bakery floor equals your success as a manager. You don’t have to be extravagant in any of the areas we have discussed; you just need to be fair and deliver on your word. Put yourself in their shoes for a minute, and you will find ways to expand your thinking so that you can recruit and retain the best of the best. Looking forward to an exciting year! SF&WB

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“Ross helps me serve my recipes to the world.” “I’m a chef at heart, not a manufacturer. I believe that all food should start with fresh, local ingredients and deliver awesome flavor! “That’s why our Cheese Tortas are such a success. We start with premium cheeses, fresh butter and herbs. And thanks to Ross, we can now produce them fast enough to satisfy customers everywhere — through retailers like Whole Foods, Costco, Neiman Marcus, Harry and David, Safeway and Balducci’s.” Looking for a new mixing strategy to boost production and improve product quality? Call 1-800-243-ROSS. Or visit www.mixers.com.

Elizabeth Fujas, Rising Sun Farms founder

Supplier Spotlight

A Leap Forward in Filling Technology – Advances in Servo Pump Filler Design ervo-pump fillers from Hinds-Bock Corp., Bothell, Wash., are designed for high-speed depositing and spreading of products. The latest advances in technology make these machines suitable for a wide variety of flowable products such as icings, fruits, batters, sauces, dressings, jellies and condiments, to name a few. The servo controller makes changeover from one size container to another quick and easy without changeparts. Recipe storage allows for depositing multiple products and containers. The operator interface controls the speed and tunable fill parameters. Servo-filling machines also feature the latest in control technology, achieving the highest efficiency with the smallest possible footprint. Servo-drive technology provides high-speed depositing with custom tuning of filling parameters to control the appearance of each fill as well as velocity. By controlling velocity, maximum speeds are achievable while maintaining clean fills. Acceleration or deceleration controls splashing and spreading. Speeds are also enhanced through the use of a servodriven traveling spout bridge, which moves the spouts with the continuously moving product or container. Servo-pump fillers are designed with sanitation in mind. A major advance in sanitary pumps is clean-in-place (CIP) technology, which means they sanitize

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themselves. Not only are there fewer parts to clean, but the front cover plates are designed with hinges for rapid sanitation swab testing. To eliminate the pooling of water, all flat surfaces have been angled. Round tubing replaces square and all overlapping or recessed surfaces have been redesigned. Suckback features allow the machine to suck the product back, to stop dripping, for a clean deposit. The latest technology in control systems allows the servo fillers to be linked via Ethernet to the plant’s control system. By constantly analyzing data, performance, uptime information, maintenance monitoring and fault alerts, the control system enables the user to achieve the highest filling efficiency and yield. Servo-driven pump fillers are also designed for high-speed, accurate spreading. Custom spouts are used to match the spread width and length for each application. When paired with other design options, including diving spout bridge for bottom-up filling, conveyors, rotary unscrambler and accumulator tables, the highest yields are attainable for a wide variety of products and applications. Servo-pump fillers for use over vertical form/fill/seal machines feature a long reach positive shutoff spout with an adjustable blowoff feature to maintain a clean seal zone and an accurate fill. They are also seamless when used over horizontal

vacuum formers. In addition to positive shutoff spouts, many options are available for difficult applications, such as agitated hoppers, diving spouts, traveling spouts and heated or cooled machines. Servo-pump fillers are also designed for depositing a wide variety of sweet goods, fruit, cheese or meat fillings onto dough and flatbreads and snack food and entrée processing. The applications are endless. Producers can apply savory meat fillings to pizzas, turnovers, meat pies, gyros and other snacks and ethnic products or accurately apply gravies and sauces on prepared fish, meat and chicken to create value-added entrées. They’re also suitable for creating a wide variety of desserts. In addition, servo-pump fillers are widely accepted by frozen meal producers because they run faster, are quieter that piston machines, require a smaller footprint, attain a higher degree of accuracy, consume considerably less compressed air and are faster to clean. When teamed with a servo-traveling spout bridge, servo-pump fillers can attain the highest speeds. Through the years, technological advancements in controls have driven the costs down and greatly increased the acceptance of programmable logic controllers (PLC), operator interfaces, plant-wide interfaces and servo motors. Through this technological leap, depositing and filling machines run faster and are easier to troubleshoot, sequence and control. This improvement has led to more sophisticated depositing and filling machine integrations than would have been impractical years ago. Servo-pump fillers truly have taken a leap forward in filling technology. Enter the 21st century. Editor’s Note: Lance Aasness, the author of the article, is vice president of sales and marketing at Hinds-Bock Corp., Bothell, Wash. For more information, call 877-292-5715, email at [email protected], or visit www.hinds-bock.com.

