Snack Food & Wholesale Bakery May 2011

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Contents

Cover Story 16 | Brownie Baking and More in Spring Valley

Photos bby Vi Ph Vito P Palmisano l i

Fourteen years ago, Old Colony Baking Co. started as a marketing firm that had its products co-packed by an outside source. Today, the Spring Valley, Ill.-based cookie and sweet goods producer, together with its sister company, Spring Valley Baking Co., produces some 25 stock-keeping units and a plethora of brownies, cookies pastries and more.

Plant Story 24 | A Quality Approach No matter how the cookie crumbles, Old Colony Baking Co. has what it takes to be a winner in the cookie, brownie and sweet goods business. Take a tour of its 11,000-sq.-ft. facility that’s equipped with four form/fill/ seal systems and generates more than 300-plus brownie bars a minute and 70,000-80,000 lb. of product each week.

Columns 8 | Editor’s Note From meetings, conventions and other industry events, editor-in-chief Lauren R. Hartman recaps her busy weeks in baking.

49 | The Nutritional Corner The Grain Foods Foundation teams up with Share Our Strength to launch the 2011 Bread Art Project. Find out how contributing columnist GFF president Judi Adams is doing her part to help prevent hunger across the United States.

72 | Engineering Management When it comes to strength in management, contributing columnist Jeff Dearduff urges us to test our personal limits to find out what we’re truly capable of.

90 | The Final Word Kraft Foods’ new face-scanning technology brings decision making in the kitchen to a whole new level, says executive editor Marina Mayer. Read on to find out how it works and why this so-called “methodology” can be the new wave of the future.

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Contents

32

Market Trends 32 Packaged for the Environment Packaging made from compostable and recycled materials is not only good for the environment, but it’s also good for bakeries, snack manufacturers and retailers, too.

New Products 40 New Products Read about some of the most recently introduced products, including MaMa Rosa’s Pizza Grillers, Fiber One 90-calorie brownies, Beanfields Bean & Rice chips and Singular Sensations lava cakes and cheesecakes.

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Special Report 50 Getting Gluten-free Right After years of withstanding “strange-tasting” products having little resemblance to “the real thing,” consumers are now getting the kinds of gluten-free foods they’re after, in a more competitive market segment for bakers and snack producers.

Ingredient Technology 64 Happy Trails When you combine fruits, nuts and chocolate chunks, you get a trail mix concoction. When you add vitamins, antioxidants and a bevy of spices and flavors, you get a better-for-you product that stands the test of time.

Production Technology

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74 Lightening the Load Many of today’s warehouse and distribution logistics feature paperless dispatching, automated order fulfillment and other topnotch advancements that allow operators to lighten their load.

79 Supplier Standpoint Almond Board of California, Modesto, Calif., offers up a host of health claims, recipe suggestions and statistics that can make any almond lover rejoice for more.

74 SNACK FOOD & WHOLESALE BAKERY (ISSN 1096-4835) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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Production, Technology & Product Development Solutions for a Changing Industry. May 2011 Vol. 100 No. 5

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

John Schrei Publishing Director [email protected]

Tom Imbordino Group Publisher [email protected]

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

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

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

Patty Catini Art Director

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

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

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

Support Services Nann Barkiewicz Production Manager [email protected] [email protected] 248-786-1652

Audience Development 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: Kevin Collopy at 800-223-2194 x684 [email protected]

Email contact: Shawn Kingston at 800-409-4443 x828 [email protected]

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

21st Century Grain Processing is a trademark of 21C Oats, Inc., a subsidiary of Viterra Inc.

Liz Wright Marketing Coordinator

Some of our best ideas come in small clusters. Creating the perfect oat cluster and coated whole grain ingredients to meet tight formula and final product specifications is only possible when your team is... creative. We work closely with our customers to ensure the perfect flavor and texture, every time. That’s unique. That’s essential.l. That’s how we roll. viterra.com

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Editor’s Note

Busy Weeks in Baking T

his year’s Winter Summit, produced by the Baking Equipment Manufacturers and Allieds (BEMA), Overland Park, Kan., immediately followed by BakingTech 2011, hosted by the American Society of Baking (ASB), Swedesboro, N.J., were truly the Best Week in Baking. Both held in Chicago in early March, the networking conferences invited participants to make more connections, visit with old and new contacts, customers and colleagues and share knowledge, ideas and experiences through technical sessions, receptions, luncheons, presentations and ceremonies. If you haven’t been to these kinds of events, you must try to go next time. The Winter Summit included an enthusiastic Think Tank roundtable, asking for feedback and improvements to the International Baking Industry Exposition (IBIE) show. BEMA’s conference also featured a powerful Lauren R. Hartman lineup of speakers [email protected] that drove home great stories about beating some of the toughest challenges in life. There were presentations on social responsibility auditing and a supermarket panel that discussed new needs and goals of in-store bakeries. A most informative session on the BISSC/ANSI standard update was given by Gale Prince of Gale Prince and Associates, while Jennifer Frankenberg of Sage Food Safety Commission, who discussed where bakers stand regarding the food safety regulation updates and gave visitors a perspective on the plans to improve the standards and practices. The ASB meetings were packed, es-

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pecially breakout sessions, i ll the h afternoon f b k i which included presentations on everything from sustainability to the Environmental Protection Agency (EPA)’s Energy Star programs for bakeries to building a Leadership in Energy and Environmental Design (LEED) bakery as well as trends in food safety systems and equipment technologies sessions, clean label strategies, ingredients/ formulation, artisan/ethnic baking, dietary fiber, resistant starch, sodium reduction, regulations and safety and sanitary design. This year’s theme at ASB, “Nourishing for Generations,” really hit home, as it showcased the proud heritage of the industry with vintage and antique artifacts of baking tools, old-time products and signs and other assorted memorabilia placed around the main meeting room at Chicago’s Marriott Hotel. ASB chairman Rowdey Brixey presented the annual Baking Hall of Fame inductees and the Robert A. Fisher distinguished service award. James Apple of Butter-Krust Baking Co., Sanbury, Pa.; E.E. Kelley of ButterKrust Bakery, Lakeland, Fla.; Ken Klosterman of Klosterman Baking Co., Cincinnati; and Alexander Weber of Caravan Products Co., Totowa, N.J., are the 2011 Baking Hall of Fame inductees (visit the Briefs section of our site, www.snackandbakery.com, for more information on the Hall of Fame members). “Nourishing is defined as proving food

Photos courtesy of BEMA, ASB

o other substances necessary for life or and a growth and to foster the development of someone or something. Both m defi nitions apply to BakingTech 2011,” d Brixey says. Bi Ed Viesturs, a high-altitude mountaineer, gave a dramatic and vista-filled account of his mountain-climbing experiences and futurist and economist Lowell Catlett returned this year to provide a light-hearted approach to the economy. Visitors also swarmed the Marketplace tabletop exhibits, which were loaded with developments, products, demonstration videos, samples and plenty of exhibitor information. At the end of March, the American Bakers Association (ABA), Washington, D.C., held their convention, titled “Enriching Bodies and Lives,” featured an interview with former Walmart chairman Lee Scott, who offered plenty of insight on Walmart’s business issues, growing productive supplier relationships and development of sustainability policies. Commodity expert Jim Bower presented guidance on the commodities markets and a fortification panel moderated by our contributing writer, Judi Adams, president of Ridgway, Colo.-based Grain Foods Foundation and the Wheat Foods Council, stressed the importance of enhancing products with folic acid, B vitamins and enriching grains. All in all, the busy month of March was a successful and productive one, and the ABA convention was a huge success as well, with an increase in attendance by 8%. SF&WB

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Advertorial

Cooperation at its Best— The Year of the Pie Larry Blagg, contributing columnist

Shawn Kearns Einstein Noah Restaurant Group, Inc. Commercial Category Split Top Buttermilk Raisin Bread

To enter America’s Best Raisin Bread Contest & view winning recipes, visit

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The California Raisin Marketing Board along with BEMA, Overland Park, Kan., the Grain Foods Foundation (GFF), Ridgway, Colo., and the American Bakers Association (ABA), Washington, D.C., participated in the Crisco National Pie Championships, April 8-10, in Orlando, Fla. This annual event draws pie aficionados from all over the United States, including commercial pie companies, professional chefs, the best amateur pie bakers in America and a 600-strong army of volunteers serving as judges, pie cutters, servers and crew who manage the Never Ending Pie Buffet in Celebration, Fla., which took place April 9-10 in conjunction with the contest. Linda Hoskins, executive director of the American Pie Council (APC), the Lake Forest, Ill., host of the pie championship, and her band of pie fanatics, drove this activity to such heights that foodies across America dubbed 2011 the “Year of the Pie.” That is an amazing testimonial to the work of the APC. The championship kicked off with presentations from Judi Adams, president of the GFF, Rob MacKee, president and CEO of the ABA, among others, with Kerwin Brown, president and CEO of BEMA, serving as MC for the day’s events. It was exciting to hear of the resurgence of the commercial pie industry and about the rebirth of this home-prepared comfort food favorite. Additional talks included the rise of gluten-free and whole-grain baked goods, the influence of the new dietary guidelines for school feeders and what’s happening in Washington, D.C., that affects all food producers and retailers. Then came the judging. Being a volunteer judge means wearing your best expandable waist clothing and being ready, willing and able to offer your opinions about a whole category or flavor of pies. Luckily, I volunteered as a pie critic/taster for just one day and only sampled 24 pies in the innovation category. Such a task should be listed in Wikipedia under the definition of “fun.” What made it even more interesting than the myriad of

The folks at the California Raisin Marketing Board passed out slices of rhubarb and golden raisin pie while at the Crisco National Pie Championship. Photo courtesy of the California Raisin Marketing Board

flavors and crusts that passed in front of us was the wide experience of my fellow judges. At our table we had folks from California, Florida and Arizona, all of whom had traveled to and stayed in Orlando at their own expense to be part of this pie extravaganza. One judge was a well-known food critic, another was the team cardiologist for the University of Southern California football team and the third was a student culinologist at a Florida cooking school. A more compatible group would have been hard to find. We took our jobs as judges seriously, but not ourselves, which made for a pleasant morning. Following the judging, we moved on to Celebration, Fla., to pass out free slices of Rhubarb & Golden Raisin and Chocolate, Walnut and Raisin pies at the Great American Pie Festival. The festival featured a two-day never-ending pie buffet, and provided an opportunity for visitors to try old favorites, rare flavors and combinations of both. The California Raisin Marketing Board is grateful to the owners of Rocky Mountain Pie Co., Salt Lake City, Utah, for baking, delivering and even helping to cut up the pies served at our booth. Who could have asked for more. To find out the pie winners and to receive recipes from the raisin pies, go to www.loveyourraisins.com or www.piecouncil.org. Editor’s Note: Larry Blagg is senior vice president of marketing for Fresno, Calif.-based California Raisin Marketing Board, which sponsors America’s Best Raisin Bread Contest. Go to www.loveyourraisins.com to enter the 4th annual America’s Best Raisin Bread Contest.

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Business Briefs

people

News Flowers Foods, Tasty Baking Announce Merger Flowers Foods, Thomasville, Ga., and Tasty Baking Co., Philadelphia, announce a definitive merger agreement whereby Flowers will acquire all of the outstanding shares of Tasty common stock in cash for $4 per share, for a total purchase price of approximately $165 million, including Tasty’s existing indebtedness. The transaction is expected to strengthen Flowers’ snack cake business

through the addition t of the iconic Tastykake snack cake brand, expand Flowers’ geographp ic reach, add two highly i effi cient bakeries with e additional capacity to support growth and generate significant operating synergies through additional revenue and cost-saving opportunities among others. The transaction is expected to close during the second quarter of 2011.

Kemper Bakery Systems, North American subsidiary of WP Bakery Group, Shelton, Conn. Jim Souza is appointed vice president and director of industrial sales, responsible for spearheading the industrial sales division, Jim Souza including industrial and turnkey projects such as mixing, donut lines, laminating lines, oven systems, cookie-cracker systems and roll and bread lines. Souza has worked in the food and dairy industries for the past 20 years, directing and managing operations, engineering, sales and customer relations functions on a global scale. Caravan Ingredients, Lenexa, Kan. Mary Bentley is named vice president of marketing and business development, responsible for leading all marketing and business development activities. Bentley maintains an extensive background Mary Bentley in management, sales and marketing, and has held various executive level positions with Sara Lee Corp., Pillsbury/General Mills and the Women’s Foodservice Forum. Most recently, Bentley ran her own consulting organization called Bentley Enterprises. Danisco USA, Rochester, N.Y. Scott Bieker joins the New Century, Kan.-based bakery group as an account manager, responsible for technical sales in the Midwest region. Scott Bieker Bieker brings 20 years of hands-on experience in the baking industry. Previously, he was a bread and roll baking instructor at the American Institute of Baking. Continued on page 14

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Business Briefs Continued from page 12

News iba 2010 Promises Everything for Bakers and Confectioners iba 2012 is described as the world’s leading international trade fair for the bakery market. To be held in Munich, Germany, at the new Munich Trade Fair Centre, Sept. 16-21, the show promises to showcase new bakery and pastry-making equipment, materials and ingredients, accessories and services as well as advances in technology, the latest in logistics, measuring instruments, packaging and process optimization. Held every three years, the show is organized by Zentralvergand des deutschen Backerhandwerks and managed by GHM Gesellschaft Handwerksmessen mbH (GHM). To learn more about iba 2012, visit www.iba.de and www.baeckerhandwerk.de.

supplier news Reimelt Corp. changes its name to Zeppelin Systems USA, Inc., bringing increased engineering synergies, economy of scale, financial stability and worldwide resources. Zeppelin Systems’ plastics producer and plastics processor business will remain housed in its Houston, Texas, office. Pcdata signs an agreement with Atyab Investments, Bakery and Oman Flour Mills for the installation of Pcdata’s warehouse management system (WMS) at Atyab Bakery in Muscat, Oman. Atyab Bakery is a groundbreaking project that will invest $31 million for a fully automated production facility, designed to produce 12,000 pieces of Arabic bread, 24,000 buns, 5,000 loaves and 5,000 croissants/Danish/puff pastries per hour. Commercial production is expected to commence in the first quarter of 2011. Pcdata’s distribution WMS, including production-controlling units, will be part of the project. SensoryEffects Powder Systems acquires Dietrich’s Specialty Processing, a provider of high-quality, customized spray drying services. Included in the acquisition will be a new state-of-the-art manufacturing facility, complete with Continued on page 14 tall form spray dryers, evaporators and extensive liquid and powder handling equipment. tna acquires Arcall, a leading supplier of innovative seasoning and cutting systems. As a result, tna can offer multiple seasoning and spraying products along with an extensive range of specialized cheese-cutting solutions, suitable for use across a wide variety of applications. These machines can also be easily integrated with tna’s existing portfolio of cutting-edge packaging equipment. Flavorchem Corp. receives SQF 2000 Level 2 certification. SQF (Safe Quality Food) is a leading, comprehensive and global food safety and quality management certification system, designed to be a food safety program, but also covers product quality—a feature that is unique to this type of certification program. Allied Blending & Ingredients establishes a lab at the BioResearch and Development Growth Park at the Danforth Plant Science Center in St. Louis. The lab, which will be completed this month, will focus on product development research and testing on formulations for processed cheese and will be the company’s first satellite location in St. Louis.

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.

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MADE IN THE USA

2808 Thomason Drive Mattoon, IL 61938 t: 217-235-1020 f: 217-235-1006 e: [email protected] w: ussoy.com

sweet goods producer

Brownie Baking and More in Spring Valley Specializing in brownie bars, cookies, animal crackers and other sweet goods, Old Colony Baking Co. and Spring Valley Baking, its sister company and contract baking facility, both in Spring Valley, Ill., believe quality is their top priority. It’s what consumers and customers have come to expect. Lauren R. Hartman, Editor-in-Chief

O

ld Colony Baking Co. started 14 years ago as a marketing firm that had all of its products co-packed by an outside source. Today, the company, based in Spring Valley, Ill., in the heart of “corn country,” markets an assortment of co-branded cookies, animal crackers, brownies and other pastry bars, while its sister company, Spring Valley Baking Co., which operates out of the same location, contract-packs a collection of taste-tempting brownies, lemon bars, chocolate chip bars and coming soon, a coconut bar, with no preservatives or trans fat. Continued on page 18

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Ann and Jeffrey Kaufman have been in the baking business for more than 30 years. They recently got back into producing and packing brownies with the addition of Spring Valley Baking along with their main cookie business, Old Colony Baking.

