FROM FORMULATION TO FINAL PRODUCT Look to ADM to increase your edge in the competitive baking segment. The ADM Bakery Platform is a network of R&D services designed to help our customers achieve maximum success. Think of us as your single point of contact for technology and resources that keep you on the cutting edge. Whether you’re looking to identify market trends, develop new products or enhance existing ones, we aim to exceed your expectations – quickly and efficiently.
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Contents
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12 | 2011 State of the Snack Industry Report: Overview
Production, Technology & Product Development Solutions for a Changing Industry. July 2011 Vol. 100 No. 7
Whether it’s a picnic, ballgame, festival or just lounging in the sun, the state of the snack industry proves that consumers are in for one wild, fun-filled, tasty ride.
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
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18 | Potato Chips
Potato chips have been around for ages and are a simple but fantastic idea in origin. But one thing’s certain: They’re as classic as a state fair.
John Schrei Publishing Director
[email protected]
Tom Imbordino Group Publisher
[email protected]
26 | Tortilla Chips
32
Today’s tortilla chip makers prove that all it takes is a blend of bold flavors, zesty spices and some pizzazz in a bag in order to keep the fiesta goin’.
Jeff Heath Publisher
[email protected] 224-554-9154
Editorial Lauren R. Hartman Editor-in-Chief
[email protected] 847-405-4015
32 | Pretzels
Marina Mayer Executive Editor
Pretzels are evolving and taking on an action-packed Mad Mouse ride of bolder flavors, different spins on ‘tried-and-true’ recipes and sandwich fillings of sweet or savory varieties.
Patty Catini Art Director
[email protected] 847-405-4008
Advertising & Internet Sales Barbara Szatko Senior Sales Manager
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40 | Crackers
[email protected] 630-527-9927
Suzanne Sarkesian Classified Sales
[email protected] 248-786-1692
Cracker producers have redefined what crackers represent to consumers—whether they’re a stand-alone item or a complementary piece to a larger snacking solution, they’re filling the void for fun-filled snacking occasions.
Jill L. DeVries Corporate Reprint Manager
[email protected] 248-244-1726
Support Services Nann Barkiewicz Production Manager
44 | Popcorn
[email protected]
Liz Wright Marketing Coordinator
Recent popcorn introductions offer up robust flavors, healthier formulations and convenience—an amusement park of ingredients for summertime snacking.
[email protected] 248-786-1652
44
Kourtney Bell Audience Development Manager Stephanie Hunt Multimedia Specialist Carolyn M. Alexander Audience Audit Coordinator
48 | Nuts & Trail Mix Nuts, trail mixes and nut-and-fruit confections offer consumers convenient, flavorful pick-me-ups, as they try to get the most out of each summer day.
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List Rental Postal contact: Kevin Collopy at 800-223-2194 x684
[email protected]
54 | Jerky & Meat Snacks
Email contact: Michael Costantino at 800-223-2194 x748
[email protected]
Even though the temperature outside may be striking a new high, today’s jerky and meat snack manufacturers are still raising their own heat with hot flavorings and spicy offerings.
58 | Pork Rinds New varieties and larger portions give pork rind-loving consumers even more snacking options.
Audience Development
BNP Corporate
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Timothy A. Fausch Publishing John R. Schrei Publishing Rita M. Foumia Corporate Strategy Ariane Claire Marketing Vincent M. Miconi Production Lisa L. Paulus Finance Michael T. Powell Creative Nikki Smith Directories Marlene J. Witthoft Human Resources Emily Patten Tradeshows & Conferences Beth A. Surowiec Clear Seas Research BNP Media Helps People Succeed in Business with Superior Information
Continued on page 4
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Snack Food & Wholesale Bakery - July 2011
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Whe n y o u r la be l s ay s “0 g t r an s -f a t” w o u l d n’t you l i k e t o rea l ly me a n i t ?
Contents Columns 6 | Editor’s Note
63 | Engineering Management
The Sweets & Snacks Expo was a festival of finger foods, says Editorin-Chief Lauren R. Hartman. Find out what new product introductions hit the show floor.
Contributing columnist, Jeff Dearduff, instills an old/new engineering concept to help manufacturers conceive ideas, design and implement processes and train employees.
60 | The Nutritional Corner
72 | The Final Word
The Grain Foods Foundation supports the new MyPlate icon, says contributing columnist Judi Adams. Find out how the newly revised graphic helps consumers eat more grains.
This year’s Dairy-Deli-Bake Seminar & Expo was a hit all around, according to Executive Editor Marina Mayer, thanks to high attendance, a bevy of new bakery products and, oh yeah, that Joe Montana guy.
SNACK FOOD & WHOLESALE BAKERY (ISSN 1096-4835) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or
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Editor’s Note
Festival of Finger Foods went to the Sweets & Snacks Expo, May 24-26 in Chicago, for the first time, and enjoyed seeing all kinds of new products. Hosted by the National Confectioners Association (NCA), Washington, D.C., the show drew plenty of inspiration. There were thousands of new, exciting snack products from hundreds of exhibitors. I was thrilled that about 40% of the exhibits featured snacks, though there were more than enough candy, chocolate and other sweet confections too numerous to mention. According to the NCA, this year’s show experienced 13% growth in the number of exhibitors and was the largest in terms of both floor space and exhibitors in the event’s 15-year history. In fact, there were more than 14,000 visitors from across the globe and 545-plus exhibitors, including 160 new ones. “We have established a waiting list for exhibitors,” Lauren R. Hartman says Larry Graham,
[email protected] president of NCA. “Our attendee registration count also tracked ahead of our record-breaking 2010 show counts, and 29% of our exhibitors were new to the 2011 event.” Fun new trends were everywhere, including a gourmet marketplace set up with hundreds of items on display, as well as a new product showcase that boggled the mind with automatic data scanning for more than 60 snacks and specialty treats. All natural played a big part in the introductions there, as consumers are looking for both healthy and indulgent products. Consumers want healthier snacks with quality, whole ingredients and no preservatives
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Snack Food & Wholesale Bakery - July 2011
without sacrificing taste, according to American Roland Food Corp., Hatfield Mass. The specialty food importer launched all-natural butter cookies made with a handful of delicious ingredients: Sables Shortbread Crisps, made from a combination of seven all-natural ingredients and real butter; and Galletes Shortbread Cookies, which hit the sweet spot between great taste and better-for-you. Americans are also developing more of an appetite for hummus, which is listed as one of the hot ingredients for 2011 by industry trend watcher Andrew Freeman. That’s why Simply 7 Snacks created plenty of buzz with its Hummus and Lentil Chips, which are all-natural chips that provide an ethnic twist for the health-conscious consumer. The Houston-based company insists that lentils aren’t just for soup and salad and hummus doesn’t have to be just a dip. “Imagine the first guy who thought to turn a potato into a potato chip,” says Simply 7 president Rashim Oberoi. “That’s us with new ingredients. And we’ve worked tirelessly to ensure that our chips taste authentic and are healthy, the way you’d expect.” Speaking of chips, Natural Snacks, LLC, Addison, Ill., showcased its Michael Season’s kettle-cooked potato chips in Lightly Salted, Sea Salt & Balsamic Vinegar, Honey BBQ, Jalapeño and Unsalted (which I truly applaud) varieties. Various snack makers featured retro themes, such as Natural Snacks with its retro Hot & Spicy Flavored tortilla chips. Freezedried fruit snacks in convenient stand-up pouches from Funky Monkey Snacks, Fishers, Ind., feature a better-for-you ingredients list, so those with food allergies can snack worry-free. For those computer and video game enthusiasts (and who isn’t?), stand-up pouches of Gamer Grub performance snacks (produced by Biosilo Foods, Inc., San Diego) boast no keyboard crumbs and no greasy fingers, though I doubt these
are in the healthy category. And Diamond Foods, Stockton, Calif., announced that its Emerald brand’s new Breakfast on the go! Nut & Granola Mix has joined Pop Secret in support of the Labels for Education program to nourish kids’ potential and energize back-to-school sales. Seasoned nuts in more exotic flavors are a big trend. Flavors from Sahale Snacks, Seattle, include Barbeque Almonds with Mild Chipotle & Ranch, Southwest Cashew with Chile & Cheddar and Tuscon Almonds with Parmesan & Herbs. Lord Nut Levington (made by Holy Cow LLC, Irving, Texas) is a new line of seasoned peanuts that come in five varieties—the Rebel Mary variety incorporates tomato and garlic powders mixed with traditional Bloody Mary ingredients. Corazonas Foods, Inc., Los Angeles, offers kettle-style potato chips in five new gourmet options with 40% less fat than most regular chips. Plus, they are gluten-free, have no trans fat and are said to have 0.4 g. of plant sterols per serving, which helps lower LDL cholesterol. Kernel Season’s, based in Elk Grove Village, Ill., unveiled bags of popcorn in several exciting kinds that are made with its popular seasoning. But the snacking doesn’t stop with that. This month, our annual State of the Snack Industry report is a festival of snacks, covering everything from trends and analysis to product performance and packaging initiatives. We start with an overview of the market, and move into potato chips, tortilla chips, pretzels, nuts and trail mix, jerky and meat snacks, popcorn and pork rinds. We uncovered interesting market share and product category reports and interviewed various snack industry product leaders, marketers, executives and plant managers. We’ll also tell you what’s in store in the snack food industry, acting as a carnival of information for producers and suppliers alike. We hope you enjoy, so grab your favorite beverage, a napkin and take a look. SF&WB
www.snackandbakery.com
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Business Briefs
people
News
IN MEMORIUM
National Baking Week Kicks Off Aug. 29-Sept. 4 hare Our Strength, the Washington, D.C.-based nonprofit organization fighting to end child hunger in America, announces National Baking Week, Aug. 29Sept. 4, as part of its Great American Bake Sale fundraising program. National Baking Week encourages bakeries, restaurants and freestanding and supermarketbased delis to host bake sales, promotions or simply donate a percentage of sales from that week to help make sure no child in America goes hungry. “National Baking Week gives bakeries, restaurants, delis and supermarkets an avenue to support the Great American Bake Sale and help us put an end to childhood hunger,” says event director Amy Crowell. “It’s a unique way to rally employees behind a common cause, and it makes customers feel good about patronizing a business that gives back to the community it serves.” Individual bakery and deli businesses can develop their own promotions, which gives them added flexibility, according to Crowell. To access online promotion elements, visit the Bake Sale Resource Center at www. greatamericanbakesale.org.
S
USDA Unveils New Food Icon n June 2, the U.S. Department of Agriculture (USDA) unveiled a replacement to its muchmaligned food pyramid, doing away with the rainbow-striped triangle with a staircase edge in favor of a simple circle designed to evoke a dinner plate, divided into four quadrants: Fruits; vegetables; grains; and protein (meat and beans). Dairy occupies a circle to the upper right of the plate. A plate symbol provides an easy-to-understand visual of how much of different types of foods Americans should be eating each day. The decades-old food pyramid was replaced with the plate-shaped icon, which experts say better depicts the balance of food groups recommended in a healthful
O
diet. First Lady Michelle Obama and agriculture secretary Tom Vilsack presented the new healthy eating guide. The icon is part of a new initiative to stress habits such as eating less, filling up half your plate with fruits and vegetables and drinking more water. The USDA first introduced the food pyramid in 1992. So far, representatives from food industry trade groups are reacting positively to the change. The American Bakers Association, Washington, D.C., reported that it’s coordinating the joint response by a dozen groups representing the grain industry. This includes a joint press meeting with members of its nutrition advisory committee to discuss the impact of the new icon on grain foods.
Earl John “Bud” Gilmartin, Jr., Commercial Creamery Co. Earl John “Bud” Gilmartin, Jr., president of Commercial Creamery Co., Spokane, Wash., passed away recently. In 1933, Gilmartin purchased Gold Medal Dairies from Kraft Foods, and in 1948, purchased Commercial Creamery Co., where he became president and added manufacturing plants in Afton, Wyo. (1973); Jerome, Idaho (1977); and Louisville (1986). Gilmartin also started several other companies with partners including an egg business headquartered in Hong Kong and a flavor business headquartered in New York. He served on Gonzaga University Board of Regents, his alma mater, as well as many boards having to do with the food industry. In lieu of flowers, memorial contributions may be made to the Bud Gilmartin Fund at Gonzaga University, Attn: University Relations, 502 E. Boone Ave. Spokane WA 99258. To leave a condolence, go to www. hennesseyfuneralhomes.com.
MGP Ingredients Inc., Atchison, Kan. Ashley Gill has been named communications specialist, responsible for assisting with the execution of overall publicity and promotional projects, including internal communications programs and marketing communications ini- Ashley Gill tiatives. Meanwhile, Stephen Glaser was appointed plant manager at the Atchison, Kan., facility, responsible for the management of all operational activities and processes, including account- Stephen Glaser ability for plant performance, safety, environmental and quality objectives and the Continued on page 10
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Snack Food & Wholesale Bakery - July 2011
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Jodie Morgan has been appointed president and general manager, bringing more than 20 years experience in commercializing chemicals and food ingredients. Previously, she was president of SPI Foods, where she reorganized and repositioned the business, including negotiating long-term sup-
supplier news The Buhler Technology Group acquired Tijdhof Persmatrijzen, Oldenzaal, The Netherlands, and was integrated into the feed and biomass business unit. The management and the roughly 20 employees were retained by the company, which will be continued under the Buhler Tijdhof product brand. ENRECO obtained third-party verification of a five-log kill step for its flaxseed ingredient processing lines, reaffirming the company’s commitment to operate in accordance with the Global Food Safety Initiative. Delkor has been named as the exclusive distributor for HMPS, a leading Australian packaging machinery manufacturer. Delkor will provide cartoning equipment for HMPS’ Australia and New Zealand markets.
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Snack Food & Wholesale Bakery - July 2011
Damien Perocheau has been named regional manager of the French operations, responsible for developing new and existing customer relationships and driving sales in the French market. He will work with current French customers, and focus on driving business growth, developing new relationships and boosting the company’s French sales.
Omega-9 Oils from Dow AgroSciences helped remove more than 1 billion lb. of saturated and trans fats from the North American diet, thanks to its new line of NEXERA canola and sunflower seeds. Blommer Chocolate is tripling capacity of its 85,000-sq.-ft. Campbellford, Ontario plant, which manufactures specialty and cocoa-based coatings and protein-forti-
fied products for the confectionery, snack and nutritional bar markets. The expansion is expected to be completed in the fourth quarter 2011. Loma Systems, an ITW co., created a strategic partnership with Dorner Manufacturing for the manufacture of conveyors for sanitary applications. This partnership allows both companies to offer proven, sanitary inspection solutions to a wide range of applications. Spraying Systems released a 72-page tank cleaning catalog called the “TankJet Tank Cleaning Products.” This catalog provides complete information on automated tank cleaning equipment and provides users on how they can increase production time and reduce labor costs without compromising cleaning effectiveness. The catalog also reviews key selection factors such as spray distance, impact, flow rate and coverage and offers guidelines, technical specifications and a list of tank cleaning accessories.
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. www.snackandbakery.com
2 0 1 1
STATE OF THE SNACK INDUSTRY Snack Food & Wholesale Bakery chats with snack manufacturers to learn
more about new products, new packaging concepts and innovative ingredient solutions—all factors in developing a picnic of fun-filled fare. Potato Chips . . . . . . . . . . . . . . .18 Potato chips have been around for ages and are a simple but fantastic idea in origin. But one thing’s certain: They’re as classic as a state fair.
Tortilla Chips . . . . . . . . . . . . . . .26 Today’s tortilla chip makers prove that all it takes is a blend of bold flavors, zesty spices and some pizzazz in a bag in order to keep the fiesta goin’.
Pretzels . . . . . . . . . . . . . . . . . . .32 Pretzels are evolving and taking on an actionpacked Mad Mouse ride of bolder flavors, different spins on ‘tried-and-true’ recipes and sandwich fillings of sweet or savory varieties.
Crackers . . . . . . . . . . . . . . . . . .40 Cracker producers have redefined what crackers represent to consumers—whether they’re a stand-alone item or a complementary piece to a larger snacking solution, they’re filling the void for fun-filled snacking occasions.
Popcorn . . . . . . . . . . . . . . . . . . .44 Recent popcorn introductions offer up robust flavors, healthier formulations and convenience—an amusement park of ingredients for summertime snacking.
Nuts & Trail Mix. . . . . . . . . . . . .48 Nuts, trail mixes and nut-and-fruit confections offer consumers convenient, flavorful pickme-ups, as they try to get the most out of each summer day.
