Snack Food & Wholesale Bakery March 2011

KWIK Lok’s New 893 Ultra Fast! Tight Packages! Prints on the Closure! e! Labels Packages!

Our customers have asked us for a bag g closing machin m machine ine th that hat at w will illl be il b ffas faster astte as ter (u ter (up to (up to 1 12 120 20 20 bags per minute), yield tighter packages, and es, print crisp i clear clea l ar information iinfo form rmat atio at tiio ion n on the the closure th c clo losu llo surre su re a nd d The all-ne ew 89 893 3 Ul Ultr tra tr a Au Auto tom to matic mat have the capability to put labels on the bagged package. Th all-new Ultra Automatic n bakery all these features, featurres es,, plus p us additional options. pl s. Bag Closing Machine gives the modern PRINTER OPTIONS: Ink Jet Turbo Printer; Cold Foil Transfer Printer; Programmable t C ld F il T f P i t P bl Thermal Printer. ADDITIONAL OPTIONS: Speed Control: Synchronizes the closing speed to the bagging speed. Closure Management System: Monitors the product, closure movement and printing cycle to determine if the bag is closed. If not, a warning signal is given. Closure Sensor: Senses if closures are present. If not, sends a warning signal to the bagger or an alarm box. Ethernet Connection: Monitor operation from a remote location. Touch Screen Monitor: English, French and Spanish.

Kwik Lok® Bag Closures: Consumer Preferred Easy to Open; Easy to Reclose - Reusable and Recyclable!

Š

CALL US TOLL FREE 1-800-688-5945

Š

&25325$7,21

(;(&87,9(2)),&(32%2;<$.,0$:$ 7(/(3+21(RU  )$;  ,QWHUQHWZZZNZLNORNFRP

Your customers and the future... "U
1VSBUPT
XF
CFMJFWF
QFPQMF
XJMM
DPOUJOVF
UP
BUUBDI
NPSF
BOE
NPSF
JNQPSUBODF
UP
UIF
RVBMJUZ
PG
UIFJS
GPPE
5IBU
JT
XIZ
XF
NBLF
JU
PVS
NJTTJPO
UP
EFWFMPQ
VOJRVF
JOHSFEJFOUT
UFDIOPMPHJFT
BOE
BQQMJDBUJPOT
UP
IFMQ
CBLFST
QBUJTTJFST

DIPDPMBUJFST
BSPVOE
UIF
XPSME
UP
CF
TVDDFTTGVM
XJUI
UIFJS
CVTJOFTT
0VS
GPDVT
PO
DPOTVNFS
QSFGFSFODFT
GVSUIFS
SFJOGPSDFT
UIJT
DPNNJUUNFOU
XJUI
UIF
1VSBUPT
4FOTPCVT
B
NPCJMF
TFOTPSZ
MBCPSBUPSZ
XIJDI
DSFBUFT
B
DPNGPSUBCMF
FOWJSPONFOU
GPS
DPOTVNFST
UP
TIBSF
UIFJS
PQJOJPOT
XJUI
VT
BCPVU
UIFJS
FWFSZ
EBZ
GPPE
OFFET
Find out more at www.sensobus.us Contact Puratos today for your unique solution!

1VSBUPT
$PSQPSBUJPO
t
5FM

t
'BY

t
XXXQVSBUPTVT

Contents Cover Story 14 | The Artisan Touch Gabby’s Bagels, Inc. has become much more than a bagel maker. Now, it’s an artisan bakery that stays ahead of the curve by combining craftsmanship, quality ingredients and artisan techniques to produce big flavors and products.

Plant Story 24 | On The Cutting Edge

Photos by Vito Palmisano

Gabby’s “small” artisan bakery may first appear unassuming, but it has plenty of big programs that keep it ahead of the competition and regulations.

66 | Supplier Standpoint How well do you know your ribbon blender? Charles Ross & Son Co., Hauppauge, N.Y., offers some important tips for blender selection and operation.

Columns 8 | Editor’s Note Editor-in-chief Lauren R. Hartman provides a rundown of our issue, which is geared to issues bakers and snack food manufacturers need to know.

50 | The Nutritional Corner Americans are eating entirely too many calories and not choosing enough nutritious foods in their daily diets, says contributing columnist Judi Adams. The 2010 Dietary Guidelines for Americans recommends foods that can help correct this bad habit.

60 | Engineering Management Contributing columnist Jeff Dearduff says the “new kids on the block” may not have what it takes to successfully work in the real world. But for some, it may just take a bit of attention, training and persistence.

74 | The Final Word According to an Australian study, women who snack while watching TV tend to eat more at a later time, says executive editor Marina Mayer. In fact, “snacksperts” are calling it “mindless eating.”

4

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Having the wrong tools can cost you time and money. That’s why only Ford offers the widest range of work vehicles,* with all of the options you need to get the job done right. The Ford Transit Connect with available customizable cargo area and Ford Work Solutions™ helps organize your tools and your jobs. And the hands-free calling will make you as versatile as your new truck.** Move up to the top of the tool chain at CommTruck.Ford.com.

*Based **Some

on division offerings. Excludes SUVs and cars. features are not available while the vehicle is in gear.

Contents

32

Market Trends

Production, Technology & Product Development Solutions for a Changing Industry. March 2011 Vol. 100 No. 3

32 | Delivering Innovation Pizza manufacturers are finding their own unique ways to create new products that meet the demands for innovative and unfamiliar varieties.

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

Special Report 38 | Food Safety Fundamentals With the recent passing of the Food Safety Modernization Act, what’s ahead for the food industry and how is it preparing to meet the changes head-on? Editor-in-Chief Lauren R. Hartman talks with several organizations that provide insight and advice for many of today’s bakers and snack producers.

Peter Havens Senior Group Publisher

New Products

Editorial

48 | New Products

[email protected] 847-405-4015

[email protected]

Tom Imbordino Group Publisher [email protected]

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

Lauren R. Hartman Editor-in-Chief Marina Mayer Executive Editor

Read about some of the most recently introduced products, including Bachman sweet potato chips and tortilla dipping strips, crispy fruit from Healthient, Inc., chip’ins from Popcorn, Indiana, and all-natural, multigrain tortilla chips from Deep River Snacks.

[email protected] 847-405-4008

Patty Catini Art Director

Advertising & Internet Sales

Ingredient Technology

Barbara Szatko Senior Sales Manager

52 | Batch-full of Yumminess

Suzanne Sarkesian Classified Sales

When it comes to flavors, sweeteners, gums and starches, many of today’s ingredient solutions offer a host of can’t-miss characteristics.

[email protected] 248-786-1692

Jill L. DeVries Corporate Reprint Manager

Production Technology

Support Services

62 | Puttin’ on the Mix

Gail Porter Advertising Production Manager

Find out which players are getting into the mix to deliver systems that come outfitted with the best of the best.

[email protected] 630-527-9927

[email protected] 248-244-1726

48

[email protected] 847-405-4104

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

Audience Development

52

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

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

BNP Corporate

62 SNACK SNACK FOOD FOOD & & WHOLESALE WHOLESALE BAKERY BAKERY (ISSN (ISSN 1096-4835) 1096-4835) is is published published 12 12 times times annually, annually, monthly, monthly, by by BNP BNP Media Media II, II, L.L.C., L.L.C., 2401 2401 W. W. Big Big Beaver Beaver Rd., Rd., Suite Telephone: (248) (248) 362-3700, 362-3700, Fax: Fax: (248) (248) 362-0317. 362-0317. No No charge charge for for subscriptions subscriptions to to qualifi qualified ed individuals. individuals. Annual Annual rate rate for for Suite 700, 700, Troy, Troy, MI MI 48084-3333. 48084-3333. Telephone: subscriptions subscriptions to to nonqualifi nonqualified ed individuals individuals in in the the U.S.A.: U.S.A.: $115.00 $104.00 USD. USD. Annual Annual rate rate for for subscriptions subscriptions to to nonqualifi nonqualified ed individuals individuals in in Canada: Canada: $149.00 $137.00 USD 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. (includes GST & postage); all other countries: $154.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2010, by BNP Media II, L.L.C. All All rights rights reserved. reserved. The The contents contents of of this this publication publication may may not not be be reproduced reproduced in in whole whole or or in in part part without without the the consent consent of of the the publisher. publisher. The The publisher publisher is is not not responsible responsible for for product product claims claims and and representations. representations. Periodicals Periodicals Postage Postage Paid Paid at at Troy, Troy, MI MI and and at at additional additional mailing mailing offi offices. ces. POSTMASTER: POSTMASTER: Send Send address address changes changes to: to: SNACK SNACK FOOD FOOD & & WHOLESALE WHOLESALE BAKERY, BAKERY, P.O. P.O. Box Box 1080, 1080, Skokie, Skokie, IL IL 60076. 60076. Canada Canada Post: Post: Publications Publications Mail Mail AgreeAgreement Bowes, P.O.Box 25542, ON, N6CON, 6B2. ment #40612608. #40612608. GST GST account: account: 131263923. 131263923. Send Send returns returns (Canada) (Canada) to to Pitney Bleuchip International, P.O.BoxLondon, 25542, London, N6C Change of address: Send Send old address label along with new to SNACK FOODFOOD & WHOLESALE BAKERY, P.O. Box 6B2. Change of address: old address label along withaddress new address to SNACK & WHOLESALE BAKERY, P.O.1080, Box Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected]. 1080, Skokie, IL 60076. For single copies or back issues: contact Gisele Manelli at (847) 405-4061 or [email protected].

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

6

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Ribbon Blenders in stock and ready to ship!

High Shear Mixers

Mix, Blend, Disperse, Disintegrate, Deagglomerate, Puree, Emulsify, Homogenize, Dry, Extract… With Ross you can do it all. Quality you can count on. Ross sanitary Blenders, High Shear Mixers and Static Mixers are engineered to High Speed Powder Induction

deliver superior performance in a multitude of food applications. Whether you’re preparing an instant cake mix or a chunky Mexican salsa, Ross can help improve your end-products, increase throughput, and lower production costs. Lower prices and faster delivery, too! With five plants in the USA alone, we are able to lower our manufacturing costs – and offer you prices that others can’t match. And since Ross stocks hundreds of mixers and blenders in standard sizes for fast delivery, you won’t have to wait for the mixer you need now. Trial / rentals are also available.

Vertical Blenders & Static Mixers

Contact Ross.

Call 1-800-243-ROSS. Or click on www.FoodMixers.com.

Editor’s Note

A Need-to-Know Basis ritical subjects somehow manage to thread their way into all of our issues and online products one way or another, but this issue of Snack Food & Wholesale Bakery considers several. Whether it’s a hot topic such as the updated Dietary Guidelines for Americans (DGA), which Judi Adams discusses in this month’s Nutritional Corner (page 50), or a special report on food safety (page 38), our March issue focuses on things bakers need to know. The revised DGA, which helps form federal food and nutrition policies and offers rules that schools and food assistance programs can use, are meant to be interpreted by nutrition practitioners to provide easily understood nutrition guidance. One topic that’s especially top of mind right now is Lauren R. Hartman food safety. There are [email protected] few other aspects of our business that are more important and affect our daily lives as much. Our special report looks at this most critical subject, as foodborne illness is so common today, yet largely preventable if those in the global food chain could be held accountable at each step for controlling hazards that can cause illness. Our report examines the new Food Safety Modernization Act (FMSA), something bakers and snack food manufacturers want to gauge in terms of how it will affect them and how it will change the way food is regulated. You’ll find viewpionts from the Food and Drug Administration’s Jenny Scott and various spokespeople at in-

C

8

Snack Food & Wholesale Bakery - March 2011

One topic that’s especially top of mind right now is food safety. There are few other aspects of our business that are more important and affect our daily lives as much. dustry associations involved in the FSMA’s passage or development. We also include a summary from a food safety workshop in February. Bakers and snack food companies can find more of these workshops being scheduled. They offer a wealth of information on equipment sanitation, new equipment designs, controlling pathogens, managing allergens and effective cleaning and sanitization procedures. New developments are coming out in equipment, such as mixers (see our Production Technology article on page 62), which now are designed to be tougher and more high-performing than ever before, as well as product introductions in sweeteners, flavors, gums and starches in the Ingredient Technology article on page 52. From reduced-sodium flavorings, monosodium glutamate replacements and new flavor systems that provide heat stability or a creamy mouthfeel to synergistic gum and starch/ gum blends that help create or enhance structural stability and improve the overall texture of the food, many of today’s ingredient solutions offer a host of can’t-miss

characteristics. In addition, frozen pizza manufacturers are creating unique products to meet demand with innovative and unfamiliar varieties. Check out our Market Trends article on page 32 for an outline of what pizza makers are doing to deliver fresh, creative pizza topping options such as Buffalo chicken, caramelized pears and cheeses that go beyond basic Mozzarella. And here’s something else to munch on: If you’re heading to SNAXPO 2011, be sure to go to our website, www.snackandbakery.com, as well as our snackandbakery.com print section (page 68), which will help prepare you for the latest advancements at the biggest show in snacks, March 20-23 at the J.W. Marriott Orlando, Grande Lakes in Orlando, Fla. Get great tidbits on what equipment manufacturers will be showcasing at their booths and find more pre-show coverage. There’s plenty going on this spring, so climb out of that winter slumber and use Snack Food & Wholesale Bakery to help get you going. SF&WB

www.snackandbakery.com

Zero trans fat? Product consistency? Whole grain? Certified organic? Gluten-free? Optimal flour protein?

Is there something missing in your mix? Meeting changing consumer trends alone can be overwhelming. That’s why at Bay State Milling, we work seamlessly alongside you, utilizing the finest ingredients to develop custom mixes that meet current health and flavor trends while staying true to your own original recipe. Like no other, our mixes reflect the consistency, performance, and value that can only be found in more than 100 years of experience. Call 1-800-55-FLOUR or visit www.baystatemilling.com and see what we can add to your mix.

GrainEssentials®

© Copyright 2011

OrganicEssentials®

800-55-FLOUR www.baystatemilling.com

BakingEssentials™

EthnicEssentials™

Business Briefs News

USDA, HHS Release 2010 Dietary Guidelines he United States Department of Agriculture (USDA) and the United States Department of Health and Human Services (HHS), both in Washington, D.C., released the 2010 Dietary Guidelines, which are designed to help Americans make healthier food choices and confront the obesity epidemic. Selected messages for consumers include enjoy the food but eat less, avoid oversized portions, make half the plate fruits and vegetables, compare sodium amounts, and more. The revised guidelines also advise Americans to balance calories to manage weight, build healthyeating patterns, monitor calorie and fat intake, incorporate more exercise and encourage retailers, schools and employers to provide a healthy-eating environment and create nutrition-related programs, among other topics. “The 2010 Dietary Guidelines are being released at a time when the majority of adults and one in three children is overweight or obese, and this is a crisis that we can no longer ignore,” says agriculture secretary Tom Vilsack. “These new and improved dietary recommendations give individuals the information to make thoughtful choices of healthier foods in the right portions and to complement those choices with physical activity. The bottom line is that most Americans need to trim our waistlines to reduce the risk of developing diet-related chronic diseases. Improving our eating habits is not only good for every individual and family, but also for our country.” One such category impacting the bakery market is refined grains. The recommended amount of refined grains is no more than 3-oz. equivalents per day, according to the

T

10

Snack Food & Wholesale Bakery - March 2011

new guidelines. “Refined grains should be replaced with whole grains, such that at least half of all grains eaten are whole grains. Consumption of refined grain products that also are high in solid fats and/ or added sugars such as cakes, cookies, donuts and other desserts should be reduced,” the guidelines state. Major sources of refined grains are yeast breads (26%), pizza (11%), grain-based desserts (10%) and tortillas, burritos and tacos (8%). The discussion of fiber intake also played a part in the revised guidelines. According to the report, the recommended daily value of fiber is 14 g. per 1,000 calories, or 25 g. per day for women and 38 g. per day for men. “Most Americans greatly underconsume dietary fiber, and usual intake averages only 15 g. per day,” the report says. “Breads, rolls, buns and pizza crust made with refined flour are not among the best sources of dietary fiber, but currently contribute substantially to dietary fiber consumption because they are ubiquitous in typical American diets. To meet the recommendation for fiber, Americans should increase their consumption of beans and peas, other vegetables, fruits, whole grains and other foods with naturally occurring fiber. Whole grains vary in fiber content.” The updated report also reaffirms the importance of enriched and whole grains as the foundation of a healthy lifestyle. That’s why bakers continue to offer innovative, healthy grain products to meet customers’ needs. These include an evergrowing variety of whole grain products

and other items that meet consumer preferences, including calcium for bone health, breads fortified with Omega-3s and lower sodium bakery products. Enriched grains are the source of eight essential nutrients such as folic acid, B vitamins, iron and fiber. According to Atlanta-based U.S. Centers for Disease Control and Prevention (CDC), folic acid is essential for expectant mothers and may also reduce the risk of heart disease and stroke in adults. Since folic acid fortification of enriched grains was implemented in 1998, neural tube birth defects have dropped 25-35%. “The American Bakers Association applauds the 2010 Dietary Guidelines for Americans that provide important tools to improve the health of all Americans and combat the obesity epidemic. Grain foods are the foundation of a healthy lifestyle since complex carbohydrates provide essential fuel the body needs,” says Robb MacKie, president and CEO of the American Bakers Association (ABA), Washington, D.C. “ABA also strongly supports the 2010 guidelines’ recommendation for physical activity and believes that exercise is an essential component of a healthy lifestyle, regardless of age. By encouraging Americans of all ages to engage in a variety of enjoyable physical activities that are age and health appropriate, we believe exercise will improve the health of our country.” The 2010 Dietary Guidelines were composed by a committee of scientific experts who reviewed and analyzed the most current information on diet and health and compiled their findings into a scientific, evidence-based report. The goal of the Dietary Guidelines is to put this knowledge to work by facilitating and promoting healthy eating and physical activity choices, with the ultimate purpose of improving the health of all Americans. To learn more about the Dietary Guidelines or to read the report, go to www.dietaryguidelines.gov. SF&WB Continued on page 12

www.snackandbakery.com

There’s something special about our sea salt. For one thing, it comes from a sea.