Photos by Vito Palmisano

www.snackandbakery.com

May 2011 - Snack Food & Wholesale Bakery

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Continued from page 16

“We got back into manufacturing with the addition of Spring Valley Baking and combined offices,” relates Jeffrey Kaufman, Old Colony/Spring Valley president. He probably has brownies in his blood, as he’s been in the brownie business for years, starting his career in 1969 with Plantation Baking, a family business, while working during his school vacations. His wife, Ann, who is chief executive officer of Old Colony and head of administration for both Spring Valley and Old Colony, also worked at Plantation as the office manager, and guided more than 20 office personnel. “I worked with my uncles Mal and Leon Kaufman and all of my training came from them,” Jeffrey Kaufman recalls. “Leon was the technical one and Mal was on the sales and administrative side. Plantation was sold in 1986 and I stayed on until 1994. My uncles were an integral part of the whole thing.” Jeffrey and Ann Kaufman started the business after spending more than 25 years at Plantation Baking. Jeffrey Kaufman learned early on that there was never a substitution for quality. Ann Kaufman left

Company: Old Colony Baking Co.,Inc. / Spring Valley Baking Co., LLC Headquarters: Spring Valley, Ill. Website: www.ocolony.com Plant Size: 11,000 sq. ft. No. of Lines: 1 No. of Employees: 28 Products (including private-label/ contract/copacked): Gourmet Fudge Brownies, Lemon Bars, Diamond Walnut

Plantation and the pair started Old Colony Baking nearly 15 years ago, and then branched out to form Spring Valley Baking in 2008. Together, the companies offer some 25 stock-keeping units, including the Old Colony and co-packed products and

Shortbread Cookies, Apple Sauce/ Oatmeal Cookies, Lemon Cookies Brands: Old Colony as well as several private-label, proprietary copacked brands

KEY PERSONNEL: CEO: Ann Kaufman President, National Sales: Jeffrey Kaufman Plant Mgr.: Gary Lucas Production Supervisor: Jessi Kierski

Spring Valley’s 10-plus SKUs. The shelfstable products include pastries and cobranded cookies, gourmet fudge brownies that can be topped with nuts, chocolate chips or Decorattes (sprinkles), chocolate chip and lemon brownie bars and animal crackers for vending, convenience store, mini-mart, grocery and foodservice channels of distribution, to name a few. Spring Valley Baking co-packs any of the products under private label and can custom-bake any size for various package configurations a customer would require, Jeffrey Kaufman says. Distributed nationally, the cookies, which come in walnut shortbread, apple sauce oatmeal, lemon, animal crackers and assortments and are packed in 1- and 2-oz. brightly printed bags, are produced for Old Colony by Cookie Kingdom, an outside source nearby. In addition to the Old Colony brand, the cookies feature labels from licensor partners such as Musselman’s, Diamond, ReaLemon and Old Colony’s own Carnival trademark. While Jeffrey Kaufman says Old Colony can’t offer any of its “branded” items specifically for private-label distribution, it can make available various cookie products to serve various needs. “We can provide a totally finished project, including, but Continued on page 20

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S U C C E S S

S T O R I E S

HOW A VEMAG R O TA R Y S H E E T E R

produced the P E R F E CT B R O W N I E A T RU E S T O RY: A Reiser customer was using a Vemag Depositor to successfully portion gourmet cookies and scones. She wanted to expand into brownie products and decided to purchase a piston filler to do the job. She quickly discovered the limitations of the piston filler – the batter had to be made less viscous to run through the machine and it required hand-spreading to fill the tray corners. Realizing how happy she was with her Vemag, she asked Reiser’s bakery specialists to engineer a solution. The result was a Reiser 18-inch Rotary Sheeter that attached to the Vemag. This heavy-duty device allowed her to make the brownies as thick and chocolatey as she originally envisioned. The Sheeter’s full-width extrusion completely filled the pan, eliminating all hand labor. It was the perfect solution! Her vocal support resulted in sales at other plants as she spread the word of Vemag’s ability to sheet viscous batters and cookie doughs.

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

Leading the food industry in processing and packaging solutions.

Continued from page 18

not limited to, formulations, packaging artwork, packaging film selection and standup displays,” he continues.

Rehabbed plant, quality image To launch the sister company/contractpackaging business, the Kaufmans bought a formerly vacant baking facility in Spring Valley, Ill., that Jeffrey Kaufman says “had to be gutted, as it hadn’t been used in probably 15 years.” The town’s name became the contract packaging company’s name, and now, the clean, refurbished 11,000-sq.-ft. operation is home to 28 employees, is kosher- and pareve-certified and features one U-shaped production line equipped with three horizontal form/fill/seal systems that all together, generate more than 300 brownie bars a minute. Newly built offices and a sample room where some of the product quality assurance testing is performed were added, as well as a new walk-in cooler for storing ingredients such as nuts, chocolate chips and fresh egg whites. Also, new plumbing, electrical systems and water filtration were installed. The production facility has a small storage warehouse and an engineer’s quarters, but it’s still compact. “It was difficult to decide where to put equipment and other things because of the limited space,” he adds. “So we warehouse our packaging materials off-site, and bring them and our raw materials in on a just-in-time [JIT] basis.” Despite the coziness, things really hum on the brownie line. Production is passionate, organized, dynamic and upbeat. Demand requires that the plant generate as much as 70,00080,000 lb. of product each week. That’s about 15,00018,000 lb. of dough a day. “Brownies are Spring Valley’s forte and quality is our image,” Jeffrey Kaufman says emphatically. “That’s a carry-

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over from my days at Plantation Baking. Quality cocoa, enriched flour, pure chocolate chips and fresh eggs are a main reason that we can provide a long shelf life. They need no refrigeration and no preservatives.” The gourmet fudge brownies are quite popular and the Kaufmans consider brownies to be the top seller. Depending on orders, which can vary each week, Spring Valley’s contact-packing facility operates three to five days a week, and has the ability to run multiple shifts or 24 hours if necessary, Jeffrey Kaufman says. “Our capacity isn’t an issue. We maintain a bake-to-order philosophy and ask for a two-week leadtime, which gives us time to schedule, bake and ship so the customer gets the freshest product available.” Reinforcing the bakery’s commitment to quality, the staff frequently conducts quality control inspections and there is a metal detector on the line. Part of the process is to take moisture readings of the product each hour as well as several visual checks. “But in our business, there’s nothing like a visual check and a taste,” says Jeffrey Kaufman. “We do a full QC check every hour.”

The quality control checks also involve monitoring dough deposit heights, conducting moisture readings, inspecting packaging film codes and shipping case codes and checking packaging seal integrity and package weights, the latter of which are checked every half hour. “We’re already in step with the food safety regulations, but that’s old training for me,” Jeffrey Kaufman says. “What I know was taught to me by my uncles. They instilled things like that in me. There was never a substitute for quality, and sanitation was always first and foremost.”

Sticking with what they know How does a baking operation like this get started in the middle of one of the worst economic situations this country’s had in years? “We had to weather the storm,” says Ann Kaufman. “It’s a challenge. Yes, we started up at the worst point in the economy. It is hard to keep a hold on costs.” It’s a tough business, Jeffrey Kaufman adds. “We raised our prices one time, which was at the beginning of this year because commodity prices were increasing so quickly and we work on very thin margins.

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not an ‘almost’ snack. But we really don’t react to many trends because our focus is here at the plant, and with the product at hand. I do think variety is the spice of life, however, and [I] hope independent manufacturers and their abilities to react quickly to customer needs come back into the market.” Ann Kaufman agrees: “For us, doing what we do best and doing what works, without trying to reach too far is important. The trends come and go, but we stay with what we have—the tried and true.”

New developments

So where can company like ours really help itself? Here at the facility, keeping watch on weights, scrap and by making sure our yields are dead-on.”

As far as trends are concerned, “we don’t pay that much attention to those comings and goings,” he adds. “When people want a snack, they want their snack,

One of Spring Valley and Old Colony’s latest endeavors was to revise the graphics on the polypropylene film wraps for the primary brownie packaging with a fresh, more contemporary look that incorporates bright colors. “Along with the new Continued on page 22

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packaging, we have also ‘tweaked’ the browning formula a bit and no longer use high-fructose corn syrup,” Jeffrey Kaufman notes. “The film wrap helps us provide the brownies with a 120-day shelf life. The brownies are shelf-stable. We also made the brownies darker and richer,” states the company’s website. “The new product in its new package is now in distribution.” Also, the companies have a new coconut bar in the works. “We think coconut is making resurgence,” Jeffrey Kaufman smiles, with his eyes twinkling. He’s also very enthused about another project; Old Colony is coming out with a grocery storesized (5-oz.) bag for the branded cookies. “We think the time is right for a larger bag size for the cookies. And very soon, we’re going to add an automatic topping applicator for the brownie line,” he points out, excitedly. “That will eliminate some labor and provide a uniform coverage of

toppings on the brownies. We also hope to someday streamline the bulk handling of the raw materials and get some bulk handling equipment, but we like hand-feeding the brownies [on parts of the line] because brownies are a very delicate item and not all automatic equipment is gentle enough.” The companies are also prepared for the recently implemented Food Safety Modernization Act as they keep the necessary records to track their products, Jeffrey Kaufman says. “We make an incoming receiving report on all raw materials and packaging materials—and we check the cleanliness of the truck that they come on. We also note all of the lot codes, and everything is dated when it comes into our facility. All of the lot codes of the ingredients are listed on a report, and bakers include lot codes on their material logs, which all tie the information together for our recall procedure.” The two major changes Jeffrey

Kaufman sees in his 30-plus years in the baking business are the differences in shortening and sugar that are now used. “At Plantation Baking, we used hydrogenated shortening. Now, we make the same high-quality product but without hydrogenated shortening. The other thing is, we don’t use high-fructose corn syrup. Invert sugar is more costly, but so are so many of the other commodities.” Even though Spring Valley is new and just getting on its feet, it’s a startup, but not really a startup, he says. “Based on all of my experience, I’ve grown up with this process, so we have an edge.” Whether it’s looking at automating more of its processes, developing a new, trend-setting brownie, or diving head-first into a new business, the Kaufmans and their staff happily seem glad to be on-thego, enjoying their tasks and eating brownies all the while. SF&WB

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From left to right, Jessi Kierski, office/production supervisor; Ann Kaufman, CEO, Old Colony Baking and head of administration for Spring Valley/Old Colony; Jeffrey Kaufman, president, Spring Valley/ Old Colony; Gary Lucas, plant manager/maintenance foreman; Krista Grady, quality assurance manager.

A QUALITY APPROACH Cookie marketer Old Colonyy Baking g Co. and its sister company p y and contract packager, Spring Valley Baking Co., which produces assorted brownies and other sweet goods, are both located in pastoral Spring Valley, Ill. Spring Valley Baking’s single production line, equipped with four form/fill/seal systems, generates more than 300 brownie bars a minute and 70,000-80,000 lb. of product each week. Lauren R. Hartman, Editor-in-Chief

o matter how the cookie crumbles, Old Colony Baking Co. has what it takes to be a winner in the cookie, brownie and sweet goods business. Its brands include Mussleman’s, Diamond (Walnuts), ReaLemon and Old Colony’s own Carnival animal cracker label, packed in 1- and 2-oz. laminated filmstock bags brightly printed with contemporary graphics. Residing in what was once a small bakery decades ago, Old Colony Baking shares space with its sister company and contract baking/packing

N

Continued on page 26

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Snack Food & Wholesale Bakery - May 2011

Photos by Vito Palmisano

Line operators orient the brownies into the infeed of the form/fill/seal machines, which wrap the fudge treats in printed film wrap.

Continued from page 24

facility, Spring Valley Baking Co., which churns out Gourmet Fudge brownies, tart and tangy Lemon Bars and Chocolate Chip Bars under the Old Colony brand and other well-known licensing partner brands. Actually, the cookies themselves are made and packaged offsite at another nearby contract-baking facility called Cookie Kingdom. But the brownies are produced and packaged in-house by Spring Valley at the 11,000-sq.-ft facility that Jeffrey and Ann Kaufman bought and began operating in 2008. Home to approximately 28 employees, the tidy facility features a single, U-shaped production line, equipped with four horizontal form/fill/seal machines that generate more than 300 brownie bars per minute. The brownies come in a 3 ¼-oz. size and a 2.7-oz. size as singles, and are sold in five-count multipacks that total 6.25 oz. “We can basically make any size for anyone,” says Jeffrey Kaufman, president of Spring Valley Baking Co. The cookies are packed for various market channels in 1-oz. bags for airlines and foodservice and 2-oz. bags for vending and convenience stores and soon, a 5-oz. bag for grocery channels. “We found this building in Spring Valley, which used to be a cookie plant about 20 years ago,” remembers Kaufman. “It had been vacant for almost 20 years, so we started a rehab; however, what was supposed to be a three-month project turned into two years. We had to start from scratch and gut the entire facility. Unfortunately, the two years took us right into the teeth of the economic slump.” But that didn’t stop Kaufman, who, together with his wife, Ann, who is also chief executive officer of Old Colony Baking, transformed the facility into a brownie baking bonanza. Demand requires that the plant generate as much as 70,000-80,000 lb. of product each week or roughly 15,000-18,000 lb. of dough a day. “There was a void in the market for brownies in 2008 when this opportunity came up,” he says. “After my work (about 25 years) at Plantation Baking, I was out of

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the brownie business for a while and there really was no packaged product like this available. So, loving what we used to do, we decided to get back into it,” he continues. “Our idea was, ‘let’s get this going and see if we have a viable business and if it works, we can always build a larger facility.’ My previous experience was invaluable, because I already knew the product,

so we set out to see if we could come close to past success, and so far, so good. Our industry is small and the consolidation has been so heavy. Spring Valley’s niche is independent. There are currently several ‘irons in the fire,’ and we just have to wait for them to happen.” Continued on page 28

The brownie batter is dumped from the mixer into a dough trough that is then hoisted overhead to the infeed hopper of a depositor/extruder.

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plicator,” he says. “This will provide labor savings and a uniform coverage of toppings on the brownies.” The smooth, chocolate chip-topped dough then proceeds into the baking chamber of the company’s three-zone, directfired oven. Chicago,” he adds. “And we use nothing but the highest quality ingredients—natural 10-12% butter fat cocoa, enriched flour, fresh eggs, natural invert sugar and pure chocolate chips.” At the time of Snack Food & Wholesale Bakery’s visit, Spring Valley Baking was producing—surprise!—gourmet fudge brownies under the Old Colony label. The shelf-stable brownies, wrapped in a printed film, stay fresh for 120 days. “Old Colony is really a marketing and distribution company and the parent of Spring Valley Baking,” Kaufman explains. “Spring Valley Baking is purely a contractbaking company, and Old Colony was Spring Valley’s biggest customer when we first began.”

Mixing, extruding, topping At the front end of the production line, flour, sugar, eggs, shortening, cocoa and other ingredients, which are stored near a bake shop area off the line, are added by hand into the plant’s single, stand-alone mixer from 50-lb. sacks or large liquid-dispensing totes. The mixer, which produces 1,000-lb. batches of brownie dough, is overseen by an operator who then dumps the mixed batter into a dough trough that is then hoisted overhead to the infeed hopper of a depositor/extruder that begins smoothing out the mixture onto a carbon steel band. As the raw dough is smoothed and flattened out further, an operator adds the customer’s choice of topping, which can include semi-sweet chocolate chips, nuts, a mix of nuts and chips, sprinkles or nothing at all. At the time of our visit, a mix of chips and nuts were being applied. The extruder maintains a consistent dough thickness. “We’re currently awaiting the arrival of our new, automatic topping ap-

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Each chamber of the oven has a top and bottom zone to evenly bake the brownies at temperatures in excess of 300ºF at a proprietary length of time. “Depending on the weather, we have to adjust our temperatures daily,” Kaufman says. “We Continued on page 30

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Continued from page 29

monitor the dampers in all three zones and adjust accordingly.” Inspection hatches at several intervals along the side of the oven can be opened by line operators during the baking process to visually check the progress of the run. After baking, the brownie dough continues to travel out of the oven into an ambient cooling system that removes as much of the heat as possible and continues on to a mesh cooling belt leading through a long cooling tunnel. Emerging from the cooling chamber, the dough is then slit lengthwise and is then automatically guillotine-cut into individual brownies as it continues to travels downline.

Wrapping and packing The edges of the brownies are also trimmed to give them a nice, finished look, and the trimmed bars convey downline through a metal detector in to a set of four

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Snack Food & Wholesale Bakery - May 2011

Brownies emerge from the slitter and guillotene cutter and proceed through a metal detector. Here, they are inspected for size and given a quality control check, which is performed every hour. horizontal form/fill/seal machines. Line operators remove the individual brownies from the conveyor and gently place them into the infeed conveyor of the form/fill/ seal machines, which use printed polypropylene film rollstock to wrap each brownie. A date coder also applies a manufacturer code and best-by date to each package. Then, as the wrapped brownies emerge from the machines, operators group and place them into a chipboard display tray that holds a total of 12 bars each. “We

don’t bulk-pack the wrapped brownies because they are very delicate and we don’t want them to get damaged en route,” Kaufman says. “The printed trays complement the brownie wraps, double as counter displays and are easy for the route people to handle.” Meanwhile, operators perform quality control inspections on an hourly basis, taking moisture readings of the product, as well as making several visual checks. “But, in our business, there’s nothing like a visual

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

can turn on a dime if need be,” Kaufman concludes. “That’s where the smaller independent companies have an edge over the larger, corporate facilities. It’s all about giving customers what they want. That’s our forte. We can make all kinds of brownies and like pastries, we can bake and package Wrapped brownies are grouped into paperboard display trays in three layers of four for a total of 12 brownies before the trays are casepacked. check and a taste,” Kaufman smiles. The quality control staff also monitors dough deposit heights, dough temperatures, inspects packaging film codes and seal integrity and checks shipping case codes. Package weights are checked on a standalone scale every half hour. Next, operators pack eight of the trays of brownies into cases for a total of 96 brownies per case. The cases are sent through an automatic taper and ink-jet coder, which applies a production and bestbuy code and an item number to the sides of the cases. Each case is also labeled with a product identification sticker to facilitate storage and customer handling. The cases are then palletized by hand. The load is stretch-wrapped on an automatic stretch wrapper to secure the cases and is forklifted into the warehouse. “We maintain a bake-to-order philosophy,” says Kaufman. “We ask for a two-week leadtime, which gives us time to schedule, bake and ship so the customers get the freshest product available.” Because the Spring Valley operation is only a few years old, changes to equipment haven’t been needed, though Kaufman says it will be nice to bring in the automatic topping applicator. “We’re still getting our legs underneath us after baking for almost two years.” The facility and the Spring Valley team are nimble and can react to customer needs quickly and efficiently. “We’re flexible and

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almost any size and weight a customer may want.” Certainly, Kaufman, his wife, Ann and their crew enjoy what they do. They started the contract-baking facility to find out if was viable, and so far, it seems that it is. SF&WB

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Market Trends Sustainable Packaging

Packaged for the Environment Packaging made from compostable and recycled materials is not only good for the environment, it’s also good for bakeries, snack manufacturers and retailers. Romy Schafer, Contributing Writer

mericans generated 243 million tons of municipal solid waste, or garbage, in 2009, according to “Municipal Solid Waste in the United States: 2009 Facts and Figures,” a report by the U.S. Environmental Protection Agency (EPA), Washington, D.C. The EPA categorizes everyday items such as packaging, grass clippings, furniture, clothing, bottles, food scraps, newspapers, appliances and batteries as municipal solid waste. Paper and paperboard, two components commonly used in packaging, including food packaging, accounted for the most municipal solid waste (MSW) generated in 2009—68.5 million tons. Plastic, another packaging staple, made up 29.8 million tons of municipal trash in 2009, with plastic containers and packaging comprising 12.5 million tons. While these numbers may seem staggering, they’re actually better than those from previous years. According to the EPA report, paper and paperboard packaging generation declined 12.5% between 2007 and 2009, while plastic packaging generation decreased 8.1% during the same twoyear period. Effective municipal recovery programs and growing consumer interest in recycling are likely contributors to this positive development. The amount of packaging headed for landfills will probably continue to decrease in the coming years as more manufacturers and retailers—especially those that sell necessities such as packaged food products— began using compostable or recyclable packaging for their products. But food packaging poses more challenges for manufacturers and retailers

A

than just recyclability. It must also address issues such as product protection, freshness, spoilage, breakage, storage and ease of display and use. After all, most shoppers buy chips, cookies and other foods based on how they taste, not because they come in recyclable containers. However, a growing number of consumers are starting to seek out snacks that taste good and make them feel good environmentally when they dispose of the packaging—and snack food manufacturers are taking note.

