Snack Food & Wholesale Bakery April 2011

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Contents

Cover Story 16 | A Passion for Bread Highland Baking Co., a 25-year-old bakery located in Northbrook, Ill., prides itself on creating custom, artisan quality breads and rolls in large volumes, but with the care and craftsmanship of the family that it is.

Plant Story Photos by Vito Palmisano

26 | One Bustling Bakery Highland Baking Co.’s impressive 250,000-sq.-ft. operation in Northbrook, Ill., is home to 14 production lines and a penchant for perfection.

Columns 8 | Editor’s Note Editor-in-chief Lauren R. Hartman is asking snack manufacturers to keep developing healthier products.

37 | The Nutritional Corner This year marks the 70th anniversary of the establishment of the Food and Drug Administration’s bread and flour enrichment programs, says contributing columnist Judi Adams. Happy Anniversary!

44 | Engineering Management To get to the next level in your management skills, you must upgrade, says contributing columnist Jeff Dearduff. Find out how to enhance the way you do business just by making a few minor adjustments.

62 | The Final Word SNAXPO is just one of those shows where you know you’re going to have a guaranteed good time, says executive editor Marina Mayer. Read on to find out what happened at the snack industry’s most coveted event.

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Snack Food & Wholesale Bakery - April 2011

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Contents Market Trends 33 | Perfectly Portioned Given all the advantages single-serve products have over their larger counterparts, it’s not surprising that more consumers are thinking small when buying snacks and baked goods.

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New Products 36 | New Products Read about some of the most recently introduced products, including Morning Rounds from Ozery Bakery, soft and chewy gluten-free granola bars from Bakery On Main, New York deli-style wraps from Tumaro’s and Hostess pink strawberry cupcakes.

Tortilla Trends TT-4 | Letter to the Industry

Ingredient Technology

Jim Kabbani, chief executive officer of the Tortilla Industry Association (TIA), addresses the industry about what members and attendees can expect from the technical seminar and the annual convention.

38 | Halting the Salt

TT-6 | TIA Tech Conference

49 | Pushing the Limits

The TIA Tech Seminar, which takes place May 23-24 at the Disney Grand Californian in Anaheim, Calif., focuses on the operational aspects of running your factory. Check out this guide for more information.

Many of today’s suppliers are developing dependable lubricants to help their customers do the job right the first time.

Ingredient suppliers are developing salt alternatives and replacements to help bakers and snack manufacturers create lower-sodium offerings.

Production Technology

54 | Supplier Standpoint Pcdata Inc., East Granby, Conn., recommends that companies evaluate the positive effect modern distribution systems can have on their bottom line.

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38 TT-8 | Best of All Worlds Ingredient suppliers offer unique formulations that stem from traditional processes but incorporate a futuristic appeal.

TT-12 | At Full Speed Ahead Tortilla and flatbread equipment manufacturers are moving forward in a bigger, stronger and more versatile way.

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Snack Food & Wholesale Bakery - April 2011

49 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. April 2011 Vol. 100 No. 4

For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected] www.snackandbakery.com

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Editor’s Note

We’re Hooked on Snacks don’t know about you, but snacking on carrots and celery all the time gets boring. I don’t think I’m alone in that assessment. And I’m certainly not alone in my habit of snacking. Consumer demand in the United States for snack foods exceeded $5.6 billion in 2010. Not million—billion. Snack packaging demand was forecast to exceed $5.6 billion in 2010, with growth fueled by rising snack product shipments, a favorable outlook for disposable personal income, according to a study by The Freedonia Group, a market research firm located in Cleveland, Ohio. The snack market, which covers potato chips, tortilla chips, nuts, popcorn, cheese snacks, pretzels, dry fruit snacks, meat snacks, corn snacks and other salted products, is obviously mature, but has grown at a modest pace with continued product innovation. And it doesn’t stop there. According to a report from Global Industry Analysts, Lauren R. Hartman Inc., San Jose, Calif., [email protected] the snack food market will reach a whopping $334 billion by 2015 and 48,519 tons in volume terms by the year 2015, driven primarily by changing consumer demographics, perceptions, priorities and affluence levels. That means more consumers are snacking more frequently, which is contributing to the recent growth. I couldn’t agree more. But are those snacks the healthy versions or could they be too salty, too fattening and loaded with empty calories? I often substitute snacks for meals and I may be a statistic: We live such hectic lives that leave little room for traditional family meals. More convenient snack foods that are tasty

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The snack food market will reach a whopping $334 billion by 2015 and 48,519 tons in terms of volume by the year 2015, driven primarily by changing consumer demographics, perceptions, priorities and affluence levels. and healthy are doubling as appetizers and meals for many consumers. That’s not really a surprise. But as consumers become more healthconscious and want more better-for-you munchies, the major food marketers are catching on or should catch on, taking the opportunity to expand their offerings to include low-fat and low-calorie snacks—

snacks with cholesterol-lowering plant sterols, snacks with less heart-wrenching sodium, snacks with fewer calories and less fat. That’s good for me and maybe you, too. However, snack manufacturers aim to cut costs and increase profits, therefore, some of the players will increasingly adopt technology into their snack production methods. There are strong opportunities for slim, lean, fat-free and guilt-free snacks. Meanwhile, innovation in terms of packaging, flavors and convenience will also continue to be major growth drivers. Markets such as Asia Pacific, Latin America and Eastern Europe represent huge potential for future expansion. The folks across the ponds like their snacks and eat them, too. Portable packaging and portion-packs certainly have also helped the market. Easy-to-carry standup pouches, 100calorie and bite-sized packs, resealable bags and finger-hugging or car-cup canisters add new dimensions to the convenience factor, which I’m convinced, will continue to prevail as a major product variable for commercial success. We’ll keep on snackin’ if the industry keeps making those snacks tasty yet healthier. I know, it’s impossible to ask for the world, and these products can’t be made unless the right ingredients at the right cost can be found. And yes, I know, the economic outlook is still rough and a lot of you are in no better shape than last year. But more widely available salt-free chips would be nice. We even hear that Kraft Foods, which is making plans to drive profit growth, created something called a “virtuous cycle,” a brand development program that cuts overhead and invests in marketing and innovation. So come on food companies—help consumers snack healthy and develop those good-for-you new products. Let’s see what you can do. Consumers will buy if it tastes good. If a snack is tasty and good for them, that would be incredible. SF&WB

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Advertorial Random Thoughts from the California Raisin World Larry Blagg, contributing columnist

uch is life—take two steps forward, one step back. When one door closes, another one opens. This month’s column is a mixture of glowing memories from a tour of California and the harsh realities of Mother Nature, as earthquakes and tsunamis create havoc on bakeries—and lives—overseas.