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“Whole grain muffins that taste great. Here’s my secret recipe.” Smart Portion™ Muffins are the first whole grain, low-fat muffins that come with awesome taste and texture. That’s why they’re a sensation in grocery aisles and in-store bakeries everywhere. Smart Portion Muffins were created by Uncle Wally’s, the fast-rising muffin company founded by cookie guru Wally “Famous” Amos. But the recipe for this success actually started right here at Ross, with a Ribbon Blender specially engineered for super-fast changeover and high volume production. We’d like to help you succeed, too. Call 1-800-243-ROSS. Or visit www.mixers.com.

Tom DiGiannurio, Senior Engineer, Ross Employee Owner

Equipment Briefs American Fabric Filter Co. incorporates many innovations to make the AFF Portable Reclaim Sifter the easiest and most efficient tool. Designed to sift small batches of dry powders, this versatile sifter is capable of batch sifting up to 600 lb. per hour and can be operated sitting atop a drum or using the adjustable height rolling base for easy relocation around the plant. American Fabric Filter Co. Wesley Chapel, Fla. 800-367-3591 www.americanfabricfilter.com FOX IV Technologies, Inc. releases the TwinPrint Tabletop, which uses the latest printing technology from Zebra Technologies – the Xi4 print engine. The TwinPrint Tabletop looks and functions like a traditional tabletop label printer, complete with serial and Ethernet communication ports and embedded fonts and languages. The system features silk-screened media paths for easy loading of media, a convenient fan-fold label docking station with capacity for more than 1,100 6x8-in. labels and intuitive displays for fast-menu hopping. The TwinPrint produces 58% less material than standard one-sided label stock with every printed label. FOX IV Technologies, Inc. Pittsburg, Pa. 877-436-2434 www.foxiv.com Rice Lake’s Versa-portion RLP-S compact bench scale provides versatility and

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a broad range of useful features. With capacities from 6 to 60 lb., the Versa-portion is ideal for food processing. Its straightforward keypad easily toggles between ounces, pounds and grams, and the custom pans and fixtures can be designed for limitless weighing potential. Rice Lake Weighing Systems Rice Lake, Wis. 715-434-5364 www.ricelake.com A new bag dump system from Flexicon collects dust generated during manual dumping and compaction of bags and conveys bulk material downstream. The unit is intended to reduce material waste and eliminate the need to clean a remote dust-collection site, while protecting workers and preventing plant contamination. Pre-engineered, pre-wired and ready to plug in and run, this compact system integrates a receiving hopper, dust collector, bag compactor and flexible screw conveyor on a frame, which streamlines installation and allows for easy relocation if required. The fully enclosed flexible-screw conveyor handles free- and non-free-flowing bulk materials ranging from large pellets to sub-micron powders, including products that pack, cake, seize, smear, fluidize, break-apart or separate, without separating blended products. Flexicon Corp. 888-353-9426 Bethlehem, Pa. www.flexicon.com

Dematic launches Alert Monitoring Service, a new support capability for automated material handling systems users. The service provides a constant view of a user’s material handling system and monitors trends to reveal issues before they become critical and potentially lead to unwanted downtime. It also provides email or text message notifications about the status of controls, computer hardware and equipment. Dematic Corp. Grand Rapids, Mich. 877-725-7500 www.dematic.us Baker Perkins introduces TruClean, a wirecut machine designed to minimize cost of ownership and improve hygiene while maintaining outstanding levels of quality for soft dough cookies and bars. The TruClean wirecut includes a new method of sealing the ends of the hoppers to the feed rolls, which eliminates leakage and is easier to maintain. Meanwhile, customers select from three levels, with the choice linked to their own cleaning regime and cross-contamination risk. The TruClean is available in a variety of band widths from 812 to 1,525mm and speeds from 60 to 200 cuts per minute. Baker Perkins Inc. Grand Rapids, Mich. 616-784-3111 www.bakerperkinsgroup.com