Biodegradable flex-packs When Frito-Lay began considering using a 100%-compostable, flexible bag for some of its products, the company spent considerable time looking at its various brands to find the right place to start. “We looked for brands that had the appropriate image and a consumer base that would appreciate this type of packaging material,” says Brad Rodgers, manager of sustainable packaging for PepsiCo Inc. advanced research, which

owns Dallas-based Frito-Lay. “SunChips seemed to be a really natural fit.” Introduced in 2009, the compostable SunChips bag consisted of two layers of film made from polylactic acid, a polymer made from annually-grown plants. An adhesive held the layers together. Unfortunately, after the bag hit the retail market, Frito-Lay discovered that the new film, which is stiffer than conventional polymers previously used by the company, made the SunChips bag too noisy for many consumers. “When you rattle or squeeze the bag, it makes this kind of tinny, sharp noise,” Rodgers explains. Negative consumer feedback prompted Frito-Lay to re-examine the film and its lamination process and ultimately change the adhesive it uses to laminate the films together. The change resulted in a “cushioning effect between the two film layers that kind of acts like a shock absorber, if you will, and actually dampens the sound waves,” Rodgers says. Introduced earlier this year, the quieter bag is a hit with consumers, and the company has received a bevy of positive customer feedback. Best of all, the new bag is still compostable. “We made sure that the adhesive we chose wouldn’t interfere with that,” Rodgers says. Frito-Lay studied the SunChips bag’s compostability in multiple environments (a laboratory, an industrial compost facility and a home composter) for several years. The results turned out positive for each. In addition, the bag has been certified “Industrial Compostable” by the Biodegradable Products Institute, a New York-based not-for-profit organization that promotes the use of compostable plastics. Prominent wording on the front of the bag Continued on page 34

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Snack Food & Wholesale Bakery - May 2011

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Photo courtesy of Snyder’s of Hanover

In April 2010, Snyder’s of Hanover began offering its Organic Pretzel Sticks line, which consists of three stock-keeping units, in packaging made from 90% Ingeo, a 100%-annually-renewable, plant-based resource. “We did it as part of our overall sustainability effort,” says Bryan Dobson, director of marketing at Snyder’s of Hanover. “As a company, we laid down some pretty lofty goals from a sustainability standpoint. What we realized that what we could do commercially was move our organic product line there. Obviously, we’re trying to add more value to our organic product lines. We also felt this was a great place to start as far as eventually broadening it to our full line of pretzels.” The company’s Gluten-Free Pretzel Sticks and Whole Wheat Nibblers are now available in this packaging, too, which sports a yellow triangle on its front panel informing consumers that the renewable package is made from plants. While Snyder’s compostable bags are also noisier than its conventional packaging, they aren’t “offensive,” Dobson says, because the company used a thicker substrate

from the beginning. Consequently, the company hasn’t received much negative consumer feedback to the bags. “It was a big concern from a consumer standpoint,” he notes. “The last thing you want is for [consumers] to take something home where the packaging takes away from the product.”

Paper packaging Versatile, recyclable and compostable—no wonder paper and paperboard continue to be packaging staples in the snack and bakery industry. Earlier this year, Acme Bread Co. in Berkeley, Calif., began packaging its artisan breads in paper bags made from 40% post-consumer-recycled waste. The company sells its products at its retail outlets in Berkeley and San Francisco and at select grocery stores in the San Francisco Bay area, including Whole Food’s Markets, Mollie Stone’s Markets and Costco. Each bag bears the text “This bag is made from 40% post-consumer-recycled fiber, FDA Approved” and the universal recycling symbol, letting environmentallyconscious consumers know that the package is sustainable. Switching to the sustainable bags was a natural move for the company, which implemented numerous environmentally friendly initiatives over the years. According to vice president Doug Volkmer, Acme Bread uses organic ingredients whenever possible, installed solar panels on its wholesale bakery and is continuing to add diesel trucks that run on biofuels to its fleet. Whole Foods Market, meanwhile, began using pizza boxes made from 100%-recycled corrugated board at some

Photo courtesy of Acme Bread Co.

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of its locations last fall. Made by ECOvention L.L.C. in New York City, the innovative GreenBox has a perforated top that breaks down into plates and a bottom that folds into a handy storage container. Both pieces can be recycled after use. Known for being environmentally responsible, the Austin, Texas-based company is using the multifunctional boxes, which bear the company’s name on the lid and usage directions on the side, for the freshlymade pizza available at its pizza counters.

Photo courtesy of John B. Sanfilippo & Son Inc.

lets consumers know that the package is 100%-compostable. Hanover, Pa.-based snack foods manufacturer Snyder’s of Hanover also entered the compostable bag market in 2009 with a compostable, handled, outer bag for its 100-calorie Pretzel Variety Sacks and Pretzel Sandwich Variety Packs. The outer bags are made from a 100%-renewable, corn-based film.

Plastic packaging Although plastics didn’t account for nearly as much of the MSW generated in the United States in 2009 as paper and paperboard, they are, according to the EPA report, found in all major waste categories and a rapidly growing segment of MSW. Few people in the snack food industry would disagree with this assessment. Fortunately, many manufacturers are continuing to introduce packaging (rigid and flexible) made from recyclable or recycled plastics. John B. Sanfilippo & Son Inc. in Elgin, Ill., owner of the Fisher nuts brand, recently began offering several of its products—a variety of peanuts, deluxe mixed nuts, mixed nuts with peanuts, cashews, almonds and pecans—in clear cans made from polyethylene terephthalate (PET), a recyclable plastic commonly used for beverage containers. The can is 40% lighter than a regular composite one and can be reused. A clear plastic label sports Continued on page 36

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Lubriplate®H-1 Class Lubricants Newark, NJ 07105 / Toledo, OH 43605 / 1-800-733-4755 www.lubriplate.com / [email protected]

Market Trends Continued from page 34

an updated logo and revised graphics, including a green circle with a tree and the words “Earth-Friendly Packaging” and a brief explanation of the company’s environmental philosophy. The company is further promoting its new clear cans with a campaign titled “Freshness You Can See.” In addition to the updated label, logo and graphics, the campaign includes two radio ads (in the Chicago and Minneapolis markets), in-store merchandising and ads in retailer publications and on websites. Others are taking a more low-key approach to their sustainable efforts. Groupe Biscuits Leclerc in St-Augustin-deDesmaures, Quebec, has been using cookie trays made from Ingeo bioplastic since 2006, says Wilson Ochoa, the company’s sustainable development projects manager. “We were using polystyrene for our trays,” Ochoa explains. “[Our supplier] Continued on page 38

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Market Trends Continued from page 36

Photo courtesy of Groupe Biscuits Leclerc

showed us the new material. We saw all the benefits for the environment, so we changed all our trays.” Leclerc’s cookie lines include Celebration butter cookies, Praeventia cookies with red wine extract, Distinction Maple Leaf cookies and Quattro crème-filled cookies. The company changed the exterior packaging a few years later, moving from flexible bags to 100%-recyclable paperboard made from 60% post-consumer materials, according to Ochoa. Text on the box now informs consumers that the trays are made from plants.

Other benefits Reducing the amount of nonbiodegradable packaging that ends up in landfills is great for the environment, consumers, retailers and manufacturers. When combined with other environmentally friendly practices, though, using sustainable packaging can also benefit bakers, snack food manufac-

turers and retailers in numerous ways. An obvious benefit is a potential reduction in a company’s waste disposal costs. Less landfill-bound garbage may mean less money spent on waste removal services. Manufacturers that switch to lightweight, recyclable materials often see a decrease in their transportation costs. “Converting all of our composite cans to plastic cans will reduce our packaging material weight by 2 million pounds annually, reducing fuel consumption on both sides of the supply chain,” says Jasper Sanfilippo Jr., president and COO of John B. Sanfilippo & Son.

Effective sustainable initiatives can also lead to a reduction in the amount of electricity and natural gas companies use, as well as how much greenhouse gas they emit. John B. Sanfilippo & Son recently received one of the Environmental Protection Agency’s 2011 Energy Star Partner of the Year Award for excellence in energy management. Over the past three years, the company developed resource conservation teams at all five of its facilities. It also conducts annual energy assessments at each plant to help establish a baseline and to set short- and long-term goals to reduce its use of water, nitrogen, electricity and gas. “Statistically, I would guess that Americans are conditioned to throw away snack food packages,” Rodgers says. “It’s kind of like the chicken and the egg—until someone puts a bag out there that is compostable, no one’s composting any bags. You have to start someplace.” SF&WB

Producing Rolls for over 45 Years Our team of experts help select the right equipment for your production, but we don’t stop there. We will work with you to improve product quality and maximize your profitability. Our 24-hour customer service hotline and fully stocked US parts warehouses add to the positive Koenig experience.

Growing Your Business through Superior Automation EQUIPMENT • INSTALLATION • PARTS • SERVICE Exclusive East Coast Distributor

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Rich Breeswine, National Sales Manager Koenig Bakery Systems 6207 Settler Road, Richmond, VA 23231 1-804-564-3997 [email protected] www.koenigusa.com

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

New Products 2 3

4

4 1

3

Company: Just Desserts, San Francisco Website: www.justdesserts.com Introduced: April Distribution: National Suggested Retail: $4.99-$5.99 for twoCompany: General Mills, Minneapolis. pack, 5.6-oz lava cake; $6.99-$7.99 for Website: www.fiberone.com two-pack 6.6-oz. cheesecake Introduced: June Product Snapshot: Singular Sensations Distribution: National are premium, individual dessert servings Suggested Retail: $3.59 for a six-pack, of freeze-and-thaw cheesecakes and 5.34-oz. box heat-and-serve lava cakes that are Product Snapshot: Fiber One 90-calorie baked with 100% natural ingredients. The brownies are a moist, chewy alternative cheesecakes are made with artisan to indulgence, delivering 5 g. of fiber. The graham cracker crust packed by hand Chocolate Fudge option is made with and come in NY Style and Key Lime chocolate-flavored chips and topped varieties. The lava cakes are injected by with dark chocolatey drizzle, while the hand providing a homemade texture and Chocolate Peanut Butter variety contains are available in chocolate, lemon and peanut butter-flavored chips and is carrot offerings. topped with a peanut buttery drizzle. Ingredients (NY Style Cheesecake): Ingredients (Chocolate Fudge): Wheat Cream cheese (pasteurized cultured milk flour bleached, chicory root extract, and cream, cheese culture, salt, carob sugar, chocolate-flavored chips (sugar, gum, guar gum and/or xanthan gum), palm kernel oil, cocoa processed with sugar, sour cream (cultured pasteurized alkali, soy lecithin, milk, salt, natural cream, milk, non-fat milk, enzyme), whole flavor), vegetable oil (canola, palm, palm eggs, graham cracker crumbs (enriched kernel), fructose, cocoa processed wheat flour [niacin, reduced iron, thiawith alkali, sugarcane fiber, vegetable mine mononitrate, riboflavin, folic acid], glycerin, water, egg whites, cocoa, leav- graham flour, sugar, palm oil, brown ening (baking soda, sodium aluminum sugar, honey, salt, baking soda, natural phosphate), natural flavor, corn starch, flavor), unsalted butter, unbleached flour salt, soy lecithin, milk, xanthan gum, (wheat flour, malted barley flour, niacin, locust bean gum. Contains: wheat, egg, iron, thiamin mononitrate, riboflavin, folic soy, milk. acid), cinnamon.

2

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Bean & Rice Chips

Company: Beanfields LLC, Los Angeles Website: www.beanfieldssnacks. com Introduced: March Distribution: National Suggested Retail: $2.99 to $3.99 for a 6-oz. bag Product Snapshot: Beanfields Bean & Rice chips are made from a combination of black beans, navy beans and rice, are corn and gluten-free and provide 4 g. of protein for each 1-oz. serving. They come in Naturally Unsalted, Sea Salt, Sea Salt & Pepper and Pico de Gallo varieties. Ingredients (Naturally Unsalted): Navy beans, black beans, long grain rice, cold-pressed high-oleic safflower or sunflower oil.

Singular Sensations Lava Cakes/Cheesecakes

Fiber One 90-calorie Brownies

MaMa Rosa’s Pizza Grillers

Company: MaMa Rosa’s, LLC, Sidney, Ohio Website: www.mama-rosas.com Introduced: May Distribution: National Suggested Retail: $4.99 to $5.99 for a 13-oz. box Product Snapshot: Consumers can get a jump on the grilling season with MaMa Rosa’s Pizza Grillers. Made to cook right on the grill in less than eight minutes, they are made with a special crust and 100% real cheese. They come in Pepperoni, Italian Sausage, Fourcheese Blend and Roasted Chicken with Barbeque Sauce varieties, and are sold either fresh or frozen. Ingredients (Pepperoni): Crust: Enriched wheat flour (wheat flour, malted barley flour, niacin, reduced iron, thiamin nononitrate, riboflavin, folic acid), water, yeast, sugar, soy oil, non-diastic malt. Contains 2% or less of the following: salt, diastetic malt, wheat gluten, oat fiber, deactivated yeast, guar gum, xanthan gum, diacetyl tartaric esters of mono and diglycerides of fatty acids, ascorbic acid, corn starch, soy protein, isolated soy flour, non-fat dry milk powder, calcium sulfate, dextrose, whole wheat flour, fumaric acid, monoglycerides, enzymes, bottom dusted with bread crumbs (wheat flour, sugar, yeast, salt) to enhance texture. Sauce: Water, tomato paste, sauce seasoning (sugar, salt, onion, spice, garlic, soybean oil, xanthan gum, guar gum, potassium sorbate, tricalcium phosphate, citric acid), modified food starch. Mozzarella Cheese: Pasteurized part-skim milk, cheese cultures, salt, enzymes, cellulose gum (anti-caking). Pepperoni: Pork (mechanically-separated pork), beef, salt, dextrose, spice, pepperoni seasoning (natural flavors including, oleoresin paprika, polysorbate 80, propylene glycol, natural smoke flavor, soybean oil, ascorbic acid [citric acid, BHA, BHT {to protect flavor}], water, cure (salt, sodium nitrate, propylene glycol [to prevent caking], Red #3), lactic acid starter culture. Contains: wheat, soy, milk.

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

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Rivland rice flours... None better under the sun! A solid reputation for superior quality, consistent supply, friendly customer service, experienced technical support and a comprehensive product safety program has earned us the first name in rice flour. At Rivland, our neighbors grow the rice and our friends transport it from the fields to our mill. We all take personal pride in ensuring the quality and safety of our rice flour from the field to you. That’s why we know there’s none better under the sun! For information, please call or visit us on the Web.

Rivland Partnership A joint venture of Riceland Foods, Inc. & Riviana Foods Inc.

P. O. Box 2636 Houston, Texas 77252 (713) 529-3251 Fax (713) 529-1661 www.rivland.com. ©2003 Riviana Foods Inc.

IFT Pre-show Coverage

Meeting

of the Minds

I

t’s almost time for a meeting of the minds. It’s almost IFT (Institute of Food Technologists) time. The IFT Annual Meeting & Food Expo is a place where top food science and technology professionals representing the most prominent organizations in the food sector, come together to learn about the most recent product, ingredient and technology developments and their potential impact on your business, as well as identify trends that will shape the industry, enhance your skills, augment your knowledge base and expand your professional network. The expo, which is hosted by the Institute of Food Technologists, Chicago, takes place June 11-14 at the New Orleans Morial Convention Center in New Orleans. The IFT Expo is home to specialty pavilions designed to offer educational forums and presentations that focus on

trends, tastings and the global marketplace. For instance, the Asia Pac Pavilion will provide a comprehensive collection of new products, ingredients and vendors from the Asia Pacific region in one convenient location, whereas the Food Safety & Quality Pavilion will spotlight instrumentation, services, processing and packaging technologies, and features the latest insight on the global food industry issue. The Healthy Food Ingredients Pavilion will showcase ways to meet the demands of health-conscious consumers and brings together the latest and greatest in nutraceutical, functional and organic products. Similarly, the Organic Food Ingredients Pavilion will highlight certified-organic products. The Sustainability Pavilion will offer a collection of contractors providing services to assist food industry organizations in meeting the growing demand for sustain-

Photo courtesy of Institute of Food Technologists

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ability in their operations. The forum will showcase the latest trends and best practices surrounding sustainability. The Global New Products Pavilion, which is presented by Chicago-based Mintel, will spotlight new products and the latest trends in consumer packaged food and drink flavors, ingredients and claims. Stick around for Mintel’s tasting session. Innova Market Insights, The Netherlands, will host a Taste the Trend Pavilion, where attendees can discover trends driving the food and beverage market, both today and in the future. This forum will include a series of presentation sessions and more than 200 international products, complete with opportunities for new beverage concepts/tastings, and feature a number of presentations focusing on key product development trends, with insights on packaging and technology, flavors and consumer trends. In the keynote session, “Delivering Science: Changing the Image of Food Science in the Marketplace,” author and writer Michael Specter and a panel of food industry experts will discuss the dangers of not following food safety protocol, its effect on the food industry and how the industry can turn the tide to ensure a safe and abundant food supply. Those in attendance can also take part in the technical field trips, which will transport visitors out of the classroom to showcase what real companies are currently doing within the food industry. Visit local area businesses such as Zapp’s Potato Chips, Gramercy, La., to gain an insider’s view into the ways in which food science and technology are being applied today. While walking the show floor, attendees can also keep an eye out for what’s new by locating yellow “What’s New” stickers at select booths exhibiting new equipment, solutions and products. For more information on IFT 2011, to register or to exhibit, go to www.am-fe.ift.org. Continued on page 44

www.snackandbakery.com

IFT Booth Profiles

[Editors’ Note: booth numbers, if made available, are current as of April 21, 2011.]