S

Glowing memories

Angela Dodd Cargill

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Snack Food & Wholesale Bakery - April 2011

Wholesale Bakery to read more about Craig Ponsford). Ponsford spoke of establishing a bakery that deals only in whole grain and glutenfree baked goods and expressed his eagerness to try new grains and new techniques in order to bring his products closer to nature. All guests enjoyed the Golden Gate views and another bakery tour at sourdough bakery Boudin’s on Fisherman’s Wharf before tucking into a seafood dinner at Scoma’s. All guests are now safely back home, selling their award-winning products in their bakeries, and encouraging others to enter the fourth annual America’s Best Raisin Bread Contest, which is set to take place Oct. 13-15 at AIB International’s headquarters in Manhattan, Kan.

Twenty guests and 12 of the 13 winners from the third annual America’s Best Raisin Bread Contest, along with members from the California raisin industry, completed a winners’ tour, March 1-6, where they traveled around Central and Northern Harsh realities California. After experiencing The Sendai earthquake and spectacular views of Yosemite’s subsequent tsunami in NorthBridal Veil and Yosemite Falls, ern Japan, followed by issues El Capitan and glimpses of Half with Japan’s nuclear power Dome among the clouds, they plants, remind us that Mother settled in to a lunch at Yosemite Nature can be quite cruel at Village, followed by a celebratimes. Word from Japan is tory dinner with board members that even the largest commerof the California raisin industry. cial bakeries, which provided The next day encompassed a Shawn Kearns, Einstein Noah Restaurant Group, Lakewood, major assistance during the tour of two raisin packing plants Colo., won the grand prize in the 1995 Kobe earthquake, are and a look at the vineyards just commercial bakery category for his challenged by a lack of raw getting ready to burst into life Split Top Buttermilk raisin bread. materials and a system of rollfor the new season. Next, a trip ing blackouts to produce enough bread to feed to the Culinary Institute of America (CIA) at those most in need. The baking industry has a Greystone, St. Helena, Calif., proved to be quite big heart in all parts of the world, and any asenlightening—and filling—as they learned of sistance that Americans can provide to the Japathe versatility of raisins in a whole range of nese will be greatly appreciated. It took more dishes prepared especially for them by the CIA’s than 10 years to rebuild the city of Kobe followtalented chefs. An herb garden tour, a lecture by ing their earthquake, and it is expected that it professional baking and pastry chef instructor will take even longer to make the infrastructure Robert Jorin on bakery trends of the future, a and other repairs in the Sendai area. wine tasting at Beringer and another wonderful I encourage all Americans to make donations meal, this time at the Wine Spectator Restaurant, to the American Red Cross, specifically desigmade the Napa leg of the tour truly memorable. nated to help the victims in Japan. The last day featured a tour of Bouchon Bakery in Yountville, Calif., part of the Thomas Keller Editor’s Note: Larry Blagg is senior vice president of Restaurant Group, which accrues $15,000 in marketing for Fresno, Calif.-based California Raisin retail sales and more than 1,000 register rings Marketing Board, which sponsors America’s Best per day in only a 300-ft. retail space. Raisin Bread Contest. Go to www.loveyourraisins. Guests then received a brief lecture by com to learn more about California raisins and Craig Ponsford in San Rafael, Calif., at his new to enter the fourth annual America’s Best Raisin commercial enterprise, Ponsford’s Place (check Bread Contest. out the February 2011 issue of Snack Food &

Business Briefs

people

News IDDBA Releases Lineup of Speakers for Dairy-Deli-Bake 2011 The International Dairy-Deli-Bakery Association (IDDBA) announced the speaker lineup for Dairy-Deli-Bake 2011, which takes place June 5-7 at the Anaheim Convention Center in Anaheim, Calif. Speakers include Condoleezza Rice, Joe Montana and Captain Chesley “Sully” Sullenberger, among others. For more information, go to www.snackandbakery.com.

Sara Lee Spins Off to Retail, Foodservice Units Sara Lee Corp., Downers Grove, Ill., has spun off its North American retail and foodservice business in a tax-free transaction, creating two publicly-traded companies. One part of the spinoff retains the Sara Lee name and is expected to account for approximately $4.2 billion of the company’s total fiscal 2011 net sales, based on the mid-point of current

guidance; the other yet-to-be-named company, internally referred to as “CoffeeCo,” will consist of Sara Lee’s international beverage and bakery businesses, as well as the current North American beverage business, and is expected to account for approximately $4.85 billion of the company’s total fiscal 2011 net sales, based on the mid-point of current guidance.

ASB Inducts Four Members in 2011 Hall of Fame The American Society of Baking (ASB), Swedesboro, N.J., inducted four new members into the 2011 Baking Hall of Fame at its BakingTech conference, which took place Feb. 28-March 2 in Chicago. Inductees include James Apple, president of Butter-Krust Baking Co., Sanbury, Pa., which licensed the Holsum brand from The Long Co. back in the 1950s and became the first bakery in its region to market cellophane-wrapped bread. E.E. Kelley, president and chairman of ButterKrust Bakery, Lakeland, Fla., was president and chairman of the Quality Bakers of America and president of the American Bakers Association (ABA). ButterKrust Bakery is said to be the largest single bakery in Florida. Ken Klosterman of Klosterman Baking Co., Cincinnati, started the family business more than 100 years ago and transformed it into three large wholesale operations. Klosterman Baking was the first of many

developments in the baking industry, including the first to create a square loaf of bread, the first to offer brown-and-serve rolls, the first to create a hamburger bun and the first to offer buns packaged in plastic wrap. Alexander Weber of Caravan Products Co. led the Totowa, N.J.-based company to develop and produce cutting-edge products, including a wide range of baking bases, concentrates and dough processing innovations. ASB inducts individuals who have demonstrated significant accomplishments in the baking industry and have proven their leadership through their innovations and advancements. Nominations for the Hall of Fame are made by ASB members and non-members. This year, 40 candidates were nominated. The honorees are now a part of an exclusive, 35-member group that has influenced the baking industry for many years.

Banner-Day, Saginaw, Mich. Joseph P. Day is named chief executive officer, responsible for supporting the bakery oven systems group, while lending his years of experience to Joseph Day the company’s continuing product development efforts. Meanwhile, J. Michael Day expanded his responsibilities to become president and COO, providing enhanced skills and J. Michael Day discipline into the overall strategic direction of the business, taking on a more active leadership role in the bakery oven group and carrying out all day-to-day operations for the bakery oven and pipe heating systems businesses. Gonnella Baking Co., Chicago Dan Herzog moves up to vice president of corporate compliance–food safety, responsible for training quality managers on food safety regulations and working with human resources to find and hire new staff Herzog members. Herzog will also serve as the lead contact in coordinating with all local, state and federal agencies dealing with food safety and with auditing agencies. Charles Ross & Son Co., Hauppauge, N.Y. Bogard Lagman is appointed regional sales manager for Asian and Middle Eastern countries, responsible for sales Bogart Lagman management of products manufactured in Ross plants. Bogard is based out of Manila, Philippines, and will be assisting customers and working directly with the company’s network of sales representatives.

Continued on page 14

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Business Briefs Continued from page 12

News

supplier news Autocrat, LLC, manufacturer of coffee extracts for snack bars, among other products, enters into a partnership with an investment group led by Trent Capital Partners and Argosy Private Equity. This agreement allows Autocrat to accelerate its growth strategy and continue advancement as a world-class food ingredient manufacturer.