© 2009 Cargill, Incorporated

Cargill is the leading national supplier of domestic sea salt that comes from a living sea. We always give you

www.cargillsalt.com

the most consistent taste and texture. No wonder the food tastes so good. See what else we bring to the table. Call 1-888-385-SALT to get our Sea Salt Marketing Guide and visit www.cargillsalt.com to learn about consumer and marketing insights that can help you grow your business using our innovative salt solutions. collaborate

>

create

>

succeed™

Business Briefs Continued from page 10

people Caravan Ingredients and Bakery Supplies North America (BSNA), Lenexa, Kan. Ian Trood is promoted to vice president, international sales development for BSNA, responsible for introducing and expanding Ian Trood U.S. product lines and developing optimal portfolios with CSM imported and locally-sourced products to newly developed international markets such as Asia, the Middle East and Africa. Meanwhile, Gary Schmidt takes over as vice president, industrial sales, responsible for utilizing his crossfunctional leadership skills to help Caravan grow its industrial sales division. Schmidt has been with Caravan Ingredients since 2008. Keith Clemens is named director, food ingredient sales, responsible for leading the food ingredients group in reaching their growth and development targets. Clemens has been a part of the food industry for more than 20 years. Grain Processing Corp., Muscatine, Iowa John Thorpe is appointed president. He joined the company in 2002 as sales manager of feed ingredients, was promoted to vice presiJohn Thorpe dent of feed ingredients in 2004, and in 2005 to vice president, industrial starch products. In 2008, he was promoted to vice president of global sales.

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.

12

Snack Food & Wholesale Bakery - March 2011

supplier news OYSTAR Names Shoulders to Lead N.A. Unit OYSTAR Gmbh created OYSTAR North America, a $250 million company with 650 employees. The new North American company combines OYSTAR USA, a Morganville, N.J.-based sales operation representing packaging machinery Barry Shoulders brands manufactured in Europe, as well as packaging equipment manufacturers OYSTAR Packaging Technologies, Davenport, Iowa; and OYSTAR Jones, Covington, Ky. Barry Shoulders, president of OYSTAR Packaging Technologies, will lead OYSTAR North America. In addition, Gordon Bonfield, president of OYSTAR Jones, has been appointed transition officer to oversee the process of combining the three companies into one efficient North American operation. Others assigned to senior management roles include: Tom Riggins, sales; Jeff Wierenga, service; and Susan Awadalla, finance.

Dorner’s new 3D CAD landing page, www.dornercad.com, is designed to save time and serves as a quick direct link to more than 1 million model possibilities. The new conveyor model configurator allows users to draw virtually any conveyor model in life-like 3D clarity—a distinct advantage in being able to see what their conveyors and equipment look like prior to purchase. Users also can draw conveyor models to exact lengths in 1/8-in. increments, which provide greater flexibility to better fit application designs. AB Mauri Fleischmann’s raises prices in the United States and Canada on all yeast products and other bakery ingredients, effective Feb. 14. Cream yeast prices increased 2 cents per pound on an as-is basis, compressed yeast increased 4 cents

per pound and dry yeast increased 6 cents per pound. Actual price changes on bakery ingredients will vary depending on product and delivery location. DuPont enters into a definitive agreement for the acquisition of Danisco for $5.8 billion in cash and assumption of $500 million of Danisco net debt. Upon closing, this transaction would establish DuPont as a leader in industrial biotechnology with science-intensive innovations that address global challenges in food production and reduced fossil fuel consumption. The acquisition is expected to be financed with about $3 billion in existing cash and the remainder in debt. The transaction should close early in the second quarter and be cash and earnings accretive in 2012, the first full year of the combined entity. Delkor receives a new U.S. government patContinued on page 12 ent for its Intelligent Positioning technology for carton closing. This new technology can make the precise correction on an individual carton basis at speeds up to 150 cartons per minute. And it reduces the number of parts and the machinery footprint by 35% compared with traditional carton closers. Clabber Girl completes another successful Safe Quality Food (SQF) Audit, and is recertified with a Level 3 status. This re-certification enables suppliers the ability to assure customers that their products have been produced, processed, prepared and handled according to the highest possible standards. Puratos introduces the Sensobus, a mobile sensory laboratory that conducts tailor-made sensory analysis projects. The Sensobus collects data from consumers in pre-defined locations, such as grocery stores. Consumers sit at one of the eight sensory-tasted booths and taste-test a selection of bakery, patisserie or chocolate prototypes. The answers are used to calculate a data mapping to indicate consumer preference.

www.snackandbakery.com

The Artisan Touch

A small but impressive operation with big plans, Gabby’s Bagels stays ahead of the curve by combining craftsmanship, quality ingredients and artisan techniques with more automation to produce big flavors and much sought-after breads and bagels.

14

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Lauren R. Hartman, Editor-in-Chief

W

Mike Conti, president (left), Rocio Villalobos in quality assurance, and Luis Tenesaca, plant operations manager, check bagged multigrain bread, which was being produced at the time of Snack Food & Wholesale Bakery’s visit.

hen you think of artisan bread, you think of hand craftsmanship. An artisan baker is usually trained to mix, shape and hand-craft a loaf of bread. But in today’s complicated world, artisans go beyond the norm in understanding how ingredients perform and how to provide the best products for customers. Gabby’s Bagels, Inc. (a.k.a. Gabby’s Bakery) is more than a bagel maker, though it did start out that way. It’s now an artisan bakery that began operating in 1996, making bagels with its purchase of the Great American Bagel Co., as in the acronym GAB, from which Gabby’s gets its name. At that time, the company saw an opportunity in the Chicagoland market to bake artisan products with wholesome, top-quality ingredients. It now bakes classic ciabatta bread, hearty pretzel bread, earthy hearth breads, rustic baguettes, apple crumb Vienna bread, buttery dinner Continued on page 16

Photos by Vito Palmisano

www.snackandbakery.com

March 2011 - Snack Food & Wholesale Bakery

15

Continued from page 16

breads with crumb toppings, savory olive baguettes, sesame-seeded items, multigrain rolls and much more. The private, $6-million company located in Franklin Park, Ill., currently rolls and produces about 65% of its more, as products fresh for restaurants well as and foodservice customers and Company: Gabby’s Bagels, Inc. hearty and Headquarters/Location: Chicago, Ill. 35% frozen for in-store bakerenormous ies and foodservice customers Plant Size: 39,000 sq. ft. bagels that predominantly. Gabby’s has No. of Lines: Five incorporate about 60 employees and apthe freshest No. of Employees: 60 pears on first glance to be what Annual Sales: $6 million of ingreone would expect of an artisan dients for operation: The 39,000-sq.-ft. Products: Artisan bread and bagels restaurants Brands: Gabby’s facility, which is smaller by and freshcomparison to most of the Distribution: Fresh locally and frozen bake/frozen plants Snack Food &Wholesale nationally customers. Bakery visits, is unassuming. A KEY PERSONNEL: Specialty closer look reveals five producPresident: Mike Conti products tion lines and three different include types of ovens that all churn V-P, Opers.: Daniel Garcia Continued on page 18 fruit-filled

At a Glance

16

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

h\Y

D9F:97H 6@9B8 CUTTING EDGE TECHNOLOGY AND THE ART OF OLD WORLD BAKING

Sours | Dough Improvers | Bases, Mixes and Concentrates | Grain Blends | Specialty Products

VUgYg a]lYg UbXWcbWYbhfUhYg Achieve easy pliability and elasticity for rolling long loaves of French and Italian breads. Speed up production of Kaiser rolls, French, Italian, & Vienna breads with bromate free, no-time dough bread bases. Give your English mufÁns outstanding volume and porosity every time.

1900 S. Park Ave. | Streamwood, IL 60107 | Toll Free (888) 276-5483 (630) 830-0340 | Fax (630) 830-0356 | www.bakewithbrolite.com

Continued from page 16

out a whopping 30,000 lb. of product each day. “It’s automated, yes, but our processing methods and fermentation steps makes it artisan,” explains president Michael Conti. Gabby’s is quite popular and has a long list of product offerings—some 300 varieties, which it is trying to streamline to gain more efficiencies. The top sellers, or most customer-requested of its products, are pretzel dinner rolls, brioche-style upscale hamburger buns, pretzel hamburger buns, 2-lb. Tuscan breads, assorted artisan rolls, ciabattas, baguettes and bolos. It has a combination of fresh products that are distributed throughout the Midwest region and fresh-baked frozen items that are distributed nationally. “What makes us an artisan bakery is that we combine artisan talent and experience,” Conti says. “The business has changed from just being a bagel producer originally to one with a lot of different Continued on page 20

Kemper Bakery Systems USA Subsidiary of the WP BAKERYGROUP

Partner for Industrial Solutions WP BAKERYGROUP. As the worldwide leader in dough mixing; bread and roll make up; and sheeting, proofing and oven technologies, WP offers the experience to design, build and deliver your fully integrated Turnkey Bakery. WP performs as your single source supplier to control the entire process. WP provides the answers to consistent product quality and efficiencies. WP – Your Partner in Success. Kemper Bakery Systems, Ltd. 3 Enterprise Drive, Suite 108 Shelton, CT 06484 . USA Phone 203-929-6530

www.wpbakerygroupusa.com VP & Director of Industrial Sales Jim Souza

[email protected]

18

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Enhanced soybean oils offer plenty to celebrate.

Continued from page 18

types of bread and rolls. In 2001, or so, we began focusing on artisan breads, more upscale breads, using a starter (a sour dough-type) handed down to us that we developed, and to more traditional methods of baking, slower methods. We’re not the kind of place that uses no-

time-dough ingredients.” Keeping ahead of the trends is a philosophy at Gabby’s. It has a clean-label

Quality Assurance Sifters Protect Your Products & Reputation Our precision sifters are custom designed to match your stringent requirements. We have an exceptional line of BISSC certified sifters to meet your food production and quality assurance applications. Gentle gyratory action, an unparalleled focus on sanitation, easy access for inspection and maintenance, dependable, safe, quiet, vibration free designs to protect your products, people, reputation and plant. Let us show you the right unit for your application, with quality assurance second to none.

www.gwmfg.com 913-682-2291

Product Protection & Production Sifters Since 1858

approach to ingredients and bakes lots of whole-grain and low-sodium products. “We’re trying to appeal to sophisticated customers who want clean-label products for health-conscious consumers,” Conti says. “Many of the pubs and taverns are hiring chefs. The sophistication level has increased with regard to nutrition and taste, so really high-quality, gourmet hamburger buns are preferred. Our pretzel rolls are becoming a very popular item because even though pretzels have been around for thousands of years in hard form, the soft rolls are really gaining steam because they add a lot of dimension to a sandwich and have a lot of eye appeal.” Clean labels and natural products also happen to be Gabby’s backbone, says Daniel Garcia, vice president of operations. “We were doing natural, multigrain products before the trends—that has been a great win-win situation for us. Other things like reduced sodium are big. We have been playing around with some new formulations that are low-sodium to meet our customers’ demands and needs. That’s not an easy task when you start reducing sodium because you have to be careful with the yeast you’re using. You can have adverse effects, so we try to adjust our systems here and manipulate them to accommodate without using artificial flavor enhancers.”

Slow and careful but also nimble While other bakeries use quick dough conditioners and mix and process dough in as little as 18 minutes, Gabby’s takes its time and uses plenty of care. “We take it slowly,” affirms Garcia. “We take maybe two hours to process our dough, and let it sit a while during production. It takes a long time to ferment our dough. We want it to develop naturally occurring acids, such as lactic acids, and at that point, once we hit a targeted pH and other parameters, we know we can start the product and get something we’re looking for. We believe that taking our time to do all of this is most beneficial.” Still, Gabby’s is also very nimble. “We have to stay flexible,” Conti points out. Continued on page 22

20

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Continued from page 20

“We’re still relatively small compared with a lot of the major bakeries out there, but we can react quickly and even come out with a new product quickly. We react fast.” The plant maintains a recycling program for paper, paperboard and corrugated and collects its floor scrap and scrap dough and donates it to a pig farm in central

Illinois through a contracted recycler, says Garcia. “So instead of throwing the scrap dough in landfills, we try to discard as little as possible.”

Steady sales despite economy The recent economic downturn has had an impact on the bakery, Conti admits, but hasn’t been as damaging as he expected. “The economy has certainly affected us as it has affected others,” he says. “But our sales volumes have held steady and we actually saw some increases last year.” However, he has seen a number of restaurants fail. “It’s been a tough economy for restaurants and that has affected us. Yet, it seems there are always a few young entrepreneurs that will keep things going. It’s tough sometimes, but a lot of people who

22

Snack Food & Wholesale Bakery - March 2011

are new to the restaurant business want to give it a try, which is good for us.” Gabby’s large list of fresh products usually carry a three-day shelf life, but depending on customer requirements and product formulations, can be developed to have a longer shelf life. The bakery also takes great pride in its research and development, he says. “We don’t say no to anything that customers want to try. We’ll produce prototypes for all kinds of things, and that’s what makes us different. It’s why we’ve been growing over the last two years. I’ve worked with some of the large corporations where I had a year to develop a project and complete it. Here, when we get an opportunity for sampling with a customer, we want to have samples to them as soon as possible.” Sample requests are turned around more quickly, too, adds Garcia. “When we get a sample request, we can come up with samples and put a lot of R&D work

www.snackandbakery.com

into something usually to a customer within 48 to 72 hours. That’s one reason we’re unique. We have great customer service and flexibility.” The company has five truck routes in the Chicagoland area and beyond and distributes its fresh-baked frozen products nationally, which is proving more successful all the time, he says. The company is trying to capture more market share on the East and West coasts and is networking with associate producers and user distributors to get its products on the market in new locations. “Our sales network is more of a broker/distributor sales arm,” Conti says. “The products are being well received on the West coast and are getting a lot of compliments and high praise.” Adds Garcia, “We have some serious competition for our pretzel rolls, but our soft pretzel rolls and breads consistently come out on top.” Over the past several years, many white tablecloth restaurants have been looking to Gabby’s because of its quality, says Garcia. “We also have clean labels and we’ll accommodate these customers at midnight or noon. It’s our job to get product to them and we do it well.” Gabby’s also stays on top of major issues in the baking industry, Conti says. The bakery is in the process of completing food safety programs as part of the Global

www.snackandbakery.com

Food Safety Initiative. “Right now, we’re about one year into completing a two-yearlong process in the BRC [British Retail Consortium global standards] certification program,” he continues. “We have to revise some of the things we do to comply and need to update some of our procedures, but it will be worth it. We are really invested in a push for food safety and are doing it from a global standpoint. It’s very important for the success and the future of our business to be certified. We have been involved with AIB for a number of years and get audited by them annually.” Gabby’s also received a Superior rating from the AIB the last two years, which climbed from 905 to 915. “We’re moving in the right direction,” Conti says. “These and the food safety programs are all based on the HACCP program but are steps beyond the HACCP. We want to be several steps ahead of competition in a lot of ways.” The bakery wants to make sure all of its procedures are up to date. “If there are any requirements that we’re missing, we have to rebuild new programs so that they will be accepted,” he says. “That kind of certification is the highest we can attain globally. Our customers are starting to require these things, so we’re taking these steps to be ahead of the game.” Gabby’s is good at staying several steps in front. SF&WB

Quality manager Mike Luna (left); Rocio Villalobos, quality assurance; and Luis Tenesca, plant operations manager, show off Gabby’s specialty, fresh-baked pretzel rolls.

On the Cutting Edge Looks are deceiving at Gabby’s Bagels. The “small” artisan bakery may first appear unassuming, but it has plenty of big programs that keep it ahead of the competition and regulations. Lauren R. Hartman, Editor-in-Chief

n 1996, when Gabby’s Bagels, Inc. began operating in a small facility in Westmont, Ill., it had just been purchased from the Great American Bagel Co., or GAB, from which it got its name. Later, the company moved to larger quarters in Franklin Park, Ill., and by 2007, was “on a roll,” expanding again and relocating to a larger facility in the same town just outside of Chicago. “We’ve been growing by leaps and bounds in the last several years,” observes Daniel Garcia, vice president of operations. “What makes us different from a lot of other artisan bakeries—and other bakeries in general—is great customer service and great flexibility.” Gabby’s also is special because it has come from being a baker that just makes bagels to an artisan facility with a high-quality philosophy that is stronger today than ever. And it won’t turn down a request to create even the most unusual combination of bread, roll or bagel ingredients. In fact, it will turn samples around within two to three days. “If a customer wants a special sea salt-topped, seaweed-containing hamburger bun, we can do it,” Garcia states. “We may not be a big fan of the taste, but we’re going to make it. In Chicago, it’s very easy to find special ingredients locally, so we’re quite fortunate.” Yet with hundreds of product varieties, the bakery still takes things slowly in its baking operation so that it can get just the right type of artisan product. The bakery is full of contradictions. Equipped with five production lines and about 60 employees, the 39,000-sq.-ft. facil-

I

ity houses five makeup lines that generate fresh and fresh-baked/frozen breads, bagels and other delicious creations at improved outputs averaging 30,000 lb. a day. That’s quite a task when you’re doing things carefully and thoughtfully. “We take our time,” Garcia says. “But we’re nimble. We can switch off from working on one product line to another, depending on what’s resting.” The dough has to sit and rest, he says, and isn’t hurried along to proof or ferment.” The majority of Gabby’s breads, rolls, buns, bagels and baguettes—about 65%—are delivered fresh to restaurant customers and foodservice mainly in the Chicago area, while the other 35% is distributed nationally as fresh-baked frozen, primarily for foodservice customers.