Jerky & Meat Snacks . . . . . . . .54 Even though the temps outside may be striking a new high, today’s jerky and meat snack manufacturers are still raising their own heat with hot flavorings and spicy offerings.
sponsored by
Pork Rinds . . . . . . . . . . . . . . . . .58 New varieties and larger portions give pork rind-loving consumers even more snacking options. www.snackandbakery.com
July 2011 - Snack Food & Wholesale Bakery
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S TAT E O F T H E I N D U S T RY Overview
Carnival of Snacks
Whether it’s a picnic, a ballgame, a county fair or just lounging in the sun, the state of the snack industry proves that consumers are in for one wild, fun-filled, tasty ride. Marina Mayer, Executive Editor
T
oday’s snacks don’t need to don fancy costumes or hide behind magical face paint to garner attention. They also don’t require stunts, tricks or fictional characters parading around the plaza. That’s because many snacks maintain authenticity, originality, innovation and pizzazz. They are themselves, showing off their tried-and-true attributes, complete with hot and savory flavorings, convenient and easy-open packaging concepts and are on a mission to provide consumers the tastiest, yet healthiest snacks possible. Whether it’s a beef jerky stick laden with hot spices, crackers that put the fun in functional, chips that feature a bevy of shapes, sizes and textures, pretzels that
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garner a new twist or those hybrid items that don’t yet seem to have a specific home on the shelf, the snack aisles are sure to be set ablaze with fun-filled options.
Figures don’t lie According to Chicago-based SymphonyIRI Group, the salty snack arena remains the highest grossing segment in the snack industry, with $13 billion in 2010. Categories such as potato chips, tortilla/tostada chips and cheese snacks garnered a majority of the winnings, raking in $4.8, $3 and $1.2 billion, respectively. The cracker category roped in $4.4 billion in sales, with all other crackers (excluding breadsticks, graham crackers, matzah, saltines and those with fillings) accounting
for $3.1 billion in sales. Snack nuts experienced $2.7 billion in sales while dried meat snacks saw $1.3 bil-
www.snackandbakery.com
S TAT E O F T H E I N D U S T RY
lion. Miscellaneous snacks, such as apple chips, carob-, yogurtand chocolate-covered snacks, nutritional snacks and trail mix took in $606.8 million in sales.
Snackscapade “[The snack category] is a great place to be,” says Jeff LeFever, director of marketing for Jack Link’s Beef Jerky, Minong, Wis. “The trend toward snacking as a behavior is only getting stronger. If the industry listens to consumers and stays ahead of changing wants and needs, the future is going to be very, very bright.” Trends such as better-for-you, unique flavor combinations, spicy and ethnic flavors and all-natural top the charts, says Steve Sklar, senior vice president of marketing for Inventure Foods, Phoenix, Ariz. To stay on trend, in July 2010, Inventure Foods debuted Boulder Canyon brand Hummus & Sesame chips, which are lightly
salted with hummus and sesame seeds and are a good source of fiber. Inventure Foods also expanded its TGI Friday’s line of snack items to include Jalapeño Cheddar Crunchy Cheddar Bites. These zero-trans-fat snacks blend jalapeño spices and cheddar cheese to deliver crunch and spice in every bite. Also hopping on the hummus ride is Houston-based Simply 7 Snacks, which in February introduced hummus- and lentil-flavored chips. The hummus chips come in Sea Salt, Tomato Basil and Spice Chili Pepper options, while the lentil ones are available in Sea Salt, Bruschetta and Creamy Dill. “Our products match up well with the trend toward more ethnic and Mediterranean foods, especially the growing interest in hummus among American consumers,” says Paul Albrecht, brand manager. “The very introduction of our products is a competition in a new category. The salted snack arena is dominated by potato chips, and while there has been great innovation in the methods to process and cook potatoes,
there hasn’t been a lot of innovation away from potatoes in different ingredients. We are trying to challenge the potato chip dominance by offering a better-for-you alternative made from unique ingredients. Hummus chips and lentil chips are creating a brand new category within the salty snack aisle.” For companies such as FunkyChunky, Inc., St. Edina, Minn., finding just one snack arena to participate in isn’t good enough. That’s why it nixed the traditional segments and blended sweet with salty to create the ultimate party of snacks. FunkyChunky’s newest creation, ChipZel-Pop, blends crisp potato chips, crunchy pretzel sticks and buttery caramel corn and with caramel and milk, Continued on page 14
www.snackandbakery.com
July 2011 - Snack Food & Wholesale Bakery
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S TAT E O F T H E I N D U S T RY Overview Furthermore, Crips Snacks, based in Derbyshire, London, created Crips 99Cals, which are crunchy, oven-baked wheat and potato snacks that offer 70% less fat than traditional fried potato chips and deliver just 99 calories per pack. They come in Thai Sweet Chilli, Sea Salt & Balsamic Vinegar and Mature Cheddar Spring & Spring Onion varieties in 0.79-oz. bags. “The new packs are designed to offer something low in calories and fat, but without sacrificing the crunch, taste and eating experience of more traditional snacks,” says Gareth Smith, managing director.
The fruits of the carnival
Continued from page 13
white and dark chocolate drizzles. This funfilled snack attack is hand-crafted in small, made-to-order batches, is OU-dairy certified kosher and comes in 8- and 20-oz. canisters. “The salty/sweet combination continues to be a big hit in our business mix,” says Ronni Feuer, founder of FunkyChunky. While some consumers are craving for the sweet and salty mix, others are opting for a more baked version. Case in point: Last year, Snikiddy, LLC received so much positive feedback from its Snikiddy Baked Fries that it added Barbeque and Sea Salt Baked Fries to the mix. “Americans love their French fries, but not necessarily the guilt that comes with eating them,” says Mary Schulman, cofounder and vice president of marketing of the Boulder, Colo.based snack producer. “Now they can fulfill
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their craving with a healthy version of fries. These two new flavors are our first dairyfree/vegan options.” In May, MARS Chocolate North America, Hackettstown, N.J., expanded its Combos team of baked snacks to include a Buffalo Blue Cheese Pretzel variety. “This new flavor features the zesty combination of Buffalo wing sauce and blue cheese surrounded by a crunchy pretzel exterior,” says Tim Quinn, vice president of trade development. “This cheesy, crunchy snack is made with real cheese and is oven baked to create a hearty snack that satisfies hunger.” Late last year, MARS also introduced revamped the packaging, complete with brighter colors and eye-catching graphics that add “hunger appeal” to each bite. “Each bag includes a photo of the food representing the Combos snack flavor from a slice of mouth-watering pizza to a bowl of zesty salsa,” Quinn adds.
Whether it’s fun in the sun or a lounge in the shade, sometimes even the healthiest snacks don’t curb that sweet tooth. That’s why some snack manufacturers turned to fruit to liven up their portfolio and offer consumers something sweet, healthy and tasty in a fruit-filled way. For instance, Peeled Snacks added organic Cherry-go-round to its Fruit Picks line of grab-and-go snacks. These gluten-, dairyand wheat-free snacks are sourced from all-natural cherries picked from small farms and deliver fiber and vitamin C. “We source Continued on page 16
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organic ingredients whenever possible, and we are dedicated to providing the healthiest snacks possible for a market of consumers demanding nourishing and tasty snacks,” says Noha Waibsnaider, chief executive officer of the Brooklyn, N.Y., company. Meanwhile, Healthient, Inc., Jupiter, Fla., debuted Crispy Fruit, a line of freeze-dried fruit snacks that are made from 100% fruit and contain no added sugar, preservatives, fat or cholesterol. This on-the-go snack comes in a 20-serving, 0.35-oz. variety pack of Pineapple, Banana and Fuji Apple varieties, which dole out 34, 61 and 47 calories, respectively. The 100-calorie FruitziO product line, produced by Crispy Green Inc., Fairfield, N.J., now includes freeze-dried kiwi options. Made with the finest freeze-dried kiwi fruit slices and a hint of pure cane sugar, this snack delivers a sweet and tart taste.
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As with any seasonal festivity, once the ride is over, the carnival packs up and leaves town until next year. However, the snack industry is here to stay year-round. “The snack food industry is growing every day,” Albrecht says. “New innovations, creativity and variety in snacks and brands continue to appear in rapid succession. We try to stay at the forefront of this activity
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hen it comes to picnics, carnival rides and barbeques, making sure that snacks are safe and healthy for young kids tends to be a top priority. That’s why Plum Organics, Emeryville, Calif., is urging babies to “eat your colors” with Super Puffs, babyfriendly snacks made with real organic fruits and vegetables and are fortified with vitamins and minerals. Touted as “super yummy,” these USDA-certified organic snacks come in 100% BPA-free containers that can be recycled or repurposed for storage, arts and crafts and more. These wheat-free puffs are available in Super Yellows (Banana and Peach), Super Purples (Blueberry and Purple Sweet Potato), Super Reds (Strawberry and Beet), Super Oranges (Mango and Sweet Potato) and Super Greens (Spinach and Apple) varieties.
S TAT E O F T H E I N D U S T RY Overview and create products that no one has seen before while sticking to our core values of a simpler, healthier snack.” That’s why brands must continue to provide quality ingredients with flavors consumers love, Quinn adds. “The key to producing a fun-filled product is continuing to answer consumers’ taste for great flavors that are on-trend,” he notes. “There is tremendous opportunity in anticipating consumer trends and responding to them in a nimble manner. We have found that ‘getting closer to our consumers’ offers the greatest opportunities for growth. And in challenging economic times, offering value to the consumer is another enduring opportunity.” From chips to pretzels to beef jerky and nuts, today’s snacks don’t need any fancy gimmicks to woo consumers—they just need to be their fun-filled, better-for-you selves. SF&WB
Pump Up the Volume
E
verything pops with Pringles, but this time, the coveted brand produced by Cincinnati-based Procter & Gamble is pumping up the volume. Now through Oct. 31, consumers can send in their receipt from any four Super Stack cans of Pringles and receive a free Pringles-branded speaker device. “Pringles is about unexpected fun and good times,” says Kristin Herrmann-Ratz, brand manger for Pringles. “The new Pringles’ speaker is just one more way to make good times even better wherever you are.” The device is designed to fit on the top of any empty Pringles can, using the emptiness to amplify the sound when attached to an MP3 player.
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S TAT E O F T H E I N D U S T RY Potato Chips sponsored by
Potato Chip Playground Potato chips have been around for ages and are a simple but fantastic idea in origin. Still, one of the industry’s most beloved snack foods, they run a Tilt-a-Whirl of flavors with shelf appeal, shapes and varieties. But one thing’s certain: They’re as classic as a state fair. Lauren R. Hartman, Editor-in-Chief
M
ost of the stories about potato chips involve their invention pegged around 1853 by a cook named George Crum, who resided somewhere along the East Coast (many websites reference New York). The stories involve Crum’s fried potatoes being returned to the kitchen because they weren’t crunchy enough, so he ended up dumping
the slices into hot grease and the rest, as they say, is history. It’s obvious that potato chips are evolving and will continue to do so for many generations to come, with new yet familiar tastes, spicy flavorings and premium ingredients. Healthier, less “bad-for-you” options are already surfacing. In these difficult times, as
Potato Chips
THE TOP
10
(For the latest 52 weeks ending Mar. 20, 2011) Rank
Dollar Sales (in millions)
Brands
1
Lay’s
2 3
% Change vs. Previous Year
Dollar Share
Unit Sales (in millions)
Unit Sales % Previous Year
$1,270.1
4.5
26.6
730.2
+0.3
Ruffles
$547.6
+14.9
11.5
273.2
+20.4
Wavy Lay’s
$327.8
-6.3
6.9
125.0
-4.6
4
Pringles
$320.6
+1.1
6.7
200.8
+2.2
5
Private Label
$270.9
-2.4
5.7
166.4
-3.6
6
Lay’s Natural
$207.8
+2,029.9
4.4
75.2
+2,820.7
7
Utz
$173.5
+1.1
3.6
105.9
+2.1
8
Lay’s Kettle Cooked
$146.6
-21.2
3.1
66.7
-15.7
9
Baked Lay’s
$131.0
-8.0
2.7
53.2
-6.5
$124.8
+11.2
2.6
51.6
+17.9
$4,774.0
+3.3
100.0
2,495.
+4.5
10
Kettle Total*:
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
Chicago-based market research firm SymphonyIRI Group’s research indicates, consumers may not be snacking as much as they have in the past, still troubled with the economy and rising food prices. About 42% of the consumers surveyed by SymphonyIRI said they are spending less right now on snacks overall, while 30% are trying to make snacks last longer and are snacking less frequently. Another 25% are eliminating impulse snack purchases at the supermarket. Snack manufacturers are feeling the pinch, too. The Snack Food Association, Arlington, Va., reports that more than 40 snack food executives met with members of Congress and key staff members in May, asking for help with soaring commodity costs as part of the association’s 2011 Legislative Summit. Yet the potato chips sector grew 22%, claims a new report from Mintel, which also says that smaller segments like popcorn and cheese snacks showed the growth of 17% and 20%, respectively. “People bought more chips during the recession because they’re a good value,” says Chris Haack, senior analyst at Mintel, Chicago. “As the economy gets stronger, we expect annual sales increases to slow, but we don’t expect markets to contract. New product innovations and the changed eating habits of many Americans will keep shoppers headed towards the snack aisle.” Continued on page 20
18
Snack Food & Wholesale Bakery - July 2011
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S TAT E O F T H E I N D U S T RY Potato Chips Continued from page 18
In that regard, Natural Snacks, LLC, Addison, Ill., sees big demand for low salt/sodium and all-natural ingredients. “Consumers are more likely to purchase a better-for-you snack than junk food,” says Christine Brown, director of marketing. “Also, the way snacks are being processed is changing, from fried to baked to popped. We’re leveraging these trends with new products such as our line of kettle-cooked potato chips, which are reduced fat, low sodium and with the majority of them having zero g. of sugars.” The cooked chips contain 40% less fat, she says. They are available in Lightly Salted, Unsalted, Honey BBQ, Sea Salt & Balsamic Vinegar and Jalapeño varieties. Launched in March, they come in a singleserve 2-oz. bag, as well as in 5-oz. bags that sell for $1.19 and $2.99, respectively. Natural Snacks’ products are made with all-natural ingredients and no preservatives, artificial colorings, artificial flavorings, hydrogenated or partially hydrogenated oils, monosodium glutamate, wheat or gluten, Brown points out. “Consumers are looking for quality food without cutting corners for the best price. They are also looking for snacks that will minimize health conditions or manage health issues, such as low sodium, low sugars and low fat,” she says. “They want a benefit factor: Snacks that add protein/fiber/antioxidants. Our focus is to meet that demand. The numbers we are receiving indicate that organic snacks are experiencing 8% growth versus natural snacks, which are seeing 7% growth.” Brown adds that Natural Snacks is expanding into local markets and also into the vending arena. “Our 100-calorie products meet the educational nutritional guidelines and our vending partners are growing in the ‘healthy vending’ category,” she adds. Thus, the meager chip isn’t so meager any more. Snacks are moving toward healthier, often all-natural ingredients and away from indulgence. Both the healthier and the all-natural segments are growing, Brown says. “Consumers will also shop price before brand, so you need to give
20
Snack Food & Wholesale Bakery - July 2011
them all of that.” Other projects Natural Snacks is working on include an aggressive search for compostable packaging. The company also started to see retailers minimize their private-label stock. “You respond to that by keeping pricing competitive, without compromising the quality of the product or the brand,” says Brown. “We are seeing nutrition keys on the front of packages. So, starting with our new kettle-cooked ripple potato chips, we are also adding this benefit to our packaging. It’s easier for consumers to see what the nutritional facts are.”