Continued from page 42

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U.S. Highbush Blueberry Council Booth #7850

SK Food International Booth # 4335

Bars are big, and they’re smaller than ever. Streamlined bars—call them thins, squares or mini-bars—that are chockfull of blueberries satisfy demands for health, taste and portion control. Blueberries keep bars moist, add mouth-watering flavor and make it real. Blueberries brighten glutenfree prdoucts, harmonize with ancient grains and work well in savory and sweet applications. Be inspired by new blueberry bar concepts—blueberry boomer bars, blueberry beauty bars, blueberry mini-bars and jelly roll blues blueberry bars. Blueberries have the natural pizzazz and formats to fit them all. In New Orleans, blueberries also star on restaurant menus all over town. Stop by the U.S. Highbush Blueberry Council booth to sample a blueberry mini-bar (or two) and pick up a free blueberry restaurant guide. San Mateo, Calif. 800-824-6395 www.blueberry.org

SK Food International supplies a full line of premium quality ingredients, including identity preserved, certified organic and conventional nonGMO dry edible beans, grains, seeds, soybeans, brans/ germs/fibers, flours/meals, vegetable oils, vinegars, sweeteners, rice products, split/dehulled soybeans and pre-cooked powders/flakes. SK Food services its customers’ needs with two main categories of identity preserved ingredients— specialized commodities and processed ingredients. Its organic products are certified by world recognized and USDA-accredited certification agency, Quality Assurance International, Inc., San Diego, Calif. SK Food is also non-GMO project verified. Through a concerted effort and determined purpose, SK Food continues to provide customers with the best value—quality, service and price—for their ingredient needs with better service, higher quality products and faster response time. Fargo, N.D. 701-356-4106 www.skfood.com

Gold Coast Ingredients Booth # 4629

AIB International Booth # 4105

Gold Coast Ingredients is a full-service flavor and color manufacturer specializing in custom formulations, including full lines of QAIcertified organic, halal and kosher flavors. Its extensive research and development laboratory helps customers stay in front of marketplace trends, assisting with flavor development for your prototype or line extensions. At the 2011 IFT Expo, Gold Coast Ingredients will be highlighting fundamental Cajun flavors such as jambalaya and shrimp étouffée, as well as showcasing sweet treats that remind you what being in New Orleans is all about. For simple or complex projects, Gold Coast Ingredients can help you bring a little of the “Big Easy” back to your lab and customers. Gold Coast Ingredients—where science, nature and knowledge are brought together for your success. Commerce, Calif. 800-352-8673 www.goldcoastinc.com

AIB International provides food safety services worldwide to the food and beverage production industry and its suppliers. Audit services include AIB’s GMP inspection, accredited certification body for BRC, SQF 2000, FSSC 22000, HACCP accreditation, OSHA, AIB gold standard and quality system audits. AIB is also a leader in food safety education. It recently introduced a four-week program for sanitarians. AIB’s school of baking also offers seminars, distance learning and consulting in baking science and technology, including its 16-week residential program. Research and technical services include contracted bakery research and consulting, product evaluations, ingredient testing, audits and food labeling services. Manhattan, Kan. 800-633-5137 www.aibonline.org

Snack Food & Wholesale Bakery - May 2011

ADVERTORIAL

www.snackandbakery.com

[Editors’ Note: booth numbers, if made available, are current as of April 21, 2011.]

Buhler Inc. Booth # 6455

IFT Booth Profiles

Tate & Lyle Booth # 6229

Buhler is a global leader in the field of process engineering, in particular production technologies and services for food production and engineering materials. With its extensive extrusion know-how and passion for customized solutions, Buhler strives to generate added value and success. The addition of Aeroglide also enables the Buhler group to offer one of the most complete lines of process technology available. From raw material handling, cooking and shaping to extrusion and drying of finished products, such as breakfast cereals and snack foods to modified flours, starches and texturized proteins, a full line of equipment combined with in-house process engineering and unrivaled after-sale support equals customized solutions without limits. Plymouth, Minn. 763-847-9900 www.buhlergroup.com

Tate & Lyle is a global provider of distinctive, highquality ingredients and solutions to the food and beverage industry. Through its large-scale, efficient manufacturing plants, Tate & Lyle uses innovative technology to turn raw materials into distinctive, highquality ingredients. These ingredients add taste, texture, nutrition and increased functionality to products that millions of people around the world use or consume every day. Decatur, Ill. 800-526-5728 www.tateandlyle.com

Cargill, Inc. Booth # 6039 Riviana Foods Inc. Booth # 6821 Riviana Foods offers a wide variety of rice products, including 3-, 5-, 7- and 10-minute instant rice, instant brown rice, quick cooking wild rice, parboiled rice and an extensive line of rice flour. Houston, Texas 713-529-3251 www.rivianaindustrial.com

www.snackandbakery.com

Cargill is up to the challenge. Cargill has the ingredients and capabilities to help you address your most pressing challenges, including formulating products for health and wellness, cost management and sustainability. Stop by Cargill’s booth to taste prototypes and take the TasteWise challenge to see if you can tell which zero-calorie lemon-lime soda is taste optimized with TasteWise-reduced calorie solutions and to learn more about Cargill’s new patent-pending technology, application capabilities and ingredients that enable better-tasting, reduced-calorie products. Wayzata, Minn. 800-227-4455 www.cargill.com

ADVERTORIAL

Continued on page 46 May 2011 - Snack Food & Wholesale Bakery

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IFT Booth Profiles

[Editors’ Note: booth numbers, if made available, are current as of April 21, 2011.]

Continued from page 45

Almond Board of California Booth # 5229 Van Drunen Farms Booth # 4556

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Van Drunen Farms manufactures an extensive line of all-natural, conventional and organic whole-food fruit, vegetable and herb ingredients. Momence, Ill. 815-472-3100 www.vandrunenfarms.com

Almond Board of California (ABC) is proud to report that almonds were the leading nut used in new food products worldwide for the third year in a row, according to the 2010 Mintel Global New Products Database. The appeal and versatility of almonds are evident in the wide variety of almond forms available for industrial use—whole, sliced, slivered, almond milk, flour, paste and more. Stop by ABC’s booth for the latest research on almond nutrition, consumer demand and food quality and safety practices. Modesto, Calif. 209-549-8262 www.almondboard.com

Arizona Instrument LLC Booth # 7352

Gum Technology Corp. Booth # 3947

Rapid loss on drying instrumentation operates using the same principle as traditional oven methods, but with the ability to address drawbacks associated with them while promoting ease of use. A prescribed amount of material is placed onto a pan, which is sitting on a balance. Once the correct amount of material is reached, the instrument heats up to a specified temperature and the water is evolved off the sample. Multiple criteria can be used to end the test, but frequently, tests are ended when the change in mass is determined to be negligible. These tests provide real-time measurements and often take a few minutes versus hours. Chandler, Ariz. 800-528-7411 www.azic.com

Gum Technology launches GumPlete stabilizing systems, developed to reduce overall hydrocolloid usage levels, help maintain system integrity and create a cleaner flavor release with great mouthfeel. The new GumPlete systems are carefully formulated blends of gums and starches that work synergistically to create specific functionalities and textures, while providing cost-effective problem-solving solutions. Think of Gum Technology’s hydrocolloid lab as your hydrocolloid lab. Using its technology, Gum Technology helps create synergistic systems, allowing for more highly functional and cost-effective stabilizers. Tucson, Ariz. 877-486-8324 www.gumtech.com

Snack Food & Wholesale Bakery - May 2011

ADVERTORIAL

www.snackandbakery.com

[Editors’ Note: booth numbers, if made available, are current as of April 21, 2011.]

IFT Booth Profiles

J.R. Short Booth # 7052 California Walnut Board Booth # 7548 The California Walnut Board and California Walnut Commission represent more than 70 handlers and more than 4,600 growers in the state. In fact, California walnuts account for 99% of the U.S. supply. Hearthealthy walnuts are an extremely versatile ingredient, and the only nut with a significant amount of the plantbased omega-3 ALA (2.5 g. per ounce). One ounce also contains 4 g. of protein, 2 g. of fiber and many antioxidants. They also add value to any item, from bakery to salad toppings to sauces. Folsom, Calif. 916-932-7070 www.walnuts.org

United Soybean Board Booth # 6221 Taste the future of soybean oil at the United Soybean Board’s (USB) Soy Connection booth. Learn about new soybean oils that deliver improved functionality and health benefits, such as 0 g. trans fat, reduced saturated fat and increased omega-3s. Talk with an expert and find the right oil solution for your products. Experience daily taste testing and QUALISOYsponsored Happy Hour featuring snacks prepared with enhanced soybean oil. Also, attend the USB-sponsored Spotlight Session “Delicious Snack Food Opportunities: Leveraging the Dietary Guidelines,” June 12, 2-3 p.m. at the Special Events Pavilion, Booth # 8153. See a live cooking demonstration, taste food samples and hear from food company consultant and dietitian Marilyn Schorin. St. Louis, Mo. 888-235-4332 www.soyconnection.com

www.snackandbakery.com

J.R. Short is the largest domestic and leading global supplier of extruded snack pellets and half-products. These pellets can be expanded by deep frying, air popping or pressure puffing into finished products. Its pellets have a place in several food categories, including snacks, cereals and sweet goods. J.R. Short is committed to delivering great taste with the healthy options consumers look for, such as whole and multigrain, non-gluten and reduced sodium. J.R. Short supports this commitment with product development and application expertise to help its customers succeed. Kankakee, Ill. 800-544-8734 www.shortmill.com

Spraying Systems Co. Booth # 4453 AccuCoat systems use closed-loop temperature control to ensure accurate application of viscous coatings up to 25,000 centipoise. The heated spray system offers many advantages over enrobing, including reduced coating use and less maintenance and downtime, and is ideal for chocolate and other temperature-sensitive coatings. In addition, Spraying Systems’ new coating headers are ideal for use with even the most difficult-to-apply coatings such as marshmallow cream, egg wash, cheese and more. The headers feature sanitary construction, are equipped with hydraulic or air atomizing nozzles and can be heated and jacketed, if necessary. Stop by Spraying Systems’ booth to see the AccuCoat Pan Spraying System in operation. Wheaton, Ill. 800-957-7729 www.spray.com

ADVERTORIAL

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Continued from page 48

IFT Booth Profiles

[Editors’ Note: booth numbers, if made available, are current as of April 21, 2011.]

Continued from page 47

Clabber Girl Corp. Booth # 4148 Clabber Girl, America’s leading producer of chemical leavening systems for home, foodservice and the commercial baker, is a long time leader in the food industry. With more than 160 years of experience, Clabber Girl continues to innovate and find solutions for their customers, and was named a Safe Quality Food (SQF) 2000 Level 3 Certified Supplier by the SQF Institute. Today, with their tested expertise in custom leavening systems, Clabber Girl food scientists introduced InnovaPhase, a line of proprietary products designed to meet the needs of today’s baking professionals. The line includes InnovaBake reduced-sodium baking powder and InnovaFree baking powder with CAL-RISE, delivering a solution for sodium reduction to meet the most recent trend in customer demands. Clabber Girl is committed to providing quality ingredients backed by a rich heritage and continuous culinary innovation. Terre Haute, Ind. 812-232-9446 www.clabbergirl.com

Cablevey Conveyors Booth # 8454 Cablevey Conveyors develops and builds state-of-theart systems used to gently convey friable food and specialty ingredient materials. Based on its patented, gentle, cable and disc technology, Cablevey’s conveyors gently move products such as almonds, roasted coffee and cereal through an enclosed tube without the use of air. Doing so virtually eliminates the product separation and degradation that occur with traditional conveying systems. Headquartered in Oskaloosa, Iowa, Cablevey’s products are used in processing facilities throughout the United States and 60 countries around the world. The family-owned company was founded in 1971. Cablevey–the gentle way to convey. Oskaloosa, Iowa 641-673-8451 www.cablevey.com

Remco Products Minsa Corp. Minsa Corp. is a pioneer and one of the leaders in corn flour production. For more than 60 years, Minsa has prevailed as an authentic supplier for the tortilla and snack industries. Recently, it introduced Soulmaize, an innovative and healthy alternative for the bakery industry. And it develops a full line of premixes especially designed for pancakes, muffins, pizza crust and more, as well as a full line of products made with natural white, yellow, red and purple corn. All of Minsa’s products are gluten-free, whole-grain and organic-certified. Minsa Corp. Muleshoe, Texas 806-789-4053 www.minsa.com

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Remco Products now offers Models 7011/7013 paddle scrapers in five colors to aid in compliance with HACCP requirements. Both models are made from FDAcompliant materials and can be used with any of the company’s color-coded, European-thread handles. The 7011 blade, for example, is made of stiff nylon and is strong enough to tackle the toughest scraping challenge, whereas the 7013 polyethylene scraper blade is flexible and makes it easier to clean curved surfaces. Remco Products Zionsville, Ind. 317-876-9856 www.remcoproducts.com

ADVERTORIAL

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The Nutritional Corner

Nourishing Those in Need— The Bread Art Project Enters its Third Year early 17 million children in America—almost one in four— struggle with hunger. To help provide hungry children in the United States with access to the nutritious meals they need to lead healthy lives, the Grain Foods Foundation, Ridgway, Colo., teamed up with television actress Teri Hatcher and Share Our Strength, a Washington, D.C.-based national nonprofit focused on alleviating childhood hunger, to launch the 2011 Bread Art Project. The campaign engages consumers in an effort to help nourish children in need while simultaneously providing nutrition information. Created in 2009, the Bread Art Project serves as a digital fundraising mechanism for Share Our Strength’s No Kid Hungry campaign, a national effort to end childhood hunger in America by 2015. Consumers are encouraged to join the effort to help fight childhood hunger by visiting breadartproject.com to create a personalized piece of bread art—at no cost—by uploading a favorite drawing or photo or designing a new one using a digital slice of bread as the canvas. For each piece of approved bread art created from April 1-June 30, the Grain Foods Founda-

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tion will donate $1 to Share Our Strength. In fact, one dollar can help provide three nutritious meals to a hungry child; $25 can help feed one child three healthy meals every day for a month and $100 can help provide backpacks full of healthy food to 25 children and their families over a weekend. Last year, consumers helped the Grain Foods Foundation raise more than $50,000 to provide food and groceries to children in need, and we hope to repeat this success in 2011.

In fact, one dollar can help provide three nutritious meals to a hungry child. www.snackandbakery.com

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

Share Our Strength is a partner of the Grain Foods Foundation, as its outreach includes educating families on preparing healthy foods on limited budgets. As we all know, staples such as bread and grains are affordable and versatile items that families can use to stretch their grocery dollars at home. Most importantly, they provide many essential nutrients our bodies need to stay healthy. To understand the impact of childhood hunger, consider this— children who struggle with hunger are sick more often, recover more slowly and are more likely to be hospitalized. They are also more likely to experience headaches, stomachaches, colds, ear infections and fatigue. Lastly, children who face hunger are more susceptible to obesity and its harmful health consequences as children and as adults. The Bread Art Project will be supported through a variety of channels, including digital and social media as well as an aggressive publicity outreach such as media events in Los Angeles and New York City. Also new this year is the Face Hunger Facebook application, which allows Facebook users to apply the one-in-fourchild-hungry statistic with their friends. To find out what it would look like if one in four of your friends went hungry, visit facebook.com/gowiththegrain. Please be sure to nourish those in need by visiting breadartproject.com and creating your own piece of bread art now. Making just one piece will help feed a little one three nutritious meals they wouldn’t otherwise have, and we’ll all be one step closer to ending childhood hunger in America. SF&WB

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Special Report Gluten-free Formulating

Getting Gluten-free Right Good taste and a crumbly, familiar texture figure prominently in the qualities consumers want in gluten-free breads and other gluten-free products. After years of withstanding ‘strange-tasting’ products having little resemblance to ‘the real thing,’ consumers are now getting the kinds of gluten-free foods they’re after, in a much more competitive market segment for bakers and snack food processors. Photos courtesy of Bloomfield Farms

Lauren R. Hartman, Editor-in-Chief

n estimated three million people in the United States have a digestive disorder known as celiac disease and cannot tolerate grain protein known as gluten. These folks are unable to eat traditional breads, pizza crusts, cakes, cookies and many snacks without pain and bloating. In fact, celiac disease can also be fatal if left untreated. When individuals with celiac disease eat such foods and others that contain gluten, their immune systems respond by damaging or destroying villi, the tiny, fingerlike protrusions lining the small intestines. Celiac disease is both a disease of malabsorption, which means nutrients normally absorbed by the body are not absorbed properly, and an abnormal immune reaction to gluten. According to a fact sheet called, “Celiac Disease,” published by the National Institutes of Health, Bethesda, Md., this averages to approximately one in 133 people in the United States who have celiac disease, as well as others who suffer from gluten intolerances. But things are changing for gluten-intolerant consumers. More and more gluten-free products are being formulated with better tastes and textures than ever before. With consumer interest in gluten-free foods mounting because of the incidence of diagnosis and awareness of celiac disease and gluten intolerances, the roster

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of gluten-free foods and drink products has grown exponentially in the past five years. Brand leaders are cropping up in this glutenfree market, which was once a niche in health food stores. Packaged Facts states that the gluten-free market, which was valued in 2004 at $580 million, leaped to an average annual rate of 29% and by 2008 was worth a whopping $1.56 billion. This trend will no doubt continue this year. In fact, the market is one of the fastest growing food trends. With the only existing treatment for celiac today being a 100% gluten-free diet, there’s tremendous opportunity for the glutenfree food industry. By the end of 2010, the market was predicted to reach $2.8 billion.