Lines are dedicated While Gabby’s started out just producing bagels, it now creates some 300 bread varieties, including pretzel rolls and buns, Tuscan breads, hamburger buns, bagels in various sizes and flavors, boules, apple crumble, focaccia, Vienna breads, olive loaves, baguettes, sesame seed buns, long baguettes, dinner rolls, Panini, hand-made, preservative-free pizza crust, submarine rolls, raisin loaves and, of course, bagels. Each of the five production lines is dedicated to a particular type of product and consists of a bagel line, one for rolls, another for sliced bread or Pullman loaves, an artisan bread line and a ciabatta line. Individual quantities range from 1.5 oz. up to 3 lb. Depending on the product and product formulation, the shelf life of the fresh items is usually three days but can Continued on page 26

Photos by Vito Palmisano March 2011 - Snack Food & Wholesale Bakery

25

The 39,000-sq.-ft. plant houses five production lines and three types of oven. Vertical mixers, left, receive main ingredients through a pump system linked to an outdoor bulk tank. Above and top left, dough is being mixed before it is allowed to rest for an hour or two, depending on the product being made.

Continued from page 25

be extended per customer requests. Production begins at midnight for the first of two 8-hour shifts, seven days a week. Orders are taken by phone and online and daily route orders are taken by phone. The

second shift starts by noon to accommodate a washdown and sanitization procedure, explains Luis Tenesaca, the operations manager who leads the plant. “Everything has to be cleaned and set up for the second shift. Machinery is sanitized and we have created

a two-hour window for this.” Allergen products are kept separate from the rest of the facility so that they don’t come in contact with other ingredients, says president Michael Conti. “We store seeds, herbs, milk, soy, rosemary and many other things in bulk bags, sacks and cases away from everything. We’re in the process of completing a two-year-long global food safety certification program and have learned a lot about managing allergens. They must also be clearly marked. All of our products contain wheat, but these particular allergens are separated.” The newest equipment in the facility is a bulk flour delivery system that was added about six months ago, which Continued on page 28

26

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Increase product yields and improve your bottom line.

Use CompactGrid™ conveyor belting… only from Wire Belt. t Heat and cool your product quicker and more efficiently t Excellent product support for smaller, delicate products t Belt joining is simple and fast t Easy to clean and sanitize, USDA Accepted t Low horsepower requirement for driving the belt t Positive drive for better belt tracking t Manufactured in stainless steel t Easy to retrofit on your conveyor t 5X greater flow through than average plastic modular belt

Clean. Safe. Sanitary…Choose a Wire Belt. Wire Belt Company of America, 154 Harvey Road, Londonderry, NH 03053 5&-

t
'"9
 &NBJM
TBMFT!XJSFCFMUDPN
t
8FCTJUF
XXXXJSFCFMUDPN ISO 9001:14001 Registered Company

After the dough rests, it is cut, divided and formed into loaves in this case (left) and loaded into baking pans and transported to a large proofer. After proofing, the pans of dough are moved to a retarder where they rest again. Next, the racks are are transported to one of several large ovens (right) for baking. Continued from page 26

Garcia says has really cut labor. “We used to have to deal with 50- and 100-lb. sacks of flour, which were heavy and laborintensive,” he notes. Several items were being made at the time of Snack Food & Wholesale Bakery’s visit, such as raisin bagels, pizza crusts and multigrain submarine rolls. Primary ingredients, such as flour, are stored in a 100,000-lb. bulk flour silo outside of the building that is linked to a transparent pump placed inside the plant that transports the flour to sifters and up and into a set of flour hoppers that lead to a weigh scale. After they’re weighed, the sifted ingredients are transported to a series of mixers. Secondary ingredients are usually added by hand and water is metered into a mixer. Gabby’s uses one vertical and three spiral mixers that each hold 300 lb., depending on what type of product is being made, Conti explains. “The spiral mixers are gentler, so we use them to mix dough for artisan breads. The vertical mixer is for bagels and other products that can handle a more rigorous system.”

One batch at a time As one batch of dough is mixed, it rests for about an hour or two, depending on the product, Conti adds. The round mixing bowls are lifted and lowered automatically

28

Snack Food & Wholesale Bakery - March 2011

and the dough is placed into a trough to sit. Next, the mixed dough is cut, divided and sent through a rounder or can be formed and portioned by hand, depending on what it will become. The portioned product is then manually placed on trays, peel boards or pans that are transported to a large proofer. There is also a separator on the bread line. Other items such as the pizza crust can be dusted by hand with flour or corn meal at this point. There are several quality control checks performed throughout the plant, including a Hazardous Analysis Critical Control Point (HACCP) using sifter screens, says Tenesaca. The steam-based proof box holds approximately 40 racks of panned product that remains in the proofer anywhere from 45 minutes to two hours at 103ºF and 88% relative humidity (RH), again depending on what is being made. Once proofed, the pans of dough emerge and head to a retarder for different lengths of time. The retarder refrigerates or cools the dough at temperatures of 38-41ºF. “I guess you could call ours a semi-automated artisan facility,” says Conti. “It’s more automated than you would think, however. You can automate an artisan program with equipment that’s a little gentler, so that it replicates the hand motions needed, but we’re not totally there yet. We

still do a lot of hand work, especially with our ciabatta line of products.” Computerized controls and software are equipped on about half of the equipment, such as the proofers, refrigeration units, bag clip applicators and date coders. Despite the automation, operators are the ones who remove the trays of product from racks in the retarder and transport them to one of three ovens. Both fresh and fresh-frozen product is handled this way. At this point, operators might split certain loaves of bread on the top for venting and then prep the loaves for the oven. Here, a baker arranges loaves of bread, or rolls, buns, etc., on an automatic conveyorized loader. The three oven types include a revolving oven for bread and rolls; rack ovens for bagels dinner rolls and pretzel rolls; and a hearth oven for breads. The deck oven has a stone floor. “We bake baguettes and Panini at 420ºF for 22 minutes to an hour, 2-lb. bread loaves take longer,” Garcia says. Many of the breads and rolls are also hand-loaded into the ovens using the peel boards. The hearth oven has 4 decks with four chambers per deck, with each deck holding up to 70 loaves. The revolving oven has eight shelves that can hold eight pans per shelf. There are six double-rack ovens that can 32 pans per oven.

www.snackandbakery.com

“We are working on a tagging process to keep track of what’s ready for the next process,” Tenesaca says. “Currently, we eyeball things and take written notes.” A quality control check for temperature takes place at this time. Breads that need to be sliced are also checked for temperature. After the products are baked, they are moved to a cooler on conveyors or are manually moved on racks. After cooling, the product goes to a quality assurance station where it’s inspected and checked for the proper size and weight. At this point, it can be sliced, if called for. Several slicers are in place for bread loaves that produce ½ to ¾-in. thick slices. “What comes out of the oven first is usually what’s packaged first,” says Tenesaca. We have some routes that leave here in the morning for foodservice, so we plan what we need to send out and what’s packed before we start production.” Once transferred to the packing room,

the baked products are bagged in clear film bags imprinted with the Gabby’s logo. The bags are then clip-closed using a clip applicator and locking clips imprinted with a date code. Products are bagged in various multiples depending on the order by operators who then place the bags on racks or in film-lined corrugated shipping cases and later transport the cases further into the packaging area for shipment or into a freezer for warehouse storage. “There are certain specifications that we check for at this point,” Conti adds. “Sometimes the product is hand-cut to fit a certain size and we cut the product, check weights of products on standalone scales. If something doesn’t meet spec, it’s put on a quality hold and management determines what to do with it.”

If frozen, the baked products are sent through a liquid nitrogen tunnel freezer for a few minutes before they’re packed in clear film bags and corrugated cases. The cases are automatically tape-sealed and stamped with a lot number, production code, manufacturing time and an expiration date for traceability. Both fresh and fresh-baked frozen products are sent through a metal detector after packaging.

Production improvements Probably the most important aspect of making artisan bread is not rushing the process, Garcia says. “We don’t rush. We let nature take its course,” Garcia points out. “Automatic systems help us out, but we also have a lot of hands-on processes. At the same time, Luis [Tenesaca] and his team are very flexible. We run custom products and allow them their own time, but also use automation wherever possible.” Continued on page 30

Is there a better way to apply viscous coatings to your products? Find out for free. Applying coatings using spray technology offers many advantages over other coating methods: • Uniform and consistent application eliminates QC problems even when applying thick, temperature-sensitive coatings like sugar slurries, egg wash, chocolate, marshmallow cream and gravy • Precise application on product minimizes waste of costly coatings and the mess caused by over-application • Manual application is eliminated improving food safety, lowering costs and increasing throughput • 95% of viscous coatings can be sprayed more uniformly, faster and with less waste. Our extensive line of products for applying viscous coatings includes standard and heated hydraulic and air atomizing nozzles, FDA-compliant spray headers, automated AccuCoat® Heated Spray Systems and many more.

Contact us today to arrange a free spray test of your coating and find out if there’s a better way to apply your coatings. Call 1-800-95-SPRAY or visit spray.com/freecoatingtest Free test will determine if your coating can be sprayed.

Spray Nozzles

Spray Control

Spray Analysis

Spray Fabrication

Plant operations manager Luis Tenesaca moves a pan of fresh-baked, flour-dusted bread loaves to a rack near the packaging room. The bakery has doubled its production and improved yield by about 38%, in addition to enrolling in a global food safety certification program.

Continued from page 29

Yet the “slow pace” is anything but. The bakery has doubled its production since Tenesaca and Garcia joined the company about six months ago, and believe that the improvement is due to crosstraining the staff. “Sanitation employees, for example, are trained in quality assurance, and the QA folks are trained in production in case an issue comes up,” Garcia says. “Today, we’re running 25 batches on same product per day versus two. Our yield before was about 60% and now it’s about 98%,” adds Tenesaca. Gabby’s is making other strides by becoming certified for food

30 SFWB0309ALIT.indd 1

Snack Food & Wholesale Bakery - March 2011

safety with the British Retail Consortium’s global standards program. “We have more paperwork, documentation and follow-up but it’s worth it,” Garcia says. “We are really invested in a push for food safety and are doing it from a global standpoint. It’s very important for the success and the future of our business to be certified.” He also credits the conscientious, talented and experienced staff. “Our team here deserve so much credit. Finding good employees that are passionate about what they do makes all the difference in the world.” Gabby’s products have become so popular that another expansion may be possible. “We’re looking at adding new roll lines or Ciabatta lines to further our production efficiency without sacrificing product quality,” Garcia says, smiling. “We are always keeping an eye out for a bigger facility, but we’re not going to make any changes until new business starts rolling in.” SF&WB

www.snackandbakery.com 1/5/09 10:50:22 AM

&RXQWLQJ6WDFNLQJ3DFNDJLQJ $XWRPDWLRQVROXWLRQV

‹–ƒŠ‹Ǧ Žƒ–”‡ƒ† ‘—–‡”–ƒ…‡”

‘”–Š‡’ƒ•–͚͠›‡ƒ”•ǡ””Ǧ‡…ŠŠƒ•„‡‡ ƒŽ‡ƒ†‡”‹–Š‡ƒ—ˆƒ…–—”‹‰‘ˆ–Š‡‘•– ˜‡”•ƒ–‹Ž‡ƒ†”‡Ž‹ƒ„Ž‡…‘—–‹‰ǡ•–ƒ…‹‰ǡƒ† ’ƒ…ƒ‰‹‰ƒ…Š‹‡”›ˆ‘”–Š‡„ƒ‡”›‹†—•–”‹‡•Ǥ

%HQHILWVRI$XWRPDWLQJ Ȉ”‡†—…‡†Žƒ„‘” Ȉ”‡‘˜‡•”‹•‘ˆ’”‘†—…–…‘–ƒ‹ƒ–‹‘‘ˆŠƒ†Ǧ’ƒ…ƒ‰‹‰ Ȉ”‡Ž‹ƒ„‹Ž‹–›‘ˆƒŽ™ƒ›•„‡‹‰‘–Š‡Œ‘„͚͜Ȁ͟ Ȉ‡‰‹‡‡”‡†–‘‡‡–›‘—”’”‘†—…–‹‘†‡ƒ†• Ȉ…‘’Ž‡–‡‘Ǧ•‹–‡‘””‡‘–‡ƒ‹–‡ƒ…‡•—’’‘”–

&RPHVHHXV 7,$&RQYHQWLRQ/DV9HJDV196HSW 3DFN([SR/DV9HJDV196HSW

‹œœƒ”—•–Ǧ‹–ƒŠ‹• ‘—–‡”–ƒ…‡”

ƒ’‡” –‡”Ž‡ƒ˜‹‰ ’–‹‘

$UU7HFK,QF     ZZZDUUWHFKFRP

Market Trends

Delivering Innovation Pizza manufacturers are finding their own unique ways to create new products that meet the demands of innovative and unfamiliar varieties. Jen Roth, contributing writer

n recent years, consumers have been exposed to new varieties of pizza that feature fresh, creative options with toppings such as Buffalo chicken, caramelized pears and an assortment of cheeses beyond basic Mozzarella. However, plain cheese and pepperoni aren’t quite making the cut as consumers’ desires for innovative options continue to grow. “We are seeing consumers’ taste preferences evolve when it comes to pizza,” says Chris Leising, brand director of Freschetta, which is owned by Schwan’s Consumer Brands, Inc. “While many continue to like cheese pizza with a tomato sauce, there has always been a subset of consumers looking for more flavorful variations in pizza, such as different types of sauces like barbeque, creamy Alfredo or pesto, as well as unique vegetable blends.”

Inspired pizzas, due out in April. “We have created eight varieties with our signature sauces and big, colorful cuts of vegetables like roasted peppers and shiitake mushrooms and premium cheese like Gouda on a crispy crust,” says Leising. The unique selections offered in the Freschetta Simply…Inspired line include Hawaiian, Farmers Market Veggie, Harvest Supreme, Southern BBQ Style Chicken, Classic Bruschetta, and Rustic Pepperoni Pomodoro. The company is also offering a few limited-edition options such as Tuscan Farmhouse and Chicken Bianco. “These flavors were developed to address consumers’ desires for more variety The Bloomington, Minn.-based and better-tasting pizzas in the frozen pizza company is using this knowledge to introcategory,” Leising states. duce their new line of Freschetta Simply… Since the pizza is not being served directly from the baker’s THE oven, the company must deliver TOP these innovative varieties in a way (For the latest 52 weeks ending Jan. 23, 2011) that keeps all the flavors fresh. Leising explains that each of Dollar Sales % Change vs. Dollar Unit Sales Unit Sales % Rank Brands (in millions) Previous Year Share (in millions) Previous Year the Freschetta Simply…Inspired 1. DiGiorno $677.0 +8.1 21.6 128.2 +9.2 pizzas are wrapped in the company’s Fresch-Taste Seal packaging 2. Private Label $294.8 -7.1 9.4 118.6 -10.7 to lock in the flavorful experience 3. Red Baron $286.1 +12.8 9.1 76.9 +15.4 while using 30% less packaging 4. Tombstone $257.9 -1.4 8.2 73.5 +0.8 than a traditional pizza carton. 5. Totino’s Party Pizza $164.5 +3.4 5.3 128.3 +7.2 “From our consumers, we’ve 6. Freschetta $154.7 +2.4 4.9 28.6 +1.8 heard a growing interest in finding 7. California Pizza Kitchen $146.0 -16.8 4.7 28.8 -14.5 a quality slice of pizza that can be 8. Tony’s $130.6 -9.7 4.2 68.2 -1.7 enjoyed at lunch or as a snack,” 9. Jack’s Original $130.0 +1.6 4.2 47.3 +3.2 says Leising. 10. Stouffer’s $80.5 -9.4 2.6 29.8 -6.7 Freschetta has delivered on this Total*: $3,132.6 -1.9 100.0 1,035.6 -1.9 opportunity by offering its new *Includes brands not shown Freschetta By The Slice, which Source: SymphonyIRI Group, a Chicago-based market research firm, comes as individually-wrapped www.symphonyiri.com single-slices in Six Cheese Medley, Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Wal-Mart)

I

Frozen Pizza

10

Continued on page 34

32

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

S U C C E S S

S T O R I E S

HOW A VE MAG CH E ESE EXTR U DE R

inspired a B E T T E R PIZZA DOUGH

D I V I D E R A T RU E S T O RY: A few years ago, Reiser installed multiple Vemags – each with a multi-outlet cheese extruder – into a customer’s plant. The systems extruded cheese onto makeup lines to produce cheese-filled dough products. After seeing the speed and portioning accuracy of the Vemag cheese extruder, the customer was inspired to ask if a similar Vemag could be used to successfully divide pizza dough. Reiser specialists and engineers worked with the customer to develop a solution. The result was a new pizza dough dividing process featuring the Vemag. The Vemag Dough Divider was able to produce exact-weight portions while meeting their high output requirements. The savings were so great that the customer converted all of their lines worldwide to Vemag pizza dough dividers.

A VEMAG DOUGH DIVIDER CAN PAY FOR ITSELF IN JUST A FEW MONTHS. Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com

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

Market Trends Continued from page 32

Chicken, Spinach and Mushroom, Vegetable Medley and BBQ Chicken options. “The makers of Freschetta pizza strive to provide unsurpassed fresh taste in frozen,” states Leising. “We are continuing to make strides by sourcing only the finest ingredients, improving packaging to provide a fresher taste experience, as well as developing methods to reduce sodium and preservatives in our products.” Pizza Patrón of Dallas, Texas, is following in the footsteps of many locallybased pizzerias by making a transition from the restaurant to the frozen foods aisle. “One trend we are seeing is a consumer mindset that is increasingly sensitive to a brand’s connection to the community,” states Andrew Gamm, brand director. “It is a local mentality, but it’s bigger than geography.”