NPD Study: Consumers Want to Eat Healthy, but Don’t The NPD Group, Chicago, conducted a study that found consumers wanting to eat healthy, but saying that they actually don’t. According to the report, titled “Healthy Eating Strategies by Generations,” 62% of adults say they intend to exercise regularly, yet just 46% say they actually do. Eating smaller, more frequent meals is the intention of 44% of adults, but only 29% actually practice this. Meanwhile, 53% say they were going to limit their calorie intake, yet just 38% of consumers say they are actually following through with this goal, the study says. “A gap between actual behavior and future intentions exists on all dimensions of healthy eating behavior,” says Dori Hickey, director of product development at NPD and author of this report. “The key is to find ways to bridge the gap by making it easier for consumers to put into practice their intentions by understanding what will motivate them to eat and live more healthfully.”

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Sensient Colors, LLC invests in adding aseptic packaging capabilities, allowing its customers to receive preservative-free colors that deliver maximum shelf life and enhance sustainability. The aseptic packaging also aligns with Sensient’s sustainability policy by reducing waste, minimizing its carbon footprint and providing recyclable options.

in the Feb. 21 issue of the Journal of Agricultural and Food Chemistry. During the eight-week study, 80 four-week-old male rats were randomly assigned diets containing 25, 100, 200 or 1000 IU/ kg of vitamin D, sourced from either a vitamin D3 supplement or bread made with Lallemand Vita D bakers yeast.

IOIIO I--Lo I-Lo Lode d rs de s Cro okl klaa aan aa n

As part of its video education series, Tate & Lyle releases new videos on its fiber website, www.promitorfiber.com. The first one, “Use Fiber to Boost Your Bottom Line,” provides commentary from Krista Falon, senior analyst at Mintel, and Tate & Lyle fiber experts David Lewis, health and wellness product manager, and Andy Hoffman, director of health and wellness innovation. The second video, “Impacting Digestive Health with Prebiotics and Probiotics,” features fiber expert Lisa Sanders. Bread made with Lallemand Vita D baker’s yeast can improve trabecular and cortical bone health and act as a vitamin D3 supplement, according to a study conducted by Purdue University, West Lafayette, Ind. The study was printed

Continued on page 14

IOI-Loders Croklaan welcomed its first bulk vessel shipment of roundtable on sustainable palm oil (RSPO)-certified sustainable palm oil in New Orleans. The oil will be offered to the market as certified, mass-balance oil with first deliveries of certified oil to customers beginning April. This market-leading initiative illustrates IOI-Loders Croklaan’s fully integrated, first-class supply chain while confirming the ability to effectively offer certified, segregated oil to the market. Sethness Greenleaf Flavors, Chicago, appointed McGill & Associates as broker representative in California, Arizona and Nevada. The Asheville, N.C., firm has more than 40 years experience representing ingredient companies in the region.

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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Frozen Baked Goods

A Passion for Bread Highland Baking, a 25-year-old bakery located in Northbrook, Ill., prides itself on creating custom, artisan quality breads, rolls and more at large volumes, but with the care and craftsmanship of the family that it is. It’s also opening a New York-style restaurant that serves its products.

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From left to right, Steve Barnhart, head of R&D; Michael Galenson, director of operations; Stu Rosen, general manager and vice president; Jim Rosen, owner, president/ CEO; Cheryl Rosen-Wedyck, director of human resources; and John Updegraff, vice president of national sales.

Lauren R. Hartman, Editor-in-Chief

A

t Highland Baking, bread is the passion, and service is the specialty. Quality of product is number one. It’s been that way for more than 25 years, as the family-owned and operated bakery in Northbrook, Ill., continues to build long-lasting relationships and meet the total bread needs of its customers. Founded by Jim and Gail Rosen in 1984, Jim being the grandson of Sam Rosen of S. Rosen’s Bakery, a Chicagoland mainstay bakery since 1909, Highland delivers fresh breads to Chicagolandarea restaurants and caterers and frozen products to all 50 states and Puerto Rico via national chain restaurants and manufacturers. It also co-packs for regional and national groceries, bakeries and other food manufacturers, matching their specifications, including flavor profile and packaging or in the easiest way for the next stage of production. Continued on page 18

Photos by Vito Palmisano www.snackandbakery.com

April 2011 - Snack Food & Wholesale Bakery

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Continued from page 17

Being a third-generation Chicagoland bread baker with more than 35 years experience as a manager of baking operations, Jim Rosen, together with his wife, dove right into the bread-baking business.

Son Stu Rosen, vice president and general manager, grew up in the family business and always knew he wanted to be in the bakery business. Daughter Cheryl RosenWedyck is the director of human resources and officially joined the company as part of the customer service department in 2002. With just five employees, the Rosens grew their company right out of its original Highland Park, Ill., location and moved to Lincolnwood, Ill., and then to its current 250,000-sq.-ft. facility in Northbrook, an existing plant that was operated earlier by a snack manufacturer and then by a top ketchup producer. “We’ve been in Northbrook since 2007,” says Jim Rosen.

Thousands of products Today, Highland is an $80-85-million

company that produces an amazing 1,000 stock-keeping units (about 200 of which are designated for frozen distribution), including hamburger buns, mini loaves, 2- and 3-lb. solid and sliced breads, pretzel rolls and buns, onion rolls, hearth and Irish soda breads, rye bread, dinner rolls, hamburger buns, Vienna bread, sour baguettes, fruit-filled breads, multigrain breads and more. The large bakery is truly impressive, generating 400,000-450,000 lb. of dough

each day and as many as 2,700 pallet loads a week. Today, there are 550 employees. Divided in half according to fresh (North) and frozen (South) production, the bakery features three tunnel ovens, four deck ovens, 16 rack ovens and a production team that’s baking, packing, freezing and shipping. Receiving a Superior rating by the American Institute of Baking (AIB)’s Consolidated Standards for Food Safety Certificate, the company is audited annually by AIB (Superior) and Silliker and just passed Levels 1 and 2 of the Safe Quality Food (SQF) program certification. “Food safety is affecting everyone in food,” Stu Rosen says. “We went the SQF path because we find more of our customer base is in foodservice instead of retail, for example. So Continued on page 20

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Continued from page 18

we’re trying to stay ahead of the curve on what customers are looking for and what’s needed.” Equipment plays a major part of that process. In fact, the bakery helped design one of its pretzel lines to be easier and safer for the products and the line operators to work with. “We would like to see equipment designers create systems with regard to food safety that are easier to access, easier to clean with a deeper clean, that could be more flexible, more washable and with

more easily removable components,” says director of operations Michael Galenson. A quality assurance program is in place that uses planned and systematic procedures to provide the consistency, quality and safety that customers demand. The procedures combine product standards and testing, personnel oversight and communication checks throughout the production facility and processes. “Our business has changed a lot,” Jim Rosen observes. “Ten years ago, we produced probably 80% fresh product and 20% frozen, where today it’s pretty much the opposite.” By dollar count, the bakery has more than doubled its production in the past few years. “In 2006, we were at $30 million and by dollar volume, we are around $80

million now, so in this weak economy, that’s pretty amazing,” says Stu Rosen. “We’ve done it with new opportunities more than anything else and establishing customers on the frozen side of our business,” adds Jim Rosen. “We are able to

produce the quality these customers wanted when their secondary suppliers dropped by the wayside [in the weak economy] and were there to take the rest of it.” Top-selling products include fresh and frozen hamburger buns, sliced pan breads, dinner rolls, breadsticks and pretzel products. The mix hasn’t really changed much, says Stu Rosen, though sub rolls are now made on the frozen side of the business. “That’s new, as well as our ability to make pretzel products quickly, but other than that, the mix of popular products remains pretty much the same,” he says.