View videos demonstrating the newest bakery & snack food equipment by visiting www.snackandbakery.com

Snack Food & Wholesale Bakery - January 2011

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Even in the hottest ovens, we stay cool. Because the efficient handling and processing of raw materials has a decisive impact on the cost-effectiveness of production in industrial bakeries, we work with you to develop and implement solutions for every stage of the process: intake, storage, proportioning, and weighing of dry and liquid products. System controls allow for customized recipes, and can easily be integrated into your production planning system. For more information go to www.buhlergroup.com.

Buhler Inc., 13105 12th Ave N., Plymouth, MN 55441, T 763-847-9900 [email protected],

Innovations for a better world.

Production Technology Belts & Conveyors

Conveying Outside of the Belt Many of today’s equipment manufacturers are designing an assortment of belts and conveyors that bring more to the snack and bakery line than just a run-of-the-mill piece of machinery. Marina Mayer, executive editor

hen it comes to belts and conveyors, bakers and snack food producers are in search of the ultimate package deal. Belts and conveyors must be easy to clean and energy-efficient, able to accommodate multiple lines and temperatures and maintain a simple design and flexible footprint. In effect, they must do it all. That’s why several of today’s manufacturers are ramping up their portfolios with a lineup of belts and conveyors that bring more to the line than just a run-of-the-mill piece of machinery.

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Conveyors that count In the fall of 2010, for instance, Dorner Mfg. Corp. introduced DustPruf conveyors for dry goods. “[They] incorporate a patent-pending SmartSlot technology, which provides an innovative mounting and accessory function while maintaining a clean, flush-side conveyor frame for ease of cleaning and wipedown,” says Michael Hosch, director of product development. To meet the changing requirements of today’s baking industry, the Hartland,

Photo courtesy of Heat and Control

Wis.-based company also added a center drive unit to its AquaGard 7360 Series conveyor, which is a stainless-steel-based conveyor designed for use in bakery processing and packaging applications. “The baking industry is going through much change today,” Hosch says. “There is a dramatic move to improving the sanitary design of equipment and conveyors used in the bakery process.” Likewise, processors require low- or no-maintenance reliability from their conveyors, easy cleaning and the flexibility to use the conveyor for different products, says Blake Svejkovsky, manager of product handling systems for Heat and Control, Inc. That’s why the Hayward, Calif., manufacturer developed the ClimbBack pan for FastBack horizontal motion conveyors. “Horizontal motion conveying significantly reduces product breakage and loss of coatings, accumulations of oil and seasonings in the conveyor pan and unscheduled downtime for cleaning, but it was

Photo courtesy of Dorner Mfg. Corp.

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previously unable to move products up inclines,” Svejkovsky says. “ClimbBack now allows products to be conveyed up to eight degrees of incline. This saves floor space by permitting closer placement of conveyors in distribution systems, and in some cases, eliminating the need for separate elevating conveyors.” Heat and Control also introduced a line of flighted incline conveyors, designed to reduce product damage, spills and sanitation costs. The line features a compact design, Svejkovsky notes. “Hinged side guides and catch pans allow the conveyor to be fully opened for easier cleaning and complete access to the belt,” he adds. “Modular construction makes it less costly to reconfigure the conveyor for future needs instead of having to buy a new conveyor.” The line of vibratory conveyors also provides an assortment of uses, including grading, alignment, dewatering, spreading and bi-directional conveying. “You can choose electromagnetic, indirect or direct drives and a variety of pan configurations to customize the conveyor for your application,” Svejkovsky says. Continued on page 78

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In 1959, twenty-two St. Mary's College students set a world record by cramming into a phone booth.