Pizza Patrón began taking its pizzas from the oven to the supermarket in October 2010 with six varieties: Pepperoni; Cheese; Meat Trio; Mexicana; Petrona; and Hawaiana, and has since introduced its first limited-time pizza in 2011— Spin-

ach Clásico, which is an alfredo saucebased pizza that uses fresh spinach sourced locally in each of its markets, Gamm says. “For Pizza Patrón, this pizza allows us to deliver added value to our customer base by providing a delicious option for Cuaresma (Lent),” he adds. “A significant number of our customers observe Cuaresma strictly, and they appreciate that we recognize their commitment.” Another manufacturer making strides in unique pizza selections is Kashi, La Jolla, Calif., with its all-natural frozen pizza selection. Made with the company’s signature stone-fired, Seven Whole Grain and Sesame blend crusts and flax, Kashi’s all-natural frozen pizzas feature fresh toppings such as tomatoes, peppers, onions, roasted chicken and unique cheeses to create a high-protein and high-fiber meal. Kashi also offers Caribbean Carnival and Mediterranean Pizza varieties on original crust and Margherita,

Market Trends Mexicali Black Bean, Mushroom Trio and Spinach and Roasted Vegetable options on thin crust. Joining the thin crust line is Kashi’s new Pesto variety, made with Roma tomatoes, caramelized onions and Mozzarella and feta cheeses over a basil pesto sauce on its signature Seven Whole Grain and Sesame crust. Advertised as a vegetarian pizza, this option offers 11 g. of whole grains.

Thin pizzas, which include Margherita, Cheese Lovers, Special Edition Pepperoni, Greek, Supreme, Italian Sausage, Grilled Chicken Caesar and Ham and Pineapple options. “Our Primo Thin line is a dieter’s

dream,” asserts Fallucca. “This is an ultra-thin crust pizza that is 100% flavor, but also has as few as 220 calories per serving. The funny thing is that it’s not a ‘diet’ pizza.” Continued on page 36

Palermo Villa, Inc., Milwaukee, Wis., owner of the Palermo’s brand of pizzas, is testing the premium pizza market with its own team of creative offerings. “The most notable aspect of the premium segment’s growth is that it is being powered by the growth of smaller craft brands, such as Palermo’s, rather than the giant national brands,” says Giacomo Fallucca, president and CEO. That’s why, in September 2010, Palermo’s launched its hand tossed-style line, “which finally brought true premium quality to the traditional thin crust segment of the frozen pizza category,” he says. “Our hand tossed-style was developed to compete head-to-head with the delivery [and] carry-out operators with a pizzeria crust and a sauce and toppings options that the whole family will absolutely love,” says Fallucca. It comes in Cheese, Sausage, Pepperoni, Supreme, Combination and Chicken and Bacon Alfredo varieties. Palermo’s also offers a line of Primo

www.snackandbakery.com

March 2011 - Snack Food & Wholesale Bakery

35

Market Trends Continued from page 35

In June 2010, Palermo’s added Chicken Fajita pizza, which uses a Mexicali sauce on the company’s signature ultra-thin crust, topped with southwest-spiced grilled chicken, fire-roasted green peppers, red onions and a blend of Mozzarella and Monterey Jack cheeses topped with a sour cream sauce, as well as a Garden Vegetable

variety, which includes a combination of fire-roasted red and green peppers and onions, black olives, broccoli and partskim Mozzarella, parmesan and Romano cheeses, topped with Italian spices. “By making pizzas that are good or better than pizzas people order out, we will continue to capture a larger percentage of the pizza occasions,” says Fallucca.

Familiar flavor in unfamiliar territory Typically, consumers would allege that you cannot make a pizza without cheese and meat, but Turtle Island Foods’ Tofurky brand is out to prove them wrong. The Hood River, Ore.-based company introduced three new vegan pizzas, Vegan Cheese, Pepperoni and Italian Sausage and Fire Roasted Veggies, in March 2010. “For the past two years, prior to introducing our three Tofurky pizzas, we noticed that in the natural foods frozen pizza category, non-dairy pizzas were among the

fastest growing items,” says Seth Tibbot, founder and president of Turtle Island Foods. But, how can Tofurky make a non-dairy pizza but still deliver the cheesy toppings that people crave? The company uses a tapioca-based Daiya brand cheese and Tofurky meat alternatives to create that familiar flavor out of un-familiar ingredients. “These pizzas were designed to not only deliver great taste, but greatly reduced cholesterol, fat and sodium,” says Tibbot. “Our message is to cut down on fat, cholesterol and sodium but still enjoy a delicious slice of pie.” Another growing trend in the pizza category is the gluten-free niche, which also challenges pizza makers to create great-tasting products out of unfamiliar ingredients. However, Glutino Food Group of Quebec, Canada, has garnered a stronghold in this arena. “Pizza is a consumer favorite, and

Automate your slicing application today! ‡3L]]DDQG)UHQFKEUHDGOLQHV ‡6DQGZLFKDVVHPEO\DXWRPDWLRQ

‡&RQWLQXRXVGRXJKVKHHWV VWURPEROLSHSSHURQLUROOV

‡0HOEDWRDVW ‡%LVFRWWL

‡%DJHOFKLSV

Grote Company, Columbus, OH U.S.A. ‡ www.grotecompany.com | [email protected]

36

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Market Trends people who need to eat gluten-free are turning to the freezer case to buy pizza they know they can trust to be great tasting and gluten-free,” says Laura Kuykendall, director of marketing and research and development. “One of Glutino’s most popular pizza offerings, Glutino Duo Cheese pizza, is made with a delicious brown rice crust and topped with a blend of grated Mozzarella and Monterey Jack cheeses.” Glutino introduced gluten-free Duo Cheese pizza multi-packs in August 2010, which come three pizzas per box, adding value to an already premium product. Joining the Duo Cheese Pizza is Glutino’s Pepperoni pizza, made with organic natural pepperoni, along with Chicken with BBQ Sauce, Spinach and Feta and dairy-free Spinach Soy Cheese pizza options. “As a leader and pioneer in gluten-free foods, Glutino believes consumers who eat gluten-free should have a wide variety of choices available to them that they can trust,” states Kuykendall. “Glutino is always trying to find innovative ways to make the most popular products gluten-free.” Pizza is popular for lunch, dinner, snack time and the occasional 2 a.m. craving, but most don’t realize that it is can be ideal as a dessert. That’s why 3 Sisters Chocolate of Jacksonville, Fla., developed six new chocolate varieties in June 2010. “We are seeing an increased interest in new flavor combinations,” says Jeff Guy, president. “Our customers are requesting more dark chocolate with toppings that are more interesting and healthier.” Joining the Chocolate Pecan and Everything Chocolate options is Goji Berry and Almond, Cranberry and Walnut, Oatmeal Rasin, Pumpkin Spice with Cayenne Peppers, S’Mores and Trail Mix. “Goji berries are being hailed as the new ‘superfood’ due to a high level of antioxidants,” states Guy. He adds that the dark chocolate used in making the company’s pizzas is higher in flavonoids than milk chocolate and the nuts provide a valuable source of protein. “We feel there are many flavor combinations still to be developed in the chocolate pizza market,” states Guy. “We will continue to develop new chocolate pizzas and then test market them direct with our customers.” Whether it’s made with whole grains, fresh vegetables and meats, a variety of sauces or even chocolate, pizzas continue to be a staple in freezers nationwide, thanks to an innate ability to recreate the category and continue delivering innovation. SF&WB

International, Innovative, Inspiring

Crusto bread line Specialist in food processing equipment • Low Stress Production of Cut and Molded Artisan Style Breads • Ideal for high absorption and pre-fermented dough’s • Product can be placed on pans, peels, or paper • Quick product changeover

Rademaker USA, Inc., 5218 Hudson Drive, Hudson, Ohio 44236, Tel. (330) 650-2345, Fax (330) 656-2802, Email: [email protected]

www.rademaker.com www.snackandbakery.com

Special Report: Food Safety

Food Safety Fundamentals With the recent passing of the Food Safety Modernization Act (FSMA), what’s ahead for bakers and snack food manufacturers, and how do they prepare to meet the changes head-on? Here’s what the bakery associations have to say concerning the issues. Photo courtesy of AIB International

Lauren R. Hartman, Editor-in-Chief

afety. It could be the most important aspect of purchasing, eating and cooking food, as well as the most important in the food supply chain in this country. Overwhelming amounts of information, including reports, press releases, association statements, online blogs, social media articles, opinions and more have been generated about this serious subject. According to recent data from the Centers for Disease Control and Prevention, nearly 48 million people (one in six Americans) get sick, 128,000 are hospitalized and 3,000 die each year from foodborne diseases. This is a significant public health burden that is largely preventable. Since the U.S. Food and Drug Administration imposed the new Food Safety Modernization Act (FSMA), passed by Congress in January, many bakers and snack food manufacturers are gearing up to accommodate the changes (also see accompanying Food Safety Workshop sidebar). But many are still confused as to how, when and if these new regulations will be implemented. The FDA created the new law because foodborne illness is largely preventable if everyone in today’s global food chain could be held responsible and accountable at each step for controlling hazards that can cause illness. However, that is easier

S

said than done. “Right now, many suppliers and bakeries are reviewing their internal programs to see where they stand,” says Gary Ades, president of G&L Consulting Group, LLC, Bentonville, Ark., and the chairman of the executive education council for the Food Safety Summit, April 19-21 in Washington, D.C. The Food Safety Summit is produced by BNP Media, parent company of Snack Food & Wholesale Bakery. Ades and his group have been reviewing client food safety programs and bench-

marking against best practices. “What many want to know is, ‘does FDA have sufficient qualified resources and funding to accomplish the [new] goals?’ Our organization offers educational training and information, and public health officials are also a good source of information and assistance yet are often overlooked. Get to know your local public health officials before there is a problem,” he advises. Robb MacKie, president and CEO of the American Baking Association (ABA), Washington, D.C., says that the new Continued on page 40

38

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Special Report: Food Safety Continued from page 38

requirements to audit sources of ingredients will impact baking and snack suppliers. “This is particularly true for ingredients sourced outside of the U.S.,” he says. “This is one area where we’re not sure if FDA understands all of the ramifications. There will be opportunities in the rulemaking process to seek further clarification on the requirements.” MacKie says that ABA members have been implementing Good Manufacturing Practices (GMPs) to reduce potential food safety issues for some time. “That doesn’t mean the practices are flawless, but we are fortunate as an industry to have had so few incidents,” he notes. “ABA’s Food Technical and Regulatory Affairs Committee (FTRAC) has been exploring common sense improvements in food safety for decades, and we are working hard to educate members on the recently enacted food safety bill.” MacKie points out that ABA has already conducted an informational webinar in conjunction with the AIB about food safety, and the FTRAC is focusing on compliance at its ABA meetings this year.

More training needed The baking industry has responded to the new legislation with a realization that expanded training will be required, says a team from AIB International, Manhattan, Kan., which collectively answered questions for this special report. The team is led

Illustration courtesy of AIB International

Photo courtesy of AIB International

by Jim Munyon, president and CEO; Maureen Olewnik, vice president of audit and technical services; Bill Pursley, vice president of food safety education; Brenda Stahl, director of microbiology; and Brian Soddy, vice president of marketing and sales. “This expanded training will include both general understanding of the new regulations, as well as, continued training on its basic requirements: hazard analysis and prevention control (including radiology), traceablity, etc.,” the AIB team says. “Diligence in recordkeeping and management of programs will also have to be enhanced. These additional requirements are in line with activities required in certification schemes, and will be further delineated by FDA as the program requirements are finalized.” Nicholas Pyle, president of the Independent Bakers Association (IBA), Washington, D.C., which says his group acted to shepherd the legislation to the best outcome, indicates that bakers and snack companies should watch out for comprehensive and lengthy inspections to be more about record-keeping compliance and less about actual manufacturing operations. “The [updated] food safety bill is a record-keeping bill with associated fines and penalties,” he says. “Most of my conversations [with bakers] have been regarding traceability information from suppliers. They are now responsible for accounting for all their inputs (by lot), from seed to store shelf. Thus, bakeries and snack companies are actively looking at compliance methodologies and staffing to meet the record-keeping provisions.” Along with plenty of other information, IBA offers a guide for bakers on how to manage recalls, and directly assists bakers in managing the media in past cases of product tampering, Pyle explains.

Bakers and snack food manufacturers also want to know how the new law will change the way FDA regulates food. The answer? By putting prevention up front. For the first time, FDA will have a legislative mandate to require comprehensive, science-based preventive controls across the food supply. Preventive controls include steps that a food facility can take to prevent or significantly minimize the likelihood of problems occurring. Under the FSMA, implementation of mandatory preventive controls for food facilities and compliance with mandatory produce safety standards will be required. And, FDA now has the power to order a product recall. To assist bakers and snack food manufacturers with food safety questions and issues, AIB on Jan. 28 provided a well-attended webinar on the practical approach to the FSMA. Among other food safety-related programs, AIB also developed a resident training course that offers four weeks of practical review of the new requirements, as well as, hands-on activities demonstrating the requirements of basic GMPs, Hazard Analysis Critical Control Points (HACCP), food defense and other requirements of a well-run food safety program. AIB, which supports the new food safety legislation, says the American Baker’s Association (ABA), itself and other industry association partners have been actively working with the American Frozen Foods Institute (AFFI) in a coalition focused on working with FDA to update Continued on page 42

40

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Special Report: Food Safety Continued from page 40

Equipment Design/Plant Design Workshop a Real Eye-Opener February’s sanitary design training seminar provided a wealth of details on equipment sanitation, new equipment designs, controlling pathogens, managing allergens and effective cleaning and sanitization procedures, as well as, a perspective from the Food and Drug Administration’s Jenny Scott. Lauren R. Hartman, Editor-in-Chief

ne way bakers and snack food producers can find out more about how to increase their products’ safety is by attending one of the myriad seminars, workshops or meetings hosted by their key industry associations. Concerns in the United States about food safety have never been higher. If you plan to purchase or design equipment for a production facility that produces low-moisture food products, then food safety is your responsibility. With the vast amount of information made available by food industry associations, there’s plenty of help for engineers, sanitarians and plant personnel to gain more understanding of how to best protect food supply. Based on the overwhelming response to earlier workshops on this subject, a third Food Safety Equipment and Plant Design Workshop for Allergen/Pathogen Control took place in Chicago, Feb. 8-9, and proved to be a highly informative eye-opener. The event focused on what the food industry can do to achieve the proper equipment, plant and process design—targeting allergens and lowmoisture pathogens—to best promote food safety. That statement was a prevalent theme during the seminar, which was sponsored by food industry associations, including AIB International (AIB), American Bakers Association (ABA), American Society of Baking (ASB), the Biscuit and Cracker Manufacturers’ Association (B&CMA), Baking Equipment Manufacturers and Allieds (BEMA), National Confectioners Association, Food Processing Suppliers Association (FPSA), National Pasta Association (NPA) and the Snack Food Association (SFA), as well as the GMA (Grocery Manufacturers of America), whose Sanitation Committee members

O

42

Snack Food & Wholesale Bakery - March 2011

“The new act grants and member comFDA with a number of panies provided the new powers, including workshop content. mandatory recall auThe large group of thority. Food facilities attendees explored will be inspected with various topics such as greater frequency wet cleaning versus and not less often dry cleaning methods, than once every five lot-and-line segregayears.” tion for a clean break, In addition to the controls for pathoassociation presentgens and allergens, Photo courtesy of AIB International ers, Jenny Scott, sechallenges and nior advisor of the Office of Food Safety, obstacles in sanitary equipment design, Center for Food Safety and Applied Nutriregulatory concerns, what the new Food Safety Modernization Act (FMSA) means tion at the U.S. Food and Drug Administrato equipment manufacturers and food tion provided a phoned-in presentation on producers and startling lessons learned FDA’s perspective on equipment sanitary the hard way by some of the country’s top design. “While FDA regulates foods and food producers who have experienced does not regulate food processing equipproduct recalls and plant shutdowns. ment, FDA does regulate the sanitary use Attendees also participated in exercises of this equipment,” she said. “Prevention that challenged how long it takes to is the name of the game, as FDA commisclean small parts and huge production sioner Margaret Hamburg, says...Equipmachinery, how to design equipment ment manufacturers have a responsibility that’s easier to clean and how to create a with respect to cleaning and sanitation. Sanitation Standard Operating Procedure Sanitary design cannot be secondary to (SSOP) for a piece of equipment. The functionally of equipment.” Scott added, group also learned about practical and “Equipment design engineers need to proven approaches to equipment and work with sanitarians, quality assurance, plant cleaning and sanitary design, the limicrobiologists and food technologists to abilities associated with failed equipment assess designs for areas that are difficult and facility designs and the importance of to clean. Design to allow quick access to using equipment and plant design checkhidden areas and make equipment easy lists (some of which have been created to disassemble and assemble.” as guidelines by the GMA) to evaluate For more information on these and low-moisture food compliance with GMA other food safety-related events, visit Sanitary Design Principles. any of the following associations: AIB “The Food Safety Modernization Act International at www.aibonline.org, GMA represents the most significant expanat www.gmaonline.org, BEMA at www. sion of food safety requirements and FDA bema.org, ASB at www.asbe.org, Indefood safety authorities since the original pendent Bakers Association at enactment of the Food Drug & Cosmetic www.independentbaker.net, ABA at Act in 1938,” stated Warren Stone, direcwww.americanbakers.org and SFA at tor of compliance and inspection at GMA. www.sfa.org.

www.snackandbakery.com

Photo courtesy of AIB International

and improve the current GMPs. A recent document submitted to FDA by this group aims to provide the food industry with guidance for establishing and monitoring GMPs within food production facilities, as well as providing FDA with a set of principles and practices the agency will hopefully utilize in developing further guidance on GMPs. FDA is in the process of developing a proposed rule that will establish science-based minimum standards for the safe production and harvesting of fruits and vegetables and will address soil amendments, worker health and hygiene, packaging, temperature controls, water and other issues. Food facilities will be required to implement a written preventive control plan, provide for the monitoring of the performance of those controls and specify the corrective actions the facility will take when necessary. Like many food companies, bakers and snack producers will see the FSMA progress slowly, Ades says. AIB agrees, saying the new programs will most likely require facilities to review, augment and enhance existing programs, including training, HACCP, traceability, record-keeping, vulnerability assessment and more. “Practically speaking, certain elements must be addressed immediately, and many must wait for FDA rule-making to occur,” says the AIB team. “Developing details of the bill’s requirements will require at least two to two-and-a-half-years of effort on the part of FDA.” Says MacKie, “One of ABA’s significant achievements in the legislative process was in shifting very prescriptive legislative mandates to FDA for proper rule-making. This will allow ABA to offer the baking industry’s perspective and seek further clarification of the law’s requirements.” FDA is aware that it may take a while before the food system is safer. “A longterm process will be needed to build a new food safety system based on prevention,” it states on its website, fda.gov. Congress established specific implementation dates

in the legislation. Some authorities will go into effect quickly, such as mandatory recall authority, while others require FDA to prepare and issue regulations and guidance documents. FDA says it’s committed to implementing the requirements through an open process with opportunity for input from all stakeholders. “The record-keeping requirements all along the supply chain mean massive redundancy of paperwork,” says Pyle. “One can only hope the process will move towards streamlining and shared efficiencies.”