Custom product development Despite the high volume, Highland develops custom products based on flavor profiles, dimensions, scoring, slicing, bread

Highland Baking Set to Further Entice Customers with Restaurant lans are underway for Highland Baking Co., Northbrook, Ill., to open D.C. Sarnies Restaurant and research and development kitchen, set to open its doors in nearby Deerfield, Ill., in early May. The new restaurant will specialize in sandwiches and classic American cuisine with a twist, offering sandwiches and burgers on Highland’s breads and hamburger buns, as well as a full menu loaded with appetizers, soups, salads, entrées and desserts. It will be managed by a completely different group than those managing the bakery. Delving into the restaurant world is tricky, but the eatery will be more than a new business endeavor, the bakery reports. It’s an opportunity to better service current and potential customers. D.C. Sarnies will also serve as a research and development kitchen for Highland and its restaurant clients. Guest chefs will have a chance to try out new sandwich builds and other recipes, while diners will be able to taste and provide feedback. “We are not opening D.C. Sarnies to go into the restaurant business,” says Stu Rosen, general manager and vice president of Highland Baking Co. “We are opening the restaurant to be better at the bakery business.”

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Continued from page 20

strength, toppings (seeds, grains, cornmeal, etc.), inclusions and more. Made by experienced bread bakers who craft signature products, freeze them and ship them daily, the bakery’s breads include hundreds of varieties within different product categories, such as table breads, dinner rolls, pan breads, hamburger buns, rolls and subs. A development team comprises certified master bakers and a research and development team, and analyzes challenges from a number of angles to determine the best solution. The extensive product list includes breads that match customers’ desired dough type, scoring, slices specs, toppings, dimensions and more.

But to the Rosens, the real meaning of “family business” is the bonds it makes with its customers, says Jim Rosen. “We want you to succeed, and will do whatever we can to help you achieve your goals.” The bakery’s other main advantage is its ability to provide custom samples quickly. “On the frozen side of our business, our turnaround on samples is very quick,” Jim Rosen says. If samples are needed, the

production facility moves right away to provide an expected time of arrival, often with a bread sample out the door within 24 hours. Another factor that makes Highland successful on the frozen side is its focus, says John Updegraff, vice president of national sales. “We really focus on the chains or large accounts and are willing to customize products for them. For restaurant chains, that’s considered a pretty big deal. They want you to make something that builds a point of difference for them. And we deliver on that, day in and day out.”

Main trends There are several bread and bakery item trends that Steve Barnhart, head of research and development, says Highland has been noticing. Among them, pretzel products, spicy, chipotle, which has been big for a few years, as well as multigrain, whole grain and natural. “Natural products are catching on more and more, and people are looking at a lot of different flavors,” Barnhart says. “It’s not just wheat bread anymore; customers want tomato, mixed herb and garlic, onion and parmesan and sweet and savory or savory and spicy—perhaps sweet and spicy or a combination of all of that. We’re open to developing just about anything the customer is looking for. We don’t stock lots of spicy peppers, but we do carry them. So if a customer wants a certain pepper, based on demand, we’re happy to source it out and create a product with that.”

We’re open to developing just about anything the customer is looking for. If a customer wants a certain pepper, based on demand, we’re happy to source it out and create a product with that.

Keeping the TLC Updegraff agrees: “We’re seeing more of the restaurant chains complementing their burgers with proprietary breads, butter flavor breads or brioche, savory breads and buns, a different kind of hamburger bun build, inclusions, jalapeño peppers, chipotle and toppings like sesame seeds. The pretzel products are also building a lot more traction as are different kinds of slider buns and minis and specialty sandwich builds like Ciabattas.” The bakery will likely expand again, and may need to add another plant or two. Continued on page 24

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Continued from page 22

“Our investment over the next number of years will be directed more to expanding our capacity and where that capacity will be located in the country versus further automating our plant,” explains Stu Rosen. “Given our demand and what we hear customers looking for, that’s the direction we will be heading. We’ll likely add a facility within the next four to five years in another part of the country, probably the West Coast would be the leading contender right now.” Adds Updegraff, “If we were to further automate, we couldn’t meet all of the proprietary needs of these restaurant chains. We have a good balance between being efficient and still being able to put some TLC

[tender loving care] in our products to give them what they want. It’s a good blend and plays well with our customer base.” Highland also is about to delve into the in-store bakery arena and co-packs for some national retailers. As if this isn’t enough, the company has plans to open a new restaurant in Deerfield, Ill., specializing in sandwiches and burgers served on Highland’s breads and buns (see accompanying sidebar). Yet with all of this, the company still never strays from the ideals of its modest beginnings: Provide a quality product and exceptional service and always treat customers and team members like family, points out Jim Rosen. “We face challenges each day, though there are different challenges, but we love what we do,” he concludes. “We constantly push ourselves to continue to grow in size, in ability and with the people we have,” echoes Stu Rosen. SF&WB

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Blending customer service with a healthy dash of automation, Highland Baking Co.’s impressive 250,000-sq.-ft. operation in Northbrook, Ill., is home to four tunnel ovens, 15 decks of hearth ovens, 16 rack ovens, 14 production lines, seven of which are dedicated to frozen products and a production team that’s always on-the-go baking, packing, freezing and shipping. Lauren R. Hartman, Editor-in-Chief

early three times the size of Highland’s last plant, the Northbrook, Ill., facility houses seven production lines in 250,000 sq. ft. Production is organized into North and South sections of the facility. North is predominantly used to bake fresh products (about 15% of the company’s overall business today) in smaller batches for local delivery. The South side is highly automated (there is still some manual labor, but less than for the fresh product) and produces frozen products almost exclusively (85%). Continued on page 28

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Photos by Vito Palmisano

Just emerging from the oven, 2-lb. loaves of glistening bread will head to a spiral cooler en route to the packaging department. Highland produces an amazing 400,000450,000 lb. of dough daily.