Dedicated plant One such improvement in the gluten-free arena is associated with Bloomfield Farms. It’s one of few companies in the United States to have opened a new plant that spe-

cializes solely in manufacturing gluten-free baking mixes. The new 15,000-sq.-ft. facility located in Bardstown, Ky., was designed so that celiac disease sufferers and their families have more baking options. The company says it will soon introduce new Continued on page 52

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products to its gluten-free line, including a retail seasoned flour for use on poultry, meat, fish and vegetables. It’s also rolling out with a gluten-free corn dog batter as well as a gluten-free funnel cake. “The gluten-free plant in Kentucky is one of few in the country,” says Sue

Sutherland, Bloomfield Farms’ president. “We make sure our products are not contaminated with gluten-containing wheat, barley, rye or oats. Instead, we use rice flour, corn meal, potato starch and other gluten-free ingredients as grain bases.” “Consumers are well informed when

they purchase gluten-free products,” observes Michael Elder, plant manager at Bloomfield Farms. “They understand ingredients, allergens and procedures taken to provide products that are deemed glutenfree. Many consumers ask what ingredients we use in our gluten-free blends and they are very interested in how we make sure our products are not contaminated with gluten. Consumers want a product that doesn’t provide a gritty texture and that does not leave an aftertaste.” Bloomfield Farms also operates a traditional wheat-based dry-food blending and packaging business, Sutherland explains. She and her husband, who own and operate nearby Blend Pak, a dry mix company about 10 miles from the plant that serves restaurants, foodservice distributors and meat processors, began hearing about the lack of options and high prices for glutenfree products and saw an opportunity to better serve that market. “With our experience in the food industry, we already knew how to make a product that looks appetizing and tastes wonderful,” she says. Located about 40 miles southeast of Louisville and 50 miles southwest of Lexington, Bloomfield Farms sells nine mixes for all-purpose baking, brownies, cakes, cornbread, cookies, loaf bread, muffins, pizza dough, pancakes and waffles. Bloomfield Farms also offers consumersized cartons of products such as Muffin Mix, Cornbread & Muffin Mix and Pancake & Waffle Mix. It sells products online through its website that range in quantity from 15-32 oz. and are priced from $3-4. Package sizes range from less than 1-to 2,000-lb. totes. The company also takes orders for batters, breading and coatings from commercial customers, including grocery stores, restaurants and manufacturers for the seafood, beef and poultry industries. “The main challenge we face in producing these products is ensuring that all raw materials that we use from suppliers are not contaminated by the presence of wheat or gluten,” says Elder. “Our raw ingredients are tested for gluten when they arrive at our facility. The second step is testing all Continued on page 54

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of our products once they are blended and packaged for traces of gluten. We use Elisa test strips that can detect gluten at <10ppm (parts per million). The last step we take is informing our distribution channels of the dangers of storing gluten-free products and gluten-containing products in the same area of their warehouses. Keeping these products separate ensures that no glutencontaining product will contaminate the packaging of gluten-free products if there

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Photo courtesy of Bloomfield Farms

was an accident or products being damaged that spill on the gluten-free products.” Mary Schluckebier, executive director of the Celiac Sprue Association (CSA), an Omaha, Neb.based non-profit organization dedicated to helping individuals with celiac disease, says, “We’re pleased that Bloomfield Farms offers so many gluten-free products to people who need them. The plant has met all the requirements for our recognition seal program, so buyers can be confident in their purchases.” The CSA seal signifies a company bearing it has passed a rigorous CSA review of ingredients and their sources of the manufacturing facility to assure allergen control,

sanitation plans, best practices, inspection of packaging materials and testing by the University of Nebraska Food Allergy and Resource program laboratory to verify the absence of allergens.

Bit of honey does the trick The National Honey Board (NHB), Firestone, Colo., recently conducted a question/ answer interview with Rudi’s Gluten Free Bakery, Boulder, Colo., in which Rudi’s discusses the challenges of gluten-free formulations and the benefits of honey. Rudi’s indicated that one of the biggest challenges it had when developing its new line of gluten-free breads was producing great tasting products. Rudi’s also had to overcome the challenges with taste. Doug Radi, vice president of marketing at Rudi’s, says the company sampled nearly every gluten-free bread on the market before it set out to create its own Continued on page 56

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version. The bakery quickly discovered that it was nearly impossible to find glutenfree bread that tasted good straight from the package. “Similarly, it was challenging to find gluten-free bread with a texture that kept the bread from crumbling when used to make a sandwich, and that provided

nutritional content close to that of regular bread,” says Radi. Rudi’s, which also makes organic breads that contain gluten, worked for almost two years with gluten-free experts to create gluten-free breads using only natural ingredients that taste terrific right from the

package and that have a texture similar to regular bread. After plenty of trial and error—the company tested more than 100 formulas—Rudi’s finally landed on a recipe that it believed to taste, look and feel like “regular” bread. “Sticking to our heritage, all of our gluten-free breads are made with only the highest quality, all-natural ingredients,” Radi says. The line of gluten-free breads comes in three varieties—Original, Multigrain and Cinnamon Raisin. One ingredient Rudi’s says it found helpful was honey. “The use of honey in Rudi’s gluten-free breads serves two key purposes,” Radi adds. “First, honey is a great way to add sweetness to a product while staying true to an all-natural heritage. Secondly, honey helps with product moisture, giving our bread that soft, moist delicious texture that makes it more like real bread.” NHB agrees that one of the most significant trends in the baking industry is the growth of gluten-free bakery foods. “But producing a gluten-free bread that tastes good is a challenge, especially if you’re not using artificial ingredients, flavors or preservatives. Many commercial bakeries are overcoming this challenge by using honey,” says Radi. For Rudi’s, honey helps provide a way to add sweetness to products while staying true to an all-natural heritage, and it helps with product moisture, giving bread a softer, moist, delicious texture that makes it more like “real” bread. “As a pioneer in the baking industry with a long tradition of innovation, we’re excited to create delicious gluten-free bread and baked goods that allow those who suffer from celiac disease and gluten intolerContinued on page 59

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Gluten-free Formulating Continued from page 56

Photo courtesy of the California Raisin Marketing Board

ances a healthy, brighter outlook by letting them truly enjoy bread again,” Radi sums up. “We want to help our customers feel like they don’t have to give anything up to go gluten-free.”

Recipes from California The California Raisin Marketing Board (CRMB), Fresno, Calif., which offers several recipes and other consumer materials for the gluten-free market, says that raisin paste and raisin juices can help improve the taste of gluten-free products. Raisin juice in formulations can help put inulin (fiber) into products. Like some pectins and fructooligosaccharides, inulin is said to be a preferred food for the lactobacilli in the intestine and can improve the balance of friendly bacteria in the bowel. “Consumers are asking for good taste and mouthfeel, which are still key to the success of a gluten-free product,” says Rick O’Fallon, director of marketing for the CRMB. “The California Raisin Marketing Board is a key player in the gluten-free market, but not with product introductions,” he explains. “Our role is one of education to healthcare professionals, bakers, formulators and consumers. Bakers can better provide gluten-free products by using the research and input from suppliers for guidance. The natural sweetness of California raisins (being 70% fructose and glucose) is the primary reason that glutenfree products with raisins have a very palatable taste.” O’Fallon says that in celiac patients, levels of harmful gut bacteria such as bacteroides, clostridium, and staphycoloccus [can be] elevated, and the levels of beneficial bacteria such as bifidobacteria are lowered. Inulin fiber, which is found in foods such as California raisins, can help promote the growth of beneficial bacteria as well as inhibit the growth of harmful bacteria. “Celiac is becoming much easier to diagnose and consumers are becoming more aware of the issue,” he says. “Celiacs suffer from inflammation due to oxidative

stress, and they can also become anemic due to low levels of iron. Antioxidant-rich foods help those conditions, so look for heavy antioxidant activity in gluten-free foods. The efforts of such TV personalities and food writers as Carol Kicinski [a professional recipe writer and TV chef], and the efforts of Alice Bast, president of National Foundation of Celiac Awareness are bringing this condition to the forefront. The bread formulations of Craig Ponsford [former chairman of The Guild and owner of Ponsford’s Place] and other bakers will be the answers for celiac consumers.” Finding the right ancient grains that exhibit the same or similar finished product characteristics as wheat flour is probably the most difficult task for gluten-free producers, adds Larry Blagg, senior vice president of marketing at the CRMB. “The good news is that California raisins, raisin paste and raisin juice concentrate call all be used with these ancient grains to produce tasty breads, pastries, scones, biscuits, crackers and cookies.” The CRMB sees the gluten-free market growing even more in the next five to 10 years. “It will continue to grow and most likely represent half of the products on today’s shelf,” O’Fallon notes. “Changes we foresee occurring in the future with Continued on page 60

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products. “Many of them are still in the trial stage, but we have had great success using our Coyote Brand GumPlete SXGGF-205 in gluten-free baked products,” says Janelle Wilt, marketing director for the Tuscon, Ariz., company. “This blend utilizes the unique synergistic effect of

Photo courtesy of Gum Technology

gluten-free foods include more availability, better taste and formulations with new and exciting products. Product expansion will likely go beyond breads to cakes, muffins and even a gluten-free trail mix.” Gum Technology is also working on a wide range of formulas for gluten-free

gums and starches to provide products with great texture. In gluten-free muffins, it provides suspension, helps to stabilize the emulsion and the cell structure during baking. Coyote Brand GumPlete SXG-GF-205 also improves moisture retention.” Wilt says the main challenge Gum Technology faces in the gluten-free arena is creating a cost-effective product that excludes gluten but still looks, tastes and feels good. “Ideally, we want a product that has good texture and flavor but also is affordable. By utilizing a starch gum blend such as Coyote Brand GumPlete SXG-GF-205, the challenge can easily be met. The blend can be used at much lower levels than starch alone or gums alone,” she says.

On the processing side While gluten-free produces are difficult to formulate, they can be just as tricky to process on conventional equipment. Glutenfree batters, in general, can be viscous and very sticky, which precludes dividing them with typical volumetric dividers such as ram and shear dividers. “Piston fillers can handle some of the thinnest gluten-free dough, but most glutenfree dough is too viscous to be accurately deposited by a piston filler,” points out John McIsaac, vice president, strategic business development at Reiser, based in Canton, Mass. “The Vemag divider is able to overcome both of these hurdles and can handle viscous and sticky batters,” he says. “The Vemag’s use of vacuum and gentle pumping meter gluten-free dough precisely and with no damage. Many early gluten-free producers adopted the Vemag years ago.”

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Gluten-free Formulating Reiser developed attachments for the Vemag for precise portioning and placement, as well as systems for single outlet production as well as the capacity to fill multiple pans and strap pans simultaneously. Products containing gluten tend to have more structure and ability to hold their shape, McIsaac says. “Gluten-free products tend to flow more. Therefore, it’s very important to get gluten-free products onto and into the pans they will bake in.” Companies are expanding research and development on gluten-free products to improve overall quality and make products that are acceptable to all consumers, with or without celiac disease. Reiser’s bakery customers say they are trying to eliminate special shopping trips for consumers. “In the beginning, gluten-free products were not developed to taste great, but simply to serve a purpose,” McIsaac continues. “That era has ended. Taste, quality, appearance and texture have taken over. Gluten-free icons and logos are popping up on all types of packages and menus. We think that more innovative products are on the way, and the Vemag has proven itself

to handle the challenges of the future of gluten-free.” From a machinery producer’s viewpoint, McIsaac believes that the gluten-free market seems to be a durable category. “We have sold machines into this market for several years and still have strong continued interest. Our customers who produce the products tell us more of their customers are ‘mainstream,’ and believe there are health benefits to a gluten-free or gluten-reduced lifestyle.”

More gluten-free technology Grain Processing Corporation (GPC), Muscatine, Iowa, found a combination of corn starches, both native and modified, that greatly improve the eating quality of gluten-free baked goods. Specifically, PURE-DENT B700 unmodified corn starch, along with INSCOSITY B656 and INSTANT PURE-COTE B792 instant modified starches, which can improve mouthfeel and extend shelf life. INSTANT PURE-COTE B792 improves textural qualities while INSCOSITY B656 increases batter viscosity, aids in moisture retention and provides freezethaw stability. B700 contributes to bulk and binds moisture. The line of starches offers a clean flavor and leaves little to no powdery mouthfeel, reports Kelly Belknap, associate scientist at GPC. “Today’s consumers are looking for products that taste great and that can be enjoyed by the whole household, not just specifically for those that have celiac disease,” she says. “We introduced a system where different starches are recommended based upon the desired application.” Belknap says that without the structure gluten provides, dough handling can be a delicate process. “Sometimes gluten-free dough becomes very sticky and is difficult to work with. Starches help to improve dough handling by binding moisture.”

The nutrition factor

Photo courtesy of Reiser

With the rapid growth of gluten-free items appearing on menus in chain restaurants and being added to grocery store shelves, the market may continue to grow, Belknap Continued on page 62

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adds, “especially when you consider the number of people who don’t have celiac, but are interested in gluten-free foods because of a different reason. I feel the quality of gluten-free foods will only continue to get better. The gluten-free market is most likely driven by more than just patients with celiac disease, though less than 1% of the population has been diagnosed,” she says. “An entire household may switch to purchasing all gluten-free foods to accommodate the one family member that does have celiac disease.” But that can be a problem, as many gluten-free foods are lacking in nutrition. “Most gluten-free formulations don’t include whole grains and are low in fiber, so I see an opportunity for formulators to add fiber as well as whole grains,” Belknap points out. Formulating gluten-free will most likely lead to an increase in ingredient costs, she believes. “But consumers who seek glutenfree will most likely be willing to pay a premium for those items.” Elder agrees with this assessment: “The cost differential between producing glutenfree products and regular foods and ingredients is relevant. The ingredients needed to make a gluten-free mix can be more expensive and the bases of these mixes are more expensive. The difference in pricing is due to wheat flour (which is the base of most gluten-containing products) being a commodity that is cheap and supply is prominent.”

Photo courtesy of Cargill Bakery

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Functional challenges Bill Atwell, research fellow and technical leader for Cargill Bakery, Minneapolis, says that gluten is more functional in some baked products than in others. “Utilizing Cargill’s broad scientific knowledge and application and ingredient expertise, we are able to work with customers to solve formulation challenges with our patentpending technology.” Cargill’s gluten-free baking bases are furthering the company’s already broad platform of gluten-free technology. “Our gluten-free bases are customizable, based on the food manufacturer’s requirements,” he says. “Cargill’s technology, ingredients and application expertise help our customers deliver superior products with the taste and texture the gluten-free consumer is looking for.” Cargill provides gluten-free bases for multiple applications such as cookies, brownies, pancakes, cakes, muffins, breads and pizza crusts. Atwell says that while many gluten-free products don’t meet consumers’ taste or texture expectations, Cargill’s bakery customers are looking to produce gluten-free products that deliver rich taste experiences that are more like traditional bakery products. “Cargill’s patent-pending gluten-free baking bases replace gluten with ingredient systems, which can shorten the development curve and deliver an authentic, satisfying taste, light and airy volume and a soft, moist texture,” Atwell adds. “These customizable bases can be utilized to meet customer needs around taste profiles and customer taste expectations.” In fact, Cargill’s gluten-free products are certified gluten-free, he says. “I recommend that anyone who is looking to get into the gluten-free marketplace work with a gluten-free certification agency like the Gluten Free Certification Organization. In order to produce such products, we recommend compliance with the gluten-free certification standards.” The gluten-free category is one of the fastest growing trends in bakery and it continues to gain momentum with an increased diagnosis of celiac disease and a

focus on allergies, says Kyle Marinkovich, marketing manager at Cargill Bakery. “We anticipate continued growth, and see this [category] as a significant opportunity for our customers and ourselves in the future.” Marinkovich sees many changes taking place in the future with regard to glutenfree foods. “Product quality will get better, there will be new flavors, more products/ proliferations of successful products, increased health and wellness benefits, including fiber, vitamins, minerals, antioxidants and the products will be more readily available in places like in-store bakeries and foodservice.”

The secret in sorghum Adding starch to sorghum dough can improve certain negative characteristics of gluten-free sorghum bread, says Virgil Smail, executive director of United Sorghum Checkoff, Lubbock, Texas. “Sorghum is a well known food grain in many parts of the world,” he says. “In the United States, sorghum is not well known as a food grain.” To expand the understanding of how to use sorghum in baking and other food dishes, the United Sorghum Checkoff; The Nebraska Grain Sorghum Board, Lincoln, Neb.; Texas A&M University, College State, Texas; and the U.S. Department of Agriculture, Washington D.C., have all been developing formulas and recipes for many gluten-free and whole grain products. “Sorghum makes an excellent, neutral-flavored whole grain flour that can be light tan or dark depending on the type of sorghum milled,” Smail says. “There are very few whole grain flours for gluten-free baked products. Also, the darker sorghum flour has high antioxidants and polyphenolics. Some hybrids have levels of antioxidants approaching chocolate. So sorghum offers many of the missing nutrients and benefits of a whole grain diet to a glutenfree diet.” Smail says that no other starches need to be added to a gluten-free sorghum recipe, but they can be used if desired. “Sorghum flour can be milled to varying degrees to mimic performance of other

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Gluten-free Formulating starches,” he says. “Because of the neutral to slightly nutty flavor of sorghum flour, we haven’t been adding grains for taste. Sorghum tastes much like wheat flour when included in gluten-free formulas. It offers a slightly less ‘whole grain’ taste than whole grain wheat, but the flavor is similar.”