What will it cost? Costs are also a critical factor when it comes to FDA enforcement of the bill. And, with the recent economy decline, manufacturing is still nowhere close to being financially fit. “A lot of these companies say they aren’t sure what [specifically] will be required,” says Ades. “More funding is going to be necessary in order for the FDA to carry out these new regulations. But the jury is still out as to whether or not it gets them.” ABA’s FTRAC will be spearheading industry input to FDA, says MacKie. “We cannot emphasize enough the importance of baking companies’ participation in the FTRACs efforts,” he says. “These are complex and potentially costly issues, and we will be looking to members to offer

suggestions on how to achieve improved food safety that builds on current industry practices and successes without unduly burdening the industry. Going forward in the current budgetary environment, it is difficult to envision FDA receiving significant new resources,” MacKie continues. “…it is imperative for the food industry to work hard at self regulation and continuous improvement.” The funding that FDA reports it has available is coming through the annual budget cycle. Fees impacts the number of full-time equivalents (FTE) it has and will be a factor in the way that FDA handles its significant and far-ranging activities, including the way this legislation is implemented. The inspection schedule in the legislation would increase the burden on the agency’s inspection functions, for example. Without additional funding, FDA will be challenged in fully implementing the legislation without compromising other key functions. “We look forward to working with Congress and our partners to ensure that we are funded sufficiently to achieve our food safety and food defense goals,” its website states. AIB notes that it is a member of the Alliance for a Stronger FDA, a collaboration of members who ensure that the FDA has sufficient resources to protect consumers. “We have been instrumental in providing input on FDA activities and in supporting FDA in their request for funding,” says the AIB group. “More funding will probably be necessary in order to carry out the requirements of the act. We cannot speculate on what the impact will be, as the rules have not been finalized and each situation will be different.” But there are obstacles to funding. A recent proposal by conservative House of Representative Republicans to cut and freeze non-defense, discretionary spending from 2011 to 2021, could impact food safety funding because they intend to cut spending across the board from more than 40% of every U.S. government sector, except Social Security and a few other areas. The jury is still out as to whether the plan will move forward, but some Republicans Continued on page 44

www.snackandbakery.com

March 2011 - Snack Food & Wholesale Bakery

43

Special Report: Food Safety Continued from page 43

question whether food safety even warrants greater spending. “The ‘pay’ for the new measure was a significant cause of the holdup in the legislation,” Pyle notes. “We [the IBA] are pleased that a $500-per-facility fee was not included in the final law. But IBA is concerned about possible user fees that could be included. We feel these are fees imposed simply for the privilege of regulation.”

Photo courtesy of AIB International

Five key elements of the law The major elements of the new Food Safety Law can be divided into five key areas: • Preventive controls—For the first time, FDA has a legislative mandate to require comprehensive, prevention-based controls across the food supply. • Inspection and compliance—The legislation recognizes that inspection is an important means of holding the industry accountable for its responsibility to produce safe food; and the law specifies how often FDA should inspect food producers. FDA is committed to applying its inspection resources in a risk-based manner and adopting innovative inspection approaches. • Imported food safety—FDA has new tools to ensure that those imported foods meet U.S. standards and are safe for our consumers. For example, for the first time, importers must verify that their foreign suppliers have adequate preventive controls in place to ensure safety, and FDA will be able to accredit qualified third-party auditors to certify that foreign food facilities are complying with U.S. food safety standards. • Response—For the first time, FDA will have mandatory recall authority for all food products, but it expects that it will only need to invoke this authority infrequently because the food industry largely honors its requests for voluntary recalls. • Enhanced partnerships—The new legislation recognizes the importance of strengthening existing collaboration among all food safety agencies—U.S. federal, state, local, territorial, tribal and foreign—to achieve public health goals. And, it directs FDA to improve training of state, local,

44

Snack Food & Wholesale Bakery - March 2011

territorial and tribal food safety officials. What more should be done with imported raw materials? The AIB team says that FDA and the U.S. food industry are concerned about food products being imported to the U.S. from all parts of the world. “The new legislation requires that food production facilities exporting into the U.S. meet the same safety and sanitation requirements expected of facilities producing food in the U.S. Thus, international food producers will, in the future, be required to be audited by a third-party checking against audit criteria provided by FDA,” the team reports.

Avoiding product recalls Out of all of the product recalls in 2010, including the massive one at Wright County Eggs last summer that garnered hundreds if not thousands of news headlines, the egg recall of 2010 was perhaps the most widespread. That recall expanded to farms scattered across the country until it grew to more than half a billion eggs nationwide. But it’s no wonder that consumers often grow tired of hearing about recall news. “Consumers care about product recalls as well, but are becoming numb [to these reports] based on the large increase in recent recalls,” says Ades. “Though it seems there have been fewer recalls at bakeries than in other types of facilities, bakers and snack food companies have always had a [high-heat] kill step (baking or frying) that addresses product recall issues related to biological issues. Their main concerns

are physical: glass; plastic; chemicals—most importantly allergens—either not identified or incorrectly identified. Undeclared allergens account for the largest number of recalls in the food industry. Allergen management is another major issue.” Though by and large, baking and snack producers have experienced a very low recall incident rate, yet they shouldn’t be complacent. Recalls are devastating regardless of the food product involved, the AIB team agrees. “Bakery and snack goods are most often recalled due to misbranding or allergen-related issues.” Adds Pyle, “There’s nothing new there. For many years, bakers and allied ingredient suppliers have utilized GMPs, HACCP and related record-keeping. This [new] legislation doesn’t mandate any new kill steps or manufacturing changes, just record-keeping.” Ideally, says MacKie, if in addition to all of the screening of inbound ingredients there was a detection system or method for most common pathogens and allergens at some point, “this would allow for early detection, correction before product ever left the manufacturing plant. This type of technology is likely many years away from being commercially viable.”

Crisis planning So how will this law make imported food safer? Consumers in the United States enjoy the benefit of imported foods from more than 150 countries. The FSMA gives FDA new tools to ensure that those imported foods meet U.S. standards and are safe for U.S. consumers. New authorities under the Act include: • Importer accountability—Importers must verify that their foreign suppliers have adequate preventive controls in place to ensure safety. • Third-party certification—FDA will be able to accredit qualified third-party

www.snackandbakery.com

auditors to certify that foreign food facilities are complying with U.S. food safety standards. • High-risk foods—FDA now has the authority to require that high-risk imported foods be accompanied by a credible third-party certification as a condition of admission into this country. Additional resources are directed toward foreign inspections. FDA now has the authority to refuse entry into the United States of a food that has failed U.S. inspection. FDA expects to hold briefings on the new legislation for its colleagues in embassies in Washington, and to brief the World Trade Organization on the new legislation. If a food safety threat does exist, it’s usually addressed as quickly as possible, says Ades. “Ingredients are sourced from all over the world,” he adds. “One of the keys to food safety is knowing and monitoring your suppliers.” But until the FSMA was passed, all too often, processors and other food companies often improved their practices after a crisis rather than before. “It’s difficult to convince [manufacturers] to spend the money for the ‘insurance policy’ that crisis planning affords,” Ades explains. “This is especially true if they have never had a problem [before]. It’s best to plan for a crisis before, not during one or after it occurs.” In 2003, AIB acquired the Baking Industry Sanitation Standards Committee (BISSC) initiatives, the requirements for which apply to the design, construction and cleaning of various bakery equipment, accessories and components. The BISSC provides a certification and third-party validation program for equipment manufacturers. The certification process helps to assure the baker or snack food manufacturer that the equipment they install in their facilities will help in their efforts to produce safe quality foods. The BISSC reports that bakery equipment must adhere to the American National Standards Institute (ANSI) safety requirements code (the latest version of Z50.1), and should be observed in the manufacture, installation and operation of bakery machinery and equipment. The

www.snackandbakery.com

initiatives are currently being reviewed and examined by BEMA in relation to the FSMA. “We are very involved in moving the standards into the American National Standards Institute accreditation process,” says Kerwin Brown, president and CEO of

BEMA, Overland Park, Kan. “This law is very important to us. We helped formulate the Sanitation Summit, which was held in February and also hired consultants to work on the BISSC/ANSI initiative.” Continued on page 46

March 2011 - Snack Food & Wholesale Bakery

45

Special Report: Food Safety Continued from page 45

Help is available Traceability systems also can be a major benefit to producers because they pin-point the source of an outbreak of foodborne illness, especially tricky considering the enormity of the supply chain. “Bakery equipment should meet BISSC certification and ISO (International Organization for Standardization) standards, and be operated and cleaned according to manufacturer recommendations,” says Pyle. Track-and-trace systems are used frequently to reduce ingredient losses, improve plant productivity and profitability and share data with enterprise resource planning (ERP) and materials requirements planning (MRP). “Programs are/have been in place for some time regarding tracability,” says the AIB team. “The food industry continuously monitors and develops better methods of product and ingredient traceability and management. We have many methods that can be used to determine

sanitation efficacy and broad microbial levels in snack food plants with a detection time of 10 hours or more. We have rapid testing kits allowing for immediate notification of allergen contamination at detection levels of 0.15 μg or higher.” In terms of microbial awareness, AIB’s ongoing research helps provide methods that ensure a real-time measurement in less than eight hours, the AIB team reports. Other systems that can help a baker’s efforts to comply with the FSMA include inspection/detection equipment, marking and coding technology, thermal processing to achieve sterility, radio-frequency

identification tagging and more. New types of equipment will most likely be developed to accommodate this task, and will be a key opportunity for equipment providers, says Ades. IBA often meets and speaks with the Environmental Protection Agency, the Occupational Safety and Health Administration (OSHA), FDA, the U.S. Department of Agriculture (USDA), the Department of Defense, as well as, state and local entities to educate them about the complexities of baking operations and member-compliance issues, Pyle explains. “All of these agencies consider their role as protecting health and the environment.” AIB provides equipment manufacturers and bakers with seminars and on-site training that cover food safety requirements of equipment design. The information shared during these programs can help equipment design and bakery or snack food engineers achieve the right formats to enhance food safety and production efficiency. “Customers need and expect expertise in training and inspection/audit activities,” the team says. “The bar will continue to be raised as technology, logistics and program management capabilities progress and improve. Offering this level of service is what the industry expects of AIB.”

A complete food safety culture It’s not easy, but in order for a company to really protect its food products, it must develop a complete food safety culture that goes beyond the basic measures of regulatory compliance to successfully tackle food safety issues. “Without a management commitment, food safety is just an afterthought. Management commitment is the basis for food safety,” Ades sums up. “Cultural change takes time and sustained commitment. You must have a full-time food safety professional in the organiza-

46

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

tion who has the necessary resources and reports to a high enough level in the company to have authority to put food safety systems in place and support them.” MacKie says he doesn’t know of a baker who doesn’t think and act like food safety is a top priority. “I am fortunate to visit many ABA members and regardless of size, products and location,” he points out, “they all pride themselves in their good manufacturing practices and their food safety audit scores. I have seen it first hand in the facilities I have visited.” Many of the associations also provide training and seminars. AIB conducts physical inspections and training on how to self-inspect food facilities, as well as offer records-based certification audits. Inspections and training programs can be customized for a facilities’ specific need and may include vulnerability assessment, environmental monitoring programs and the basics of HACCP and GMPs. AIB also

offers scheduled seminars, on-site training and Internet-based courses and webinars. ABA and AIB also recently presented a joint membership call on the legal aspects of the new FSMA. “The food industry recognizes that each facility focus on food safety has to be a team effort from the president down,” says AIB. “Our membership and active involvement with ABA’s FTRAC allows us to participate in open and honest industry discussion with industry members about issues critical to food safety.”

Programs and opportunities In 2008, FDA implemented the Reportable Food Registry (RFR), a program whereby when a facility becomes aware of a food safety issue, it must immediately report the situation to FDA through an RFR portal. The company also must inform if the product may have been delivered containing a potential food safety risk. If the food safety

issue didn’t originate at the facility in question, the company must also inform the organization that shipped out the product. AIB offers seminars covering RFR, as well as, measures and direction on linking corrective action with methods of documenting and managing the threat. Each case is different and requires trained and qualified personnel to manage it. Any crisis at a food industry operation should serve as a learning opportunity, Pyle says. “Manufacturing practices constantly evolve to increase efficiencies, safety and production. We in the United States are blessed with the safest food supply in the world. Most U.S. operations are already in the culture of HACCP and GMP, so we just don’t see a big ‘food safety problem.’ Yet we can see hyper-sensationalized press accounts about this farm or that producer cutting corners, compromising food safety and they seem to get their comeuppance, and in some cases, jail time.” SF&WB

Hang up your gloves. A better way to wash and sanitize scale parts is right at your fingertips! Presenting the Douglas Model 1536-SPW. Meet today’s high standard for cleanliness and sanitation at the push of a button with this versatile, highly effective washing and sanitizing system. Installed in a pit or used with a ramp, this walk-in type batch washer cleans scale parts such as weigh and feed buckets, chutes, funnels, feed pans and other detachable items. This powerfully efficient machine also features pre-programmed wash times and a digital display that monitors key performance criteria and service requirements. And with a typical wash/rinse cycle of just 5 minutes, clean-up is quick and economical!

CALL 800-331-6870

for pricing, literature and specifications on a model suited to your needs. 2101 CALUMET ST. • CLEARWATER, FL 33765 • (727) 461-3477 (800) 331-6870 • FAX (727) 449-0029 • www.dougmac.com

www.snackandbakery.com

March 2011 - Snack Food & Wholesale Bakery

47

New Products 3

4

2

3

1

2

Chip’ins

Bachman Sweet Potato Chips, Tortilla Dipping Strips

Company: The Bachman Co., Wyomissing, Pa. Company: Popcorn, Indiana, Website: www.bachmansnax.com Englewood, N.J. Introduced: January Website: www.popcornindiana.com Distribution: National Introduced: January Suggested Retail: $3.79 for a 10-oz. bag Distribution: National Product Snapshot: Bachman’s toasted Suggested Retail: $3.99 for a 7.25-oz bag Sweet Potato tortilla strips contain Product Snapshot: In honor of National 18 g. of whole grains per serving and Popcorn Day, Jan. 19, Popcorn, Indiana offer a good source of vitamins A and C. Company: Healthient, Inc., Jupiter, Fla. Website: www.healthient.com created chip’ins, a popcorn chip. Made Sweet potatoes are blended with 100% Introduced: January with 100% all-natural ingredients, stone-ground corn to add that unique Distribution: National chip’ins are gluten-free, air-popped, savory taste. The tortilla dipping strips Suggested Retail: $22.00 for a triangle-shaped chips and come in White are perfect for scooping dip from a bowl Cheddar, Buffalo Wing, Sea Salt and or straight from the jar. This all-natural, 0.35-oz. bag gluten-free snack delivers 21 g. of whole Product Snapshot: Crispy Fruit is a line of Jalapeño Ranch varieties. freeze-dried fruit snacks that are made Ingredients (Jalapeño Ranch): Corn, sun- grains per serving. from 100% fruit and contain no added flower oil, salt, jalapeño peppers, onion Ingredients (Sweet Potato Chips): Whole sugar, preservatives, fat or cholesterol. powder, garlic powder, whey, maltodex- grain white corn, corn or sunflower or soybean oil, dry sweet potato, evapoThis on-the-go snack comes in a 20-serv- trin, Cheddar and blue cheese (cultured ing variety pack, including Pineapple, milk, salt, enzymes), yeast extract, canola rated cane juice, salt, corn bran, natural Banana and Fuji Apple varieties. oil, parsley, paprika, citric acid, lactic flavors, turmeric extract, annatto (for acid. Contains: milk. color). Ingredients (Pineapple): Pineapples.

1

Crispy Fruit

4

All-natural, Multigrain Tortilla Chips

Company: Deep River Snacks, Old Lyme, Conn. Website: www.deepriversnacks.com Introduced: January Distribution: National Suggested Retail: 99 cents for a 1.5-oz. bag; $2.49 for a 5-oz. bag Product Snapshot: These all-natural, multigrain tortilla chips are made with whole grains, all-natural ingredients and feature the Whole Grains Council seal of approval. They come in Nacho Kick, Guacamole, Twist of Lime and Hint of Salt varieties. Ingredients (Nacho Kick): Whole corn, sunflower oil and/or corn oil, brown rice flour, flaxseeds, turbinado cane sugar, oat fiber, sesame seeds, sunflower seeds, quinoa, salt, maltodextrin, Cheddar/Romano cheeses (pasteurized milk, cheese cultures, salt, enzymes), onion powder, buttermilk powder, yeast extract, tomato powder, garlic powder, sugar, paprika, spices, natural flavors, lactic acid, paprika extract (color), citric acid.