22 is Still The Record The Industry’s Original CB5 Baking Band® is Still Inspected with 22 Quality Checkpoints to Guarantee True Tracking and a Long Operating Life. Ashworth introduced and patented the CB5 Baking Band ® in 1963 and after 46 years, it remains the industry leader. Ashworth’s CB5 is hand woven by expert craftsmen and inspected with 22 different checkpoints to ensure the highest quality belt. Each CB5 is tested for true tracking prior to leaving the factory. The dense breathable weave provides even heating and outstanding relief of cooking gases. For perfectly baked products, rely on the performance of Ashworth’s Original CB5 Baking Band ®

Contact Ashworth Today - We’re Just a Phone Call Away! +1-800-682-4594

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Production Technology Continued from page 76

For a precise, on-machine seasoning application, Svejkovsky adds, Heat and Control’s Revolution system is now available with a loadcell in the conveyor pan. “We call it the WeighBack option on the FastBack product feed conveyor,” he says. “The loadcell accurately measures product flow so the seasoning applicator delivers precisely the right amount of seasoning to meet your target. This prevents wasteful over-seasoning.” For its part, tna North America developed what it calls the next generation of vibratory conveyors. The roflo 3 offers reduced noise levels, zero maintenance, a simple and clean design and a patented gateless discharge (i.e. no need for any form of mechanical gate mounted on the end of the tray), says Roger Treacher, key accounts manager — conveying systems — for the Coppell, Texas, company. “As a result of the ever-increasing demands of food safety, greater pressure is

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applied to the suppliers for simpler, easier and safer equipment to operate and clean,” Treacher adds. “tna has made huge strides to minimize each of these areas, examples of which include our gateless design distribution system, which greatly reduces cleaning downtime due to a complex mechanical gate being removed from the direct product stream, fully welded pans (no opportunity for bacteria buildup in crevices), no internal bolt heads or fasteners in the product zones and 2B mill and polished finishes on our stainless-steel contact parts. In addition to these detailed design areas, we also look at the overall system to evaluate the product path, product zone and product area, to ensure they are safe from potential product contamination via other areas or services within the facility, which are outside of our scope of supply (i.e. painted service runs etc.).” In recent months, Hapman launched the Helix Hi/Lo flexible screw conveyor with

Photo courtesy of Hapman

a sanitary mass-flow hopper, according to Mike Zeluff, product manager, flexible screw conveyors. “The hopper’s unique design aids in discharging sluggish and non-free flowing ingredients,” he adds. Its unique design allows a single operaContinued on page 80

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Increase product yields and improve your bottom line.

Use CompactGrid™ conveyor belting …only from Wire Belt. t Quicker & more efficient heating & cooling of product. t 5X greater flow through than average plastic modular belt. t Excellent product support for smaller products. t Fast & simple belt joining. t Conserve energy, low horsepower requirement. t USDA Accepted, easy to clean. t Manufactured by Wire Belt Company, the name you trust.

Wire Belt Company of America, 154 Harvey Road, Londonderry, NH 03053 5&-

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Production Technology Continued from page 78

tor to safely and easily handle washdowns, auger changeouts and service from the floor level. Plus, the mass-flow hopper encourages discharge of sluggish or non-freeflowing ingredients without the need for a separate in-hopper agitation. “There is a great demand for quickcleaning conveyors to assure food manufacturers maintain the highest level of sanitation,” Zeluff says. “Hapman’s various designs accommodate stringent guidelines

for cleaning and ease of maintenance. Welds are ground to a sanitary finish with no standing water on any surface and standoffs are used for equipment wiring avoid product buildup and contamination.” Meanwhile, KESS Industries introduced a reciprocating conveyor that aids in metering product onto belts that are at a 90-degree angle to the flow of the conveyor, says Ray Cassingham, sales and estimating, for the Auburn, Wash.-based company. “The applications reciprocating conveyors are used for are orienting product to be turned 90 degrees for packaging, or to be metered onto another belt for a different process,” Cassingham adds.

Belting it out Photo courtesy of KESS Industries

Conveyance will always be a part of the large bakery process, says Jonathan Lasecki, chief engineer of Ashworth Bros.,

Photo courtesy of Ashworth Bros., Inc.