Photo courtesy of United Sorghum Checkoff Program

Many consumers of gluten-free diets are beginning to realize they are missing out on the benefits of a whole grain diet, including insoluble fibers, antioxidants and polyphenolic and prebiotic fiber benefits, Smail adds. “Many gluten-free products are based on rice flour, which is not a whole grain. Sorghum solves the problem of offering whole grain gluten-free products with a neutral flavor. Whole grain sorghum goes very well into all batter-based baked products like muffins, cakes, pancakes, etc.” In addition, sorghum isn’t much of a challenge to work with when developing gluten-free recipes. “It really has no technical hurdles,” Smail points out. “For every new application, formulation work is necessary to optimize for flavor, texture, shelf life and processing. The largest hurdle most bakers must overcome is to find a glutenfree bakery that can manufacture for them in a wheat-free environment. Most existing bakeries have too much wheat flour contamination to produce a gluten-free product on existing lines.” In the future, Smail sees a strong focus on healthy products, including whole grain, nutrition bars, breakfast products and baked sweet goods that will be desired

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by celiac sufferers. And the cost won’t be as painful as with other ingredients. “The cost difference between whole grain sorghum flour and whole grain wheat flour is very slight,” he says. “We expect every mainstream bakery to launch gluten-free products under their existing labels. The largest constraint to accomplishing this is the lack of gluten-free bakeries. But a stabilized market will help companies make the investment to build more bakeries for gluten-free applications.” Likewise, ADM Millings’s Harvest Pearl white sorghum flour and white whole grain sorghum flour have a neutral flavor and work well as the primary flour choice in gluten-free products, reports Brook Carson, technical product manager at ADM, Overland Park, Kan. “By using a base ingredient with such a neutral taste formulating the rest of the system is much easier,” Carson says. “We have worked hard to create a flour product that’s economical but also consists of a fine granulation to contribute to an acceptable mouthfeel in the finished product.” Carson says that producing some gluten-free products, such as cakes, cookies and pancakes can be done with the same techniques as those for non-gluten-free, but gluten-free breads prove to be more difficult. “The bread dough has a very different consistency compared to a traditional dough so different processing systems and methods are required,” she says. Bakers and ingredient providers will continue to develop these products and improve the quality. “The gluten-free market will continue to grow, though maybe not as rapidly as it has over the last couple of years,” she relates. “The celiac community will continue to demand high-quality products. As more individuals are diagnosed with celiac disease, more families will attempt to embrace a gluten-free diet. Other individuals, who have not been diagnosed with celiac disease will continue to ‘try out’ a gluten-free diet to cure a wide variety of ailments. Gluten-free foods will continue to improve in quality. As the market becomes more competitive, the products will have to improve to stay on the shelf.” SF&WB

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Ingredient Technology Fruits, Nuts & Chocolate Formulations

Happy Trails Many of today’s fruits, nuts and chocolate formulations deliver a host of healthier attributes, fused with vitamins, nutrients, antioxidants and a taste you can’t resist. Marina Mayer, Executive Editor

hen you combine fruits, nuts and chocolate chunks, you get a trail mix concoction. When you add vitamins, antioxidants and a bevy of spices and flavors, you get a better-for-you product that stands the test of time. Now, bakers and snack manufacturers can walk down happy trails knowing that their selection of fruits, nuts and chocolate pieces contain the best of the best in terms of flavor, function and all-around wholesomeness.

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Fruit of the year This year, bakers and snack producers are taking advantage of the “quasi-mythical power” of blueberries and using them to rev up interest in beauty-from-within foods and health-halo desserts and snacks, says Thomas Payne, industry specialist for U.S. Highbush Blueberry Council, San Mateo, Calif.

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Photo courtesy of U.S. Highbush Blueberry Council

Because blueberries are a natural ingredient and provide nutrients, sweet flavorings and real fruit benefits, they have become more of a value-added inclusion versus just a fruit offering. For starters, frozen natural blueberries make rich smoothies and energy drinks and complement creamy dairy products. They also can be used as fillings for pies,

tarts, bars, confectionery items and more. Blueberries provide formulators with a natural way to add appealing color, Payne says, and the sugar/acid ratio makes them a candidate for blending with other highacidic juices. “Phytochemicals found in fruits such as blueberries continue to be investigated for their health benefits in slowing the aging

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Ingredient Technology Photo courtesy of U.S. Highbush Blueberry Council

in. People already identify blueberries with the healthiest possible eating. Lists of superfruits not only include blueberries, they compare everything on the list with blueberries. People trust blueberries; they trust what they grew up with. They remember their parents and grandparents eating and loving blueberries. They serve blueberries to their children. Blueberries have always been considered good, wholesome and delicious--comfort food with benefits.”

Go Fig-ure The California fig industry introduced the concept of adding figs to chocolate to also answer the need for “more fruits and vegetables.” That’s because California figs are rich in antioxidants and provide 5 g. of dietary fiber or 20% of the Daily Value. “Consuming one serving of dried figs provides 8% of the recommended daily value for potassium, while fresh figs offer 10%,” says Karla Stockli, chief executive Continued on page 66

When you add vitamins, antioxidants and a bevy of spices and flavors, you get a better-for-you product that stands the test of time. process, including memory loss,” Payne says. “Studies of older laboratory animals consuming blueberry-supplemented diets have shown measurable improvements in memory, coordination and balance. Research is also uncovering neuron regeneration in older animals fed blueberries.” Additionally, the new Dietary Guidelines for Americans 2010, which were revised in January 2011, advise consumers to make half your plate fruits and vegetables. “This is an encouragement for food designers to include blueberries in their product lines,” Payne adds. “Food safety is also a big issue, and consumers have been given reason for concern about the origins of their foods, especially with the exotic and unfamiliar. That’s where blueberries come Photo courtesy of California Fig Advisory Board

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Ingredient Technology Continued from page 65

officer for the California Fig Advisory Board, Fresno, Calif. “Thus, one serving of California figs can help close the fiber and potassium gap.” California figs are an excellent source of dietary fiber and contain potassium, calcium, iron, magnesium, phosphorus,

copper, manganese and other important nutritional components. “Ounce-for-ounce, figs provide a nutritional punch that’s hard to match by any other fruit,” Stockli says. And, they are synergistic with light and dark chocolates and integrate well due to their compatible moisture content and pH

balance, Stockli adds. “California figs have always been a value-added inclusion in European-style chocolate confectionery,” she adds. “In the past two years, North American confectionery companies have begun to utilize figs, fig paste and fig ingredients such as diced figs, fig nuggets and fig juice concentrate. Chocolate companies are integrating fig paste into interiors of chocolates, panning whole figs and fig bits.”

Nuts about nuts These days, it seems as though every baker and snack manufacturer is going nuts over nuts. That’s because when they’re combined with chocolate, they are a betterfor-you, yet tasty add-on to just about any snack or baked good.

Photo courtesy of Georgia Nut Co.

“Research shows that the addition of almonds to a chocolate product satisfies consumers’ desire for that perfect ‘guiltless indulgence,’” says Harbinder Maan, manager, North America ingredient and category marketing for Almond Board of California, Modesto, Calif. “And almonds do much more than provide unique crunch and contrast to the rich, creamy sweetness of chocolate.” For starters, almonds offer a natural way to enhance the flavor profile, as well as provide limitless nutritional benefits for gluten-free foods, satiating snacks, breakfast options and more, Maan says. Meanwhile, consumers see the additional health benefits many nuts have to offer, Continued on page 68

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Filled with “good” monounsaturated fat

13 essential nutrients

AND YOU THOUGHT YOU WERE JUST ADDING ALMONDS. A lot goes in with a little almond and you can take that to heart. That’s why millions of people trying to maintain healthy cholesterol levels have made them their nut of choice. And when they see a helping of almonds in your new products, they’re more likely to choose them as well. It’s the perfect ingredient to create a deeper, more lasting relationship. Good news about good fat: U.S. Dietary Guidelines recommend that the majority of your fat intake be unsaturated. One serving of almonds (28g) has 13g of unsaturated fat and only 1g of saturated fat. Scientific evidence suggests, but does not prove, that eating 1.5 ounces per day of most nuts, such as almonds, as part of a diet low in saturated fat and cholesterol may reduce the risk of heart disease.

Ingredient Technology Continued from page 66

says Kurt Thorsen, vice president, sales and marketing of Georgia Nut Co., Skokie, Ill. “Consumers see the health benefits, and the products are viewed as an affordable indulgence, even in today’s economy,” he adds. “The combination of dark chocolate and almonds is especially appealing—sales

of these products have grown significantly because both products are antioxidantrich.” Nuts are versatile, Thorsen says, and can be added to snacks and baked goods to add spice, season or even offer some affordable indulgence.

Photo courtesy of Cargill Cocoa & Chocolate

Chocolate is in charge While fruits and nuts garner extra attention for their healthy attributes, chocolate continues to take charge thanks to a bevy of antioxidants and other nourishing benefits. That’s why Cargill Cocoa & Chocolate launched 62% cocoa solid gourmet chocolate chips under its Peter’s Chocolate line. The bittersweet chips deliver a smooth, rounded flavor and provide an intense chocolate impact, suitable for rich ganache or high-quality baked goods, says Courtney LeDrew, marketing manager for the Lititz, Pa., company.

Photo courtesy of How Do You Take Your Coffee, Inc.

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Ingredient Technology

Photo courtesy of Almond Board of California

“Chocolate is a great ingredient that can promote health benefits for a number of reasons,” LeDrew adds. “Foremost, it simply tastes great. Also, it inherently has a number of healthy aspects, especially dark chocolate. Finally, it does a great job at masking some of the nutritional fortificants that, on their own, can have a very strong flavor that’s difficult to overcome.” Chocolate also offers up a sensory experience. “There is also an increase in chocolate and savory combinations,” LeDrew adds. “This can range from cocoa nib-encrusted scallops seared in cocoa butter to chocolate raspberry vinaigrette on a green salad. Savory chocolate bars and confections are more common; not only can you find a bacon chocolate bar in your local candy shop, you might also see a chocolate porcini mushroom truffle or a basil thyme confection.” For companies such as How Do You Take Your Coffee? Inc., blending chocolate with roasted coffee beans adds an entirely new spectrum to the category. For trail mix blends, the Reno, Nev.-based company offers Java Rocks sugar-coated, lava-colored, rock-shaped chocolate chips that Continued on page 70

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Ingredient Technology Continued from page 69 Photo courtesy of U.S. Highbush Blueberry Council

incorporate finely ground coffee beans with cocoa to create a “volcano blend.” They come in Milk and 72% Dark varieties. Also ideal for trail mix are Roboostas, which consist of a blend of high-energy Robusta coffee berries, cacao fruits and sugar cane and are naturally fortified with organically occurring caffeine. “Items made with high cacao content dark chocolates that were considered unusual specialty foods a few years ago have now found their way to the mainstream,” says Sam Williams, Jr., president. “Today, the energy seems to be around quality ingredients and in pairing unexpected ingredients with chocolate.”

What does the future have in store? When it comes to fruits, nuts and chocolate, the future looks bright, especially since these ingredient solutions have something to offer everyone. Creative combinations of fruits and sa-

When it comes to fruits, nuts and chocolate, the future looks bright, especially since these ingredient solutions have something to offer everyone. vory spices, for instance, will sprout within the chocolate field, Stockli says, adding opportunity for bakers and snack producers to capture a complete balance of nutrition and flavor to a formulation. There will be a stronger focus on health and healthy consumption, LeDrew says, as bakers and snack manufacturers continue to experiment with ingredients such as cranberries, blueberries and almonds, which are known for their healthy properties. Natural is becoming hot, Payne says.

That’s why the U.S. Highbush Blueberry Council created the Real Blueberry Seal “to help food producers feature real blueberries in their products,” he adds. “The Real Blueberry Seal signals instantly—at a glance—that the product contains real Highbush blueberries.” Regardless of how you mix or match your fruits, nuts and chocolate, this fusion creates a host of happy trails for bakers and snack manufacturers in search of the next best thing. SF&WB

Made with premium chocolates and Arabica coffee beans that are selected, roasted, and ground especially to eat, 100% natural Java Chips® are an ideal solution for chefs, bakers, and baristas seeking to create memorable recipes requiring coffee and chocolate. As layering/decoration for cakes and pies, inclusion in bars, muffins, or pancakes, as a mix-in or topping for frozen desserts and specialty drinks, Java Chips® are a versatile, efficient, and visually striking ingredient.

www.takeyourcoffee.com getbeaned@takeyourcoff ee.com ge g ettb b PH: 775.473.3100

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Ingredient Briefs

Loders Croklaan introduces SansTrans VLS 30, an all-purpose shortening designed to offer a 30% reduction in saturated fat without increasing the annual shortening cost. Another option, SansTrans VLS 40, is an emulsified shortening that offers formulators the ability to reduce saturated fat by up to 15% and decrease the annual shortening cost by up to 10% annually. Both SansTrans options are suitable for cookie, cake and muffin applications. Loders Croklaan North America Channahon, Ill. 800-621-4710 www.croklaan.com

O-tentic Napoletana from Puratos is an active sourdough that helps create flatbread, pizza crust and naan while retaining the look and taste that’s true to its history, tradition and origin. It delivers a clean bite after reheating, great extensibility, easy scaling, clean recipe optimization and a mild fermentation flavor without the time and cost of fermentation. It contains allnatural ingredients and provides flexibility. Puratos Corp. Cherry Hill, N.J. 856-428-4300 www.puratos.us

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Sensient Colors offers SensiPearl, a pearlescent pigment product line that differentiates food products through luster effects, color shifts and iridescent shimmers. These FDA-approved mica- and titaniumdioxide-based pigments add innovative visual effects to foods such as confections, frosting, marshmallows, gelatin desserts, and more. SensiPearl comes in a variety of custom colors. Sensient Flavors and Fragrances Group Milwaukee, Wis. 800-558-9892 www.sensient-tech.com

OptiSol 5000 from Glanbia Nutritionals is a natural, clean-label, flaxseed-based ingredient replacer for high-cost gum systems in tortillas, breads, sweet baked goods, batters and a variety of other product applications. OptiSol 5000 provides a bevy of hydrocolloid benefits, including moisture control, shelf-life extension, viscosity generation and cryoprotection. It also delivers enhanced nutritional benefits, as it is naturally high in ALA Omega-3 and fiber. Glanbia Nutritionals Fitchburg, Wis. 800-336-2183 www.glanbianutritionals.com

Real cheese can pose a challenge for product developers vying to use it in dry meal packets, instant dry blends, bread mixes and others. Van Drunen Farms’ freezedried cheese offers quality, marketability, rich texture and high levels of protein and calcium and other nutrients such as vitamin A. It comes in powder or shred format and in multiple varieties, including cheddar, Colby, Monterey jack and mozzarella. Van Drunen Farms Momence, Ill. 815-472-3100 www.vandrunenfarms.com

Caravan Ingredients developed fudgebased no preservatives, a chocolate base that aids in producing icing, brownie batters and sweet goods that contain 0 g. trans-fat per serving. Bakers just need to add water and sugar. Caravan Ingredients Lenexa, Kan. 800-669-4092 www.caravaningredients.com

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Engineering Management

Know Your Own Strength person can sometimes overpower a situation with shear physical strength. Other times, mental strength wins the battle. And, if you really have your game together, you can conquer troubles with your emotional strength. When it comes to strengths in management, how can you truly know you are the Charles Atlas of the group, otherwise known as “the world’s most perfectly developed man?” Many of you have taken some kind of personal survey, gave it a half-hearted effort and received some blubberish report that proved you were right about yourself all along. In other words, you were probably not right by any stretch of the imagination. A couple years ago, I was introduced to the Clifton StrengthsFinder program, which measures the presence of 34 talent themes of naturally recurring patterns of thought, feeling or behavior. The more dominant a theme is in a person, the greater the theme’s impact on that person’s behavior and performance. At first, I thought this would be another kinda-sorta helpful survey that I could choose to use or lose. But the key was that each book has a code embedded in it somewhere. That code was used to enter into the survey via their website. The survey asked a series of questions, then divulged answers and delivered a report that outlines what your top five strengths are as they relate to management and interaction with others. The top five not only tell you a little bit about yourself, but also guide others in how to deal with you, provided you share the results with them. The results of my survey are as follows:

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Of the 34 possible strength themes, my top five were strategic, maximizer, analytical, arranger and responsibility. Having the strategic label tells me that I tend to see patterns rather than complexity in situations. This gives me the ability to always ask the simple but important questions, such as “what if this happened or that happened,” usually followed up with “okay, when that happens, here is what we need to do next.” They say that having this strength, you can usually “see around the next corner,” and strategize your next move before issues arise. In order to work side by side with a strong strategic person, expect to be ready to move quickly but orderly. The maximizer is a person who looks to take something that is already strong and turn it into something superb. Average is never good enough. When you find something or someone that is already satisfactory, you feel compelled to nurture, refine and stretch it into excellence. The maximizer tends to spend time with people who appreciate your particular strengths and likewise, the maximizer wants to spend time with people who have found and cultivated their own strengths. When working with a maximizer, be ready to be pushed to perfection. Analytical is a theme that can usually be found in the person to whom you must prove your findings. It’s not that there is a desire to dispel the other person’s idea; the analytical person just needs to know why they think a certain way and how they came to the conclusion they did. The analytical person doesn’t work well with folks who are poor with detail and documentation. This strength also drives a person to “peel the onion” on a troublesome issue until the root cause is revealed. Working with someone who is analytical could cause you to be dragged down roads