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

48

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Snackandbakery.com

Headed to SNAXPO? re you heading to SNAXPO 2011? If so, Snack Food & Wholesale Bakery invites you to swing by our booth #721 and pick up a copy of the February 2011 issue, featuring our 2011 Snack Manufacturer of the Year— Shearer’s Foods, Inc. Find out how the Brewster, Ohio-based powerhouse is perfecting the art of snacking, even in a down economy. Also, join us as we look inside this blossoming business and take a tour of its new state-of-the-art LEEDcertified facility in Massillon, Ohio. Get prepared for SNAXPO, which takes place March 20-23 at the J.W. Marriott Orlando, Grande Lakes in Orlando, Fla., by visiting our website,

A

www.snackandbakery.com

www.snackandbakery. com, and flipping through our pre-show coverage, complete with hall hours, details about informational sessions, registration instructions, and more. While on our site, get a sneak peek at what equipment manufacturers will be showcasing at their booth by checking out our SNAXPO 2011 widget, complete with videos from SNAXPO exhibitors. In addition, become a fan of Snack Food & Wholesale Bakery through Facebook, www.facebook.com/snackandbakery, or follow us on Twitter, www.twitter.com/ SFWB, to get the latest in news items,

featured new products and equipment and ingredients pertaining to the snack and bakery markets. Also, log on to our site and subscribe to receive our free monthly magazine and our free weekly e-newsletter, Operations Weekly. To advertise in Snack Food & Wholesale Bakery, on our website or in Operations Weekly, please contact Jeff Heath at [email protected] or Barb Szatko at [email protected].

March 2011 - Snack Food & Wholesale Bakery

49

The Nutritional Corner

GFF’s Perspective on the New Dietary Guidelines for Americans n Jan. 31, Katherine Sebelius, secretary of the Department of Health and Human Services (HHS), Washington, D.C., and agriculture secretary Tom Vilsack announced The Dietary Guidelines for Americans 2010 (DGA), which are a set of recommendations issued every five years. This is its seventh iteration. Intended to serve as the foundation for nutrition guidance in America, the DGA helps shape federal food and nutrition policies, such as those surrounding school feeding and food assistance programs. Written for a scientific/clinical audience, the DGA are meant to be interpreted by nutrition practitioners so they can in turn provide easy-to-understand (yet scientifically sound) nutrition guidance to the average American. The process of developing the DGA is quite lengthy, and each update involves a thorough review of the scientific literature to determine any new areas or revisions the DGA should address. The guidelines were composed by a committee of scientific experts who reviewed and analyzed the most current information on diet and health and compiled their findings into a scientific, evidence-based report. Once this report is released, it is open for comments from the public before the final guidelines are released. Along with other members of the grain chain, the Grain Foods Foundation (GFF), Ridgway, Colo., submitted comments to the Advisory Committee on behalf of the industry reminding them about the need for a balanced approach when creating recommendations for grain foods. Each edition of the DGA has delivered an over-rearching focus, and the 2010

O

50

Snack Food & Wholesale Bakery - March 2011

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

Americans are eating entirely too many calories and not choosing enough nutritious foods in their daily diets. The Dietary Guidelines for Americans seek to change that. edition is no different. Given the obesity epidemic affecting the lives of too many Americans, the DGA was written for our population to accomplish two primary goals: 1) maintain calorie balance over time to achieve and sustain a healthy weight and 2) focus on consuming nutrient-dense foods and beverages. Simply put, Americans are eating entirely too many calories and not choosing enough nutritious foods in their daily diets. The DGA recommendations seek to change that. GFF fully agrees with the guidelines’ emphasis on the importance of calorie balance, physical activity and choosing nutrient-dense foods. We know that grain-based foods are an essential part of a balanced diet that can help Americans meet their nutrient requirements while controlling their calories. In addition, the DGA offers key recommendations for both ‘Foods and Food Components to Reduce’ and ‘Foods and Nutrients to Increase,’ and like the 2005 version, continues to promote whole grains. We support the recommendation that Americans consume at least three 1-oz. servings of whole grains per day, which is nearly three times what the average adult is currently eating. Research

shows that whole grains offer a number of health benefits—they can help lower blood pressure and the risk of heart disease and improve satiety and regularity. That said, the DGA specify that Americans should limit consumption of foods containing refined grains, particularly those that contain “solid fats, added sugars and sodium.” We have been working to clarify the committee’s use of the word refined grains. There are a variety of non-whole grain products that provide health benefits, such as enriched grains, which represent an important, nutrient-dense group of foods essential for a balanced diet and healthy weight. Enriched grains are a source of key nutrients such as B vitamins, including thiamin, riboflavin and niacin, as well as, folic acid and iron. In fact, enriched grains are the No. 1 source of folic acid in Americans’ diets (read more about the benefits of folic acid in my column of the February 2011 issue). GFF has had opportunities to share perspective on the DGA through our social media channels as well as media interviews with experts from our Scientific Advisory Board. We will continue to identify key opportunities for representing the industry and discussing the importance of grain foods in a healthy diet. SF&WB

www.snackandbakery.com

“I need my products to do more than just taste good.” In baking and snack food production, every product has to tell a story. It starts with a great name, continues with a tempting aroma, and finishes with an impeccable flavor. Honey Whole Wheat Bread. Beehive Cookies. Honey Barbecue Potato Chips. These products not only taste good, they sound good. I may be the author of my bakery and snack food formulas, but honey tells the story.

For more information, visit www.bakingwithhoney.com

Ingredient Technology Sweeteners, Gums, Starches, Flavors

Batch-full of Yumminess When it comes to flavors, sweeteners, gums and starches, many of today’s ingredient introductions offer a host of can’t-miss characteristics. Photo courtesy of American Key Food Products

Marina Mayer, Executive Editor

or years, ingredient suppliers have been developing run-of-the-mill solutions— ones that offer healthy attributes and premium mouthfeel and taste. Today, however, food scientists and technicians have stepped it up a notch by expanding and diversifying their portfolios to include a bevy of flavors, sweeteners, gums and starches that deliver pliability, freeze/thaw stability, improved texture, partial replacements and better-for-you label claims. Take a look at this year’s new creations

F

and find out how these solutions can offer up a batch full of “yumminess.”

Flavors that function

Photo courtesy of National Honey Board

52

Snack Food & Wholesale Bakery - March 2011

For the past eight months, Sensient Flavors has expanded its DairyBoost portfolio of flavors to improve the nutritional profile of sweets and baked goods by reducing the use of dairy products without sacrificing flavor, says Emil Shemer, director of food solutions for the Indianapolis-based company. “Sensient offers manufacturers almost endless possibilities for natural milk, cream, butter and cheese flavor systems with the DairyBoost portfolio of premium dairy flavors,” Shemer says. “With flavors such as fresh milk, sweetened condensed milk, melted butter, fresh butter and drawn butter, the DairyBoost portfolio of

flavors delivers premium dairy taste while improving the nutritional profile of many products.” Baked goods such as crackers, biscuits, cookies and cereal bars are bake-stable and feature a true dairy character, including creamy mouthfeel and natural richness, whereas sweets such as baked desserts, chocolate and sugar confections, are heatstable and provide a creamy mouthfeel. Sensient Flavors has also enhanced its flavor offerings for sodium reduction and monosodium glutamate (MSG) replacement, Shemer says. “The natural flavor systems allow manufacturers to reduce sodium by 2535% or more per serving and to replace monosodium glutamate,” Shemer notes. “In addition to offering the natural flavor systems, Sensient Flavors partners with its Continued on page 54

www.snackandbakery.com

Ingredient Technology Photo courtesy of Gum Technology Corp.

Continued from page 52

customers to develop reduced-salt products that mimic full-salt versions and that compensate for additional product profile changes that may occur due to the reduction in salt.” Likewise, Bell Flavors & Fragrances, Northbrook, Ill., introduced a black garlic flavor within its Umami Signatures line. Designed to replace MSG content and enhance reduced-sodium products, the black garlic flavor helps boost flavor profiles. “In our savory flavors for dips, sauces and snacks, we have removed hydrolyzed vegetable proteins (HVPs) using proprietary technology to redesign flavors containing the flavor nuances present without the actual HVP,” Shemer adds. For its part, Philadelphia-based David Michael & Co. developed Fresh Flavors, a line of non-characterizing flavors that when added to a product containing fruit, it builds back the freshness for a “just picked” sensation. “Flavor trends can bring excitement to a new product line and liven up classic favorites,” says Erin O’Donnell, marketing manager. “Pies are the new cupcake for 2011, so we expect to see a lot of indulgent pie-type flavors pop up in non-traditional applications. Popcorn is a great example. We expect to see more flavored popcorn beyond the usual butter, cheese and caramel. How about coconut curry or blackberry pie-flavored popcorn?” Also getting into the flavorful mix is Gold Coast Ingredients, a supplier of

flavors that are used in dough as well as topical applications. “These flavor systems are designed to perform within their intended matrix processing limitations and give the consumer a fully integrated flavor experience,” says Toni Gitter, technical sales representative for the Commerce, Calif., company. “Due to the increased visibility inside a top chefs’ kitchen, consumers are becoming more familiar with complicated and layered flavor profiles. We have seen an increase in combining sweet/salty/savory in snack products, plus requests for specific items like ancho chili, green peppercorn, manchego cheese plus uncommon fruits like baobab. Flavors can be added to any type of food, so product developers can offer more exotic flavor combinations while achieving consumer acceptance.”

Sweet as silk When it comes to sweeteners, one thing is certain—foods must taste sweet without doling out a host of too-sweet attributes. That’s why companies like Roquette America, Inc. offer a wide range of sweeteners, including SweetPearl (crystalline maltitol), Maltitol syrups, Sorbitol and Mannitol. “These sweeteners allow formulators to do a complete or partial replacement of sucrose to reduce sugar and caloric content, depending on what type of nutritional claim they are trying to achieve,” says Isabella Campbell, technical sales and Carl Jaundoo, associate program coordinator Continued on page 56

54

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Ingredient Technology Photo courtesy of National Honey Board

tions specialist for the National Honey Board, Firestone, Colo. “[Honey] offers food manufacturers the opportunity to provide a sweet product using a natural sweetener that promotes a clean label,” she adds. “Honey also has many functional benefits in bakery foods, such as allowing bakers to extend the shelf life of their products with a natural ingredient. Honey’s fructose content holds in a bakery food’s moisture, thus reducing dryness in products. Honey’s high acidity (average pH 3.91) also inhibits mold growth.” Honey also delivers a sweet and appealing flavor profile that can mask off-flavor notes of whole grains or nutraceutical ingredients, Manelius says, and provides a natural energy boost through its 17 g. of carbohydrates per tablespoon for food and energy bars. Continued C ti d ffrom page 54

for the Keokuk, Iowa-based company. Meanwhile, Corn Products U.S., Westchester, Ill., recently launched Enliten Reb A, a high-intensity, naturally-based, low-calorie sweetener obtained from the Stevia rebaudiana bertoni plant. It is highly soluble and stable, even under extreme processing conditions, and is designed for cakes, pastries and chocolate, among others. “Enliten is derived from a unique, patented stevia plant variety,” says Rick Francolino, food scientist. “It can be incorporated at low use levels as it is about 200 times sweeter than sucrose and imparts sweetness in reduced or lower calorie/sugar products while maintaining the qualities demanded by today’s health conscious consumer.” Honey also is an ideal sweetener for enhancing flavor profiles and producing products with all-natural and pure ingredients, says Emily Manelius, communica-

Gums that bind When it comes to baking, certain products require certain specifics to ensure that ingredients stick, rise and hold. “Some of the common challenges that bakers and snack producers encounter deal with texture and hydration,” says Eric Ferreira, senior technician quality control for Gum Technology Corp. “As producers look to remove an ingredient that is vital to providing textural stability to the food product, such as fat, gluten or sugar, synergistic gum and starch/gum blends can be used to create the network that is necessary for the structural stability and overall texture of the food.” As a result, the Tucson, Ariz., company created a lineup of gum blends under the Coyote Brand umbrella. For starters, Konjac A allows for added pliability in dough, extended shelf life with increased stability through freeze-thaw cycles and improved chewiness texture of bagels, according to Ferreira, whereas the

© 2010 National Starch LLC

56

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Ingredient Technology Photos courtesy of Gum Technology Corp.

CKX-Fat Replacer, a konjac, k j xanthan h and d microcrystalline cellulose gum blend, is used to create a fatty texture to replace fat in traditionally high-fat baked goods such as cakes, cookies, muffins and scones. The Stabilizer ST-101 blend of xanthan and guar gums improves dough elasticity and freeze-thaw stability in breads and crusts by reducing moisture migration. “Along with these improvements, it plays an important role in gluten-free

products d as it i successfully f ll creates a mesh h network needed to replace the structural stability that is lost without gluten in a bread system,” Ferreira says. “This blend has been implemented in baked goods such as gluten-free breads, muffins, cookies, pie crusts and pizza crusts.” Meanwhile, its starch/tara blend called GumPlete SH-0140 is used in fruit prep bake fillings. “It has been shown to prevent pastry fillings from becoming too molten during heating so that the filling does not flow out of the pastry during the baking process,” Ferreira adds. “It also binds moisture in the filling effectively enough to prevent moisture absorption in spongier m breads during heating.” Cargill’s CitriTex GSG 71, which was launched in June 2010, w is a functional system that contains gums and can be used to replace g 50% of the oil in muffins, cakes and snack cakes, allowing the product to be labeled as “reduced p fat,” says Bill Gilbert, technical specialist for bakery snacks and cereals, Cargill Texturizing Solutions, r Minneapolis. M “CitriTex helps bakers meet a key consumer desire for indulgent products with better-for-you charp acteristics,” he says.

Spreading the starch S When it comes to starch, less is W Photos courtesy of Gum Technology Corp.

www.snackandbakery.com

Continued on page 58

© 2010 National Starch LLC

March 2011 - Snack Food & Wholesale Bakery

57

Photo courtesy of Penford Food Ingredients

Ingredient Technology

58

Continued from page 57

more. However, several ingredient companies have formulated solutions that deliver better quality products, allowing consumers to scratch that saying. For example, Penford Food Ingredients commercialized its technologies to include PenTechGF, an ingredient system used to create gluten-free breads, rolls, muffins and pizza crust, says Ying Bian, senior applications scientist for the Denver-based company. “These systems make products that are equal or better in product quality than their gluten-containing products,” Bian says. Penford also developed the PenBind 1700 and PenCling 700 series of modified corn starches, which are designed to improve shear and acid, retort and freeze/ thaw stability. “These starches are used in low pH as well as dairy-based baked good fillings and sauces,” Bian adds. Furthermore, American Key Food Products (AKFP) developed Premium Cassava Flour derived from cassava roots, the same source of tapioca starch, and when blended with native potato starch, can deliver tasty breads and pizza crusts. “Aside from its value as a gluten-free ingredient, it is also a useful ingredient for snack applications because of its high starch content,” says Mel Festejo, chief operating officer for the Closter, N.J., company. “The Premium Cassava Flour has inherently low levels of reducing sugars and is key to addressing acrylamide concerns in extruded snack products.” AKFP also re-introduced a native pea starch, which is manufactured and processed by AKFP’s supply partner, Emsland Group of Germany. Designed for use in extruded snacks and baked goods, it offers a fairly high amylase content, providing better gelling, binding and moisture retention properties and extended shelf life. Whether the product is equipped with starch, gums, flavors or sweeteners, today’s snack foods and baked goods deliver a batch full of everything good—and good for you. SF&WB

SFWB10094NPI.indd 1

Snack Food & Wholesale Bakery - March 2011

9/29/09 1:47:03 PM

www.snackandbakery.com

Ingredient Briefs

Sethness Products introduces its newest Class I powdered caramel color. The commercially available SB116 is a label-friendly powder developed to improve the visual appeal of baked goods and dry blends. It’s produced from non-genetically-modified sucrose. Sethness Products Co. Lincolnwood, Ill. 847-329-2080 www.sethness.com

Herza Schokolade produces small chocolate shapes to be mixed into coffee-flavored brittle, biscuit or fruit chips, melt-in-the-mouth nougat, truffle products and caramel or to be used as decorations. These chocolate chips vary in shape and size and are available with a shiny finish or coating. Special effects can also be achieved with two-tone products. For example, diamonds, where one side is made of light and the other side is dark chocolate. Herza Schokolade GmbH & Co. KG +49 (0) 40 - 500 176-0 www.herza.de

SF&WBtv

SensoryEffects Inclusions introduces a new line of gooey inclusions for a wide range of baked goods. These gooey products do not melt away and deliver a sticky, gooey texture after baking. They are available in cinnamon, caramel, marshmallow and maple and come in a variety of shapes and sizes. SensoryEffects Inclusions Defiance, Ohio 800-957-3130 www.sensoryeffects.com

Ascentra sodium-reducing flavor enhancer from DairiConcepts is a convenient, cleanlabel, powdered ingredient that naturally amplifies the perception of salt and other savory nuances as it lowers sodium content. Instead of providing an upfront salty “hit,” Ascentra enhances existing savory flavors, yielding a richer, more rounded flavor than is available through traditional, all-salt formulations. Ascentra also provides opportunities to lower ingredient costs by replacing higher-cost ingredients with more economical ones. Made from a proprietary, whole milk-based fermentation process, Ascentra does not contain monosodium glutamate (MSG), hydrolysed vegetable protein (HVP) or yeast extract. Although rich in potassium, it does not contain potassium chloride, eliminating metallic flavor notes. DairiConcepts LP Springfield, Mo. 877-596-4374 www.dairiconcepts.com

Van Drunen Farms’ freeze-dried blueberries are naturally full of flavor and nutrients, low in calories and a good source of antioxidants and vitamin C. They are also 100% natural. During freeze-drying, the cell structure of the berries remains intact, preserving the nutritional value, color, flavor and piece identity of the product better than other drying methods. Just a brief soaking in water brings them back to nearly their original shape, ready to use just like fresh berries. Available in whole, sliced, diced and powder form, these blueberries are an ideal additive to muffins, bagels, scones, confections, cookies, energy bars and snack foods. Van Drunen Farms Momence, Ill. 815-472-3100 www.vandrunenfarms.com

Cargill Salt develops Premier Light Salt 50/50 Blend, a convenient and cost-effective, reduced-sodium solution for salted snacks, breads and other bakery products. Premier Light Salt 50/50 is a blend of food-grade potassium chloride and sodium chloride that provides 50% less sodium than regular salt. Cargill Salt Minneapolis, Minn. 800-227-4455 www.cargillsalt.com

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

www.snackandbakery.com

www.snackandbakery.com

March 2011 - Snack Food & Wholesale Bakery

59

Engineering Management

New Kids on Our Block n several occasions throughout my short writing career, I have penned columns about the issues we experience with the newer generation as they enter the industrial workplace—their work ethics are not what they should be and are not self-motivated when it comes to taking on initiatives. This bothers us older folks— you know who you are—because we tend to think they are lazy and that it will only get worse. However, on a recent mini-vacation to Nashville, Tenn., I was introduced to a new perspective on this issue. While sitting in a quaint little bed and breakfast, my wife and I met a couple from Huntsville, Ala., who were both engineers. In fact, the wife is employed at the NASA Space Center in Huntsville. We began talking about the younger generation and how they may not be “cut out” for the real world, and she shared her thoughts, based on her experience with college interns and newly ordained engineers. She said the kids coming out of college aren’t necessarily lazy; rather they are just conditioned to expect everything organized and done for them, as that is how the 50-somethings have raised them. From the time they were toddlers until they went to college, we have picked out what they should wear, scheduled their lessons and doctor appointments and drove them everywhere they needed to be. Because of our attentiveness as parents, they never had to worry about being on time or worry about where they needed to be next. It’s almost as though we raised our kids to live a high-roller, privileged lifestyle, no matter what our circumstances had been. These kids grew up having “people.” Based on my own experiences, I believe you can apply this idea to anybody who is under the age of 30, entering the workplace. If you have somebody coming to your workplace that is in this age group and seems to have an old-style work ethic,

O

60

Snack Food & Wholesale Bakery - March 2011

this is someone who must have been raised like we were, right? This group is the most coachable and likely to be around for a while, developing themselves every day. As for those newbies who can’t figure out their left shoe from their right one on their own, those are the ones we must spend our energy on and keep a watchful eye on, all while not giving up.