Inc. That’s why the Winchester, Va., manufacturer introduced the Omni-Pro 150 FlexLite. “This belt is an extension of our OmniPro family but instead of having a wire mesh overlay, it features a formed flat-wire picket,” Lasecki adds. “This belt is perfectly suited to cooling of panned or large baked products. It is one of the strongest belts available, allowing longer runs with Continued on page 82

APPETITE FOR SUCCESS? SCHAAF

FOOD

EXTRUSION

TECHNOLOGY

Do you wish to explore products with ‡ multiple colours? ‡ open pored surfaces? ‡ thinwall technology? ‡ 3D shapes? ‡ fillings and closed edges? Just get in touch with us for further information on the latest technology or simply schedule a visit! Turbo extrusion, Co-extrusion, Colour-injection, LDI – Liquid Direct Injection etc.

www.foodextrusion.com

...we shape the world!

y an K C m PA G e r F2 3 R T E r f, d IN ldo t an S se 3, s e ll Du Ha

Schaaf Technologie GmbH • [email protected] • phone: + 49(0)6434 91720

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Solve. Simplify. Save. Intralox’s new, breakthrough technologies can grow profits on your conveyor belts. Patented Intralox ThermoDrive® Technology —Continuous, easy-to-clean surface dramatically improves food safety

Patented Intralox ARB™ Technology —Activated belt rollers intelligently automate process flow

Food processors need simple ways to solve problems and save money. Intralox ThermoDrive and Activated Roller Belt technologies are both easy and cost-effective to implement and have proven immediate impact on plant operating costs. Call us today! Speak to a customer service representative who specializes in your industry: US/Canada 1.888.680.2358, Europe +800.2253.7437, or www.intralox.com.

Production Technology Continued from page 80

fewer transfers. Like all the Omni-Pro belts, this belt has full 360-degree welds and it is manufactured to have zero-tension welds to provide longer belt life.” Meanwhile, Wire Belt Company of America’s latest innovation is the CompactGrid, which delivers ease of cleaning and flow-through capabilities, especially in

Photo courtesy of Wire Belt Company

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Snack Food & Wholesale Bakery - January 2011

applications where product coating, drainage or air and liquid circulation are factors, says Jamie Card, marketing specialist for the Londonderry, N.H., company. “The stainless-steel construction and hygienic design of the belt and sprockets makes CompactGrid ideal for clean-inplace (CIP) systems,” she adds. “CompactGrid’s openness of 3/8x3/8-in. pitch makes it one of the safest belts available to the food and snack industry. The belt practically eliminates the possibility of propagation of pathogens, which can be seen in belts that have connecting rods, as seen on a flat wire belt. The 70% open area along with the belt thickness of 0.20 in. not only assists during sanitation, but [also] with air circulation and drainage that is restricted by the traditional flat wire style of conveyor belting.” Wire Belt also offers Flat-Flex belting with tighter meshes that is primarily used in chocolate enrobing where there is less

Photo courtesy of Berndorf Belt Technology USA

chance of the candy to exhibit the marks of the belt on the bottom of the product, Card adds. “The unique qualities are the tight transfers, open mesh design for heating and cooling and ease of cleaning.” For its part, Berndorf Belt Technology USA, based in Elgin, Ill., launched

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Production Technology the bernmatic BTRV Belt Tracking Roller from Berndorf Band Engineering GmbH, which offers precise belt tracking due to continuous belt monitoring, says Daniela Weiszhar, marketing manager. “Some advantages of the new bernmatic BTRV Belt Tracking Roller include easy integration into existing systems, a compact design, belt tracking independent of speed and reduced downtime from optimal belt guidance,” she adds. “The bernmatic BTRV Belt Tracking Roller increases the overall life of your belt and allows your belt to run perfectly for perfect product quality.” Weldon Solutions, headquartered in York, Pa., introduced PanVerter, which takes advantage of a series of conveyor belts to control the flow of pans, meter individual pans into an in-line rotor, turns pans upside down and

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automatically clean pans while they are upside down, says Charles Gales, manager of automation sales. “Each section of conveyor was designed with specific belt characteristics in mind,” he adds. “Belt material and construction were selected based on speed, sprocket diameter, coefficient of friction, heat resistance, durability and sanitation. [Plus,] the dual-magnetic conveyors of the