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you may not be used to traveling. My next theme is arranger. Just like a conductor of an orchestra, this strength provides the know-how and confidence that brings a lot of complicated individual components together in harmony. The arranger is very organized but flexible, working from a plan but knowing that the plan might have to be adjusted along the way. Others may be in awe of your ability to have so many things going on in your head while appearing totally controlled and comfortable. No matter what, the goal is to come up with and execute the most productive configuration for the task. If you run into a situation in the workplace that’s confusing and seemingly out of order, this is the person you want to have “accidently” enter the room. Responsibility is the last of my top five strength themes. Having this theme causes me to take psychological ownership of a problem, project or situation. There is also a commitment factor here, meaning no matter how challenges present themselves, you will stick with them until they’re resolved, simply because you own them. This strength supports conscientiousness, an obsession to do things right. One of the negatives to this strength however, is that because you always get things done, people will dump on you when they need something done right and fast. You will have to watch how much you take on as you could get buried alive. When working with a person that has this strength, leave your excuses at the door. So there you have it. I have revealed myself. Now it’s your turn. Find one of these strength-finder surveys, take it wholeheartedly and see how you fare. Maybe you can find out something about yourself that can help you lift some heavy weights off of your shoulders. SF&WB

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Equipment Briefs Hinds-Bock’s high-speed, multi-piston, cantilevered depositors are designed to work over conveyors in bakeries for depositing of muffin, cake and snack batters with or without particulates. They run 1,000 deposits per minute depending on pan configuration, deposit size and batter viscosity, and are designed for quick disassembly, easy sanitization and product changeover. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com Make quicker belt changes with Dorner’s cantilever stand mounts. Cantilever stands support the conveyor from only one side, which is ideal when conveyors are placed it tight locations or for applications that require higher than normal belt changes. The unique side-support design of the cantilever stand mount also provides easy access for employee interaction and more efficient cleaning by eliminating obstructions to the conveyor. The mounts are engineered to work with Dorner’s 2200 and 3200 Series conveyors. Dorner Manufacturing Hartland, Wis. 800-397-8664 www.dornerconveyors.com Radio Frequency’s Macrowave UltraSeries pasteurization systems apply a high frequency electric field to effectively control pathogens, bulk or bagged pasteurization and/or insect de-infestation of flour, grains, xanthan gum and more. Utilizing clean electrical energy from the grid, the material to be treated is conveyed through a high frequency electrode array, where the alter-

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nating electrical energy causes the material to heat rapidly and uniformly throughout the product thickness. The technology is “instant-on, instant-off,” using energy only during the treatment process. Radio Frequency Co. Millis, Mass. 508-376-9555 www.radiofrequency.com FOX IV Technologies introduces the Model 5422 next-off printand-apply labeler for printing and applying 8.5x14-in. labels. Designed for 24/7 operation in the most demanding environments, the Model 5422 uses FOX IV’s exclusive Uniwall design that mounts the Zebra 220 Xi4 printer components to a rugged industrial center wall. FOX IV Technologies, Inc. Pittsburg, Pa. 877-436-2434 www.foxiv.com Assmann introduces the molded-in full-drain outlet (FDO) assembly for 2,500-plus-gallon tanks. This outlet provides the ability to drain the tank without the need for mechanically-installed nozzles, and is used where heavy solids or salts may accumulate in the bottom of the tank. The FDO also helps eliminate difficult maintenance work, stands up to virtually any service condition and is available with multiple expansion joint options. Assmann Corp. of America Garrett, Ind. 888-357-3181 www.assmann-usa.com Mondi developed its Green Range of industrial bags, designed to save natural resources, reduce waste and provide a measurably reduced environmental footprint. ONE, a one-ply bag especially suited for high-speed filling, reduces packaging weight and volume. ONE is made of 110

gsm high-performance paper, ensuring quick de-aeration of the bag while the outstanding strength and stiffness of the paper guarantees a smooth application on the filling spout and high handling resistance of the filled bag. Mondi Industrial Bags, a unit of Mondi Group Austria, South Africa 44 (0)1932 826 300 www.mondigroup.com Schneider Packaging introduces the iP robotic palletizer for high-speed palletizing applications. Equipped with a FANUC Robotics articulated arm robot, this highlevel robotic palletizer is integrated with an automatic pallet lift and product collation system designed to handle products at significant speeds, 24/7, even in harsh environments. The auto indexing minimizes the amount of motion required by the robot to perform palletizing while maximizing speed, efficiency, cost and labor savings. Schneider Packaging Equipment Co., Inc. Brewerton, N.Y. 315-676-3035 www.schneiderequip.com Charles Ross & Son introduced the Sanitary VersaMix Multi-Shaft Mixer, designed to process viscous formulations, including fillings, flavorings and more. Optional features include vacuum-capability, clean-in-place spray nozzles, temperature probes, interchangeable jacketed mix vessels, powder induction capability (available on special design rotor/ stators), sight/charge ports, control panels and PLC systems. This mixer can produce one to 4,000 gallons capacity. Charles Ross & Son Co. Hauppauge, N.Y. 800-243-9677 www.mixers.com

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Production Technology Warehouse & Distribution Logistics

Lightening the Load Many of today’s warehouse and distribution logistics are designed with time, efficiency and accuracy in mind. Marina Mayer, Executive Editor Photo courtesy of ToolBox Software North America Inc.

hese days, heavy, bulky equipment is a thing of the past. Now, it’s about light loads, compact pieces and features that offer functionality and efficiency. The same goes for many warehouse and distribution logistics, which entail paperless dispatching, automated order fulfillment and other top-notch advancements that allow operators to lighten their load.

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Enhancements that last Over the last eight months, ToolBox Software North America Inc. made a great deal of improvements and additions to its dispoTool paperless dispatching warehouse management system (WMS). Specifically designed for bakeries, the dispoTool is installed in more than 600 facilities worldwide, including Pan-O-Gold Baking Co., St. Cloud, Minn. “Actually, we are involved in ongoing projects on the East Coast and in the Midwest,” says Joerg Schlag, president and CEO of the Fountain Hills, Ariz., company. “Besides the pick- or put-to-light function, by using multiple color displays in the dispatching, we install more and more connection tools at multi-site bakeries for

intercompany data exchange.” DispoTool also helps use existing space more effectively, significantly reducing picking errors and dispatching costs. For example, bakeries using dispoTool report up to 30% savings in labor costs, Schlag says. “Not to mention the savings from accuracy and OTIF (on-time-in-full). POD (proof-ofdelivery) is also a feature, with an increasing demand from the market. DispoTool covers POD as well as track and trace throughout the supply chain,” he adds. Due to the changing frozen and parbaked goods markets, ToolBox Software improved WMS functions such as stock location assignment and pallet handling. “ToolBox today still concentrates 100% on bakeries only, covering any kind of baked goods, no matter if fresh wholesale, retail, par-baked, frozen or long-shelf-life products,” Schlag says. “Some time ago, all of our of installations were a number of displays with touchscreen PCs. This is still the case, however today, we implement dispoTool with hand-

helds, RFID [radio frequency identification] readers, portable printers, scanning stations and sometimes even without any displays at all.” The folks at ToolBox Software also installed complete track-and-trace systems throughout plants in the United States and Canada, Schlag says. “In other words, we go much further than simply the warehouse.”

Closing the loop For Pcdata, a standard warehouse offering includes pick-to-light, put-to-light and voice technology, says Marc Braun, president of the U.S. division. However, over the past year, the East Granby, Conn., manufacturer closed the loop by expanding its solutions downstream to provide full tracking-and-tracing capability, otherwise known as POD. “Any bakery with a number of SKUs [stock-keeping units] and any number of customers can benefit from our solution,” Braun says. “This is reflected in our current install base. These include bakeries that produce cake and long shelf-life items only, Continued on page 76

Photos courtesy of Pcdata

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Propel your business. Out-think the box.

THE NEW FREIGHTLINER GAS CHASSIS WALK-IN VAN gives you all the payload, reliability and durability Freightliner Walk-In Van chassis are known for, but in a gasoline package for lighterduty applications, shorter runs and lower cost of entry. That’s out-of-the-box thinking. From gas, diesel, full electric, hybrid electric and even hydraulic hybrid, you’ll be amazed what you can do on a Freightliner Walk-In Van Chassis. Find out at www.freightlinerchassis.com, or call Freightliner Custom Chassis Corporation at (800) 545-8831. Specifications are subject to change without notice. Freightliner Custom Chassis Corporation is registered to ISO 9001:2008 and ISO 14001:2004. Copyright © 2011 Daimler Trucks North America LLC. All rights reserved. Freightliner Custom Chassis Corporation is a subsidiary of Daimler Trucks North America LLC, a Daimler company.

Production Technology Continued from page 74

let’s spice things up a little... tna completes acquisition of leading seasoning solutions provider, Arcall tna has spiced things up a little in the seasoning industry with its recent acquisition of Arcall, a leading supplier of innovative seasoning and spraying systems. With a combined experience of over 80 years, tna can now bring you an extensive range of on-machine seasoning [intelli-flav® OMS ], main-line seasoning [intelli-flav® MLS] and cross-band spraying [intelli-spin®] solutions suitable for wet, dry or slurry applications. We would be delighted to show you the additions to the tna seasoning and spraying solutions at Interpack Germany 2011, Hall 17, Stand 28 or online at tnasolutions.com.

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Creating a buffer zone The Cimcorp MultiPick, developed by Finland-based Cimcorp Oy, is a robotic gantry system that provides fast order fulfillment with reduced costs, greater capacity, 100% accuracy and improved traceability and logistics, according to Anssi Kiiski, sales manager. “The MultiPick combines buffer storage and order fulfillment in a single automated system. Fresh inventory is stored in stackable plastic totes, with each stack comprising a single SKU on the floor beneath the MultiPick gantry system. One or more MultiPick robots can pick any number of totes from a stack at a time in the correct order for the dispatch schedule. Orders are loaded into vehicles in an optimal delivery sequence that saves time, energy and increases customer satisfaction. At the end of a shift, MultiPick can also automatically empty the entire picking area for faster cleaning,” Kiiski says. The MultiPick also offers flexibility with a user-friendly interface and software that can be easily reprogrammed to add more SKUS or to enable bakeries to cost-effectively scale their operations to meet daily, weekly, monthly and seasonal order fluctuations, Kiiski says. “MultiPick warehouse controls integrate seamlessly with WMS systems, providing real-time reporting on its task status from goods receiving, buffering to picking, replenishment, order consolidation, palletizing, loading and dispatch,” he adds.

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fresh bread and roll facilities as well as plants that bake-to-freeze and/or any combination of the above. Our solutions are completely scalable, and have been installed and successful at sites as small as 20 routes or customers.” The POD application enables 100% proof of delivery for goods at specific customer locations without the need for “customer” staff to be onsite. POD will check and control the unloading of product at the destination, what and how much to unload and verify the location where to unload. Pcdata’s POD also helps users track what product and baskets/trays have been delivered, Braun adds. “The user can key in the number of baskets received. Over time, a profile forms for each customer/site and losses accumulated from each.”

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As several bakeries are still recovering from the down economy, they’re also re-evaluating their plant equipment and, at times, are even making investments and improvements along the way. That’s why it’s important for WMS to be designed to function across the board. “The biggest challenge is really first to understand and then to re-organize the whole process from the bagger to the driver,” Schlag says. “Grown habits and attitudes must be changed and streamlined. Therefore, the results are phenomenal. Depending on the complexity of the process, this analysis may take multiple days and nights. No bakery is the same as another one, not even within one group. Understanding these differences and to work out a unique concept is definitely a major strength of ToolBox. We then guide the customer throughout the complete implementation and stay as long as necessary onsite. By using easy-to-operate touchscreen PCs and hand-helds in multiple languages, the staff usually adopts quickly to the system.” Continued on page 78

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Production Technology Continued from page 76

Another challenge is the change in how management carries out their track-andtrace operations. “First, there is the conversion from a paper and pencil system to a computerbased solution, which is hard for many of

the employees in the warehouse,” Braun says. “The second big change is moving from a knowledge-based situation, where certain individuals in the warehouse ‘call the shots’ to a situation where everybody needs to follow standard operation proce-

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dures. This is always hardest on those who are used to being the individuals responsible to get the products out in a timely fashion,” Braun says. Pcdata overcomes this obstacle by providing thorough training. During the initial startup of the system, for example, Braun says pcdata ensures that everyone from the team is present and that operators/managers are available for questions. “Everyone from the supplier, the team in the warehouse and the local site management must be on the same page in order to ensure a successful project,” he says. For a WMS that targets bakeries only, timing can be a major challenge. “For bakery goods to be delivered with maximum freshness, the bulk of baking and order-picking operations must take place at night, with a narrow production envelope with inflexible timelines,” Kiiski says. “This requirement has traditionally given bakeries the problem of finding sufficient reliable staff to pick their orders during the night-shift hours. Add to this the high staff turnover resulting from the repetitive nature of the work and heavy lifting involved, and it’s easy to see why automation is an attractive alternative to manual systems.” Cimcorp’s MultiPick resolves this dilemma, thanks to its rapid handling of perishable products. “MultiPick takes care of the entire material flow after production right up to the shipping dock, with its ultra high-density storage ensuring the buffer capability required to balance continuous production with specific delivery windows,” Kiiski adds. Regardless of the challenges, the future for warehouse and distribution logistics holds strong as customers become more aware of its time-saving capabilities. “A distribution system is not only a tool for saving money, but will be a more and more an important management system,” Schlag says. “The bottleneck of bakeries is usually the dispatching/distribution. Eliminating this issue, along with track and trace is the core target of distribution systems in the future.” Now, that’s lightening the load. SF&WB

1/20/09 11:46:19 AM

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Supplier Standpoint

California Almonds Deliver Natural, Wholesome Benefits

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onsumers all over the world enjoy California almonds as a natural, wholesome and quality snack and ingredient. Almonds are available in more processed forms than almost any other nut, which, combined with their irresistible crunch and flavor, makes them easy to incorporate into any consumer packaged application. In fact, according to the 2010 Mintel Global New Products Database (GNPD), almonds were the leading nut used in new food products worldwide for the third year in a row. Additionally, the total growth of new almond products from 2009 to 2010 (up 5%) outpaced new food product introductions in general (up 3%), the GNPD survey says.

Consumer demand In North America, it’s evident that consumers enjoy almonds. For the second year in a row, in 2010, consumers ranked almonds as the most essential and irreplaceable nut, and the nut that consumers reported eating most, according to a North American Consumer Attitudes, Awareness and Usage Report, Sterling-Rice Group, 2010. For consumers looking for snacks to help with weight management, almonds add nutritional benefits, increased satiety and a crunch that’s hard to beat. It’s no wonder consumer demand continues to rise. When asked why they choose almonds, consumers rank “tastes better” as second only to “more nutritious” as the top reason for selection, so food professionals can be confident that including almonds will add value consumer appeal to any product.

Breakfast Almonds are also a natural fit at breakfast and are considered by North American consumers to be the nut that best fits with breakfast foods versus other nuts, says a Breakfast Outlook Report, Sterling-Rice Group, 2009. Almonds lead top-of-mind awareness as a nut associated with breakfast cereal, as 58% of North Americans think of almonds first when they think of nuts in cereal, states a North American Consumer Attitudes, Awareness and Usage Report, Sterling-Rice Group, 2010. Al-

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monds also outscore other nuts on two key attributes consumers say they are looking for when choosing breakfast products—“is tasty and nutritious” and “fills me up until lunch.” These attributes are considered even more important than ease of preparation, indicating that consumers are willing to take the time to enjoy wholesome breakfast products, which is backed by a Breakfast Outlook Report, Sterling-Rice Group, 2009.

Almonds and chocolate The number of annual new chocolate product introductions worldwide more than doubled in the last decade (from 1,313 in 2001 to 5,296 in 2010), according to Mintel GNPD. Additionally, new products with nuts accounted for approximately one quarter of all chocolate product introductions, more than one third of which included almonds.

What’s more, more than two-thirds of consumers (69%) worldwide believe nutrition is important when choosing chocolate products, and survey respondents felt that chocolate with almonds was “more nutritious” (75%), “tastier” (74%) and “crunchier” (73%) than chocolate without almonds, according to a Global Chocolate Study, Sterling-Rice Group for the Almond Board of California, 2010. “Consumers are looking for products that combine great taste with a nutritious boost,” says Stacey Humble, senior director, global marketing for Almond Board of California (ABC), Modesto, Calif. “Almonds are recognized as both wholesome and delicious, so it’s easy to understand why consumers want to see more almonds. A true powerhouse ingredient, almonds combine flavor, crunch and global appeal with nutritional benefits.”

Nutritious allure of California almonds Almonds provide delicious crunch, unrivaled flavor and a host of nutrients. In fact, a 1-oz. handful of almonds (about 23) provides protein (6 g.), fiber (3.5 g.) and magnesium (76 mg.) and is an excellent source of vitamin E (7.4 mg.). A single ounce of almonds also offers potassium (200 mg.), calcium (75 mg.) and iron (1.1 mg.). Lastly, with only 1 g. of saturated fat and 13 g. unsaturated “good” fat, they are always cholesterol free. Almonds are even considered a good fit with many popular weight-loss plans such as Weight Watchers, the Mediterranean Diet and the South Beach Diet. They offer key benefits, namely satiety, fewer calories for more nutrients, crunch and undeniable tasty flavor. Clearly, California almonds can add so much to any application. ABC promotes almonds through its research-based approach to all aspects of marketing, farming and production on behalf of the more than 6,000 California almond growers and processors who produce approximately 80% of the world’s almonds, many of whom are multi-generational family operations. Established in 1950 and based in Modesto, Calif., ABC is a non-profit organization that administers a growerenacted Federal Marketing Order under the supervision of the United States Department of Agriculture, Washington, D.C.

Health claims Good news about good fat—U.S. Dietary Guidelines recommend that the majority of your fat intake be unsaturated. One serving of almonds (28 g.) has 13 g. of unsaturated fat and only 1 g. of saturated fat. Scientific evidence suggests but does not prove that eating 1.5 oz. per day of most nuts, such as almonds, as part of a diet low in saturated fat and cholesterol may reduce the risk of heart disease. Editor’s Note: Almond Board of California, Modesto, Calif., provided information for this article. For more information, including its nutritional brochure and technical kit, go to www.almondboard.com.