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Ever automating The frozen division provides hamburger buns, specialty pan breads and many other types of bread to foodservice customers nationwide as well as restaurants, such as Arby’s, Chili’s BJ’s Restaurant and Brew Pub and many more, while the fresh product is trucked throughout the Chicago area. There are 14 truck routes. Operation is three shifts a day, five days a week on the frozen side of the business, but if a special promotion is needed or depending on the season, more shifts can be added. The smaller-batch fresh-product production lasts seven days a week, says Michael Galenson, director of operations. A USSR émigré and holder of a degree in food and restaurant management from a college in Moscow, Galenson has a long history in the foodservice industry. He joined Highland in 1996 as the plant manager. Highland was able to install most of its existing equipment in the Northbrook plant, but bought a second tunnel oven and several rack ovens, a third stone hearth, a deck oven, a 2-pocket multipurpose divider, a 6-pocket roll line and, with demand escalating for frozen products, a 2,200-pallet freezer. Today, the production facility features seven lines feeding four tunnel ovens for frozen products, seven dedicated lines feeding 16 rack ovens and 15 decks of hearth

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ovens on the fresh side of the plant. A second-story space over part of the building is not yet used, says Stu Rosen, general manager and vice president, but could be put into service in the future. At the time of Snack Food & Wholesale Bakery’s visit, the facility was producing pan breads, mini buns, hamburger buns and sliced breads, among other items.

Special ingredients Allergen ingredients are kept in separate, clearly marked containers on rollers that can be moved if needed. These containers are sectioned off to the side of production. “We use anything from spices to seeds to California raisins to chocolate chips,” says Steve Barnhart, head of research and development. “Depending on the inclusion, it can go into the mixer with the rest of the ingredients or at the end of mixing by folding in slowly.” Barnhart says that some customers are starting to want real product inclusions in their breads instead of flavorings. “That may be because of the movement toward clean labels,” he says. “People want to know what’s in their bread, that they’re eating something that’s made of all-natural ingredients. That’s been a big trend.” Water is metered to the lines and the flour is transferred from a silo distribution system to computerized individual weigh stations on the large mixer hoppers. Minor ingredients are carried over on pallets, bags or boxes, depending on the frequency of

their use, and are scaled by hand. Advanced computer controls provide flexibility with a variety of the products, though computerization isn’t plant-wide yet, says Galenson. “Order processing is computerized and individual machines have computerized controls,” he says. A series of small mixers work on fresh dough in the North side of the plant, and four large-capacity horizontal mixers are used on the frozen South side. Primary ingredients and flours, bases, conditioners, coloring/flavoring, additives, eggs, butter, oil and spices are stored in an adjacent warehouse, but the majority of the primary ingredients for the frozen products, such as bulk flour, are stored in a set of bulk silos on the other side of the building that each hold 300,000 lb. That’s important, as the plant produces an astounding 400,000450,000 lb. of dough daily or up to 2,700 pallet loads a week. After the ingredients are mixed into dough, depending on the line, they are dumped into a hopper leading to a chunker that cuts individual pieces in a pocket divider. The dough is then formed into balls or another shape by various equipment, including conical rounders that rotate to form and shape the dough. Depending on the product, a dusting of flour or corn meal prevents sticking and adds flavor. The pieces then are dropped into a basket maize system where the dough rests for about 10-15 minutes. This is done so that when it’s formed into its final shape, the dough won’t tear or fight the shape, Barnhart says. The dough can also be left round or curled up to form breadsticks, a submarine shape, loaves or various other products and then be placed in pans, on trays or on peel boards. On the stress-free (Ciabatta) line, the dough travels on a series of conveyors to a sheeter, which gives it its final shape. A series of rollers reduce its thickness to ultimately produce all sorts of shapes— squares, rectangles and other forms with the right attachments. The pans are automatically pregreased to help the bread release from the pans after baking. On another line, sheeted breadsticks,

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Pieces of dough are dropped into a basket maize system that allows them to rest for 10-15 minutes prior to further handling and moulding.

for example, are picked up by operators and are loaded into baking pans that feature grooves to hold the breadsticks in place. “We have very flexible, versatile machinery,” points out Stu Rosen. “Some of our systems can make multiple sizes and shapes of different products.” Adds Barnhart: “If a customer wants a certain type of Ciabatta, but wants a lot of it, we can meet that demand because we have a line that can produce that quantity. The equipment produces a lot of volume and throughput.” Next, the trays, peel boards or pans are manually placed on movable racks

that are moved into one of the proofing boxes. The line staffers place 30 racks of 30 pans or trays per rack into one of four proofer boxes on the (frozen) South side of the plant. Each proofer is dedicated to an oven.

On to proofing Proofing takes approximately 45 minutes to 1.5 hours at 90-105ºF and 75-85% RH, but this also varies with the product, weather conditions, size and shape. Just after proofing, the products receive toppings, such as sunflower/poppy seeds, crushed oats or sesame seeds in the case of

hamburger buns, and are scored or docked. When the racks of products are removed from the proofer, they’re moved to one of the four tunnel ovens fed by the seven lines making products for frozen distribution. There are two tunnel ovens in place, measuring 80-ft. long and two measuring 120-ft. long. The shorter ovens can handle 4,400 buns per bake while the longer ovens bake up to 6,700 buns at a time. “The 80-footers predate the 120-footers,” Barnhart explains. “Certain lines produce enough product to feed the bigger ovens and others go to the shorter ovens. The reason that we have five mixers and four ovens on this side is because we do a sponge-and-dough method [a two-stage method of mixing] for some products.” Products can bake at temperatures that range from 300-450ºF for eight minutes to one hour, depending on the application. In some cases, product is placed by hand on a conveyor leading to the tunnel oven. Hamburger buns are grouped in counts of seven, with each pan holding 24 pieces. Pans then travel on a conveyor heading toward one of the 120-ft.-long ovens, and are staged to slowly enter the 120-ft. tunnel oven. Scoring is performed automatically at this point, if necessary. A starch-based shine spray also is automatically applied to the tops of buns, rolls, breads, etc., after exiting the oven. From the ovens, the baked items are automatically depanned as suction cups gently grip them and deposit them on the upper level of a conveyor while the pans travel onto a lower level of the conveyor and head back to the front of the line from where they started. The products then move into one of several large ambient-temperature spiral cooling conveyors where they travel for anywhere from 40 minutes to 1.5 hours to cool. Each oven has its own dedicated spiral cooler. Next, the products progress onto a four-lane conveyor and are checked for the proper weight, color and size, which is done in the nearby packaging area. The product needs to cool prior to packaging Continued on page 30

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Continued from page 29

to remove any moisture that evaporates. At this point, a spot check is made. In fact, there are several quality control checks conducted throughout the facility, and Highland follows the Hazard Analysis Critical Control Point (HACCP) program and there are inspection points all throughout production. “We check quantity, quality of all incoming ingredients as well as the truck it comes in, and everyone who encounters the process is inspecting throughout the process,” Galenson points out.