Photo courtesy of Weldon Solutions

rotor allow for pans to be turned over or passed through at a constant elevation. This provides production flexibility since pans can be cleaned every time that they pass through the baking line or at desired intervals.” To stay in line with ever-changing industry demands, Intralox L.L.C. developed a series of belt technologies. For starters, the Activated Roller Belt (ARB) technology enables both packaged and unpackaged products to be manipulated in various ways to assist in singulation, switching and merging, says Donald Osborne, bakery team leader, The Americas. Meanwhile, the ThermoDrive technology combines the reliable, positive drive benefits of modular belting with the cleanability of solid plastic belting, Osborne adds. And the Intralox i-Drive allows modular plastic belts to run for as long as necesContinued on page 84

January 2011 - Snack Food & Wholesale Bakery

83

Production Technology Continued from page 83

sary, potentially reducing the number of drives and completely eliminating transfers, which can cause product disorientation and product damage, Osborne says. “Today’s bakers and snack producers are looking for conveyors and conveyor belts that are easy to clean and meet all of the current government standards for sanitation and food contact,” Osborne says. “They also want belts that can provide longer belt life and allow for quick product changeovers.”

Staying within the lines While this laundry list of new innovations meets the needs of bakers and snack producers, challenges such as sanitation and stricter governmental requirements continue to force many equipment manufacturers to stay within budget. “The major challenge is to provide a

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Snack Food & Wholesale Bakery - January 2011

Photo courtesy of Intralox

design that meets the stricter requirements for sanitation along with maintaining a competitive price point that is expected by the baking industry,” Hosch says. In addition, the ability to quickly and thoroughly clean conveyors during the scheduled sanitation period is very important to food safety, product quality and efficient operation, Svejkovsky says. “This means conveyors must operate

cleanly during the production shift, with no unscheduled shutdowns to remove seasoning buildups from the pan. FastBack’s gentle horizontal motion and one-piece stainless-steel pans have set the industry standard for these goals,” he adds. On the other hand, many of today’s requirements are not completely new, according to Treacher. Rather, “they represent a heightened intensity of what manufacturers have always looked for, due to increasing regulatory and competitive pressures. Cleaning has always been important, but with the requirements for short runs\fast changeover and increasing focus on allergens\cross-contamination, this is elevated to a whole new level,” he adds. Today’s manufacturers are thinking outside of the box by creating a host of belts and conveyors that bring so much more to the table than any old run-of-themill machine. SF&WB

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Ad Index Company

Page

Company

ADM Cocoa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11, 65 www.adm.com

Fritsch USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 www.fritsch-usa.us

ADM Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21, BC www.adm.com/milling

Georgia Nut Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

AIB International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 www.aibonline.org/schoolofbaking

Grain Millers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 www.grainmillers.com

Almond Board of California . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 67 www.AlmondBoard.com

Great Western Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 51 www.gwmfg.com

ALIT SRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 www.alit.it

Heat and Control Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25, 49 www.heatandcontrol.com/s1 www.heatandcontrol.com/s2

Arizona Instrument LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 48 www.azic.com American Society of Baking / ASB. . . . . . . . . . . . . . . . . . . . . . . . . . . 91 www.asbe.org Ashworth Bros., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 www.ashworth.com Bay State Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 www.baystatemilling.com

www.georgianut.com

Hinds-Bock Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33 www.hinds-bock.com Hixson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 webinars.snackandbakery.com International Bakers Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 www.Áavors.org Intralox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 www.intralox.com

Berndorf Belt Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 43 www.berndorf-usa.com

Koenig Bakery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 www.koenigusa.com

Blue Diamond Almonds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 63 www.bluediamond.com/industrial

Kwik-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 www.kwiklok.com

BluePrint Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78, 82 www.blueprintautomation.com

LeMatic Innovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 www.lematic.com

Brolite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 www.bakewithbrolite.com

Natural Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 www.npisoy.com

Buhler Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 75 www.buhlergroup.com

NCA Expo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 www.sweetsandsnacks.com

Cablevey Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 83 www.cablevey.com

Quickdraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 www.quickdraft.com

Caravan Ingredients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 85 www.caravaningredients.com

Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 www.reiser.com

Cargill Salt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 www.cargillsalt.com Charles Ross & Sons Company . . . . . . . . . . . . . . . . . . . . . . . . . 71, 73 www.ribbonBlenders.com