Major milestones Chip companies such as Utz Snack Foods, Hanover, Pa., are celebrating quite a bit of longevity these days. Utz, for example, reached its 90th anniversary and marked the occasion with commemorative 90cent chip bags. The company has been a fixture in Hanover, starting when Bill and Salie Utz began making kettle chips in their kitchen. Now, Utz employs more than 2,200 people, has four manufacturing plants and produces a full line of snacks. “We’re hoping to spur some interest with the 90-cent bags, let people know we’re here and still successful,” says Tom Dempsey, president. Each week, Utz produces more than 1 million lb. of potato chips. “Number one, you can’t do it without luck and No. 2, you need vision,” says Dempsey. “The Utz Rice family has brought vision, and we took advantage of expansion, so we’re probably the biggest regional snack company or at least close to it in the potato chip perspective.” “Consumers are looking for food that is all-natural,” adds Utz’ Alec Sivel, vice president of marketing. “More than 50% of Utz’s snack line is all-natural, and has been from the start. These snacks are made with only
the finest quality products, with no preservatives, monosodium glutamate, artificial flavors or additives. All-natural doesn’t only apply to Utz non-seasoned items—many of our seasoned items such as BBQ Chips, Smokin’ Sweet Kettle Classics Chips, Cheddar Cheese Sunflower Chips, Butter and White Cheddar Popcorn, Sweet Chili and Salsa Fresca Rice Crisps are all-natural. Our best selling item, Regular potato chips, is not only all-natural, but contains the lowest sodium levels in the industry…another emerging consumer trend.” Other trends Sivel sees include the growth in functional foods. “Foods that can provide extra nutritional ingredients such as whole grains, fiber and calcium,” she says. “If competitive items seem comparable on all fronts (price, weight, etc.), but one item offers an added nutritional benefit, then it’s our opinion that the consumer will more often than not choose the one with the added nutritional benefit.” But the hottest trend right now is the huge interest in healthier foods. “Healthy has morphed from low fat, low calories to all-natural and fortified,” she says. “’Betterfor-you’ no longer means snacks that help you watch your weight; it now represents foods that can provide nutritional benefits as well. Meanwhile, Herr Foods, Inc., Nottingham, Pa., toasted its 65th year of producContinued on page 22
www.snackandbakery.com
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S TAT E O F T H E I N D U S T RY Potato Chips Continued from page 20
ing various snacks such as potato chips, pretzels, tortilla chips, cheese curls and pork rinds. And there are countless other chipmakers celebrating milestones with new
chips in snazzy jalapeño and chili flavors, sophisticated balsamic vinegar and sea salt versions and new cues on barbecue, which is as popular as ever. But barbecue is now even morphing into hickory or honey barbe-
cue and more. For example, Herr’s joined forces with T.W. Garner Food Co., the Winston-Salem, N.C., maker of Texas Pete to bring Texas Pete hot sauce chips to the Herr’s lineup. “This new flavor of Herr’s chips is guaranteed to be one hot item,” says Ed Herr, president. “Hot sauce lovers, your chip has come in.”
Seasonings to savor Shearer’s Foods, Inc., Brewster, Ohio, launched chips with 0 g. trans-fat under its Shearer’s line. Available in Classic, Rippled, Barbeque and Sour Cream & Onion options, the chips are made with 100% premium high-oleic canola oil. “’Better-for-you’ products that also taste great is an emerging trend,” reports Jeff Binczyk, vice president of marketing for Shearer’s Foods. “Consumers want their healthy foods, but they aren’t willing to give up taste.” Binczyk says a hot trend is the ability and willingness for consumers to try new seasonings and flavors. “Food is very dynamic right now, with consumers viewing shows on the Food Network, for instance, that are romancing food and driving experimentation.” Shearer’s Rippled Home Run Hot Dog potato chips, which in May starred on Food Network’s Unwrapped series, maintain a classic take on American food. The chips, packed in 11-oz. bags, are loaded with the classic hot dog flavor of plump, juicy wieners smothered with mustard and relish. The seasoning was developed by a Shearer’s product development team along with its seasoning suppliers to ensure the flavors are perfectly balanced. The seasoning is placed on a special v-cut potato chip, which results in a more intense flavor experience. Creating a cult-like following, SFWB0209JR_OL.indd 1
22
Snack Food & Wholesale Bakery - July 2011
1/20/09 11:46:19 AM
www.snackandbakery.com
S TAT E O F T H E I N D U S T RY Potato Chips
the Rippled Home Run Hot Dog chips are available at grocery and convenience stores in Ohio and surrounding states, as well as through Shearer’s online store at www. shearersstore.com. In addition, on April 1, Shearer’s launched wild riceworks, a crisp extension of its successful riceworks brand. Wild riceworks is a hybrid between a chip and a cracker. Available in Sea Salt and Black Sesame Seeds, they are all-natural, gluten-free and provide a good source of fiber. Black sesame seeds are also a hot new trend. That’s why on May 1, Shearer’s launched four new varieties (Original; Rippled; Barbeque; and Sour Cream and Onion) that have 0 g. of trans-fat and are cooked in canola oil. Binczyk says that in this economy, consumers want and love to snack. “We operate in a competitive category, with lots of price promotion and new item activity. As far as organic versions are concerned, our portfolio of these products is quite limited,” he says. “The snack category is very impulse-driven, so features and displays drive high lifts for our products. Space is limited for these types of vehicles, however, so we need to be fact-based in gaining this type of real estate in a retail store.” Shearer’s makes both branded and private-label products, so he knows there’s a place for both types of product at the supermarket. “Both products need to provide differentiation and be of high quality for this to work,” Binczyk adds. [Editor’s update: Shearer’s recently opened a plant in Massillon, Ohio, which is the world’s first LEED Platinum snack manufacturing facility. The company is in the process of rolling out a second phase of the plant, as well as communicating the benefits of a sustainable manufacturing facility to consumers.]
www.snackandbakery.com
“We now have national distribution, with multiple plants across the United States,” Binczyk points out. “Filling in those geographic distribution gaps is a focus for us right now.”
Kettle chips go Hawaiian and then some As many chipmakers attest, exotic flavors are a popular trend this summer, and one indication is Hawaiian-brand kettle-style Continued on page 24
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July 2011 - Snack Food & Wholesale Bakery
23
Puzzled about color selection?
Potato Chips Continued from page 23
The solution is ROHA.
potato chips and snack rings, which became available nationally this spring from Pinnacle Foods, Mountain Lakes, N.J. The line offers four exotic and unique options, including Original, Luau BBQ, Sweet Maui Onion and Wasabi. Having a loyal following on the West Coast, the Hawaiian brand brings something unique to the supermarket, says Terri Barberi, brand development manager in the specialty foods division of Pinnacle. With the tagline, “Lolo ‘Ono,” which translates to “crazy delicious,” Hawaiian kettle-style potato chips use a traditional Polynesian recipe that originated the chips. Hawaiian kettle-style potato chips and snack rings are recognized not only for superior taste and quality, but also for the artistic, colorful, tropical artwork that appears on the packaging. “We are delighted to bring a taste of the islands to the rest of the country to expand people’s taste horizons,” says Barberi. “The distinctive flavor profiles, crunchy texture and unique packaging all combine to offer consumers a product that is above comparison, and we know they’ll love it.” Hawaiian kettle-style potato chips come in 2-, 8-, 16- and 32-oz. bags and sell for $2.99-$3.49. They are distributed by Tim’s Cascade Snacks, Algona, Wash., and Snyder of Berlin, Berlin, Pa.
-VYL_JLW[PVUHSS`Z[HISLHUK]PIYHU[MVVKJVSVYZ JOVVZL96/(»Z-+ *+`LZ3HRLZHUK,_LTW[ 5H[\YHSJVSVYZ ([96/(-VVK*VSVYZJ\Z[VTLYZHYLHZZ\YLKVM JVTWSL[LZ\WWVY[MVYJVSVYTH[JOPUNZOLSMSPML SVNPZ[PJZHUKUL^WYVK\J[KL]LSVWTLU[HZ^LSS HZ[OLSH[LZ[SLNPZSH[P]LHUKYLN\SH[VY`JVTWSPHUJL 96/(-VVK*VSVYZ¶HSS`V\YJVSVYULLKZMYVT VULZV\YJL
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For more information, call 1-888-533-7642 or visit www.ROHAGroup.com ROHA Food Colors. St. Louis, Missouri
Familiar flavors from elsewhere Speaking of Snyder of Berlin, its Open Pit barbeque- and Vlasic dill pickleflavored potato chips are its latest product entries. The Open Pit variety captures the flavor of the famous bottled barbeque sauce while the Vlasic dill pickle has a tart, pickle taste but with a crisp crunch. The 9.5-oz. bags sell regionally at a suggested retail price of $3.49. The company also tapped into the low-sodium market with Low Sodium BAR-B-Q flavored potato chips, which deliver 50% less sodium than its regular chips. That’s good news because with less sodium, an interesting thing happens, says Snyder of Berlin. The sweetness of BAR-B-Q starts to sing just that much more. The richness of the other savory spices comes forward, so while consumers might think they’re giving up the extra salt, they’ll have just as much BAR-BQ, according to the company. Soon, consumers will have one more reason to love a can of Pringles. Diamond Foods, San Francisco,
S TAT E O F T H E I N D U S T RY Potato Chips
the company that acquired the Pringles brand from Procter & Gamble, Cincinnati, will be giving away free speaker devices that fit on the top of any Pringles can to amplify sound when attached to an MP3 player or similar music device, the company says. Now through October, consumers can send in the original receipt from any four Super Stack cans to receive the speaker device by mail. “Pringles is about unexpected fun and good times,” says Kristin Herrmann-Ratz, Pringles brand manager. “The new Pringles speaker is just one more way to make good times even better, wherever you are.” Specially marked Pringles speaker design cans are now available in Original, Cheddar Cheese and Sour Cream & Onion kinds. All Super Stack flavor purchases qualify to receive speakers.
With the carnival of flavors and chip types to munch on, consumers should never get bored. Today, they have so many choices, interesting new ingredients and health benefit options in potato chips, that
they should have a fun-filled, snack-filled summer. SF&WB Editor’s Note: To learn more about these and other new potato chips, go to www.snackandbakery.com and check out our online new products section.
There’s more on the line than your bottom line. To us, it’s elementary.
Making that bold statement Like many of the trends seen lately, Diamond Foods’ Kettle Brand also is making a bold flavor statement with Zesty Ranch, which scores a full-flavored win on the snack loop-de-loop. Its Zesty Ranch Krinkle Cut line’s new All Natural potato chip option is made with only all-natural ingredients and features a creamy ranch flavor on a crunchy, thick potato chip, with natural onion and black pepper blended with tangy sour cream and savory herbs. “It’s not your typical ranch experience,” notes Carolyn Richards, chief flavor architect. “Zesty Ranch is savory with a peppery kick, followed by lightly tangy sour cream layered on the ultimate crunchy chip. This is ranch done right.”
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SPLENDA® and the SPLENDA® logo are trademarks of McNeil Nutritionals, LLC.
July 2011 - Snack Food & Wholesale Bakery
25
S TAT E O F T H E I N D U S T RY Tortilla Chips
A Festival of Flavors Today’s tortilla chip makers mix better-for-you options with pleasure, as they continue to deliver bold flavors, intricate shapes and a whole lot of fun in each bag. Marina Mayer, Executive Editor
C
onsumer perception of “health” continues to evolve, according to Michael Joyce, vice president of marketing for Deep River Snacks. “Consumer trends tend to follow extremes; consumers want zero-calorie or zero-fat products that taste great,” he adds. “As a snack [manufacturer], we understand that consumers crave that indulgent crunch of a salty snack.” That’s why tortilla chip producers such
as Deep River Snacks are developing snacks that not only deliver that better-for-you option, but also provide a portfolio of fun-filled products, perfect for any carnival, outdoor picnic or fiesta. In January, Deep River Snacks, Old Lyme, Conn., launched a host of all-natural, multigrain tortilla chips made with whole grains, all-natural ingredients and that feature the Whole Grains Council seal of approval. They come in Nacho Kick, Guacamole, Twist of Lime and Hint of Salt varieties, which are recommended to pair
Tortilla Chips
THE TOP
10
(For the latest 52 weeks ending Mar. 20, 2011) Rank
Brands
Dollar Sales (in millions)
1
Doritos
$1,158.3
2
Tostitos
3
Tostitos Natural
4
Tostitos Scoops
$204.3
-39.4
7.0
57.9
-40.0
5
Santitas
$168.2
+13.8
5.7
84.9
+15.1
6
Private Label
$155.0
+0.2
5.3
86.3
-0.2
7
Mission
$81.3
+3.9
2.8
29.6
+2.4
8
Barcel Takis
$33.5
+37.4
1.1
26.3
+35.6
9
Baked Tostitos Scoops
$31.5
-13.5
1.1
8.9
-14.7
$27.1
+31.9
0.9
9.5
+40.9
$2,931.5
-0.1
100.0
1,316.3
+1.9
10
On the Border Total*:
% Change vs. Previous Year
Dollar Share
Unit Sales (in millions)
Unit Sales % Previous Year
+5.0
39.5
632.2
$372.3
-27.1
12.7
113.5
-25.1
$240.5
+802.2
8.2
74.1
+957.2
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
+5.4
with salsa or guacamole. “The multigrain consists of powerful grains like quinoa, flax and brown rice, which gives the consumers the crunch they crave and the full flavor they demand,” Joyce adds. “Our Nacho Kick is multigrain. We have taken an old standard and made it better for consumers.” To celebrate its 30 years as a brand, Natural Snacks, LLC expanded its MexiSnax line of better-for-you tortilla chips to now include a “classic label” 14-oz. bag, available in Lightly Salted, Nacho, Pico de Gallo and Sesame offerings. “We went back with a retro look to keep the package simple,” says Christine Brown, director of marketing for Natural Snacks, LLC, the Addison, Ill.-based snack producer of Continued on page 28
26
Snack Food & Wholesale Bakery - July 2011
www.snackandbakery.com
“Now we can mix high viscosity emulsions 600% faster.” The Ross PreMax is the first batch rotor/stator mixer that delivers both ultra-high shear mixing quality and high-speed production. In side by side tests, the PreMax produces thickened dressings and sauces much faster than a traditional high shear mixer.
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With a patented, high-flow rotor/stator design, the PreMax also handles viscosities far beyond the capacity of ordinary batch high shear mixers. In many applications, this can eliminate the need for supplemental agitation.
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The PreMax with a Delta generator operates with a tip speed of 5,000 fpm and handles viscosity up to 50,000 cP.
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S TAT E O F T H E I N D U S T RY Tortilla Chips
Sometimes finding a place on the shelf is a challenge, especially as some snack manufacturers create new products that Continued from page 26
the Mexi-Snax brand. Also new to Mexi-Snax portfolio is a Hot & Spicy variety, which was also brought back from “retirement” and underwent a makeover. “The new package is designed to dramatically enhance shelf presence,” Brown adds. All of the above items are made with all-natural ingredients, no preservatives, artificial colors/flavors or hydrogenated or partially hydrogenated oils. Plus, they are wheat and gluten-free. Also hopping on the bold and spicy ride is Kettle Brand. The Salem, Ore., company extended its TIAS! lineup of tortilla chips to now include Sweet Baja Barbeque, which is smoked and sweetened with a touch of honey, delivering the flavor of a backyard fiesta, and Chili con Queso, which presents a spicy, cheesy blend simmered with onions, garlic and red and green bell peppers. “We chopped chilies, minced
pair up against multiple channels. garlic, grated cheese and blended in fresh herbs, sour cream and spices to develop fresh flavors that are so bold, you can taste the Southwestern sun in every bite,” says Julie Dunmire, marketing director. “Our
bold flavors are a nice complement to a chip that’s deliciously light and crispy, creating irresistible seasoned triangles of toasted organic corn.” For its part, Prime Choice Foods, Henderson, Nev., launched betterfor-you tortilla chips under its Savory Balance brand. These organic, kosher and glutenfree tortilla chips contain a full serving of fruits and vegetables in each 10- to 12-chip serving. Made from a powder form containing apples, oranges, tomatoes, carrots, cranberries and broccoli, each chip is rich in vitamins, antioxidants and lycopene, as well as all-natural ingredients, such as non-genetically modified corn, sea salt and non-hydrogenated oil. Aside from offering ethnic flavorings and targeting that ever health-conscious consumer, Continued on page 30
28
Snack Food & Wholesale Bakery - July 2011
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S TAT E O F T H E I N D U S T RY Tortilla Chips
Continued from page 28
sometimes finding a place on the shelf is a challenge, especially as some snack manufacturers create new products that pair up against multiple channels. To cater to the all-American party goer, Popcorn, Indiana created chip’ins, a chip that’s a cross between popcorn and a tortilla chip, made with all-natural ingredients, is gluten-free and air-popped. These trianglular-shaped chips come in White Cheddar, Buffalo Wing, Sea Salt and Jalapeño Ranch varieties. “We already give our consumers who love popcorn something that they can dip into—like a guacamole or salsa or dip—and really enjoy the health benefits of popcorn without actual popcorn. You can’t do that with popcorn. We reinvented the chip—that’s how we like to think about it,” says Hitesh Hajarnavis, president and CEO of the Englewood, N.J., company. Instead of taking the bold route, Los Angeles-based Beanfields LLC opted for more authentic funfair. That’s why it created Beanfields Bean & Rice chips, made from
30
Snack Food & Wholesale Bakery - July 2011
a combination of black beans, navy beans and rice. These corn- and gluten-free chips provide 4 g. of protein (equivalent to a 4-oz. glass of milk) and 4 g. of fiber (about the same as a half-cup serving of raisin bran) for each 1-oz. serving. They come in Naturally Unsalted, Sea Salt, Sea Salt & Pepper and Pico de Gallo varieties. Offering a new twist to an otherwise already amusing concept is Bachman’s toasted Sweet Potato tortilla strips. Sweet potatoes are blended with 100% stone-ground corn to add that unique savory taste. Produced by the Bachman Co., Wyomissing, Pa., these chips contain 18 g. of whole grains per serving and offer a good source of vitamins A and C. The tortilla dipping strips are perfect for scooping dip from a bowl or straight from the jar. Frito-Lay Inc. turned the funhouse upside down when it released Tostitos blue, restaurant-style chips. Designed to add color to any bowl of tortilla chips, these blue-colored tortilla chips are made from 100%-natural blue corn, heart-healthy oils and a sprinkle of salt. The Plano, Texas, division of PepsiCo also rediscovered the tortilla chip and
brought to life the Tostitos Artisan Recipes line of tortilla chips. These chips are made with real black beans, garlic and chipotle peppers, and come in Roasted Garlic & Black Bean and Fire-Roasted Chipotle varieties. “Since first entering the market more than 30 years ago, Tostitos tortilla chips have been known for bringing people together to share fun, memorable experiences, making our great-tasting chips the must-have staple for just about any type of event or gathering,” says Justin Lambeth, vice president of marketing. “With the introduction of Artisan Recipes, we’ve put a new spin on the classic tortilla chip, baking real ingredients into every chip for a taste so unexpected and delicious, consumers can enjoy them straight from the bag.” For some consumers, health may be top priority, but it’s not the only priority. Today’s snack makers prove that all it takes is a blend of bold flavors, zesty spices and some pizzazz in a bag in order to keep the fiesta goin’. SF&WB Editor’s Note: For more information about these and tortilla chips, go to www.snackandbakery.com and check out our online new products section.
www.snackandbakery.com
S TAT E O F T H E I N D U S T RY Pretzels
Pretzel Party of Fun Pretzels, like other snacks, are evolving and taking on an action-packed Mad Mouse ride of bolder flavors, different spins on ‘tried-and-true’ recipes and new types of sandwich fillings of sweet or savory varieties. Lauren R. Hartman, Editor-in-Chief
P
retzels in various guises are growing in popularity and in sales. They’re taking new forms, are stuffed with fillings and are being flavored with special coatings or seasonings. They’re being reformulated to be glutenfree, trans-fat-free and lower in calories and sodium. Despite the economy being no fun and games, this is a time of opportunity for snack marketers, according to market research firm SymphonyIRI Group, Chicago.