Well-planned product flow “The lines are arranged so that everything flows in one direction, so that there is no crossover between things or cross contamination,” says Barnhart. “Advanced automation has allowed us to provide a wider range of products to many more customers. Everyone asks for something different, so being able to meet their demands has

Large hamburger buns convey downline where they’re sprayed with a starch-based shine mixture that adds a glossy top to the just-baked buns. really benefitted our market share.” The conveyor can also take products through a slicer if necessary before they are wrapped in clear film or in bags, depending on the quantity and application. They also go through a metal detector that checks for minute contaminants. Packaging is performed mostly manually in clear film multipack wraps, individual bread bags and multipack bags, depending on customer requirements. Packaged products are

placed in corrugated cases (erected automatically) that are lot-stamped and inkjetcoded with production codes. The cases are manually loaded onto pallets, which are automatically stretch-wrapped before they’re sent either to a pallet freezer in the building that maintains a -5ºF temperature or go directly to an outside cold storage facility with similar temperature settings. “We put 2,200 pallets into the freezer,” Galenson says. “Our frozen products have

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Products travel through an ambienttemperature spiral cooling conveyor anywhere from 40 minutes to 1.5 hours to cool. Each oven has its own dedicated spiral cooler. procedures, maintenance and prepares for the next week.

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a six-month shelf life.” Production speeds vary by the line but average 2,150 per hour for pan bread and 21,000 pieces per hour for buns. Most fresh orders are taken over the phone until 11 p.m. Customers can call at 3 a.m. that day and receive delivery the same day, says Jim Rosen, president/CEO and owner. Orders for frozen products are taken by fax, electronically by email or electronic data interchange (EDI). Frozen production lasts five days a week, from Sunday afternoon until Friday afternoon when the plant performs its cleaning

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Highland added several pieces of new equipment since it moved into the Northbrook facility and continues to add new systems, which it did recently, and upgrade as necessary, says Barnhart. “We have increased production by more than double, as well as the amount of product varieties we make,” he adds. “So we’ve added to the number of our makeup lines since we moved in, including a ‘stress-free’ Ciabatta line that is practically operator-less that mimics a lot of the hand work we do on the ‘fresh product’ side of the facility, a sub roll line and lines that can produce multiple types of product and equipment that takes up less floorspace.” The lines can be changed over as much as a few times a day or once a week, Barnhart reports. “That depends on orders.

It varies with our orders and what our customers want.” Barnhart says that the bakery recycles various materials, including plastics and corrugated, and has a lot of its food waste repurposed as pig and cattle feed.

Balancing it all How does Highland balance its strict quality control measures with being flexible and creating custom products at a faster pace, as well as meeting all of its food safety standards and more? “We have a lot of good team players and get everyone’s input,” Barnhart says. “Everyone here has a lot of great experience that they bring to the table. Quality of product is number-one. That’s the No. 1 thing that we strive for. After we develop the quality the customer looks for and we want, the next goal is to make the product as quickly and efficiently as possible without sacrificing the quality.” SF&WB

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Snack Food Today CoroWise (Cargill), Corazonas Foods Form Partnership Corazonas Foods, Los Angeles, makers of Corazonas-brand snacks, and Cargill, Inc., Minneapolis, producer of CoroWise plant sterols, join forces to lower cholesterol and make it easier for consumers to enjoy healthy snacking. Corazonas’ team of tortilla chips, potato chips and oatmeal squares will now be made exclusively with CoroWise plant sterols, which have demonstrated in numerous clinical studies the ability to decrease “bad” (LDL) cholesterol. The amount of plant sterols in each Corazonas snack will remain unchanged, with 0.4 g. per ounce (one serving) of potato or tortilla chips and 0.8 g. in each oatmeal square. The Food and Drug Administration-authorized health claim currently recommends consumption of at least

0.4 g. of plant sterols twice a day to start seeing cholesterol-lowering benefits. “People make healthy New Year’s resolutions every year, but a lot of times, especially when it comes to diet, they wind up feeling deprived, frustrated and end up abandoning their resolutions,” says Ramona Cappello, founder of Corazonas Foods. “We want consumers to know they have options, and support them in setting goals they can actually keep this year: To make smart food choices and resolve to enjoy snacking again. Along with our new partnership with the CoroWise brand, we’re excited to give people trying to manage cholesterol some truly delicious snack options that may help lower cholesterol with clinically-proven ingredients.”

Signature Brands Opens New Popcorn Production, Distribution Facility Signature Brands, LLC opens a new 207,000-sq.-ft. popcorn popping production and distribution facility near its headquarters in Ocala, Fla., which once in full operation, will employ more than 600 staff members, including year-round and seasonal, and operate 24/7. Signature Brands, which is owned by Switzerland-based The Hero Group, acquired Popcorn Expressions, a holiday popcorn producer, in August 2008. Since the acquisition, Signature Brands has been producing decorative tins for other holidays, including Halloween and Easter, and is introducing a smaller size for everyday snacking, says marketing senior vice president Nando Zucchi.

Baptista’s Bakery Considering Adding Production Lines Baptista’s Bakery Inc., a manufacturer of private label-baked custom snacks, is considering adding another production line to its Franklin, Wis., headquarters, says Nan Gardetto, chief executive officer. The Franklin Community Development Authority will consider approving a $17-million industrial revenue bond sale, which Baptista’s says it might use to help finance the expansion. The company would then borrow the money by selling the bonds to investors, and then repay that debt over several years. Gardetto started Baptista’s in 2000, one year after her family sold Milwaukee-based snack mix maker Gardetto’s Bakery Inc. to General Mills.

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Study: Pistachios Are a Heart-smart Snack For some time, pistachios have been deemed a hearthealthy snack. Now, studies prove that they’re also a heart-smart snack. New research from a study conducted by Penn State University, University Park, Pa., shows that phytosterols found in pistachios may improve cholesterol, a factor in cardiovascular health. “We already know that pistachios are a naturally cholesterol-free food, but this new study suggests that phytosterols, or plant sterols, in pistachios may help to reduce the absorption of cholesterol,” says Constance Geiger, nutrition expert for the Western Pistachio Association, Fresno, Calif. “Lowering cholesterol may reduce the risk of heart disease, so these findings give people even more reasons to snack on delicious pistachios.”