Schaaf Technologie GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 www.foodextrusion.com Sensory Effects Inclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 www.sensoryeffects.com

Christy Machine Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53, 59

SK Food International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 www.skfood.com

ConAgra Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29, 31 www.conagramills.com

Solvay Chemical, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC-3 www.solvaychemicals.us

Delkor Systems, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 www.delkorsystems.com

Wire Belt Company of America . . . . . . . . . . . . . . . . . . . . . . . . . 79, IBC www.wirebelt.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) 4244-6499 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]

Snack Food & Wholesale Bakery - January 2011

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.

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The Final Word

, It’s Great to Finally Meet You ooking back, 2010 was quite a year. From product recalls, food safety issues and large company buyouts to portion-controlled and single-size product servings, eco-friendly plant enhancements and the blossoming private-label movement, this industry has been busy. As a consumer though, I’ve also been busy trying to keep tabs on what products are healthy, which are not and whether or not I should switch from brands to privatelabel items or just buy the brands using a coupon. I’m also even studying ingredients labels and Nutrition Facts listings. I think I speak on behalf of the industry when I say, all of this is making me tired.

L

a healthy but balanced diet. “The updated USDA dietary guidelines, in conjunction with technological advancements and the First Lady’s ‘Let’s Move’ program, will mark 2011 as the year that empowered Americans make permanent, positive changes in their diets,” says Phil Lempert, the Supermarket Guru. “Finally, people will stop lasering in on single nutrients and begin approaching food holistically.” Imagine that, not focusing on just one nutrient and looking at food in the big picture. What a concept. In addition to the enhanced dietary guidelines, Lempert also introduced a 2011

We all may be tired, but here’s to looking forward to a new-and-improved, energized year, assuming everyone wakes up and follows the rules. From the looks of how 2011 will turn out, now is not the time to catch up on that much-needed sleep. That’s because the New Year will impose some fun, exciting and even industry-changing things that we can’t afford to miss. For starters, the U.S. Department of Agriculture (USDA) updated the dietary guidelines to now act as a lean, mean, fatfighting machine. Whether the focus is on energy balance, weight management, nutrient adequacy or fatty acids, the revised guidelines present a foundation for how Americans should eat in order to maintain

94

Snack Food & Wholesale Bakery - January 2011

forecast that outlines a host of new trends set to impact the snack food and wholesale bakery industry. For example, foods containing Vitamin D will be touted as the best thing in the aisles, and some producers may even turn to naturally occurring Vitamin D solutions to provide that added healthy bonus. Meanwhile, companies will enforce clearer claims on their products and will better highlight better-for-you attributes, such as vitamins, minerals, fiber content, lower sodium, etc. Some companies have already made this switch by introducing

Marina Mayer, executive editor [email protected]

a lineup of packaging changes that were put in place primarily to better “speak” to consumers (check out the Market Trends article of Snack Food & Wholesale Bakery’s December 2010 issue to learn more about what types of packaging initiatives are in store for the New Year). From my own research, social media and other networking sites are transforming brand awareness into a league of its own. Whether it’s a Facebook contest, an iPhone application, a survey on Twitter or a voting poll on a particular website, companies are giving shoppers every opportunity to be involved with increasing recognition of a particular brand or variety. I predict this will only continue to evolve because let’s face it, everyone has an opinion. I also foresee consumers sticking with private-label brands as they’ve learned (and I have to) that they’re pretty much the same as their branded counterparts — just easier on the bank account. For the past couple of years, the snack food and wholesale bakery markets have been riding the waves of a roller-coaster economy and continue to please the everchanging, sometimes-fickle consumer. Despite the many challenges though, everyone survived — well almost everyone (we can’t forget the lovely “egg” people). Some companies have managed to turn today’s challenge into tomorrow’s opportunity. (Snack Food & Wholesale Bakery’s 2011 Snack Manufacturer of the Year did just that. Look for the feature and plant story in next month’s issue.) We all may be tired, but here’s to looking forward to a new-and-improved, energized year, assuming everyone wakes up and follows the rules. SF&WB

www.snackandbakery.com

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