The chances are tempered only by the industry’s ability to understand and address the needs and wants of consumers. Snacks play various roles in consumers’ lives, and in the last several years, SymphonyIRI says, largely in response to a prolonged economic rollercoaster ride, those roles are changing. They continue to change today, as the economy slowly takes the merry-go-round out of the recession. “We see two major trends emerging and shaping the snack foods category,” says Shannon Gilreath, assistant marketing manager at Farm Rich Products Corp., St.
Pretzels
THE TOP
10
(For the latest 52 weeks ending Mar. 20, 2011) Rank
Dollar Sales (in millions)
Brands
1
Snyder’s of Hanover
$286.2
2
Rold Gold
3
Private Label
4 5
% Change vs. Previous Year
Dollar Share
Unit Sales (in millions)
Unit Sales % Previous Year
-1.8
32.6
120.7
$187.6
+0.1
21.4
85.7
+1.8
$115.9
+10.0
13.2
80.7
+16.6
Combos
$79.4
-4.4
9.1
49.1
-5.6
Utz
$43.2
-0.6
4.9
17.5
+2.6
6
Herr’s
$20.5
-3.4
2.3
8.6
-4.1
7
Rold Gold Natural
$16.4
-----
1.9
7.8
-----
8
Snyder’s of Hanover 100-Calorie Pack
$12.1
+0.7
1.4
3.3
-2.2
9
Bachman
$11.7
-8.3
1.3
4.2
-6.5
$11.7
-----
1.3
3.9
-----
$876.8
+2.9
100.0
424.5
+4.7
10
Snyder’s of Hanover Total*:
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
-1.1
Simons Island, Ga. “Nesting is one. With a tight economy, more consumers are cooking and entertaining at home. As people look for ways to minimize household expenditures, they’ll look for quality products that are affordable but have the tastes and quality they want to serve friends and family. We see this trend continuing throughout 2011 and driving demand for frozen snacks that fit these parameters.” Around for hundreds of years, pretzels have certainly stood the test of time, becoming one of America’s favorite snacks. Studies show that about 52% of Americans are watching their diets and are eating healthier than they did a year ago, says Gilreath. “In fact, the U.S. population in general is becoming more health-conscious and looking to lose weight and improve nutrition. Consumers still want indulgences, but want something that is healthier and/or better for you. This means that people who purchase in our category are most interested in seeing healthier versions of frozen snacks such as whole-grain, low-sodium, low-calorie and low-fat options/versions.”
Lip smackin’ snackin’ Consumers who seek healthier snacks can also look in the freezer case, as Rich Products’ Farm Rich brand updated its popular pretzel snack with the introduction of Farm Rich Stuffed Pretzel Bites, a bite-sized pretzel snack stuffed with cheese. Stuffed Pretzel Bites are soft pretzel pieces filled with cheddar cheese that go from freezer to oven (or microwave) to plate in minutes. One serving of Stuffed Pretzel Bites (three pieces) has 110 calories, 3 g. of Continued on page 34
32
Snack Food & Wholesale Bakery - July 2011
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S TAT E O F T H E I N D U S T RY Pretzels Continued from page 32
fat and no trans fat. Designed as a wholesome snack or appetizer for anything from an after-school treat for hungry kids to a hassle-free party item, Stuffed Pretzel Bites are a healthier alternative to chips or French fries, the company says. Convenient and easy-to-prepare in minutes, the mini cheese-stuffed soft pretzel bites come out of the oven or microwave warm and ready to eat. “We know that consumers want pretzels and view them as a healthier choice,” says Gilreath. “We pride ourselves on bringing a wide array of interesting products into the marketplace that are tried-and-true. This product takes cheese and cheese sticks to brand new heights, giving consumers a more fun, exciting way to satisfy their cheese craving. Pretzels are a great carrier for cheese, so [this product] naturally lends itself to Farm Rich’s portfolio.” Gilreath says snacking is trending toward the presence of positives and the absence of negatives. “Presence of positives would refer to fresh, low-calorie and balanced ingredients and the absence of negatives would be no trans fats, non-greasy and no high-fructose corn syrup,” she says. At a suggested retail price of $6.99 per 34- to 38-piece bag, Farm Rich Stuffed Pretzel Bites enable consumers to serve family members and friends warm, tasty, better-for-you products without putting a dent in the budget. The product is available nationwide at Walmart and grocery stores. “We took the best of the soft pretzel concept and created our own cheesy, bitesized snack with flavor that
will appeal to the entire family,” says Jennifer Meetz, director of marketing for Farm Rich. “They’re so quick to make, anyone can enjoy them at a moment’s notice, even on their busiest days.” Meetz says that pretzels have emerged as a big trend in the snack food category, and are set to take the lead. In fact, a Mintel 2010 Frozen Snack Study showed that consumers prefer mini hot snacks with cheese filling for added flavor, and that stuffed, cheese-filled products will drive future growth in the frozen pretzel category. Likewise, J&J Snack Foods, Pennsauken, N.J., introduced Superpretzel soft pretzel mini hot dogs to its Superpretzel soft pretzel line. Wrapped in gourmet pretzel dough, the mini dogs are 100% all beef and are pre-formed from frozen, so they’re heat and serve. Suitable as snacks, appetizers or kids’ meals, they come packed in 6- to 10-count bags per carton.
“Consumers want more for their money and when it comes to snack foods, they are seeking more from their favorite brands than just a quick bite. They are looking to snacks as meal replacements—snacks that offer balanced nutrition and convenience,” Abbenante says. “They also want new, vibrant flavors to appeal to their adventurous sides and keep their taste buds excited,” he adds. “Flavor notes such as bold and spicy are a real crowd pleaser. You can find them across the board in the snack food category.”
Thrills and taste Perry Abbenante, vice president of marketing for Snack Factory’s Pretzel Crisps brand, says consumers want healthier options when it comes to snack foods. “They seek better-for-you, all-natural alternatives to traditional snack food favorites such as pretzels, potato chips, corn chips and cheese curls. Consumers are willing to try the newest innovations as long as they know they are getting more than just a tasty snack. They want a snack that will not only curve their appetite between meals, but feature healthful benefits and nutritious, high-quality ingredients.” They’re marketed by Skillman, N.J.based Snack Factory, which makes a host of thin and crunchy pretzels that double as crackers and pair well with dips and meats, cheese, fruit and vegetables.
The Snack Factory is becoming one of the fastest growing snack companies in the United States. The savvy use of product development technology and social media are boosting its momentum. Its sales grew 15% last year to more than $50 million, Abbenante reports. The tasty, low-fat, low-calorie product is the primary growth driver. “When it comes to creating new Pretzel Crisps flavors, we’ve recently enlisted the help of a technology company that specializes in marketing innovation software and services to streamline the new product development process,” he says. “They’ve played an integral role in identifying favorites among consumers, from color to packaging concepts to flavor descriptors. With their help, we’ve been able to determine which new flavors to add to our brand portfolio.” This month, the Pretzel Crisps line will expand with the launch of new indulgent and deli-style bold and spicy offerings. “This will be the first new product announcement since last year when the brand introduced two new Continued on page 36
34
Snack Food & Wholesale Bakery - July 2011
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S TAT E O F T H E I N D U S T RY Pretzels
Photo courtesy of Gracious Gifts
Continued from page 34
flavors to the Pretzel Crisps deli-style line and launched the Modern Classics Pretzel Crisps line,” Abbenante adds. It also launched new items in its bold and spicy category—Jalapeño Jack and Chipotle Cheddar. Inspired by the successful Buffalo Wing flavor, the new extensions are the perfect addition to the Pretzel Crisps portfolio. “We’ve seen tremendous sales growth in just the last year as a result of our offerings. Our data…shows a continuous trend of phenomenal growth with triple digit numbers in many of our key markets,” he notes. Some of this is due to the ways in which the company engages with consumers on Facebook, Twitter and its website, he says. A new Dark Chocolate & Peppermint Holiday Indulgents flavor will also be launched in the deli section, and shippers will be created, so that the product can be placed in different locations throughout the store. New primary packaging doesn’t hurt, either. The full product line packaging revamp now reflects the innovations inside the bags with brighter colors, an updated logo and sparkling new photography that showcases Pretzel Crisps’ stackably thin
goodness. The new packaging also has more capacity and includes 20% more crisps per bag. Here’s something else that’s goodfor-you in the snack carnival: Expanding its line of organic pretzel offerings, Snyder’s of Hanover, Hanover, Pa., introduces Organic Whole What Pretzel Nibblers in stores nationwide. They sell for $3.49 for an 8-oz. bag. Certified USDA-organic, these Nibblers are made with organic whole wheat flour, organic blue agave syrup, organic expeller-pressed sunflower oil and organic rosemary. The unique nibbler shape makes them a portable, pop-in-your-mouth snack, according to Snyder’s of Hanover. With 2 g. of fat per serving and 120 calories, the new whole wheat nibblers join the Organic Pretzel Sticks in Honey Whole Wheat, 8 Grains and Seeds and Whole Wheat and Oat as its latest organic pretzel offering. Meanwhile, Snyder’s of Hanover’s York Peppermint Chocolate Pretzel Sandwich snacks feature a York peppermint pattie filling. Its flavored pretzel pieces bite-size morsels are bursting with an array of unique varieties, including Sea Salt & Cracked Pepper, which join Cheddar Cheese, Hot Buffalo Wing, Jalapeño and Honey Mustard & Onion. The pieces come in 2.25-oz. bags. The company also launched two new gluten-free 100-calorie multipacks: Eatsmart Naturals Garden Veggie Crisps and Gluten-Free Pretzel Sticks. Each multipack bag containing 0.75 oz. has 100 calories. The large eight-count multipack has a suggested retail price of $4.99. The Garden Veggie Crisps are made with sunflower oil and 40% less sodium, as well as real potatoes, tomatoes and spinach. The Gluten-Free Pretzel Sticks have a real crunch and only 1.5 g. of fat per serving.
Another twist on pretzels includes FixMix pretzels from Gracious Gifts, Edina, Minn. FixMix pretzels are crunchy pretzel nuggets drizzled with buttery caramel and a combination of dark, milk and white chocolates.
Inspired twisters While gluten-free diets top the charts of menu trends, Kim & Scott’s Gourmet Pretzels, Chicago, says that gluten-free consumers are playing the fishing game, hunting for delicious meal alternatives. “We’re seeing trends of healthy and convenient,” says Kim Holstein, president and chief inspiration officer. “Also, we see trends of meal morphing, the combining of snacks and meals. But the single, hottest trend is the impact of health and wellness in the frozen aisles. The all-natural aisle is emerging and expanding into other areas of the store.” In January, the company nationally launched a new line of gluten-free soft Bavarian pretzels at a suggested retail price of $6.49. Packed in an 8-oz. carton, the gluten-free soft pretzels were two years “in the baking.” Kim & Scott’s provides a great soft pretzel experience and a hand-twisted appeal. Whole Foods stores in various regions carries the product and can also be purchased on the company’s website at www.kimandscotts.com and at the company’s Chicago café, Café Twist. “These days, people are really looking to get the most for their money. They want a great value and they care about quality. Because of the economy, more people are shopping at the grocery store versus eating Continued on page 38
36
Snack Food & Wholesale Bakery - July 2011
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>LRLLWHJSVZLL`LVUV\YYH^TH[LYPHSZ¯I`SVVRPUNV\[[OL^PUKV^HUK ^H[JOPUNV\YZV`ILHUZNYV^ 5VIVK`LSZLJHUNP]L`V\[OPZRPUKVM[V[HSJVU[YVSV]LYZ\WWS`X\HSP[`HUK`LZ L]LU[OLM\UJ[PVUHSP[`VMZV`PUNYLKPLU[Z<::V`»ZWYVWYPL[HY`NLUL[PJZ`PLSKH M\SSYHUNLVM6YNHUPJHUKUVU.4ZV`PUNYLKPLU[Z(SSMLH[\YLOPNOWYV[LPUJVU[LU[ ISHUKÅH]VYHUK\UL_WLJ[LKILULÄ[ZZ\JOHZLNNYLWSHJLTLU[YLK\J[PVUVMHKKLK MH[PUMVYT\SH[PVUZHUKTVYL -\SSMH[HUKSV^MH[ZV`ÅV\YZ:V`ÄILYÅV\YZ9VHZ[LKZV`ÅV\YZ)P[Z WPLJLZ :V`TPSRIHZLZ,]LUYVHZ[LKHUKZLHZVULKZV`U\[Z(SSMYVT\UPX\LZV`ILHUZ YLSPHIS`NYV^UMVY¯HUKWYVJLZZLKI`¯\ZHSVUL 3L[\ZZOV^`V\[OLT\S[PWSLSHILSPUNHUKM\UJ[PVUHSHK]HU[HNLZVM<::V`6YNHUPJ HUKUVU.4ZV`PUNYLKPLU[Z6\YILHUZHYLPUV\YIPUZ^HP[PUN[VNV[V^VYRMVY`V\
MADE IN THE USA
2808 Thomason Drive Mattoon, IL 61938 t: 217-235-1020 f: 217-235-1006 e:
[email protected] w: ussoy.com
S TAT E O F T H E I N D U S T RY Pretzels Continued from page 36
out,” says Holstein. “People might use a snack as a light meal. We are exploring organic opportunities.” The new gluten-free soft pretzel boasts a blend of five ancient grains, including sorghum flour, millet flour, quinoa flour, amaranth flour and teff flour. In addition to rice flour, the ancient grains offer more fiber, and therefore, are a healthier pretzel, Photo courtesy of Kim & Scott’s Gourmet Pretzels
38
Snack Food & Wholesale Bakery - July 2011
says Scott Holstein, COO and founder of Kim & Scott’s. “Some gluten-free products rely solely on rice flour as their alternative grain,” he adds. “Ancient grains allow us to bake a more nutritious food, something gluten-free dieters often need and want.” The company has baked nut-free gourmet pretzels in a nut-free facility for the past 15 years. Now, not only can consumers with nut allergies enjoy the soft snack, but also those with other dietary constraints can enjoy it too. Kim & Scott’s looks forward to its nut-free and gluten-free pretzels not only selling in frozen grocery aisles, but also ballparks. “There are great opportunities for growth for innovative, healthy and delicious food…that’s also convenient,” says Kim Holstein. Gluten-free and allergy-conscious cuisine was included in the top 20 food trends this year, according to the “What’s Hot in
2011” survey, produced by the National Restaurant Association, Washington, D.C. “We’re always looking to bake new flavors and not only tempt the taste buds, but also satisfy dietary restraints,” continues Kim Holstein. “Every one deserves to enjoy flavorful soft pretzels and with the addition of our gluten-free pretzel, the soft pretzel can be a mainstay in everyone’s kitchen.” The company also downsized its packages, which use less paperboard. “As a result, our delivery trucks can hold more cases,” she says.