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Mark your calendar for these two

22ND ANNUAL TORTILLA INDUSTRY ASSOCIATION CONVENTION & TRADE EXPOSITION

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WWW.TORTILLA-INFO.COM

Letter to the Industry

Dear Members of the Tortilla Industry,

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he Tortilla Industry Association (TIA), which represents the fastest growing sector of the baking industry, with approximately $11 billion in estimated 2011 revenue and a doubledigit growth rate, invites you to share the passion and the profits by joining us for our two main events of this year—the TIA Technical Seminar and the TIA Convention. First on the calendar is our technical seminar, which takes place May 23-24 at the Disney Grand Californian in Anaheim, Calif. This event is returning to its usual spring timeframe after shifting last fall to colocate with the triennial International Baking Industry Exposition (IBIE). The technical conference focuses on operational issues associated with tortilla and flatbread production, and features a tabletop exhibits reception. It kicks off with a full day of educational sessions. Topics to be presented include updates on the latest in food safety regulations, safe handling of ingredients, preparing for third-party audits, commodity and ingredient pricing and trends and improving supervisory skills. A working lunch will feature an “ask the experts” open panel in which attendees can submit questions in advance or on the spot. Immediately following the educational sessions is a cocktail reception featuring tabletop displays from suppliers, cocktails and hors d’oeuvres from 5-7 p.m. Because we also provide an opportunity to learn best practices first-hand, the second day consists of field trips to several facilities. Beginning at 8 a.m. on May 24, conference attendees will board buses that will transport them for a full day of factory tours and training sessions. The first session runs from 9:15-11:15 a.m. and will be presented by Casa Herrera of Pomona,

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Snack Food & Wholesale Bakery - April 2011

Calif. Next, the group will visit a factory hosted by Lawrence Equipment in South El Monte Calif., from noon-2 p.m., along with lunch. The third stop includes demonstrations and training sessions hosted by J.C. Ford Co. of La Habra, Calif., where beer, snacks and refreshments will be provided from 2:45-4:45 p.m. Our events are intended to give attendees ample opportunities to meet and talk

Jim Kabbani, chief executive officer Tortilla Industry Association, Arlington, Va.

with others in the industry. We want our members to have time to learn from each other’s experiences through networking, as well as to develop valuable new business and sales contacts. We also arranged for discounted tickets at Disney’s theme park for attendees who bring their families. Then, our main event of the year, TIA’s 22nd Annual Convention and Trade Exposition, which was shifted last year to May as part of accommodating the IBIE co-location, will return to its traditional timeframe, Sept. 12-13 at Caesars Palace, Las Vegas. The annual convention offers more business-related educational sessions and features a two-day tradeshow with full-size exhibit booths from leading suppliers in the industry.

An interesting opportunity presented itself to TIA during the course of planning our 2011 convention’s return to its traditional September timeframe. Although we initially planned to hold our 22nd Annual Convention and Trade Exposition at the Paris Hotel in Las Vegas, the Harrah’s chain, parent company of several Las Vegas hotels, including Paris, Bally’s and Caesars, contacted the association late last year and offered significant incentives to consider helping the Harrah’s chain take advantage of an opportunity of its own that would maximize utilization of their meeting facilities by moving the dates and location of the TIA event. Therefore, I am happy to report that in exchange for scheduling our convention back to its traditional September timeframe, we were able to negotiate substantial concessions that help us provide terrific value to our membership, exhibitors and attendees. As a result, convention attendees will receive a discounted room rate of only $89 per night at Caesars Palace. Also, the exhibit hall is larger and able to accommodate a larger number of booths and exhibitors. I am confident that our 22nd Annual Convention at Caesars Palace is going to be our best yet, and hope you will make plans to come and see for yourself. TIA’s convention committee is also working on leveraging some of these incentives into upgraded entertainment at its annual banquet and lining up the best speakers yet at its educational sessions. To register for both events, to receive updates or to learn more information, go to www.tortilla-info.com.

TORTILLA TRENDS

TIA TECH CONFERENCE

T

hings change quickly in today’s business climate—government regulations, competition, formulation, tools and equipment and even your staff. To stay on top and get ahead, the Tortilla Industry Association (TIA) provides the tortilla and flatbread industry with the latest information on the key topics needed to survive, thrive and prosper. The TIA Tech Seminar, which takes place May 23-24 at the Disney Grand Californian in Anaheim, Calif., focuses on the operational aspects of running a factory and on safety and regulatory issues. The seminar also allows others in the industry to learn from experiences through networking and on-hand best practices by going on a field trip to several facilities. To register, reserve a booth or to learn more information, go to www.tortilla-info.com.

Photo courtesy of Tortilla Industry Association

Agenda Monday, May 23 8:30-9:00 a.m. Introduction by Jim Kabbani, chief executive officer of TIA 9-9:50 a.m. Safe Handling of Ingredients 10-10:50 a.m. GMP/HAACP Training 11-11:50 a.m. Preparing for Third-party Audits Noon-12:50 p.m. Working Lunch: “Ask The Experts” 1-1:50 p.m. LEED Certification/Going Green/Social Accountability/Non-GMO 2-2:50 p.m. Commodity and Ingredient Pricing, Cost Trends 3-3:50 p.m. Trends in Healthy Tortillas and How to Formulate: Sodium Reduction, Fiber, etc. 4-4:50 p.m. Improving Your Supervisory Skills 5-7 p.m. Tabletops and Cocktail Reception Tuesday, May 24 8-8:30 a.m. Board buses for field trip and factory tours 8:30-9 a.m. En route to first location 9:15-11:15 a.m. Factory tour and training session presented by Casa Herrera 11:15-11:45 a.m. Board buses and drive to second location Noon-2 p.m. Factory tour and training session presented by Lawrence Equipment, working lunch 2-2:45 p.m. Board buses and drive to third location 2:45-4:45 p.m. Factory tour and training session presented by J.C. Ford 4:45-5:15 p.m. Board buses and return back to hotel

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Snack Food & Wholesale Bakery - April 2011

TORTILLA TRENDS

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hen it comes to tortillas and flatbreads, different is the same. While one type of tortilla may contain extra fiber or be a good source of whole grains, at the end of the day, it’s still just a tortilla. For many of today’s ingredient suppliers, however, tortillas and flatbreads don’t

have to carry the same ‘ole/same ‘ole attributes. In fact, a tortilla can deliver glutenfree ingredients and promote a longer shelf life all at the same time. Meanwhile, flatbreads can offer a multitude of spices and all-natural ingredients but also pride on form, functionality and texture. Some would say that these attributes offer up the best of both worlds.

“Tortillas have become mainstream and are a viable alternative to traditional bread,” says Ann Rolow, business manager, North America, for Kemin Food Technologies. “When we look at the bread aisle, we no longer see white sandwich bread. Instead, we see a massive variety of whole grain, good-for-you, tasty options. This is also the direction the tortilla needs to follow, to maintain its status in this food category.” In order to compete with the bread aisle, tortillas and flatbreads need to offer the same shelf appeal, so-to-speak. That’s why Des Moines, Iowa-based Kemin introduced FORTIUM, a line that takes shelf life one step further by protecting the color and flavor of fresh-baked tortillas. “One of the challenges with the usage of whole grains is the development of off flavor due to the natural oils contained in the germ,” Rolow says. “When the grain is cracked or ground, these oils are prone to oxidation, which changes the flavor characteristics of the tortilla over time. The addition of FORTIUM to the freshly ground grains or to the tortilla formulation will extend shelf life and prevent the development of the bitter off-flavors.” Kemin also launched FORTIUM TR30, a unique blend of natural and plantderived ingredients that delay oxidation to maintain color in paprika and red-colored spice blends.