We as professional managers and oldtimers in the industry must find ways to recondition the youngsters and convince them that if they are going to make it in the workplace, and in life, they must fully participate. So, what steps can we take to convert the youngster that has had everything done for them while “reforming” them into someone who will be a productive, valuable part of a team, department and company? The easy thing to do is give up on them once you find out they can’t move past one task unless fully directed. Having this new information about why they may be the way they are just might help you figure out some creative ways to convert what looks like a slacker mentality into a selfmotivated one. In no way am I suggesting that we give in to their ways and continue the enabling behavior; rather we as professional managers and old-timers in the industry must find ways to recondition the

Jeff Dearduff [email protected]

youngsters and convince them that if they are going to make it in the workplace, and in life, they must fully participate. When you break down the gaps, it comes down to some fairly understandable and correctable items. First, you know this newer mentality can produce good results at a specific task after direction, but they can’t make adjustments when they run into something out of line with what they were shown, almost like a computer or an automated robot. They tend to stop what they are doing until someone can help them out. As a result, we need to teach them to stretch themselves and give themselves permission to try something a bit risky. Giving them opportunities to “try something” will build their confidence, and after they have a “win” or two with these risks, they will become even stronger in their self-belief. Secondly, we might have to get a little harsh with them. The bottom line is that when you pay them for 40 hours of work, they must know you need 40 hours of work out of them. This may push them to come looking for the next thing to do rather than just sitting back waiting on you. Suggest early on that you will pay them for what they do, not for simply being present. That will get their attention. In the old days, some jobs paid on piece-work. In other words, “if you did it, you got paid.” Why should we take on this level of responsibility? If any of you have parented in the past 20 years, you may have had a role in developing this type of person. On top of that, if you ever want to move on in your career or even retire one day, you need to have developed employees who can carry on the tasks and functions you once performed. Remember, you once were a new kid on the block too. SF&WB

www.snackandbakery.com

Equipment Briefs

To complement the existing lineup of automated bin washers, Douglas Machines developed a new model that has the flexibility to wash and sanitize two stainless-steel or plastic bins at the same time, eliminating the need to buy two separate machines to double the throughput. The Douglas Model BW-2000 saves water, chemicals and labor while reducing the incidence of injury normally associated with trying to hand wash these types of heavy containers. Douglas Machines Corp. Clearwater, Fla. 800-331-6870 www.dougmac.com Sifter Parts & Service developed an inspection porthole on its line of CS-1 gyratory sifters that allows easy access to visually inspect 100% of the screen area without the need to disassemble the sifter. The view port is easy to use and requires no tools; operators simply unscrew two wing nuts and remove the metal cover plate. The optional view port is available on select decks for the CS-1 sifter and includes front and rear side portholes with cover plates, self-adhering gaskets for the cover plates and nylon wing nuts. Sifter Parts & Service, Inc. Wesley Chapel, Fla. 800-367-3591 www.sifterparts.com Heat and Control’s new MasterTherm Kettle Fryer (MTKF) uses a thermal fluid heat exchanger to deliver up to 80% thermal efficiency and more than 500 finished lb. per hour of batch fried potato

SF&WBtv www.snackandbakery.com

chips. MTKF can produce any style of kettle chip with excellent consistency. Oil heating is gentle and uniform throughout the fryer, yet rapidly adjusts to changes in product load. Standard features include continuous fines removal, electro-plated heat exchanger tubes, Chip-Stirr automatic slice agitation system, PLC control for repeatable batch quality, a full-length hood to conserve energy and protect oil quality, a clean-inplace system and stack Oil Mist Eliminator. Heat and Control, Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com Diversey Inc. introduces the Fryer Boil-Out (FBO) program. Designed to clean carbonized soils from fryers and other industrial food manufacturing equipment, the One Step FBO enhances the traditional fryer cleaning process by significantly reducing the amount of cleaning and rinsing time, energy, chemical and water used, thus increasing efficiency and providing customers with a more sustainable method for cleaning commercial fryers and contributing to a healthier, safer and cleaner environment. The One Step FBO streamlines the process into one simple procedure using a combination of highly effective products and cleaning processes that eliminate up to 65% of water and energy, 30% of chemical and 49% of the time required. The One Step FBO program also offers a customized fryer audit, a cost calculator, specialized technical support and ongoing results monitoring for each user. Diversey, Inc. Sturtevant, Wis. 262-631-4001 www.diversey.com

The ring, layer and sheet cake line from Hinds-Bock is a fully automatic high-volume depositing line designed to increase productivity, decrease labor costs and improve the bottom line. Optional automation modules include pan oiler, primary batter depositor or a secondary depositor for swirled, layered batters or fillings such as fruit, cream cheese, mousse or chocolate. The line is designed to operate with individual or strapped pans and is available in single or multiple lanes to meet the production speed requirements of even the largest wholesale bakery. It also is equipped with optional positive shut-off spouts, automatic swirling stations, dry ingredient depositors for nuts, chocolate chips, sugar, sprinkles or flakes or streusel depositors. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com Zipbox, a joint venture between T.H.E.M. and Zip-Pak, launches a proof-of-principal cartoner to facilitate short-run production of the Zipbox package for cookies, snacks and frozen foods. Zipbox is a film-coated paperboard carton with an attached flexible film header containing a DoubleZip zipper profile that presents the stability of a carton with the convenience of a resealable flexible package. It is designed to facilitate direct-filling of products without the need for an inner liner. By removing the liner, the package style can hold up to 40% more contents, maximizing the product-topackage ratio and cube utilization to reduce transportation costs. T.H.E.M. Marlton, N.J. 856-988-8436 www.them.net

View videos demonstrating the newest bakery & snack food equipment by visiting www.snackandbakery.com March 2011 - Snack Food & Wholesale Bakery

61

Production Technology Mixers

Puttin’ on the Mix Many of today’s equipment manufacturers are standing tall by developing mixing systems that come outfitted with the ‘best of the best.’ or years, mixing systems were just responsible for blending ingredients in an orderly and timely fashion. Now, they must be thorough, consistent and easy to use. They must offer low maintenance but match high standards. They must be versatile, economical and able to keep up with large volumes and a variety of recipes. They must be able to endure fast changeover in a fast-paced environment, and most importantly, they must be sanitary. That’s why many of today’s new mixing systems come equipped with a bevy of features and characteristics that can help customers produce the best quality products in the best possible ways. For example, WP Kemper Bakery Systems, a U.S. subsidiary of WP Bakery Group, introduced the Titan mixer.

F

Designed with hygiene in mind, the Titan mixer sports a three-zone system to ensure the best dough processing results, says Patricia Kennedy, president of the Shelton, Conn., company. “It has the option of a washdown version where the whole machine can be hosed down for greater hygiene,” she adds. “The mixer monitors itself, continuously checking the temperature of the bearings, motors and hydraulic systems, and then informing the operator of any

Photo courtesy of Admix Inc.

Marina Mayer, Executive Editor

Photo courtesy of WP Kemper Bakery Systems

potential problems before they arise.” In addition, the automatic lubrication uses cartridges, ensuring that the mixer is always lubricated without any operator intervention, and space under the mixing bowl allows for standard dough troughs or a direct transfer system. “Customers are moving toward a more flexible production with high-quality products, but still keeping the industrial process to reduce costs. The Titan is designed for these customers because it does not compromise dough quality, as we still have an interaction between mixing and oxygen (mixing bowl not sealed) and the industrial process can still be upheld. With batch mixing, there is also the flexibility of being Continued on page 64

62

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

SEE US AT INTERPACK 2011 See our solutions… Hall 3 / Booth No. A21/B46

12 – 18 MAY 2011 DUESSELDORF, GERMANY Booth area: 1400 m2 59 machines in 10 lines www.haas.com/interpack

Production Technology Continued from page 62

64

Snack Food & Wholesale Bakery - March 2011

dispersing ingredients without fish-eyes, lumps or agglomerates. The cheaper part comes from the system’s enhanced technological attributes. For example, the mixers increase production, reduce overall production costs, produce faster batch times, lower energy

bakeries had capital to purchase ribbon blenders. Now we are seeing an increasing number of orders from small- and medium-scale companies that usually cater to specialty health snacks and baked goods,” says Christine Banaszek, application engineer for the Hauppauge, N.Y.-based

costs, reduce maintenance and downtime and allow for ingredient savings. Additionally, the ergonomic design makes the system safer. “Processors are constantly faced with the challenge of changing formulas to keep up with consumer trends and demands (i.e. looking for nutritional enhancements),” Cheries says. “The versatility of our equipment allows processors to adapt to these new formulas without having to change their equipment.” Meanwhile, Charles Ross & Son Co. created ribbon blenders that feature a discharge screw positioned across the entire bottom of the trough and are powered by a separate direct drive system for independent speed control, thus eliminating dead zones and enhancing mixing. “It used to be that only large-scale

manufacturer. (Learn more about Charles Ross in our Supplier Standpoint section of this issue, on page 66). Charles Ross also introduced a new mixing and dispersion system that combines a Ross High Shear Mixer and a specially designed PowerMix for manufacturing fine dispersions. The two mixers are mounted on a common base and connected with piping to allow continuous circulation of materials, while a built-in control panel permits fine control of all agitator speeds, amperage and run times. “Experience has taught us that versatility is key,” Banaszek says. “Since mixtures come in many sizes and densities, we strive to provide the proper piece of equipment that can handle the customer’s portfolio of products. If one blender is intended for several formulations, the machine features

Photo courtesy of Charles Ross & Son Co.

able to change products from one mix to the next,” Kennedy says. For its part, Admix, Inc., Manchester, N.H., developed a fast-feed powder induction and dispersion system for applications such as sugars, sweeteners, whey and soy proteins, gums, dairy powders, non-fat dry milk, gelatin, flavorings, starches, salt, phosphates, carbomers, carrageenan, sodium hexametaphosphate, caffeine, nutraceuticals, maltodextrin, vitamins and more. Designed to offer controlled powder feeding rates from 300-400 lb. per minute, this system offers consistent powder delivery, enables processors to add dry ingredients to mix vessels in a more ergonomic fashion, thus reducing operator injuries, and provides a shear that ensures maximum yield. Plus, a single fast-feed skid can be used for multiple tanks for holding or suspending product prior to filling or packaging, says Keith Cheries, director of sales and marketing. “Many processors are making the move from corn syrup to sugar,” he adds. “Admix offers the fast-feed powder induction and dispersion system to induct and disperse granulated sucrose at up to 400 lb. per minute, allowing processors to make 10,000 gallons of liquid sucrose conservatively in four hours.” Customers are also looking for more soluble fiber and using inulin, which can be extremely difficult to disperse and can cause various processing challenges, Cheries notes. “Those tough clumps of undispersed inulin may ultimately clog strainers and depositors downstream. The Admix Rotosolver high-shear mixer will disperse inulin in your thick, high solids base,” Cheries adds. When creating mixing systems, Admix follows the “FBC’s of processing,” otherwise known as faster, better, cheaper and safer, he notes. For instance, Admix equipment reduces batch times by as much as 80%, Cheries says, allowing processors to increase the functionality of ingredients, reduce waste and reclaim out-of-spec product. These systems also deliver better results by properly

www.snackandbakery.com

Production Technology must accommodate the customer’s expectations in terms of cleanability, flexibility in working volumes, heating/cooling requirements, controls and integration with upstream and downstream equipment, etc.”

Likewise, The Peerless Group has been working on new designs to improve overall sanitation and cleanability, says Matt Zielsdorf, vice president of sales. “Peerless mixers have always had one of the smallest footprints in the industry and by making VFD [variable frequency drive] motors standard, we have allowed users to avoid the spikes in power consumption that were typical with two-speed motors,” he adds. In response to higher sanitation efforts, the Sidney, Ohio, company now pro-

Photo courtesy of The Peerless Group

Sanitary design a must

vides shaft seals that do not require daily maintenance or cleaning, and introduced an electric tilt option that allows bakers to

www.snackandbakery.com SFWB0808KNAP.indd 1

eliminate the need for hydraulics near their mixing systems, Zielsdorf notes. “Sanitary design tops our list of must-haves recently,” he adds. “Customers demand that our designs be flexible to allow them to run different batch sizes, not to mention their needs to be able to run different products in our mixers. They may buy the mixer today for white pan bread, but know that eventually they will mix denser whole grain/whole wheat doughs that ultimately require a stronger mixer.” When it comes to compact designs, high standards, enhanced capabilities or improved functionalities, today’s mixing systems deliver the best of the best for all applications and usages. SF&WB

March 2011 - Snack Food & Wholesale Bakery 6/24/08 11:39:33 AM

65

Supplier Standpoint

How Well Do You Know Your Ribbon Blender? he batch ribbon blender’s simplicity, functionality and waffordability all contribute to its widespread use within the world of baking and snack foods. It is commonly used for dry blends such as bread, cake and muffin mixes, flavorings, spices and trail mixes as well as for wet applications such as extruded cereals and snack foods. Although this type of blender design is well-known in the industry, many may be unaware of the key design factors that drive mixing productivity and efficiency. Not all ribbon blenders are designed to be nor are created equal.

uct being mixed). A ribbon blender’s full working capacity typically corresponds to a batch level right around the height of the top ribbon. At rest, materials shouldn’t be above the ribbon agitator. Overfilling can lead to long blending cycles or unsatisfactory mixes.

T

Theory of operation Ribbon blenders consist of a U-shaped horizontal trough and an agitator made up of inner and outer helical ribbons that are pitched to move material axially (in opposing directions) and radially. This combination promotes fast and thorough blending. Tip speeds in the range of 300 feet per minute are typical.

Drive design choices Traditional ribbon blenders utilize a belt drive for power transmission between the motor and gear reducer. The drive system includes flexible belts and a set of pulleys to produce the desired speed and torque ranges. Some manufacturers standardize on chain drives instead of belts. Recent designs have eliminated belt drives to avoid losses in horsepower and efficiency through belt slippage. One of the most important evolutionary developments of ribbon blenders was the shift to the gearmotor direct-drive design. A gearmotor is a one-piece motor reducer. The motor’s lowinertia rotor is specifically matched to the characteristics of the gear unit. This results in a high dynamic capability essential for high start/stop cycles such as ribbon blending operations and longer service

66

Snack Food & Wholesale Bakery - March 2011

Operational versatility

life maintenance required lif and d eliminates li i i i d to align and adjust belts and couplings. Today’s compact gearmotor designs also enable smaller mounting platforms, which improve the ribbon blender’s overall space requirement.

Soft start and speed flexibility On belt-driven systems, some manufacturers rely on soft start couplings for “dead-load” starting situations. Shot-filled couplings are prone to overheating, which ruins the coupling. A coupling design can also drive up blender costs and add extra maintenance. Advances in gearmotor design, in combination with modern electronic drive technology, opens up possibilities that were not available in the past. Variable frequency drives (VFD) allow for a soft start and provide a convenient way p of controlling speeds during o blending and discharging. b For F most ribbon blender applications, gearmotor/ a VFD technology is the most V reliable and cost-effective r option. Sophisticated PLC o systems can be integrated to s program steps and recipes in p more complex processes. m

Mixing performance M Optimal mixing in a ribbon blender requires enough batch material—equivalent to at least 30-40% of the rated volumetric capacity (working with smaller volumes, the blender fails to generate adequate contact between the agitator and the prod-

Proper sizing of a ribbon blender accounts for both capacity and product density. If intending to process a variety of formulations in a single ribbon blender, one must consider the entire range of densities and how this affects maximum and minimum batch sizes in terms of mass.

Cleanup and removable ribbons A well-designed blender holds close tolerances—in the range of 1/8 to 3/16 in.—between the outer ribbon and the trough to prevent “dead zones” in the batch. The interior stainless-steel surfaces must be well-polished and each weld should be “radiused” to prevent material buildup. The ribbon blender may be cleaned with a brush, steam, air or water spray. In most applications, there is no need to remove the agitator when cleaning or disassembling the seals for maintenance. If you intend to remove the ribbon agitator during maintenance, be sure to let your blender manufacturer know this before you purchase. Simple customizations can be made, including match marks on the shaft flanges to ensure proper realignment. However, if you anticipate removing the agitator at more frequent intervals, say after every batch, a more elaborate modification will accommodate this requirement. Use of a flat-flange clamshell coupling will allow operators to raise the ribbon agitator out of the blender without moving the end shafts, bearings or seals. This is a more expensive design, but one that will save you hours between batches. Editor’s Note: Article author Christine Banaszek is the application engineer at Charles Ross & Son Co., Hauppauge, N.Y. For more information, contact her at 800-243-ROSS or email [email protected].

www.snackandbakery.com

ABA Thanks the

2011 Convention Sponsors

ENRICHING BODIES&LIVES

March 26-30 | J.W. Marriott San Antonio Hill Country | San Antonio, Texas

BART BA RTLE RT LETT TT

www.kwiklok.com

McGAHEE, LACY and ASSOCIATES Designed to Perform. Backed by Service.