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S TAT E O F T H E I N D U S T RY Combinations of fun Combos baked snacks now feature a Buffalo Blue Cheese Pretzel variety. The crunchy, cheesy, oven-baked snack incorporates real cheese and a spicy chicken wing flavor with tangy blue cheese. At $1.99-2.29 for a 7-oz. bag, the new entry is nationally available from MARS Chocolate North America, Hackettstown, N.J. MARS says that Buffalo wings are so popular with consumers that the flavor was a perfect fit. “We are always looking for new flavors that provide a ‘substantial’ snack to satisfy consumers,” says Craig Hall, general manager of ice cream and substantial snacks category at MARS. “The pretzel category is growing, so it made sense to combine these flavors into another great savory baked snack,” he says. Utz Quality Foods, inc., Hanover Pa., collaborated with Disney Consumer Prod-
ucts, Burbank, Calif., to launch co-branded snacks in the shape of iconic Disney characters, starting with a pretzel assortment shaped as the Cars movie racer, Lightning McQueen. Available in grocery stores, club stores, mass merchandisers, dollar, drug and C-stores since late April, the shaped pretzel items come in a 14-oz. flex bag, a 22.5-oz. clear plastic barrel containing 45 singleserving-sized bags and a 17.5-oz. sack, containing 35 individual-serving-sized bags. The co-branded snacks offer a “healthier alternative for parents looking to provide kids with ‘better-for-you’ snacks,” says Dylan Lissette, Utz executive vice president and chief operating officer. They have 100 calories or less per serving, are low fat and have no trans or saturated fat and no cholesterol. “These shaped pretzels will become part of the Utz Snacking Smart line, where a logo on
the front panel of the package makes it easy to identify the product as a healthy snack option,” Lissette adds. “Products that carry this logo meet the zero trans-fat, no saturated fat and no cholesterol criteria.” The chance to collaborate with Disney was part of the company’s ongoing goal to provide fun, delicious and healthier snack foods for customers, according to Lissette. “Now more than ever, we know that parents are much more knowledgeable about what they purchase and are interested in finding ways for their children to snack healthier,” says Lissette. “And to be able to provide that type of healthier snack in favorite Disney character shapes that their kids want gives parents the best of both worlds.” SF&WB Editor’s Note: To learn more about these and other new products in the pretzel aisle, go to www.snackandbakery.com and check out our online new products section.
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July 2011 - Snack Food & Wholesale Bakery
39
S TAT E O F T H E I N D U S T RY Crackers
Party on a Plate Today’s cracker manufacturers are filling the void for fun-filled products that also deliver on wholesome good taste. providing a carnival of items that deliver both fun and better-for-you attributes.
Marina Mayer, Executive Editor
F
or years, crackers have been the primary go-to staple for snacking. Consumers can pair them with cheese and meat, and presto—they create a party on their plate. Lately though, cracker producers have redefined what crackers represent to consumers—whether it be a standalone item or a complementary piece to a larger snacking solution. Either way, cracker manufacturers are sticking to their whole grain roots and
Putting the fun in functional When it comes to healthy snack options, you never know what you’re going to get, especially if they’re laden with better-for-you ingredients. But several of today’s cracker makers nixing those pesky stereotypes are putting the fun in functional. For starters, in October, 34° Crispbread launched its lineup of whole grain
Crackers
THE TOP
10
(For the latest 52 weeks ending Mar. 20, 2011) Rank
Brands
Dollar Sales (in millions)
% Change vs. Previous Year
Dollar Share
Unit Sales (in millions)
Unit Sales % Previous Year
1.
Sunshine Cheez-It
$342.4
+0.6
11.1
126.0
+0.1
2.
Nabisco Ritz
$299.4
-6.3
9.7
111.5
-2.5
3.
Nabisco Wheat Thins
$264.2
-2.4
8.6
95.0
-3.0
4.
Nabisco Triscuit
$245.4
+2.9
8.0
88.9
+2.5
5.
Pepperidge Farm Goldfish
$240.7
+0.7
7.8
106.1
-1.0
6.
Private Label
$147.2
+4.2
4.8
76.5
+4.2
7.
Keebler Club
$131.2
-3.8
4.3
47.1
-4.7
8.
Stacy’s Pita Chips
$97.5
+41.4
3.2
29.0
+36.1
9.
Keebler Townhouse
$92.3
+28.2
3.0
33.6
+25.7
Pepperidge Farm FlavorBlasted Goldfish
$69.8
+12.0
2.3
32.2
+6.1
Total*:
$3,081.2
+1.9
100.0
1,166.4
+2.1
10.
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
40
Snack Food & Wholesale Bakery - July 2011
crackers in 0.5-oz. single-serving snack packs. Each snack pack contains 8-10 crackers in a protective paperboard sleeve enclosed in a moisture-resistant film. “Consumers are looking for convenience,” says Craig Lieberman, founder and president. “We added a single-serving pack to fill this need.” This month, the Denver, Colo.-based company launched Parmesan and Cheddar Crisps. “These crackers will have just the right amount of cheese in them to allow for snacking and also serving with dips and spreads,” he adds. The cracker category is currently benefiting from an amalgamation of several consumer trends, says Jim Garsow, director of marketing for TH Foods, Inc., the Loves Park, Ill., producer of Crunchmaster crackers. “At the same time,” he adds, “consumers are no longer willing to sacrifice taste and texture (crispy/crunch). This has
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S TAT E O F T H E I N D U S T RY
ing option that will excite their taste buds while keeping them full between meals,” Alvaro Trinidad, senior brand manager, says in a press release. “By baking the vegetables, cheese and herb flavors right into the cracker, Cracker Creations fills the gap for adults who want a sensible, fresh and all-natural snack.” Furthermore, Kraft Foods, Inc., Northfield, Ill., hopped on the fun-filled ride by creating Wheat Thins Crunch Stix, under the Nabisco line. Available in Chipotle Pepper and Cinnamon Kick, these toasted stick-shaped snacks deliver 11 g. of whole grains per serving and come in a stand-up container for easy snacking. created an excellent growth opportunity for manufacturers such as TH Foods that has proprietary baking technology to accommodate these requirements.” TH Foods’ Crunchmaster brand has expanded to include two new extensions to its Multi-Grain line—White Cheddar and Roast Vegetable—and two add-ons to its 7 Ancient Grains team—Hint of Sea Salt and Cracked Pepper & Herb. All Crunchmaster
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items are cholesterol-, sugar- and glutenfree, low in fat and sodium, high in fiber and are made with whole grains. “We manufacture a number of baked snack products using our proprietary technology that have been popular,” Garsow adds. “By changing the shapes (i.e. into a triangle/tortilla), making them thinner and applying more intense flavors, we have been able to compete in the natural snack category as well.” Snyder’s-Lance, Inc., Charlotte, N.C., also joined in on the fun by offering Cracker Creations, which are premium seasoned crackers with vegetables, cheese and herbs baked right into the cracker and donning a real cream cheese filling. The Garden Vegetable variety features the taste and aroma of tomatoes, bell peppers and onions, while the Parmesan Herb kind boasts a rich, buttery taste of grated Parmesan cheese. “Our research revealed that consumers are looking for a premium snack-
Adding the finishing touches No cracker is complete without the finishing touches, and for some, that means sprinkling on some cinnamon, dunking in chocolate or adding notes of spices or seasonings. That’s why PARTNERS, Kent, Wash., introduced Mia Dolci Cookie Crisps crackers, which are made with all-natural ingredients and come in Toasted Hazelnut, Cinnamon Crisp, Chocolate Vanilla Swirl and Lively Lemon options. “The industry has a great opportunity to Continued on page 42
July 2011 - Snack Food & Wholesale Bakery
41
Crackers
Continued from page 41
participate in the better health of America,” says Cara Figgins, vice president. “Unless the snack food industry truly steps up to this healthier mind set, sales will slow. Innovators with healthier options will prevail.” Bakery Americas, Bannockburn, Ill., expanded its Wasa Crispbread lineup to include Thin & Crispy Flatbread crackers. This team of whole grain thin crackers is made with all-natural ingredients, oven baked for a one-of-a-kind taste and delicately seasoned. Thin & Crispy Flatbread crackers come in Original, Sesame and Rosemary options. “In many focus groups, consumers tell
us that consumers eat crackers as a replacement for potato chips as they know potato chips are not good for you. We made our crackers very crispy and the texture and crunch are similar to potato chips,” explains Catherine Terry, marketing manager for Bakery Americas. Plus, Thin & Crispy Flatbread crackers are packaged tightly in two separate stayfresh packs to minimize waste. On the exterior of the box are the Whole Grain Stamp and the Bob Greene Best Life Diet stamp. Under Minneapolis-based General Mills’ Nature Valley umbrella of better-for-you products are Granola Thins, delicate 80to 90-calorie granola squares that feature crispy granola on one side and creamy peanut butter or dark chocolate on the other. They come in Peanut Butter and Dark Chocolate, and are marketed as the perfect accompaniment to coffee or tea. Meanwhile, Byron Bay Cookie Co., Australia, came from down under to create Wafer Thin Crispbread crackers. These crackers are ideal for entertaining or everyday snacking and come in Original, Sesame Seed, Pepper & Chives, Gluten-free Rosemary & Sea Salt and Gluten-free Original varieties. Whether it’s a fun-filled cracker or one that provides the wholesome goodness to fit any health-crazed diet, the cracker aisle offers everything one needs to host a party on a plate. SF&WB Editor’s Note: To learn more about these and other new products in the cracker aisle, go to www.snackandbakery.com and check out our online new products section.
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Snack Food & Wholesale Bakery - July 2011
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S TAT E O F T H E I N D U S T RY Popcorn
Get Popping Recent popcorn introductions offer up robust flavors, healthier formulations and convenience—an amusement park of ingredients for summertime snacking. Romy Schafer, Contributing Writer
F
or many Americans, summer doesn’t officially begin until a carnival makes its annual stop in their town, bringing with it a week of fun for folks of all ages—from face painting and pony rides for the kids, to lightening-fast rides for thrill-seeking teens and bingo for seniors. Then, of course, there’s the food. Edibles ranging from standard carnival fare to ethnic specialties allow carnival-goers to enjoy old favorites and sample new treats. Similarly, recent ready-to-eat and microwavable popcorn introductions offer
something for everyone, too: Savory flavors for popcorn aficionados; betterfor-you ingredients for health-conscious shoppers; and convenience for busy consumers. Rudolph Foods Co. Inc. knows a thing or two about zesty snacks. The Lima, Ohio-based company offers a variety of hot-and-spicy pork rinds and cracklins in its Grandpa John’s, Pepe’s El Original, Rudolph Foods and Southern Recipe lines. Now, it’s doing the same thing for popcorn. In June, Rudolph Foods unveiled a popcorn addition to its Southern Recipe
Popcorn
THE TOP
10
(For the latest 52 weeks ending Mar. 20, 2011) Dollar Sales (in millions)
% Change vs. Previous Year
Dollar Share
Unit Sales (in millions)
Unit Sales % Previous Year
Rank
Brands
1
Smartfood
2 3 4
Crunch ‘n Munch
$24.7
-6.5
5.8
14.6
-2.6
5
Private Label
$24.6
-1.5
5.8
15.0
-10.2
6
Orville Redenbacher’s Poppycock
$22.5
+149.9
5.3
7.3
+150.1
7
Popcorn Expressions
$17.5
+9.6
4.1
3.6
+10.3
8
Jay’s O-Ke-Doke
$12.6
+3.1
3.0
5.8
+1.7
9
Wise
$11.4
-8.7
2.7
6.6
-8.1
10
Lance
$9.7
-16.3
2.3
6.7
-15.0
Total*:
$423.6
-1.5
100.0
241.7
+0.6
$118.8
-7.0
28.0
64.9
-4.9
Cracker Jack
$39.1
+11.8
9.2
34.5
+17.4
Popcorn, Indiana
$26.1
+43.6
6.2
10.9
+75.3
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
brand—Cheesy Cajun Popcorn. “In the South, we love pimento cheese, and we also like Cajun seasoning,” says Mark Singleton, vice president of sales and marketing. Rudolph Foods settled on the spicy flavor after focus groups selected it over numerous cheese choices. “It’s got the right amount of cheese and has a good Cajun kick to it,” Singleton notes. Slated to launch in convenience stores in August, Southern Recipe Cheesy Cajun Popcorn will be available in 2-oz. bags at a suggested retail price of 99 cents. Consumers with food or dietary issues can indulge in some flavorful snacking as well, thanks to Kernel Fabyan’s Gourmet Popcorn. The St. Charles, Ill.-based company recently unveiled a healthy version of three of its retail popcorn products—Kernel’s Caramel, Golden Cheddar and Classic Mix, which is a blend of caramel and golden cheddar known as Chicago-style popcorn. “Based on the research we’ve done, a lot of retail-based consumers now are very knowledgeable about [food] labels, healthy food and snacks,” says Rich Balance, chairman and CEO. “We thought that adding zero trans-fat, all-natural, gluten-free products would be nice for those consumers.” The new products are available at select Continued on page 46
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Snack Food & Wholesale Bakery - July 2011
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Ignite Your Product Development Process! Prepared Foods’ 29th annual New Products Conference is the food & beverage industry’s premier event for gaining valuable insights into exciting global new products, culinary advances and emerging consumer trends.
Sunday, September 11, 2011 12:00 – 4:00 pm
Fishing Tournament Sponsored by Innophos 7:00 – 9:00 pm
Welcome Reception Sponsored by Tabasco
Monday September 12, 2011 7:30 – 8:30 am
Breakfast Buffet Sponsored by Tree Top 8:30 – 8:45 am
Opening Remarks Michael Leonard, Group Publisher, and Claudia O’Donnell, Chief Editor, Prepared Foods 8:45 – 9:30 am
Keynote Address: Inform, Educate, Inspire Speaker: Dennis (Denny) J. Belcastro, Executive Vice President, Industry Affairs and Membership Services, Grocery Manufacturers Association The Grocery Manufacturers Association guides, mobilizes and inspires the consumer packaged goods industry in the United States, throughout its 100-plus year history serving to assist in various times of need, advancing the causes of sustainability and nutrition and, most recently, working with Michelle Obama’s campaign to combat childhood obesity. GMA’s Denny Belcastro will explore the industry’s new opportunities, challenges and potential, while also delving into how the industry can work together to overcome the hurdles it and consumers are facing. 9:30 – 10:15 am
Family Brand Dynamics: Decoding The Drivers of Family Brand Success Speaker: Laurie Klein, Vice President, The Family Room What’s behind the success of the country’s most iconic family brands? How does your brand measure up? In this new research study from The Family Room, we’ll dissect the main factors leading to family brand affinity such as overall appeal, brand trust, brand momentum, purchase decision dynamics and 20 other attributes associated with high affinity family brands. Over 200 brands have been analyzed among thousands of parents and their kids. In
today’s grocery store, the largest brands are those that have captured the hearts of the whole family. Learn how to build family affinity for your new brands to strengthen your overall sales.
10:15 – 10:45 am
Refreshment Break 10:45 – 12:00 Noon
Truly Global Strategies? Speaker: J. André de Barros Teixeira, Recent Vice President, International R&D, Campbell Soup Company, Belgium, Formerly, President and General Manager, Coca-Cola, Russia With many companies increasingly globalized, there rests a potential conflict: these companies are striving to develop products for consumers around the globe, but consumers by their very nature are ultimately local. Teixeira, former president and general manager of Coca-Cola, Russia, and former vice president, global innovation and development, Interbrew, Belgium, examines the changes affecting consumers and companies, new ways to look at demographics and how to avoid commonplace behavior in market research. 12:00 – 1:30 pm
Luncheon Sponsored by Sargento Food Ingredients 1:30 – 2:15 pm Speaker: To be announced 2:15 – 3:00 pm
Genuine Growth Speaker: Greg Klein, EVP Marketing and R&D, Sadler’s Smokehouse How does a regional producer of premium pitsmoked BBQ products go national during the worst economic downturn in 30 years? Greg Klein, EVP Marketing and R&D, will share key strategic decisions regarding new products, packaging and manufacturing processes that have led Sadler’s Smokehouse to new heights in the fully cooked meat/HMR category. Learn about Sadler’s going to market strategies that successfully landed their products in Costco, Walmart, and Sam’s Club. 3:00 – 3:30 pm
Refreshment Break 3:30 – 4:00 pm
introduced a new product in foodservice and retail markets. Learn the story behind the winning products.