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Snack Food Today Snack Flavors Reach Higher Altitudes For some snack manufacturers, there’s no such thing as reaching the glass ceiling. That’s because there’s always room for bigger, better and bolder product varieties. Take, for instance, Open Pit barbeque- and Vlasic dill pickle-flavored potato chips from Snyder of Berlin, Berlin, Pa. The Open Pit barbecue variety captures the authentic flavor in every bottle of Open Pit barbeque sauce, while Vlasic dill pickle delivers that signature pickle taste in a crispy, crunchy format. They sell regionally for a suggested retail price of $3.49 for a 9.5-oz. bag. For a limited time only, COMBOS baked snacks now come in a Buffalo Blue Cheese Pretzel

Larger Portions Increase Consumption in Young Children Snacks served in large portions increased the amount consumed by preschool-aged children, according to a recent study from The University of Tennessee, Knoxville, Tenn., and published in the Journal of the American Dietetic Association. “What makes this current study significant is that it looks at snacks specifically,” says Phil Lempert, founder of Food Nutrition & Science and CEO of The Lempert Report and SupermarketGuru.com. “Since young children consume a large amount of energy from snacks, it’s important to look at the relationship that snack portion size and energy density have on energy intake in this age group. With childhood obesity on the rise, parents and educators need to be thoughtful about the types of snacks they provide.” This is one of the first studies conducted on children with snacks. Previous studies reviewed entrees, but found energy intake to be substantially affected by energy density, not portion size.

ConAgra Unveils New Bag-to-Bowl Design for Orville Redenbacher’s Popcorn ConAgra Foods, Omaha, Neb., launched The Pop Up Bowl, a new bag-to-bowl design for its Orville Redenbacher’s brand popcorn that pops into a ready-to-serve, free-standing bowl filled with popcorn. The Pop Up Bowl cooks on its side and features a transparent top, allowing consumers to watch their popcorn pop and see when it’s ready. It retails for $2.99 for a 3-pack and $4.49 for a 6-pack and is available at grocery and mass retailers nationwide.

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Snack Food & Wholesale Bakery - May 2011

version. Produced by MARS Chocolate North America, Hackettstown, N.J., this cheesy, crunchy, oven-baked snack is made with real cheese and blends a spicy chicken wing flavor with creamy, tangy blue cheese. It sells nationally for a suggested retail price of $1.99-2.29 for a 7-oz. bag. “At MARS, we are always looking for new flavors that provide a ‘substantial’ snack to satisfy consumers,” says Craig Hall, general manager of ice cream and substantial snacks. “Buffalo wings are very popular with consumers, and the pretzel category is growing, so it made sense to ‘combo’ these flavors into another great savory baked snack.”

Chip Makers Celebrate Milestone Anniversaries UTZ Snack Foods, Hanover, Pa., celebrates its 90th anniversary by introducing commemorative 90cent bags. “We’re hoping to spur some interest, let people know we’re here and still successful,” says Tom Dempsey, president. “We very much appreciate the support customers and retailers have given us here in central Pennsylvania.” Consumers are also invited to take a free tour of the plant and learn about the history of the company and see how a potato is transformed into a potato chip. Meanwhile, Herr Foods, Inc., Nottingham, Pa., rejoices 65 years of producing a variety of snack items, including potato chips, pretzels, tortilla chips, pork rinds and cheese curls. “Businesses come and go, you know,” says James (Jim) Stauffer Herr, founder. “But I think we can just keep going and get bigger. I’m expecting that we’ll continue to do well.”

www.snackandbakery.com

Snackandbakery.com

Live From the Production Floor ew to Snack Food & Wholesale Bakery’s website is “Live From the Production Floor,” an online photo gallery of plant shots from tours of bakeries and snack manufacturing plants. Go behind the scenes and check out never-before-seen images from inside the facilities of previously featured companies, such as Shearer’s Foods, Inc., Snack Food & Wholesale Bakery’s 2011 Snack Manufacturer of the Year, February 2011, as well as Gabby’s Bagels, Inc. and Highland Baking Co., both covered in our March and April 2011 issues, respectively. While on our site, go to our “White Papers” section to get detailed reports on distribution centers, moulders, baker’s

N

www.snackandbakery.com

yeast or learn how to improve production efficiency. Feel free to send us your white paper to publish as well. Also, we encourage you to 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, new products, equipment developments and ingredient solutions pertaining to the snack and bakery markets. Meanwhile, 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].

May 2011 - Snack Food & Wholesale Bakery

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A Practical Event for Product Developers Prepared Foods’ R&D APPLICATIONS SEMINAR is a 2 day, practical “how to” applications-oriented event dedicated to further educating the food & beverage industry’s formulators on specific application challenges.

TUESDAY AGENDA • August 2, 2011 7:30-8:30 am

BREAKFAST BUFFET

8:30-9:10 am

KEYNOTE ADDRESS: The Making of Soaring Successes and Cheerless Failures in Products for Health Flavors & Colors

9:15-9:55 am

The Power of Natural Colors Sensient Color Group

Product Development Advances

Healthful Foods & Beverages

Kosher 101 Orthodox Union

Great Science Meets Great Taste: A New Revolutionary Approach to Improve the Taste of ReducedCalorie Beverages Cargill

10-10:25 am

Emerging Ingredients

Beverages & Prepared Foods

Alert Serenity PL Thomas

TTB Regulations and their Impact on Formulating Alcoholic Beverages with Flavors Comax Flavors

REFRESHMENT BREAK Applications Lab A: Join the Texture Revolution! Designing Sauce Texture - TIC Gums

10:30-11:45 am Applications Lab B: Improving Better-For-You Products with Dairy Flavors - Edlong Dairy Flavors

11:50 am-12:30 pm

Flavors & Colors

Product Development Advances

Healthful Foods & Beverages

Emerging Ingredients

Measuring the Color of Food Konica Minolta

Integrated Workfl ow with Product Development Software Advanced Software Designs

Polyphenol Fortification for Functional Food Applications: Challenges and Opportunities Verdure Sciences Group

Whey-derived Ingredients with Improved Functional Characteristics Glanbia Nutritionals

12:30-1:30 pm

Beverages & Prepared Foods

LUNCH BREAK Applications Lab A: Tree Top

1:30-2:45 pm Applications Lab B: Health & Wellness Additives for Frozen Beverages - Sargento Food Ingredients

2:50-3:30 pm

3:35-5 pm

Ingredient Systems for Weight Management

Product Development Advances

Stevia: The Natural and Zero Calorie Alternative to Sugar Jungbunzlauer

Ingredient Selection: How Nutrition Trends and Food Policy Shape Ingredient Decisions The Cherry Marketing Institute

Healthful Foods & Beverages

Emerging Ingredients

Flaxseed - Health and Functionality Flax Council of Canada

Beverages & Prepared Foods Emulsion Technology with Functional Milk Proteins - Improving Product through Natural Sources Arla Foods Ingredients Group

R&D Applications Seminar Chicago Expo & Happy Hour

Register today by scanning mobile tag and you could win an iPad!

2011 SPONSORS

KEYNOTE SPEAKERS The Making of Soaring Successes and Cheerless Failures in Products for Health

Food, Flavor, & Beverage Future Trends: Authenticity, Risk and Experimentation Take the Lead

Speaker: Bob Jones, Principal, Scientia Advisors LLC From years of experience within the food industry, Jones will explore factors that have made the difference between products that soared and those that became cheerless failures. He will explore ways to use these insights in the development of wellness products that will succeed in the marketplace.

Speaker: Suzy Badaracco, Toxicologist, Chef, Registered Dietitian, Culinary Tides, Inc. Understand the issues and elements pertaining to elements influencing food, flavor and beverage trends. Participants will be able to predict the opportunities and pathways for making flavor, and beverage products successful in the marketplace.

WEDNESDAY AGENDA • August 3, 2011 7:30-8:30 am

BREAKFAST BUFFET

8:30-9:10 am

KEYNOTE ADDRESS: Food, Flavor, & Beverage Future Trends: Authenticity, Risk and Experimentation Take The Lead Baked Goods

9:15-9:55 am

Oat Fiber = Benefits & Application J. Rettenmaier USA LLP

Healthful Foods & Beverages

Product Development Advances

Confections

Starches, Gums & Fiber

Technomic

Regulatory Trends in the Food and Beverage Industry Advanced Software Designs

Formulation, Manufacture, and Use of Confectionery Coatings Clasen Quality Coatings

Use of Functional Native Starches National Starch Food Innovation

10-10:25 am

REFRESHMENT BREAK Applications Lab A: Diana Naturals

10:30-11:45 am Applications Lab B: TBD 11:50 am-1 pm

LUNCH BREAK Baked Goods

Healthful Foods & Beverages

Product Development Advances

Confections

Starches, Gums & Fiber

Caramel with Improved Nutrition and Machinability Roquette America Inc.

Formulating with Multifunctional Ingredients for Better Consumer Product Performance Z Trim Multifunctional Ingredients

1-1:40 pm

MALTS - Field To Table Malt Products Corporation

Barley – A Super Grain for Even Healthier Whole Grain Foods ConAgra Mills

The Case For Social Media and What R&D Professionals Need To Know CMG Media Group International

1:45-2:25 pm

Trancending Trans Fats: An Innovative Approach To Reducing Saturated Fats Caravan Ingredients

Making Dairy Products Healthier to Provide Greater Consumer Appeal in the Marketplace BASF Nutrition Ingredients

Thermal Processing Of New Age Beverages MicroThermics Inc.

Yogurt Texture National Starch Food Innovation

2:30-3:10 pm

Formulating With Soy-Based Egg Replacers Natural Products Inc.

Hydrocolloids: Formulating for Weight Management Ashland Aqualon Functional Ingredients

Pea Fiber- A New Option for Fiber Enrichment SunOpta Ingredients

REGISTER TODAY!

Register by May 13 and you could win an iPad! www.PreparedFoods.com/rd

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

CONSULTING

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

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Phone:   Fax: 847-288-9709 Website: WWW4AND4#%COM E-mail: CONTACT 4AND4#%COM www.snackandbakery.com

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EQUIPMENT FOR SALE

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EQUIPMENT FOR SALE

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INGREDIENTS

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www.snackandbakery.com

Ad Index Company Website

Page

Company Website

Page

Company Website

Page

21st Century Grain Processing/Viterra . . . . 7 www.viterra.com

Freightliner Custom Chassis Corporation 75 www.freightlinerchassis.com

pcdata inc. . . . . . . . . . . . . . . . . . . . . . . . . . 77

AIB International . . . . . . . . . . . . . . . . . . . . 22 www.aibonline.org

Georgia Nut Company . . . . . . . . . . . . . . . 68 www.georgianut.com

Prepared Foods’ R&D Applications Seminar Chicago . . . . . . . . . . . . . . . . . . . . . . . . . . 82-83

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

Gold Coast Ingredients . . . . . . . . . . . . . . . 37 www.goldcoastinc.com

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

Grain Millers, Inc. . . . . . . . . . . . . . . . . . . . 56 www.grainmillers.com

www.reiser.com

Arizona Instrument LLC. . . . . . . . . . . . . . . 12 www.azic.com

Gum Technology . . . . . . . . . . . . . . . . . . . . 52 www.gumtech.com

www.remcoproducts.com

Bay State Milling . . . . . . . . . . . . . . . . . . . . 58 www.baystatemilling.com

How Do You Take Your Coffee? . . . . . . . . . 70 www.takeyourcoffee.com

Brolite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 www.bakewithbrolite.com Buhler Inc. . . . . . . . . . . . . . . . . . . . . . . . . IBC www.buhlergroup.com Cablevey Conveyors . . . . . . . . . . . . . . . . . 54 www.cablevey.com

www.pcdatainc.com

www.PreparedFoods.com/rd Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Remco Products . . . . . . . . . . . . . . . . . . . . . 13

Rivland Partnership . . . . . . . . . . . . . . . . . . 41 www.rivland.com SK Food International . . . . . . . . . . . . . . . . 28 J.R. Short . . . . . . . . . . . . . . . . . . . . . . . . . . 78 www.shortmill.com Kess Industries, Inc. . . . . . . . . . . . . . . . . . . 14 www.kessind.com Koenig Bakery Systems . . . . . . . . . . . . . . 38 www.koenigusa.com

www.skfood.com SnackandBakery.com . . . . . . . . . . . . . . . . 81 www.snackandbakery.com Spraying Systems Co. . . . . . . . . . . . . . . . . 21 www.spray.com/freecoatingtest

Kwik-Lok . . . . . . . . . . . . . . . . . . . . . . . IFC-3, 5 www.kwiklok.com

Tate & Lyle . . . . . . . . . . . . . . . . . . . . . . . . . 29

Lubriplate . . . . . . . . . . . . . . . . . . . . . . . . . . 35 www.lubriplate.com

Tate & Lyle . . . . . . . . . . . . . . . . . . . . . . . . . 31

MINSA . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC www.minsa.com

tna north america . . . . . . . . . . . . . . . . . . . 76

Moen Industries . . . . . . . . . . . . . . . . . . . . . 36 www.moenindustries.com

U.S. Highbush Blueberry Council . . . . . . . 69

National Honey Board . . . . . . . . . . . . . . . . 39 www.bakingwithhoney.com

United Soybean Board . . . . . . . . . . . . . . . 23

Corn Products International . . . . . . . . . . . 55 www.cornproducts.com/trends/beverage

National Starch Food Innovation . . . . . . . . . . . . . . . . .57, 59, 61, 63 www.foodinnovation.com

US Soy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Danisco USA Inc. . . . . . . . . . . . . . . . . . . . . 51 www.danisco.com

PACK EXPO Las Vegas 2011 . . . . . . . . . . . . 27 www.packexpo.com

California Raisin Marketing Board . . . . 10-11 www.LoveYourRaisins.com California Walnuts . . . . . . . . . . . . . . . . . . . 43 www.walnuts.org Cargill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 www.cargill.com Charles Ross & Sons Company . . . . . . . . . 9 www.PowderInjection.com Clabber Girl . . . . . . . . . . . . . . . . . . . . . . . . 60 www.clabbergirl.com/innova/

www.tateandlyle.com

www.splendasucralose.com

www.tnasolutions.com

www.blueberry.org

www.SoyConnection.com/QUALISOY

www.ussoy.com Van Drunen Farms . . . . . . . . . . . . . . . . . . . 66 www.vandrunenfarms.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

PRINT & INTERNET ADVERTISING Jeff Heath E-mail: heathj@ bnpmedia.com T: (847) 405-4074

CUSTOM MEDIA Jeff Heath E-mail:[email protected] T: (847) 405-4074

Barbara Szatko E-mail: [email protected] T: (630) 527-9927

LIST RENTAL Postal information contact: Kevin Collopy at 800-223-2194 x684; Kevin.Collopy@infogroup. com

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 2010 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 #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2.

May 2011 - Snack Food & Wholesale Bakery

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The Final Word

Kraft’s Face-Scanning Technology S ometimes just making minor decisions, like what I want to snack on from the vending machine, can take days, if not weeks to figure out. Who knew that choosing a bag of pretzels was so challenging—and time consuming? Then there’s mindless minutes standing in front of the freezer just determining if we should have chicken or beef for dinner (ladies, you know you’re with me on this one). Looks like I’ll be spending more of my time actually enjoying my food versus picking it out, thanks to Kraft Foods’ new face-scanning technology. Forget body scanners and pat-downs. This puts cyber tech on a whole new pedestal. The Northfield, Ill.-based food giant joined forces with Intel Corp., Santa Clara, Calif., to introduce a meal planning device that scans your face and uses analytics determined from your look, to see which reci-

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Snack Food & Wholesale Bakery - May 2011

pes you would like to make. You mean, all I have to do is stand there and let this “machine” make the decision for me? Where do I sign up? Based on the second-generation Intel Core i7 processor, this self-serve kiosk can be used to obtain recipes, provide shopping suggestions, print promotional coupons and deliver product samples. Here’s how it works: The machine judges age and gender by scanning your face, then uses the shading caused by your natural facial features to make out what you look like. This technology is said to be about 86% accurate in figuring out if the user is a male or female, and is slightly better at telling the difference between children and the elderly. It also is said to work well (70%) when figuring out if you are an adult or a “young adult.” And if picking out your food isn’t enough, the machine can also read your

Marina Mayer, executive editor [email protected]

Looks like I’ll be spending more of my time actually enjoying my food versus picking it out, thanks to Kraft Foods’ new facescanning technology. supermarket loyalty cards to evaluate what you buy on a regular basis, which helps you stick to dietary restrictions. It also enables users to create a Kraft iFood Assistant account, which houses user information much like an online account. Retailers and brands can use the meal planning solution to connect with consumers beyond the point-of-sale (as seen in the corresponding image). The digital signage is equipped with Anonymous Video Analytics technology to obtain accurate audience measurement data, such as how many consumers interacted with the display, for how long, their gender/age, what time of day, etc. Doing so provides immediate feedback and helps retailers adapt to consumer wants and needs. The challenge with this so-called “methodology” though is that the face scanner cannot determine food allergies or other eating habits (or restrictions), so shoppers will have to do some thinking along the way. Some days, technology can be our worst nightmare, but in the instance that I can’t decide what to eat, I’m glad I can rely on a machine to do the decision making for me. SF&WB

www.snackandbakery.com

Innovative extrusion processes without limits. With our extensive extrusion know-how and passion for customized solutions, Buhler strives to generate added value and success for any product concept. With the addition of Aeroglide® to the Buhler family, we now offer one of the most complete lines of process technology available anywhere. From raw material handling, cooking and shaping through extrusion to drying of finished products - from breakfast cereals and snack foods to modified flours and starches and texturized proteins. In short: extrusion processes without limits. Visit us at the IFT Food Expo. June 12-14, 2011. New Orleans, LA. Buhler Booth # 6455. Buhler Inc., 13105 12th Ave N., Plymouth, MN 55441, T 763-847-9900, [email protected], www.buhlergroup.com

Innovations for a better world.