Packaging Specialists

Special Thanks to:

70

ABA Celebrates the

th

Anniversary of the Enrichment of Flour

Snack Food Today Oberto Brands Undergoes a Makeover Oberto Brands revamps the recipe and ingredients for its signature Oh Boy, Oberto! beef jerky line to now include only “simple,” all-natural ingredients. The all-natural beef jerky comes in Original, Teriyaki, Peppered and Hickory varieties, as well as BBQ Pork and Teriyaki Turkey, boasting the same recipe, but with pork and turkey instead of beef. The new line will appear on shelves in May, and the existing beef jerky product will be phased out between now and then. “Our motivation for the change was

Frito-Lay Goes All Natural Frito-Lay, Plano, Texas, will produce half of its products solely with all-natural ingredients, phasing in the new ingredient lists over the course of the year. This ingredient overhaul will impact more than six-dozen Frito-Lay brands, including all varieties of Lay’s potato chips, Tostitos tortilla chips, SunChips multigrain snacks, Baked! snacks and Rold Gold pretzels. In another move, Frito-Lay North America, a PepsiCo division, is giving up on one of its boldest better-foryou snacks—TrueNorth. It launched the TrueNorth line of premium nut products in 2007, but it never really caught on with health-conscious consumers. The line was sold to DeMet’s Candy, Stamford, Conn., a chocolate confectionery manufacturer that owns Turtles, Stixx and other candy brands. DeMets will reportedly integrate TrueNorth into its existing portfolio of confectionery products.

simple—to deliver a better tasting jerky that our consumers feel better about eating,” says Tom Ennis, chief executive officer for the Kent, Wash.-based snack manufacturer. “Oberto’s new beef jerky recipe uses straightforward, natural ingredients found in any home kitchen. Our new product is now much tastier, much better quality and responds to strong consumer demand for more wholesome packaged snacks with simple ingredients.”

Snack Better With Diamond Foods Diamond Foods’ Emerald Nuts and Pop Secret brands have joined forces with Kettle Brand chips to bring www.diamondsnackbetter.com, a website designed to help consumers snack better. This site provides information about product healthfulness and links to active sites discussing Diamond-sponsored athletic events, running groups, marathons, and more. The website also delivers facts and statistics about healthy snacking, such as recommendations to eat every three to four hours for energy. Emerald Nuts is the snack nut brand of Diamond Foods, Inc., located in South San Francisco, Calif., whereas Pop Secret is the popcorn brand. Kettle Foods, Salem, Ore., is the owner of Kettle Brand all-natural chips.

Universal Food Co. Expands U.S. Presence Universal Food Co., a specialty meat snack producer and owner of the Golden Island brand, adds space to its Rancho Cucamonga, Calif., headquarters. It leased an 8,000-sq.-ft. office space, hired close to 20 more employees and invested around $500,000 in new renovations and equipment to keep up with projected growth. “Moving our administrative staff from our current facility

68

Snack Food & Wholesale Bakery - March 2011

into this new space gives us extra capacity to manufacture our products,” says Anna Kan, president. The Golden Island brand of Asian-flavored jerky can be found in Costco, central markets and various Asian stores. Universal Food also opened an online store at www.goldenislandgourmet.com.

www.snackandbakery.com

To advertise, contact Suzanne Sarkesian 248-786-1692 • [email protected] EQUIPMENT FOR SALE

CONSULTING

completely remanufactured tunnel ovens

after photos

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

We rebuild baking ovens from the ground up. Direct and indirect fired from the small revolving type to 100ft. or longer. For all types of baking performance problems let T&T provide the solutions. If you need to upgrade capacity of an existing tunnel oven, T&T can build and install extensions which might be less expensive than to purchase a new or replacement oven. An older oven, upgraded by T&T with today’s technology can deliver highly competitive baking performance against a new one for less than 50% of cost. We have a current list of ovens on inventory. Contact us for more information, company brochures and photos by phone or the web site.

T&T also offers Factory Mutual and OSHA compliance upgrade work on older baking ovens. www.snackandbakery.com

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

69

OVEN RACKS

Superior Commitment to Excellence Save up to 60% of your valuable work space with Magna Nesting Rack Designs! Magna Industries is a US manufacturer specializing in stainless steel and aluminum equipment solutions for storage, proofing, baking, freezing and transporting products.

Contact the rack company that saves you money and space.

Call 732.905.0957 or visit online at www.magnaindustries.com EQUIPMENT FOR SALE

$"--
'3"*/
-"45


Southern Perfection Fabrication Quality Bakery Racks, Dollies, Baskets & Trays

'SBJO
IBT
NPSF
1SF0XOFE
1BDLBHJOH

1SPDFTTJOH
NBDIJOFSZ
UIBO
BOZ
DPNQFUJUPS
BU
UIF


-08&45 13*$& (6"3"/5&&% $"--
'3"*/
(3061



Advantages: s Competitively Priced s Quality Guaranteed s Small Quantity Orders No Problem

l

*Specia

ie with Free Doll skets 0 ba every 20 t. u bo gh

1-800-237- 4726

www.southernperfection.com

XXXVTFEQBDLBHJOHDPN

70

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

EQUIPMENT FOR SALE

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

Improved hygiene, cleaning and sanitizing for WIP areas

·

Chemical & blood resistant

·

Non-porous

·

Substantially longer life compared to wood pallets

·

Improves efficiency in handling

·

Transfer raw ingredients and packaging materials to a hygienic pallet for in house use.

PlasticPallet.com

Pallet Inverter ·

Simple 180 degree inversion to recover damaged bags for Good Housekeeping and GNP.

·

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

·

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

·

Cleans wood, plastic & aluminum pallets, totes, containers and freezer spacers

·

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

PalletInverter.com

Pallet Washing System

#HERRYgS)NDUSTRIAL%QUIPMENT#ORPs600 Morse Ave., Elk Grove Village, IL 60007

800.350.0011 s www.Material-Handling.com

PalletWasher.com

OVEN RACK CASTERS

WHAT IS IT? A PLACE TO FIND THINGS THAT:

$"33:
1 1"/4
t
t
3 t
3 30--
0 0/
8 8)&&-4 53"7&-
5 50
% %&45*/"5*0/4 WANNA SEE?? GO TO:

www.SHOPCraftRacks.com www.SchaumburgSpecialties.com www.snackandbakery.com

USED WALK-IN-COOLER-FREEZERS REFRIGERATION SYSTEMS – EQUIPMENT HUGE INVENTORY, ALL SIZES Buy Sell - Nationwide - Wholesale Prices

Tel. 216-426-8882 www.awrco.com [email protected] March 2011 - Snack Food & Wholesale Bakery

71

EQUIPMENT FOR SALE

NEW AND USED PROCESS AND PACKAGING EQUIPMENT s!BACUS7RAPAROUND,ABELER"!'2

s*ACKSON(EAVY$UTY33$ISHWASHER 4EMPSTAR

s$OTT"ONAPACE"LISTER0ACKAGER)N 0ACK

s#USTOM-ADE#HOCOLATE#OOLING4UNNEL

s,IQUID6ERTICAL&ORM&ILL3EALER$8$' 

s2EDIPAX(EAD)NLINE0RESSURE,IQUID&ILLER

s.EW5SED.ET7EIGH&ILLERSCUSTOMIZABLE

s3KIN0ACKAGING-ACHINE -ODEL4"

s.EW5SED ,ONG3TAINLESS3TEEL#ONVEYORS

s3EMI !UTO33!UGER&ILLER&,' !

s.EW5SEDv v33&EED!CCUMULATE4ABLES

s*ET(EAT4UNNEL -ODEL"3 ,!

3140*8*
'(/'+-2+
-2*7 for Tablets, Capsules, Liquids, and Powders 63(*77
59-41*28 Mixers, Tanks/ Kettles, Granulators, & Coated Pans ;;;).7*28(31

=

*1'-0
7'0*7).7*28(31 MOST EQUIPMENT CAN BE INSPECTED IN TORONTO!!! 2700 - 14th Avenue, Unit 6 - Markham, Ontario L3R 0J1 ,32*






=

$300
6**
##

=

'<



 

INGREDIENTS

CUSTOM TANKS & PRESSURE VESSELS Vessels, reactors and storage tanks designed to meet your special requirements! • 2 ASME Certified plants in the USA • USFDA, BISSC, ABS, API and UL code requirements • 316 and 304 stainless steel, and many alloys Call Ross today!

1-800-524-ROSS www.storagevessels.com

SANITARY RIBBON BLENDERS

World’s #1 Manufacturer! • All stainless, highest quality • Sizes 1 to 500 cu.ft. • Many sizes in stock Call now!

1-800-243-ROSS USA Tel: 631-234-0500 • Fax: 631-234-0691 www.ribbonblenders.com

CONSULTING

subscribeforfree.com WANTED TO BUY

WE BUY ALL FOOD

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

CONSULTANTS PETTY DON

LABELS

LABELS

• NO PLATE/DIE CHARGES • SUBJECT TO ACCEPTANCE

• HIGH QUALITY • LOW COST

847-729-2222 [email protected]

Let our team of three seasoned consultants make overall operation improvements in your snack food operation - tortilla chips, corn chips, potato chips, and extruded snacks.

[email protected]

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

72

Snack Food & Wholesale Bakery - March 2011

www.snackandbakery.com

Ad Index Company Website

Page

Company Website

Page

ABA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 www.americanbakers.org

Great Western Manufacturing . . . . . . . . . . . 20 www.gwmfg.com

ADM Cocoa . . . . . . . . . . . . . . . . . . . . . . . . . BC www.adm.com

Grote Company . . . . . . . . . . . . . . . . . . . . . . 36 www.grotecompany.com

AIB International . . . . . . . . . . . . . . . . . . . . . 41 www.aibonline.org

Gum Technology . . . . . . . . . . . . . . . . . . . . . 35 www.gumtech.com

ALIT SRL . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 www.alit.it

Haas-Meincke . . . . . . . . . . . . . . . . . . . . . . . 63 www.haas.com/interpack www.meincke.com

Company Website

Page

Rademaker USA, Inc. . . . . . . . . . . . . . . . . . 37 www.rademaker.com Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 www.reiser.com Remco Products . . . . . . . . . . . . . . . . . . . . . 39 www.remcoproducts.com Roquette America, Inc. . . . . . . . . . . . . . . . . 13 www.roquette.com

Arizona Instrument LLC 46 www.azic.com

International Bakers Services . . . . . . . . . . . 23 www.Áavors.org

Arr-Tech, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 31 www.arr-tech.com Bay State Milling . . . . . . . . . . . . . . . . . . . . . . 9 www.baystatemilling.com BluePrint Automation . . . . . . . . . . . . . . . . . . 49 www.blueprintautomation.com Brolite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 www.bakewithbrolite.com

Knappen Milling Company. . . . . . . . . . . . . . 65 www.knappenmilling.com

Sensory Effects Inclusions . . . . . . . . . . . . . 53 www.sensoryeffects.com Siemer Specialty Ingredients . . . . . . . . . . . . 34

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

www.siemerspecialtyingredients.com

Lawrence Equipment . . . . . . . . . . . . . . . . . IBC www.lawrenceequipment.com

Sifter Parts & Service, Inc.. . . . . . . . . . . . . . 65

Moline Machinery LLC . . . . . . . . . . . . . . . . . 22 www.moline.com

Spraying Systems Co. . . . . . . . . . . . . . . . . . 29

Cargill Salt . . . . . . . . . . . . . . . . . . . . . . . . . . 11 www.cargillsalt.com

National Confectioners Association . . . . . . . 21 www.sweetsandsnacks.com

Charles Ross & Sons Company . . . . . . . . . . 7 www.ribbonBlenders.com

National Honey Board . . . . . . . . . . . . . . . . . 51 www.bakingwithhoney.com

www.sifterparts.com

www.spray.com/freecoatingtest United Soybean Board . . . . . . . . . . . . . . . . 19 www.SoyConnection.com/QUALISOY Van Drunen Farms . . . . . . . . . . . . . . . . . . . 45 www.vandrunenfarms.com

CMC America Corporation. . . . . . . . . . . . . . 16 www.doughmixer.com

National Starch Food Innovation 54, 55, 56, 57 www.foodinnovation.com/bakery

Douglas Machines . . . . . . . . . . . . . . . . . . . . 47 www.dougmac.com

Natural Products, Inc. . . . . . . . . . . . . . . . . . 58 www.npisoy.com

www.wirebelt.com

Ford Commercial Trucks . . . . . . . . . . . . . . . 5 www.commtruck.ford.com

Puratos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 www.puratos.us

WP Bakery Group . . . . . . . . . . . . . . . . . . . . 18

Wire Belt Company of America . . . . . . . . . . 27

www.wpbakerygroupusa.com

Reader & Marketing Services LETTERS Lauren R. Hartman Snack Food & Wholesale Bakery 155 Pfingsten Road Suite 205 Deerfield, IL 60015 E-mail: hartmanl@ bnpmedia.com SINGLE COPY SALES/BACK ISSUES Ann Kalb T: (248) 244-6499 E-mail: [email protected]

www.snackandbakery.com

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

PRINT & INTERNET ADVERTISING Jeff Heath E-mail: heathj@ bnpmedia.com T: (847) 405-4074 Barbara Szatko E-mail: [email protected] T: (630) 527-9927 CLASSIFIED ADVERTISING Suzanne Sarkesian E-mail: sarkesians@ bnpmedia.com T: (248) 786-1692

BNP Media 155 Pfingsten Road, Suite 205, Deerfield, IL 60015 Phone: (847) 405-4000 Fax: (847) 405-4100 Reaching a total qualified circulation of 14,000 copies. Source: Dec 2009 BPA publishers statement.

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

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

March 2011 - Snack Food & Wholesale Bakery

73

The Final Word

Mindless Snacking hen it comes to food, it seems as though it’s the same story, different day. One day, bread is a necessary avenue for consumers to obtain their recommended serving size of whole grains and fiber, but the next day, it’s labeled unhealthy because of its high carbohydrate content. One day, popcorn is light, fluffy and healthy—the next day, scientists and researchers are concerned about the chemicals found in the butter flavoring (Diacetyl, a chemical used in butter flavoring, may damage the lungs by reacting and forming complexes with amino acids in cell membranes, according to RTI International and the National Institute of Environmental Health Sciences, both located in Research Triangle Park, N.C.). Now, so-called “snacksperts” are attacking how consumers snack, stating that Americans are advised to avoid snacking while watching TV because it will only cause them to eat more later. I guess that means me devouring a box of Little

W

Debbie’s while watching The Biggest Loser presents more side effects than just guilt? According to the study conducted by Australian researchers, snacking while watching TV forces people to “forget” how much they’ve actually eaten, and therefore they feel as though they need to eat again shortly after the TV program ends. However, the study only targets females, as the male study group didn’t present “enriching” results (glad to know that us women continue to dazzle these snacksperts). The study involved two experiments. In the first study, 16 healthy-weight women were invited to eat chocolate, potato chips and other snack items while watching an episode of Friends or Seinfeld, (my invitation must have gotten lost in the mail), whereas the other half snacked while sitting quietly. Both groups were given 20 minutes to consume as many snacks as they wanted, the study says. In study two, 84 women followed the same steps as the previous group, however,

Thanks to our fastpaced, on-the-go society and the assortment of snacks designed for on-the-go consumers, we are forced to conduct “mindless eating” because we’re constantly distracted.

74

Snack Food & Wholesale Bakery - March 2011

Marina Mayer, executive editor [email protected]

they were broken up into segments and made to watch different genres of TV, i.e., boring, sad and funny. The findings show similar results— the TV-while-snacking group tended to consume more food later than the sittingquietly-while-eating bunch. In addition, the study states that the type of show didn’t augment the results, proving that it doesn’t matter what type of TV is being viewed, it’s just the distraction of watching TV that creates this “must-eat-more-later” syndrome. “Eating is a very complex behavior,” says David Lau, professor of medicine at the University of Calgary and president of Obesity Canada, an obesity awareness group. “[When people snack in front of the TV], their minds are off. It’s really mindless eating.” What does this mean then for those of us who snack at our desks or munch in the car c while sitting in never-ending traffic? Thanks to our fast-paced, always-on-theT go society and the assortment of snacks g designed for on-the-go consumers, we d are forced to conduct “mindless eating” a because we’re constantly distracted. b So what gives? Are we really hurting ourselves in the long run by going, going, o going or does it help to invest in betterg for-you snack items so that the “mindless f eating” isn’t so bad? e Either way, these snacksperts have another thing coming to them if they think a I’m going to give up my snacking-whileI watching-TV habit. Sometimes I just can’t w resist a bowl of popcorn while succumbing r to an hour of Jersey Shore. Then again, t many of today’s TV programs deliver what m I call “mindless viewing.” Who’s bringing the snacks? SF&WB

www.snackandbakery.com

PRODUCT DEVELOPMENT Snack food manufacturers have come to rely on ADM Cocoa for consistency and quality. But what really sets us apart are the added extras you can’t get anywhere else. Like product development. Come to us with an idea, we’ll help you transform it into a high-performance product your customers will crave. To find out more about how ADM’s technical expertise can give you an advantage, visit us at adm.com/ambrosia.

ADM. Chocolate…and so much more.

For customers around the world, ADM draws on its resources—its people, products, and market perspective—to help them meet today’s consumer demands and envision tomorrow’s needs. © 2011 Archer Daniels Midland Company

800-558-9958 | [email protected] | www.adm.com