5:00 – 6:30 pm
Excellence in Innovation Celebration Reception Sponsored by American Egg Board Network and toast the 2011 Excellence in Innovation Award winners. Taste some of the winning products and enjoy drinks and good conversation before you head out for dinner.
Dinner on your own.
Tuesday, September 13, 2011 7:30 – 8:30 am
Breakfast Buffet Sponsored by ConAgra Foods 8:30 – 9:15 am
A Call to Innovation and Action: A Professional Call to Arms Speaker: Christopher W. Miller, PhD, NPDP, Founder and CEO, Innovation Focus The companies represented at the New Products Conference have substantial influence over the diet of the American population. Through creativity, we can create a healthier more vibrant society. This session is a call to action for our profession to do more than our job and to take on a leadership role in our companies and in our categories; to excite our stockholders and our customers with the possibilities of what food technology can offer in the coming decades. 9:15 – 10:00 am
Free for All: Allergen-Friendly Innovation Speaker: Dr. Lucy Gibney, M.D., President/CEO, Lucy’s Despite being among the industry’s fastest growing trends for years, gluten-free and allergen-friendly foods remain a work in progress and still face issues regarding taste, texture, quality and safety. The challenges are many, but the opportunities are even greater. Dr. Lucy Gibney, Founder and CEO of Lucy’s, discusses the medical facts surrounding this important topic, as well as her experience in product development and food manufacturing, all from the perspective of a physician and entrepreneur.
Excellence in Innovation Awards Ceremony Join us in celebrating the industry-nominated, innovative product development teams that recently
10:00 – 10:30 am
Refreshment Break
For the complete program please visit www.PreparedFoods.com /npc
Popcorn Continued from page 44
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grocery stores and upscale retail outlets. An attractive, resealable retail bag with high-resolution photography touts their all-natural ingredients and lack of trans-fat and gluten. Meanwhile, Kernel Fabyan’s Original recipe popcorn will continue to be available to whoever wants it, according to Balance, and at Kernel Fabyan’s Gourmet Popcorn Shoppes in Geneva, Ill.; Naperville, Ill.; Deer Park, Ill.; and downtown Chicago (at presstime, the latter location hasn’t opened yet). Versions of Kernel’s Golden Cheddar, Classic Mix and Caramel come in 4-, 7- and 9-oz. bags, respectively, with a suggested retail price of $5.79-$5.99. “We are bringing to retail our concept of high-end, made-freshdaily, gourmet products that have evolved from our stores over the years,” says Balance. “That’s the theme that we’re trying to convey.” Another Illinois popcorn maker, Holly’s Gourmet Popcorn in Mokena, began shipping single-serve, 99-cent bags of its Caramel, Chicago Style and Cheezy popcorns to convenience and grocery store partners in January. “We saw the need for a high-quality popcorn at that price level, especially with the way the economy is going,” says president Steve Hamilton. The company also sells a variety of basic popcorn flavors, chocolate-drizzled popcorns and specialty varieties in multi-serve bags and tins. All are made with quality ingredients, such as real butter, brown sugar and real Wisconsin cheddar cheese. The single-serve bag holds 2 oz. of Cheezy cheese popcorn, the company’s most popular flavor, and 2.25 oz. of the Caramel and Chicago Style varieties. The company plans to roll out four additional offerings (Butter, Kettlecorn, Caramel Nut and Spicy Cheese) in single-serve bags in August. Consumers who prefer hot popcorn with an old-fashioned popcorn flavor—the kind associated with stove-top popped popcorn— will appreciate Jolly Time Homemade Pop Corn from American Pop Corn Co. According to Tom Elsen, vice president of marketing for the Sioux City, Iowa-based company, the microwavable product offers “the unmatched flavor of freshly popped popcorn prepared on the stove-top, drizzled with melted butter and lightly salted.” Like many carnival foods, which are generously portioned and served in containers that encourage sharing, Jolly Time Homemade Pop Corn also offers consumers a convenient, new way to make and share the tasty, popped kernels—the Insta-Bowl bag, which is a popping bag that turns into a bowl with the pull of a string. “That’s really the first innovation in the category for many, many years,” notes Elsen. “It’s all been unique flavor profiles—that’s where the innovation has been focused. But now, here’s something that’s pretty unique
S TAT E O F T H E I N D U S T RY cotton candy and fresh, buttered popcorn with them. Thankfully, snack retailers can step in and satiate consumers’ cravings for flavorful, easy-to-eat snacks by adding some new popcorn creations to their
lineup, offerings consumers a bit of fun and flair year-round. SF&WB Editor’s Note: To learn more about these and other new popcorn products, go to www.snackandbakery.com and check out our online new products section.
in terms of the product and the preparation itself. It’s going to create a lot of interest and excitement.” Jolly Time Homemade Pop Corn began appearing on store shelves in October 2010 and is now “probably in a third of the supermarkets,” says Elsen. “We’re still in the introductory stages.” A box contains three 3-oz. bags that offer 2.5 servings of popcorn each, and sells for $2.39-$2.89. Kernel Season’s, one of the country’s top brands of popcorn seasonings, is being expanded to include a new line of all-natural, ready-to-eat popcorn, giving consumers a chance to enjoy seasoned popcorn on-the-go. The line focuses on all-natural ingredients such as whole grains, natural sunflower oil, real cheese and clarified butter for “better-for-you” snacking, according to the Elk Grove Village, Ill.-based company by the same name. The popcorn also contains 0 g. of trans-fat per serving and no artificial colors or flavors. The 5-oz. bags come in Real Butter, Aged White Cheddar, Zesty Chipotle Nacho and Sweet ’n Salty Kettle Corn varieties and are available nationally in retail locations for a suggested retail price of $2.79-$3.79. As with most good things, carnivals leave town before many people are ready to see them go, taking their funnel cakes, SFWB1008AC.indd 1
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9/4/08 9:18:45 AM
July 2011 - Snack Food & Wholesale Bakery
47
S TAT E O F T H E I N D U S T RY Nuts & Trail Mix sponsored by
On-the-Go Snacking Nuts, trail mixes and nut-and-fruit confections offer consumers convenient, flavorful pick-me-ups, as they try to get the most out of each summer day. Romy Schafer, Contributing Writer
H
ot weather and activity-filled days prompt many consumers to opt for light, fuss-free fare during the summer months. After all, who wants to spend time in the kitchen preparing a sit-down meal when there are carnivals, festivals and fairs to attend? A bag of all-natural nuts or trail mix can make for a healthy, take-along snack (or meal) for those who want to get the most out of every summer hour. Ford’s Gourmet Foods’ Fire Dancer
Honey Jalapeño nuts, for instance, are made with North Carolina-grown jumbo peanuts, sugar, honey, jalapeño pepper powder, paprika and other all-natural ingredients. In addition, they contain no preservatives and are gluten-free, certified-kosher and parève (made without milk, meat or their derivatives). Consumers can find them in select specialty retailers nationwide, as well as on the company’s website, for a suggested retail price of $8.99 per 11-oz. tin. According to Patrick Ford, vice president
Nuts & Trail Mix
THE TOP
10
(For the latest 52 weeks ending Mar. 20, 2011) Rank
Brands
Dollar Sales (in millions)
Dollar Share
Unit Sales (in millions)
Unit Sales % Previous Year
1
Private Label
2
Planter’s
3
Blue Diamond
4
Emerald
5
Frito-Lay
6
Wonderful Pistachios
$105.8
+0.2
7
Wonderful Snack
$41.4
-----
8
Planter’s Nutrition
$40.5
-0.7
1.8
8.2
+1.4
9
Lance
$27.0
+29.1
1.2
35.1
+31.8
Nature Valley Nut Clusters
$22.2
+3.5
1.0
7.5
+0.7
$2,262.8
+4.7
100.0
913.1
+4.1
10
Total*:
$665.1
% Change vs. Previous Year +3.1
29.4
199.7
$503.7
+1.1
22.3
212.1
+2.7
$175.5
+8.7
7.8
59.4
+2.0
$127.3
+14.7
5.6
40.9
+14.5
$122.7
+0.8
5.4
151.1
-1.9
4.7
17.3
-24.8
1.8
11.5
-----
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
+4.2
of marketing for the Raleigh, N.C.-based company, customer requests prompted Ford’s Gourmet Foods to add a honeyroasted flavor to its Fire Dancer line. “Some people would tell us they like the sweet and the heat together, like with our hot Bone Suckin’ sauce, so we thought it would be an easy move to put the sweet in with the allnatural, spicy flavors,” says Ford. “They’ve been a tremendous hit.” Poppa D’s Butter Toffee Redskin peanuts, an all-natural, butter toffee, redskin peanut that combines sweet and salty flavors, have been a hit with consumers, too. According to Lee Goldberg, co-founder and managing partner of Poppa D’s Nuts in Orlando, Fla., the company expected to sell about 5,000 bags during its first six months. Instead, it sold more than 30,000 bags. “We blew our expectations out of the water,” he says. These peanuts are available in 2-oz. Continued on page 50
48
Snack Food & Wholesale Bakery - July 2011
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snack-sized bags and 4-oz. stand-up, resealable bags for $2.50-$3.95 in select stores nationwide, including 7-Eleven stores in Florida; KwikShop stores in the Midwest; Rouses Supermarkets in Louisiana and parts of Mississippi; and mom-and-pop stores, bars, sports arenas and other venues as well as on the company’s website. Poppa D’s expects its next nut offering to be a hit, too. “Everybody’s been requesting a hot nut,” says Goldberg. Poppa D’s Hot Nuts are peanuts seasoned to taste like hot chicken wings, according to Goldberg, who won’t divulge the seasoning’s ingredients. The soon-to-be-launched product initially will be available in 4-oz. bags and only in Florida for $2.59. Consumers who buy Our
Daily Eats’ Thai Chili peanuts and Maple BBQ peanuts in bulk at food co-ops and in 12-oz. bags at farmers’ markets will soon be able to purchase them in 4.5- to 5-oz. bags at select retail outlets. “Our goal is to take those [flavors] and package them in standup, zip bags within the next six months or so,” says Paul Barrett, who co-owns the Albany, N.Y., company with his wife, Caroline Lewin Barrett. Both products are made with Virginia jumbo peanuts roasted with maple syrup. The Maple BBQ variety is then treated with classic barbecue spices, such as chili, coriander and black pepper, while the Thai Chili kind is seasoned with chili, lime leaf and sea salt. “It starts out a little limey,” says Barrett. “Then, it can get a little sweet, and you end up with a little warmth in the end. It’s a nice snacking nut.” The Our Daily Eats’ nut mixes, pepitas and salad topping are available in more
than 70 retail outlets on the Atlantic Coast from Maine to Florida, as well as in stores in Pennsylvania and Oklahoma. Bag sizes range from 3.5 oz. to 4.5 oz. for $4. Lord Nut Levington, a new line of seasoned peanuts launched in March by Holy Cow L.L.C. in Irving, Texas, offers consumers a choice of five unique offerings ranging from spicy to sweet: Rebel Mary, tomato and garlic powders mixed with traditional bloody Mary ingredients; El Cheddarales, cheddar cheese and jalapeño powders; Mamma Mia, a combination of tomato, garlic and cheese powders; Thai Dyed, a blend of Thai curry and lemongrass seasonings; and Cinnapplooza, a combination of cinnamon, apple and vanilla flavors. “We were looking to come up with very creative flavors and something different for peanuts,” explains company founder Sanjiv Patel. “There really aren’t that many [peanut] flavors out there. Traditionally, there’s honey roasted, dry roasted and salted. Then, people start doing different types of nuts.” But Holy Cow is all about branding, too. “I just don’t feel like this category is fun enough, so we’re building this whole branded experience,” says Patel. “The names are all tied into stories.” Consumers can discover the stories by purchasing an 8-oz. canister for Continued on page 52
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Snack Food & Wholesale Bakery - July 2011
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SAVVY SNACKING
6 grams of protein power
Crave-worthy crunch
Energy that lasts
© 2011 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.
S TAT E O F T H E I N D U S T RY Nuts & Trail Mix Continued from page 50
$5.49 on the company’s website. Patel says he plans to distribute the Lord Nut Levington line nationally with a $4.99 per can price point for retail outlets. Since its launch, the line has been picked up by KeHE Distributors, a U.S. distributor of natural and specialty food products, and United Natural Foods Inc. (UNFI), an independent national distributor of natural, organic and specialty foods and related products. Patel also is in discussion with a variety of retailers.
Hitting the trail While nuts make the perfect summertime between-meal snack, trail mixes can offer on-the-go individuals a convenient, nutritious meal. “Our trail mixes are all-natural,” says Stephanie Blackwell, owner of Aurora Products Inc. in Stratford, Conn. “We use the same ingredients in our trail mixes that we sell solo. Our biggest seller is our Cranberry Health Mix, which is doing phenomenal. We sell hundreds of thousands of pounds of that because it’s a good trail mix. It’s got walnuts, cranberries, almonds—it’s a very nutritious meal.” Recent additions to Aurora Products’ extensive product line, which includes all-natural granola, grail mix, nuts, dried fruit and trail mixes, are Crunchy Asian Mix and Red, White and Blue Mix. The former contains edamame beans, cashews and wasabi peas, while the latter features yogurt-covered raisins, dried blueberries
52
Snack Food & Wholesale Bakery - July 2011
and dried cranberries. Both are available in 11-oz. plastic tubs with a suggested retail price of $4.99. “If you want a really good-quality trail mix that has nutrients, then you pay a little bit more for it,” says Blackwell, explaining that many low-cost trail mixes often contain lots of raisins, small nut pieces, a few cranberries and imitation M&Ms. Aurora Products’ products are sold primarily on the East Coast at supermarkets, all-natural food chains, T.J.Maxx, Marshalls and other retail outlets. They’re also available through the company’s website. Major health food stores nationwide and online are where consumers will find EatStrong Trail Mix, introduced in March by New York-based EatStrong, a company that specializes in weight management and sports nutrition. According to its package, EatStrong Trail Mix is “real food in a snack.” The blend of walnuts, cashews, pistachios, almonds, sunflower seeds, flax and organic chocolate drops was developed to serve as a pre- or post-workout snack, or as a quick source of fuel during the day. A 1.6-oz. packet of EatStrong Trail Mix retails for $2.50.
Tempting combinations Consumers looking for all-natural products that can be eaten as healthier alternatives to traditional snacks and used as toppings on salads, yogurt and ice cream—popular summertime foods—will appreciate Nutorious LLC’s award-winning Nutorious Nut Confections. The Green Bay, Wis.-based company currently offers five all-natural, low-sodium varieties: Ooo La La Original, a blend of walnuts, almonds and pecans in a buttery, sweet confection; Cherry Vanilla VaVoom, a blend of walnuts, almonds, pecans and dried Montmorency cherries in a Madagascar bourbon vanilla; Cranberry Orango Tango, a blend of walnuts, almonds, pecans and dried cranberries in a pure orange oil; Blueberry Lemon Merengue, a blend of walnuts,
almonds, pecans and dried blueberries in a pure lemon oil; and Cha Cha Chipotle, a blend of walnuts, almonds and pecans in a sweet, sassy confection. “Our product is one that you crave, not one that you eat because it’s supposed to be good for you,” says Jennifer Gille, co-owner. Nutorious Nut Confections are available in specialty, gourmet and natural retail outlets predominantly in Boston, New York City and Los Angeles. A 4-oz. bag retails for $3.99-$4.49; a 2-oz., single-serve bag size is being placed in select food service accounts. A secret Canadian family recipe passed down through generations is the basis for Granny Carol’s Yummie Crunch, according to Carol Dolan, owner of Granny Carol’s, Laguna Hills, Calif. The delectable treat contains peanuts, cranberries, Yummie Crunch squares, yogurt coating and other ingredients. “There is nothing quite like it out there,” Dolan says. “My sister won a contest with it years ago,” she explains. “Since then, we’ve been making it for special occasions and family gatherings.” Dolan began selling Granny Carol’s Yummie Crunch in June 2010 at a local outdoor marketplace. It’s now available in a few local stores and online. One-pound gift tins and 8-oz. bags retail for $11.99 and $4.99, respectively. A 4-oz. bag with a suggested retail price of $2.89 will be available soon, says Dolan. Like most good things, summer and all the activities associated with it eventually come to an end. But that doesn’t mean summer loves do. Consumers will continue to crave and buy the savory snack nuts and trail mixes that captured their hearts and taste buds long after they’ve stored their baseball equipment, bikes and tennis racquets. SF&WB Editor’s Note: For more information about these and other new snack nuts and trail mixes, go to www. snackandbakery.com and check out our online new products section.
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S TAT E O F T H E I N D U S T RY Jerky & Meat Snacks
Hotter Than Hot
Even though the temperatures outside may be striking a new high, today’s jerky and meat snack manufacturers are heating things up on their own with hot flavorings and spicy offerings. Marina Mayer, Executive Editor
F
ighting the heat can be a challenge when it comes to keeping food safe and sanitary during barbeques, picnics and festivals. Between spoiled cheese, rotten fruit and bugs crawling up and down your snacks, today’s “global warming” weather isn’t necessarily food-friendly. However, the folks behind the jerky and meat snacks category are actually turning up the heat and churning out products that
are not only fun-filled, but tasty, healthier and portable enough for on-the-go travel. “Two emerging or ‘growing awareness’ trends that we see are the desire for better satiety (a snack that fills me up) and ‘nutritional anchors,’” says Jeff LeFever, director of marketing for Jack Link’s Beef Jerky. “Satiety has long been an advantage of meat snacks, compared with other salty snacks, as meat snacks are naturally high in protein. Nutritional anchors are more of an observation of the current health-seeking trend, which seemingly migrates over time.”
Jerky & Meat Snacks
THE TOP
10
(For the latest 52 weeks ending Mar. 20, 2011) Rank
Dollar Sales (in millions)
Brands
% Change vs. Previous Year
Dollar Share
Unit Sales (in millions)
Unit Sales % Previous Year
1
Jack Link’s
$403.1
+10.4
56.4
116.8
+9.2
2
Private Label
$46.7
-2.0
6.5
11.6
-3.6
3
Jack Link’s MATADOR
$41.9
+69.2
5.9
8.5
+68.3
4
Slim Jim
$22.3
-14.7
3.1
7.5
-27.5
5
Oh Boy! Oberto
$18.6
-47.0
2.6
4.2
-40.0
6
World Kitchens
$18.6
+28.7
2.6
2.1
+42.9
7
Tillamook Country Smoker
$12.0
+11.6
1.7
4.9
+34.4
8
Old Trapper
$11.1
+104.0
1.6
4.0
+78.6
9
Pemmican
$11.0
-48.0
1.5
2.3
-48.9
$10.7
+15.6
1.5
1.1
+19.7
$715.1
+5.6
100.0
190.9
+4.7
10
Love’s Total*:
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
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In response to these trends, the Minong, Wis., jerky producer created a slew of products and line extensions to keep the summertime fun going. For instance, Jack Link’s Sasquatch Big Steaks boast larger-than-life dimensions, such as providing 20% more beef steak in a more than 16-in. stick. They come in Angry (Original) and Zen (Teriyaki) varieties, as well as Steakhouse Recipe and Oven-Roasted Turkey Steak options. Just in time for hunting season, Jack Link’s Original and Teriyaki Beef steak products will be available in orange-colored packaging featuring Realtree Camo patterns through December. These pocket-sized offerings can be easily stored in a field bag or jacket and require no refrigeration. Jack Link’s also expanded its MATADOR beef jerky lineup to include Flamin’ Hot Sticks, which blend MATADOR’s orig-
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S TAT E O F T H E I N D U S T RY
inal snack stick with a hot and spicy flavor. And if that wasn’t hot enough, Jack Link’s Cholula Hot Sauce jerky features Cholulabrand hot sauce and hits store shelves in the coming weeks. “Hot sauces continue to grow in popularity and hot flavors are the No. 4 flavor segment for jerky (behind Original, Teriyaki and Peppered),” LeFever says.
Also blazing the trail with hot, hot, hot products is Thanasi Foods. The Boulder, Colo.-based company partnered with Kikkoman Sales USA, Inc., San Francisco, to launch Duke’s Kikkoman Teriyaki. “As always, our signature small batch marinating and smoking process makes Duke’s even more delicious and tender than alternative jerky products on the shelf. Duke’s is, and always has been, proudly made in the USA,” says Justin Havlick, president of Thanasi Foods. Thanasi also debuted Black Magic Peppered beef jerky, which like all of its products, is comprised of 100% USDA-approved Angus beef. “One of the keys [to producing fun-filled products] is taking snacks that are social and fun to eat and adding the ingredients of iconic brands that create a sense of nostalgia, [such as] Kikkoman Teriyaki-flavored beef jerky for that long summer hike,” Havlick says. “The companies that will succeed will have an uncontested consumer satisfaction and loyalty through healthy,
premium and sustainable foods that are differentiated by flavor, ingredients, true quality and a delicious eating experience worth returning for daily.” For its part, Ford’s Gourmet Foods, Raleigh, N.C., introduced Bone Suckin’ jerky, which is hand made by the Cow Creek Band Indians in Oregon and contains apple cider vinegar, black pepper and garlic. Plus, it is all-natural, gluten-free and contains no preservatives or nitrates. “We work with Native Americans. They make [the jerky] for us,” says Patrick Ford, vice president of marketing. “They know how to make beef jerky, and they’ve been making it for hundreds of years. They make it with real, whole muscle. They don’t put chemicals in it to get the end product.”
Climate control While some jerky manufacturers have managed to raise the temperature, others are maintaining climate control by providing products that boast all-natural ingredients rather than heat. That’s because consumers are seeking healthier options in the snack category, says Tom Ennis, chief executive officer of Oberto Brands. “Oberto is listening to this demand and generating additional sales opportunities by appealing to changing consumer tastes. Specific to Oberto, we opted to do a major product overhaul and made our jerky allnatural and preservative-free. Oberto beef jerky is now a much tastier and healthier option,” Ennis adds. Continued on page 56
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S TAT E O F T H E I N D U S T RY Jerky & Meat Snacks Continued from page 55
In the spring, the Kent, Wash., manufacturer expanded its signature Oh Boy, Oberto! brand to include an all-natural kind that comes in Original, Teriyaki, Peppered and Hickory offerings. The new recipe uses only simple, all-natural ingredients, including beef, sugar, beef broth, water, salt, spices, natural flavorings and vinegar to produce a seasoned, smoked and dried-toperfection product. “The line also includes an exciting BBQ Pork and Teriyaki Turkey boasting the same all-natural recipe, but with pork and turkey instead of beef,” Ennis notes. Oberto also redesigned its packaging to better showcase the recipe switch and prominently display the all-natural attributes
on the front of the packaging, Ennis says. The key to producing a fun-friendly product, Ennis adds, is to the consumers something they can enjoy. “Look at jerky. It’s a great snack, synonymous with ball games, road trips, hiking, camping and
many more summer activities. Jerky is easy to grab-and-go, store and take with you wherever you go to have fun,” he notes. “It’s an ideal snack for warm weather, as you’re not going to get a sugar rush followed by an energy slump, which is even worse on a hot day. Jerky keeps people energized and out there doing what they love—whether heading out for a hike, catching a little league game, enjoying a favorite pro team or heading out on a summer adventure.” In response to consumers “getting tired of the traditional hard and leathery texture of the product,” Florio Sports, LLC, the Long Valley, N.J., makers of Ripken Power Shred jerky, launched Original, Teriyaki and Sweet n’ Spicy options, available
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Snack Food & Wholesale Bakery - July 2011
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S TAT E O F T H E I N D U S T RY in a pouch or a can. “[Jerky is] the new baseball snack. Out with salty peanuts, buttery popcorn and sugary crackerjacks—in with the highprotein, delicious, 100% made in the USA beef jerky,” says Frank Florio, president and founder.
Florio Sports uses only beef made in the United States, and uses the brisket of beef, which is a softer, tastier and more expensive cut of beef, Florio notes. Florio Sports also presented a new packaging format—the metalized pouch, which “ensures freshness and reduces the risk of product breakdown
due to light or oxygen exposure. This is due to the fact of our superior oxygen barrier and total barrier to light/UV rays,” Florio says. Likewise, the Performance Enhancing Meat Snack Co., Englewood, Colo., expanded its Perky Jerky line of meat snacks to include Turkey Perky Jerky, featuring strips of turkey blended with a hint of guarana and other flavors. Plus, it is low in fat and delivers 50 calories per serving. Whether it’s geared for summertime fun or just providing a better-for-you option, today’s jerky and meat snack producers are keeping it real, tasty and authentic. SF&WB Editor’s Note: To learn more about these and other new jerky and meat snack products, go to www.snackandbakery.com and check out our online new products section.
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S TAT E O F T H E I N D U S T RY Pork Rinds
Porcine Pleasures New varieties and larger portions give pork rind-loving consumers even more snacking options. Romy Schafer, Contributing Writer
F
or many consumers, graduation parties, reunions and other summer get-togethers with family and friends are the perfect occasions for a pig roast. Guests often reminisce about the taste of the succulent meat and crispy skin long after the event. Shoppers, particularly men, can now satiate their cravings for crunchy pig skin in a big way any time of the year with Lee’s Pig Skins Colossal Cracklins, produced by Rudolph Foods Co. Inc., Lima, Ohio. “It’s actually the biggest cracklin on the mar-
ket,” says Mark Singleton, vice president of sales and marketing for Rudolph Foods, which also offers Colossal Cracklins under the Pepe’s El Original and Southern Recipe brands. “We thought the consumer would react well to a bigger presentation of the product. It just looks like a man-sized chunk of pork.” Colossal Cracklins are made from pork fat with attached shoulder skin and come in Original, Bold & Spicy BBQ and Chile Limon. They’re available in 1.34- and 3.5oz. bags that retail for 99 cents and $1.99,
Pork Rinds
THE TOP
10
(For the latest 52 weeks ending Mar. 20, 2011) Rank
Dollar Sales (in millions)
Brands
% Change vs. Previous Year
1
Baken-Ets
$71.0
+9.7
2
Tom’s
$21.1
3
Turkey Creek Snacks
$19.2
4
Golden Flake
$16.5
5
Private Label
$13.9
6
Mac’s
$8.7
+22.1
7
Carolina Country Snacks
$6.3
-10.6
8
Lee’s
$5.6
+30.2
9
Wallace’s
$5.5
-9.0
10
Guerrero
$5.3
+6.7
$249.8
+3.6
Total*:
Dollar Share
Unit Sales (in millions)
28.4
48.3
+1.6
8.5
18.3
-4.1
0.0
7.7
17.7
+1.5
-10.8
6.6
11.2
-7.7
+0.5
5.6
9.2
+3.8
3.5
6.2
+29.1
2.5
4.1
-9.4
2.2
3.3
+30.7
2.2
4.7
-10.0
2.1
2.0
+5.6
100.0
179.5
+3.5
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
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Snack Food & Wholesale Bakery - July 2011
Unit Sales % Previous Year +10.6
respectively, at major retail outlets across the South and Southeast and regions with many Hispanic consumers (who traditionally eat a lot of pork). “You can’t pick up a [Hispanic] food magazine without reading about pork,” says Singleton. “Hispanic consumers not only use our pork rinds as a snack, they use them as a food ingredient in meal preparation.” This bodes well for Rudolph Foods, given that its No. 1 consumer is Hispanic, according to Singleton, and that this segment of the population is continuing to grow. Despite their popularity, pork rinds are considered by some consumers to be an unhealthy snack. “[Our products are] zero
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S ST T AA T TE E OOF F T THHE E I N I NDDUUS ST TRR YY
carbs and zero trans fat,” says Singleton. “They’re a really simple, natural product— one of the oldest snack foods. The product has such a history with people all over the world. Any place that had a consumption of pig or swine had a consumption of pork rinds, and that remains true today. We’re bringing back part of most people’s history.” Turkey Creek Snacks’ pork rinds and cracklins also are “strong with the Hispanic [consumer],” according to Randy Oglesbee, sales manager for the Thomaston, Ga.based company. No doubt the company’s 2010 addition to its pork rinds line—Chicharron Chili-Lime Fried pork skins—are popular too, with these consumers and other pork rind lovers.
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The tasty snack is made with pork skins, seasonings and natural and artificial flavors. It is available nationwide in 2-, 3- and 4-oz. bags with suggested retail prices ranging from 99 cents to $1.59. History shows that getting together with friends and family during the summer months and enjoying foods prepared over an open flame, like roast pig, is one of America’s favorite pastimes. During the rest of the year though, consumers can choose from a variety of flavor-packed pork rinds and cracklins to add a dash of summer to any meal or snack occasion. SF&WB Editor’s Note: To learn more about these and other new pork rind products, go to www.snackandbakery.com and check out our online new products section.
July 2011 - Snack Food & Wholesale Bakery
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The Nutritional Corner
Grain Foods Foundation’s Perspective on MyPlate he eagerly awaited MyPlate icon was released last month, and we at the Grain Foods Foundation, Ridgway, Colo., commend the U.S. Department of Agriculture (USDA), Washington, D.C., for its work in developing it. The new icon replaces the MyPyramid graphic, aiming to help consumers follow a healthy eating pattern based on the Dietary Guidelines for Americans (DGA) released earlier this year. While the guidelines were written for a scientific/clinical audience and help shape federal food and nutrition policies, such as those surrounding school feeding and food assistance programs, MyPlate is intended for the consumer audience. It’s meant to convey the principles of the DGA in an easy-to-understand, consumer-friendly way. The updated visual is in the shape of a dinner plate and is divided into colored sections designed to represent each food group. The grains group occupies a signifi-
T
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Snack Food & Wholesale Bakery - July 2011
cant wedge of the graphic in recognition of their important contributions to a healthful diet. The fruit, vegetable and protein groups are also represented on the plate; the dairy group is symbolized with a small drinking glass alongside. According to the USDA, the average adult should consume six 1-oz. servings of grain foods daily, with at least half of those servings coming from whole grain sources and the remaining from enriched. Because of their unique health benefits, it’s crucial to include both whole and enriched grains in a balanced diet. Whole grains are a source of fiber, selenium, potassium and magnesium, which collectively may help boost immunity, lower blood pressure and prevent heart disease as well as some forms of cancer. Enriched grains contain B vitamins and iron as well as folic acid, a nutrient associated with the prevention of some birth defects. In fact, the Centers for Disease Control and Prevention, Atlanta, recently identified folic acid fortification of enriched grains as one of the top public health achievements of the last decade for its role in helping prevent neural tube birth defects, an achievement that has saved $4.7 billion in direct medical costs. The latest edition of the DGA placed a real emphasis on the importance of calorie balance, and the new icon is meant to support this by helping Americans make better food choices. In light of the visual nature of the icon and the guide-
Judi Adams, president, Grain Foods Foundation and the Wheat Foods Council
lines’ focus on weight and portion control, I’d like to remind everyone of what a 1-oz. serving of grains looks like for building balanced, calorie-appropriate meals. A 1-oz. serving of grains is defined as: • 1 slice bread • ½-cup cooked oatmeal • ½ 8-in. tortilla • ½-cup cooked brown or white rice • 1-cup ready-to-eat cereal • ½-cup cooked pasta • 5 whole wheat crackers • 7 saltine crackers Beyond the promotion surrounding its release, MyPlate’s rollout will continue over the next couple years with distinct periods focused on different dietary guideline messages throughout that time. Some of these messages are, “Make at least half your grains whole grains,” “Enjoy your food, but eat less,” “Drink water instead of sugary drinks” and “Make half your plate fruits and vegetables.” Each of them falls under the guidelines’ three themes—balancing calories; identifying foods to reduce; and identifying foods to increase. There will be a number of opportunities in the coming years for the Grain Foods Foundation outreach to coordinate with the MyPlate messaging plan. We have already shared our perspective on the new icon through the foundation’s social media channels, and we view MyPlate’s release as the perfect time to remind consumers that grain foods are the foundation of a balanced, healthful diet. We will continue such outreach surrounding MyPlate and the Dietary Guidelines for Americans to ensure our industry’s voice in our country’s public health conversation remains as strong as ever. SF&WB
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Ingredient Briefs
TIC Gums introduces FASTir xanthan gum EC, which is a more improved version of agglomerated xanthan gum. Developed using the company’s latest, patent-pending manufacturing process, FASTir xanthan EC Gum does not require oil slurry or any other special handling and provides more consistent quality and shorter supply chain. Plus, it disperses more uniformly and hydrates quicker than any other type of xanthan gum available. TIC Gums White Marsh, Md. 800-899-3953 www.ticgums.com
Ocean Spray launches a new pomegranate variety to its renowned BerryFusions Fruits line. Pomegranate adds fruit appeal to a variety of applications, such as bakery, snacks and confectionery. An alternative to the named fruit or extruded gums, jellies and other fruit imitators, these dried fruit pieces deliver taste, texture and distinctive points of color, without the processing challenges commonly associated with real fruits. Pre-soaking is not required, and the product does not absorb moisture over time. Further advantages include retained piece identity, absence of color bleed and stable pricing and supply. Ocean Spray Ingredient Technology Group Lakeville-Middleboro, Mass. 800-662-3263 www.oceansprayitg.com
Cargill introduces Clear Valley 80 higholeic canola oil, a natural, high-oleic oil that delivers the same nutritional benefits featured in earlier generations of Clear Valley products. It offers low levels of saturated fat and 0 g. trans-fat (per 14-g. serving). Because it resists oxidation and the development of flavor off-notes, Clear Valley 80 high-oleic canola oil allows food manufacturers to forgo familiar formulation challenges associated with the use of canola oil to create great-tasting snacks and baked products. It also offers an extended shelf life, may allow customers to switch to more environmentally-friendly packaging and delivers superior oil functionality for processed foods. Cargill, Inc. Minneapolis, Minn. 952-742-6360 www.cargill.com
PureCircle launches NSF-02, a new patented and proprietary flavor modifier designed to work in combination with PureCircle’s high-purity stevia sweeteners, Reb A and SG-95, sugar or high-fructose corn syrup to enhance flavor, sweetness and taste. NSF-02 delivers a range of better-tasting, low-cost, natural product formulations with reduced calories. PureCircle Ltd. Oak Brook, Ill. 630-361-0374 www.purecircle.com
Barry Callebaut rolled out its innovative dark chocolate made with Stevia extract in the North, Central and South American markets. In developing the new chocolate, Barry Callebaut replaced sugar with an all-natural sweetener solution comprised of dietary fibers, the natural sugar alcohol erythritol and Stevia extract, which alone, offers zero calories per serving. The new product is also said to provide the same great taste, texture and aroma as fine, traditional chocolate. It is designed for a variety of applications, including molding, enrobing and inclusions, or customized for a specific application to provide food manufacturers a one-of-a-kind chocolate. Barry Callebaut USA LLC Chicago, Ill. 866-443-0460 www.barry-callebaut.com
At the IFT Annual Meeting and Food Expo, June 11-13 in New Orleans, Archer Daniels Midland (ADM) showcased baked chocolate raspberry nutrition bars made with a combination of CardioAid plant sterols, NovaSoy soy isoflavones, Kansas Diamond white whole-wheat flour, Prolite wheat gluten, cocoa and oils. ADM also displayed whole wheat beignet pastries made with Kansas Diamond white whole-wheat flour, ADM’s proprietary vegetable shortening, frying oil and Sweet N’ Neat Fibercal to add taste and functionality. ADM also celebrates 100 years of deZaan Belgian chocolate by featuring chocolate truffles made with pure deZaan Belgian chocolate. Archer Daniels Midland Co. Decatur, Ill. 800-637-5843 www.adm.com Continued on page 62
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Ingredient Briefs Continued from page 61
QualiTech Flavor-ettes with OmegaPure are particulate inclusions formulated with ultra-refined fish oil, designed for dry mix applications, snacks and baked goods. Available in sweet and savory varieties, these inclusions add flavor, mouthfeel, visual appeal and healthy nutritional labeling, and provide an alternative to costly, hardto-handle fruits. They also can be formulated to deliver value-added ingredients such as real fruit, vegetable content, reduced sugar, nutraceuticals, and with no trans fat for a more nutritious final product. They come in cinnamon, blueberry, strawberry, lemon, chocolate and jalapeño flavors, among others. QualiTech Chaska, Minn. 800-328-5870 www.qualitechco.com
J.R. Short developed the foundation for a new category of snacks based on its proprietary micro pellet extrusion technology. Best known for its application to potatoes, this unique micro pellet extrusion technique brings the advantages of enhanced texture and low-fat content to grain-based products such as corn and rice as well as whole grains and whole multigrain combinations. J.R. Short Kankakee, Ill. 800-544-8734 www.shortmill.com
SF&WBtv 62
Puratos presents Freshness Solutions, which consists of freshness enhancers developed to help maintain total freshness. For instance, it provides increased resiliency, which reduces instances of damaged products during packaging and transportation. Freshness Solutions also adds longer lasting freshness, softness, moistness, cohesiveness, resiliency, quality improvement and reduction in cost. Puratos Corp. Cherry Hill, N.J. 800-654-0036 www.puratos.us
Freeze-dried raisin powder from Van Drunen Farms is a specialty ingredient designed to add the appeal of plump, sweet raisins to baked goods. Freeze-dried raisin powder is free-flowing and eliminates the need for chopping, dicing or grinding. Simply add to filling mixes, cakes and muffins, cookie and bar formulas, breads and rolls, cereals and snacks, or use it in toppings and frostings. Plus, freeze-dried raisin powder retains all of the natural whole goodness of raisins, contributing antioxidants, iron, potassium and both soluble and insoluble fiber as well as subtle sweetness to recipes. Van Drunen Farms Momence, Ill. 815-472-3100 www.vandrunenfarms.com
Sensient Colors offers SensiPearl, a pearlescent pigment product line that differentiates food products through luster effects, color shifts and iridescent shimmers. These FDA-approved mica- and titanium dioxide-based pigments add innovative visual effects to foods such as confections, frosting, marshmallows, gelatin desserts, and more. SensiPearl comes in a variety of custom colors. Sensient Colors, LLC St. Louis, Mo. 800-325-8110 www.sensientfoodcolors.com
Danisco introduces PinVita Phytosterols, a cholesterol reduction said to benefit cardiovascular health by lowering the level of unfavorable LDL cholesterol in blood. Derived from a natural and sustainable pine source, PinVita is easy to formulate when working with fats, oils and bakery products. PinVita limits the impact on taste, texture and appearance and is suitable for allergen- and GMO-free products. Danisco USA Inc. New Century, Mo. 913-764-8100 www.danisco.com
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Engineering Management
CDIO: An Old/New Engineering Concept s I was passing through Dulles International Airport in Chantilly, Va., last month, I came across this goofy airplane hanging from the ceiling. It had a very small cockpit and a super long wingspan. The body of the plane looked pretty skimpy and the wings looked like they were covered with paper. I stopped and read the plaque that described the project and the airplane to learn that it was the result of an engineering project at Massachusetts Institute of Technology (MIT) in Boston. There were two interesting facts about it: 1. It was a human-powered craft; and 2. It was managed through an engineering process called CDIO, or conceive, design, implement and operate. Separately, these words are very understandable and commonly used, but when you assemble them, CDIO becomes an engineering concept. CDIO was created at MIT in the late 1990’s as a new way to teach engineering principles, but I am suggesting we borrow the ideas and use the concept in our bakery engineering projects. One of the things we see in the baking industry is that we make a lot of really good advancements and improvements with machines and systems, but we sometimes don’t know how we arrived at the solution. There are a lot of acronym-based processes that we can use to facilitate continuous improvement in our plants, but this may be an “old/new” one that we can add in specifically for walking through an engineering project. For example, the concepts stage includes defining the specific needs of a customer, whether it is internal or external to your department or organization. You also want to consider all of the different
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known technologies that you can apply to the problem or project and all of the external forces that can affect your outcomes, particularly with regulations, company strategies, business plans and finances. To conceive, in this context, means to “have an idea for.” But in order to have a clear idea, you need to understand all of the things that can affect your goal. With all of your idea elements vetted out, you are now ready to move into the second stage: Design. This stage is where you focus you energies on the physical creation that will solve your problem. The plans, drawings, simulations, material specifications and identifications are key to getting through this stage. The result of this step is the detail and direction that will become the food for implementation. The implementation stage takes the results of the design stage and moves the project from paper to plant. In this stage, you will see a transformation where raw materials become solutions. Your procurement, fabrication, manufacturing, final assembly, shop testing and final installation all fall into this stage. Online testing of the machine, systems, adaption or modifica-
Jeff Dearduff
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tion will need to be validated before you can be moved into operation. The final stage of this concept is called operate. This stage is designed to take everything that was thought through, designed, built, tested and validated and finally put it to work. It is this stage where your ideas and goals are used in the process to solve whatever problem or need you were experiencing. Like anything else, I like to take standard concepts and adapt them to the real world of the bakery. With that in mind, I would like to add a couple more letters from the alphabet to the original concept’s acronym. The first is a “T” for training. We know that in our bakeries, if we put something new on the floor, part of its success or failure is based off of how it is received by the operations folks. If we stick it out there and hold onto the information, often the idea is rejected and sometimes a potentially successful idea can be scrapped due to this lack of buy-in. So, before you put out a new “something,” try to pull everybody together who might be involved and explain what it is intended to do and emphasize that the goal is to make the operation more efficient and the work environment better for the people. The other add-on is another “C” for confirm. After the engineering solution has been rolled out and used in operations, it pays to go back and recount all of the steps to identify gaps that can be adjusted for and corrected before the concept is utilized again. When you confirm each step, you will add benefit to the next project that you deploy. So there you have it. The acronym is now CDIOTC. Feel free to add any more letters to it to use as an old/new tool. SF&WB
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Equipment Briefs lower exhaust volume. Has a clean-in-place system to reduce sanitation labor. Heat and Control, Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com
Lanly Co. supplies a line of snack food dryers, including the Model 2500, which includes a 50-in.-wide balanced mesh weave type 304 stainless-steel conveyor belt. The dryer utilizes a natural gas burner with proven top-down, high-volume air supply and exhaust fan for moisture removal. A set of removable filters for recirculating air maximizes clean air flow and facilitates maintenance. The dryer produces up to 2,400 lb. of a variety of extruded snack products per hour. The Lanly Co. Cleveland, Ohio 216-731-1115 www.lanly.com
Heat and Control’s new MasterTherm kettle fryer can produce 500 finished lb. of batch fried potato chips per hour. Cooking oil is heated gently and uniformly throughout the fryer by a thermal fluid heat exchanger, which is immersed in the oil. Generous spacing between the heating tubes facilitates cleaning and eliminates areas where fines can accumulate. Each tube expands independently, greatly reducing damage caused by thermal stress. Tubes are electro-polished to simplify cleaning. A full-length hood covers the kettle for safety. Additional benefits include heat retention for high-energy efficiency, steam blanketing to purge oxygen and prolong oil life,
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Baker Perkins’ Snack Master extrusion system provides a healthy way of processing snack pellets. The Snack Master system comprises the versatile SBX Master extruder and a range of post-extrusion forming equipment, including options that demonstrate the system’s ability to make a wide range of different snacks, from direct expanded types to higher value-added products; an adjustable face cutter that offers easy blade changes in 15 minutes; an innovative die that produces a thin, wide sheet of dough that is cut into regular, geometric shapes by an in-line rotary cutter; and a pillow crimper for the CoEx Master coextrusion range, which incorporates fillings with contrasting textures and colors into a cereal outer to create individual pillows, tubes, bars or wafers. Baker Perkins Inc. Grand Rapids, Mich. 616-784-3111 www.bakerperkinsgroup.com Great Western Manufacturing’s GyroSift GS36 provides gentle gyratory sifting motion and the utmost sanitary design thanks to its stainless-steel contact areas and snap-on neoprene gaskets. Designed for applications requiring smaller screen areas, the GyroSift GS36’s V-belt drive
and counterweight assembly ensures that the sifter speed and circle are matched to provide optimum separation performance, from flakes to fine powders. The trays use mechanically stretched screens to provide optimum screen tension and sanitation. Great Western Manufacturing Leavenworth, Kan. 800-682-3121 www.gwmfg.com
Hinds-Bock manufactures a large family of stand-alone muffin batter depositing machines and industrial muffin systems for high-volume bakers or plants with varieties of muffins, cupcakes, cakes or specialty loaf cakes. For example, the “automatic answer” machine provides high production from a compact automatic configuration. The complete industrial muffin lines produce up to 18,000 lb. per hour and include pan oiling, paper cup denesters, single or multiple batter depositors with diving positive shut-off spouts, bulk loading, intermediate hoppers and dry ingredient depositors. These machines feature the latest servo technology and operator interface panels, as well as diving positive shutoff spouts for bottom-up filling, preventing stringing or trailing of batters and allowing for clean handling of even the thickest products. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com Charles Ross’ double planetary mixers now incorporate more clean design features to help users improve the efficiency of high viscosity mix-
View videos demonstrating the newest bakery & snack food equipment by visiting www.snackandbakery.com
Snack Food & Wholesale Bakery - July 2011
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Equipment Briefs ing processes. Traditionally equipped with rectangularshaped paddles, these double planetary mixers move batch material by rotating the blades on their own axes while orbiting on a common axis. Newer design helical blades prevent the climbing issue experienced with traditional rectangular stirrers. And, the high-viscosity blades feature a precisely angled helical contour, which generates a unique vertical mixing action—the sweeping curve firmly pushes the batch material forward and downward, keeping it within the mixing zone at all times. Charles Ross & Son Co. Hauppauge, N.Y. 800-243-7677 www.mixers.com
Quadrel Labeling Systems introduces ModuLine, an economically priced labeling system equipped with non-proprietary controls. ModuLine features a userfriendly color touchscreen operator interface and is capable of applying front/ back or wraparound labels at rates up to 200 products per minute. Quadrel Labeling Systems Mentor, Ohio 440-602-4700 www.quadrel.com Lantech’s Q-300XT stretch-wrapping machine improves operator friendliness with a larger load-placement window for its automatic film cut-and-clamp system. Designed to eliminate fork-driver dismounts,
the patented XT film cut-and-clamp system features space-age composite parts and allows a 10-in. offset for most loads, while providing automatic attachment of the film to the load and cutting the film upon completion of the wrap cycle. The fully guarded cutand-clamp system flips up for easy cleaning. The Q-300XT wraps loads up to 80 in. tall and weighing up to 4,000 lb. Plus, the machine’s electronically controlled, variable wrap force and 200% pre-stretch on the film ensures consistent, tight loads with economical use of film, reduced labor and improved ergonomics. Lantech Louisville, Ky. 800-866-0322 www.lantech.com Continued on page 66
AXIS Automation re-engineered and launched the AXIS Salter, which dispenses salt with no more than +/- 1% variation by volume across dispensing widths ranging from 12-84 in. The self-contained vacuum conveyor was developed to reduce salt fines during handling. Whether it’s used as a stand-alone unit or is fully integrated into the production line, the one button startup requires no adjustment after initial setup. The AXIS Salter is in accordance with BISSC standards, ensuring sanitary, reliable and continuous production without compromise. AXIS Automation, LLC Hartland, Wis. 262-367-4444 www.axisautomation.com www.snackandbakery.com
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Equipment Briefs Dematic Grand Rapids, Mich. www.dematic.us/ rapidpick
Continued from page 65
Dematic launches the RapidPick system, a new solution for high-performance split-case order fulfillment. The RapidPick system uses the goods-to-person design—delivering splitcase items to an operator in a configuration that allows pick rates of up to 1,000 line items per operator, per hour. It allows for high pick accuracy because only one SKU is presented to the operator at a time, in the desired sequence. The RapidPick system is compact and typically uses a 30-65% smaller footprint than other systems. Plus, it is made up of modular mechanized components—replenishment stations, pick stations, racking and the inventory staging buffer module. The software manages the SKU inventory, replenishment and directs the order fulfillment process, including monitoring the staff.
Spiroflow Systems expands its line of conveyors to expand DYNAflow tubular chain drag conveyors. Material is moved by heavy-duty discs connected by articulated metal links (chains) that are equipped for heavy-duty applications. The discs can be made from a variety of materials, including steel and cast iron, which enables them to operate at temperatures up to 482oF. These chain drag conveyors are also totally enclosed, resulting in dust- and contamination-free handling, require minimum energy consumption, handle hot, cold, wet, dry, hygroscopic or temperature-sensitive materials, will not separate blends and produce minimal noise, among other benefits.
Spiroflow Systems, Inc. Monroe, N.C. 704-291-9595 www.spiroflowsystems.com Akro-Mils introduces new sizes to its ShelfMax product line. The sizes include 11-5/8x8-3/8x6, 17-7/8x8-3/8x6 and 23-5/8x6-5/8x 6 in. These heavy-duty bins are available in five colors and feature greater storage options for end users, including up to 85% more holding capacity than traditional 4-in. shelf bins and up to 25% more holding capacity than 6-in. storage bins. The bins’ rolled ridges provide added strength and durability when filled to maximum capacity. They are also easy to label for quick inventory identification and come with optional width dividers to expand sorting options and efficiencies. Akro-Mils, a division of Myers Industries, Inc. Akron, Ohio 800-253-2467 www.akro-mils.com
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