Photo courtesy of Kemin

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TORTILLA TRENDS

Photo courtesy of Caravan Ingredients Photo courtesy of Caravan Ingredients

“The use of whole grains has become mainstream for a healthy life, and color adds variety and appeal to chips and wraps,” Rolow adds. “Our products offer a natural means to protect the nutritional qualities, flavor and visual appeal formulated into tortillas.” For its part, Caravan Ingredients developed Tortilla Suave, a conditioner that combines the latest in extended shelf life and anti-sticking technology to create highquality tortillas. “Conventional flour tortillas require a significant shelf life while still maintaining functionality for retail and foodservice. Producers need a soft and pliable tortilla that has great flexibility and anti-sticking capabilities. These functional requirements of a finished tortilla have become a real point of differentiation between the manufacturers of these products,” says Nick Scheurer, tortilla and flatbread products

manager for the Lenexa, Kan., company. “Tortilla Suave, for example, provides anti-sticking capabilities while also providing softness and flexibility attributes in the finished product.” Clabber Girl Corp., Terra Haute, Ind., is helping tortilla manufacturers extend the shelf life of their products with Innovaphase, a two-phase encapsulated Fumaric that helps provide better pH control throughout the shelf life of the product. “Tortilla manufacturers have a need to create new products to keep up with trends. They need no- and low-sodium solutions. They are being challenged to develop good shelf-life products, for example, and gluten-free products. What we’re helping to provide there is better pH control,” says Lou Fahey, national sales manager for the industrial sales division. The two-phase system allows some needed leavening during the mixing phase, Fahey says, while the second phase

activates in an oven, augmenting added preservatives for longer shelf life and improved product performance. “A tortilla manufacturer works on a slim margin, so it’s not willing to sacrifice taste and cost,” he adds.

Photo courtesy of Cain Food Industries, Inc.

Cain Food Industries, Inc. also provides solutions in relation to the extended shelflife trend with CFI-10 Powder, a dough conditioner that enhances texture and resiliency of the tortilla, thus extending its shelf Continued on page TT-10

TORTILLA TRENDS

April 2011 - Snack Food & Wholesale Bakery

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Photo courtesy of Allied Blending & Ingredients, Inc. Continued from page TT-9

life, says Wilfredo Rivera, regional sales manager for the Dallas-based company. With regards to flatbreads, he adds, Cain offers FBDC P37, which is designed to mellow and relax the dough for superior machinability while promoting moisture retention, resulting in a softer, more flexible flatbread. “In the baking industry, we continue to experience micro trends. Some consumers want healthier products like reduced salt and sugar, while others want a variety of flavors, for instance corn tortillas versus flour tortillas. That’s right, a flour-based tortilla made with corn. Its products like these that benefit from strengthener such as N’hance Ultra, which allows these products to deliver great taste and superior performance to enhance our culinary experience when dining out,” Rivera adds. Cain also produces Tortilla BASE K, which is a balanced base specifically formulated for the production of flour tortillas. “The free-flowing powder is easy to scale and use. Formulated to combine with wheat flour, water and shortening, Tortilla BASE K reduces mix times resulting in a mellow and relaxed dough,” he notes. “By adding Tortilla BASE K, you will decrease dough elasticity to improve rounding and pressing and reduce shrink back and curling of your edges. During processing and packaging, Tortilla BASE K reduces sticking and allows for ease of separation of the finished product. The resulting product has a desirable appearance and outstanding eating qualities.” Additionally, Thymly Products, Inc., Colora, Md., has been working to extend the shelf life of corn and flour tortillas through the use of its gums and starches, says Trey MullerThym, sales. “We have found that both products tend to have a greater shelf life when you combine multiple gums and starches, giving a synergistic affect that might not be seen when using just one,” he adds. “The other

positive side that is quickly noticed by our customers is they actually can use less, which reduces their bowl cost. We feel that these combinations will grow in popularity as we continue to see gum prices rises.” AB Mauri Fleischmann’s, Chesterfield, Mo., also provides extended shelf-life solutions. “Tortilla and flatbread manufacturers are turning to AB Mauri Fleischmann’s to improve the current quality of their products and expand product offerings,” says E.B. Russell, technology development manager for the AB Mauri Baking Technology Group. “We offer bakery ingredients that improve the shelf life through anti-staling technologies and preservation systems, as well as meeting consumer demands for healthier (low-fat, low-sodium, high-fiber

and natural) products. Utilizing the entire AB Mauri Fleischmann’s product line enables a tortilla or flatbread manufacturer to create new products and improve the quality of their current ones.” Form and function

In addition to a longer shelf life, today’s tortillas and flatbreads need to provide function and formality fused with an authentic, high-quality appeal. That’s why Ventura Foods developed NTrans, a no-trans, clean, simple solution that is lower in saturates and acts as a highly functional product shortening. “The issue is always safety, healthier, natural and cleaner labels,” says Frank Stynes, senior vice president of the Brea, Calif., company. “Our NTrans is labeled as soybean oil and emulsifiers. That’s all.” Likewise, a number of bakers and food manufacturers are looking for ways to create high-quality, greattasting, gluten-free products, says Brook Carson, technical products and market development manager for ADM. That’s why the Decatur, Ill., company developed Harvest Pearl, a white or white whole grain sorghum flour that’s designed specifically for gluten-free flour tortillas.

Photo courtesy of AB Mauri Fleschmann’s

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TORTILLA TRENDS

Photo courtesy of ADM

ues to garner additional opportunities to develop premium products. “With the proliferation of wraps being added to menus across quick-serve and casual-serve restaurants, their appeal will only increase,” says Marge O’Brien, insight manager for Caravan Ingredients. “Flatbreads offer a better-for-you, versatile

“Harvest Pearl white sorghum flour is a gluten-free flour that provides a neutral flavor profile, light color and fine granulation—all important when trying to develop gluten-free products that mimic traditional wheat-containing products,” Carson adds. Additionally, its Prolite wheat protein isolates are created as a clean-label ingredient that improves sheeting and masks the bitterness of whole grains in tortillas and flatbreads. “Tortilla and flatbread producers use Prolite to improve machinability and flavor of whole grain products,” Carson notes. “Sorghum flour can be used as a primary flour source to help minimize costs of creating gluten-free products. Several components are required to replace the functionality of wheat, and sorghum can be an important factor.” Meanwhile, Allied Blending & Ingredients, Inc. (ABI), Keokuk, Iowa, offers up function in the form of a BatchPak, which is a compilation of customized, functional ingredient formulations that meet consumer demands for nutritionally-enhanced products, such as extended shelf life, low sodium, heart healthy and clean-label products. “ABI identifies specific functional ingredients and assembles them together in our BatchPak format so that the customer does not have to inventory each ingredient,” says Randy Schmelzel, president. “The BatchPak provides consistency of use on a batch-to-batch basis, and the customer is relieved of researching and testing each ingredient for their unique application. The BatchPak accomplishes that for them.” At the end of the day, the explosion of the tortilla and flatbread market contin-

TORTILLA TRENDS

option and we see many variations in the marketplace ranging from hemp seed to gluten-free, vegan to whole grains, as well as lower sodium product offerings.” Tortillas and flatbreads may be just that—tortillas and flatbreads—but at least now, they offer the best of all worlds. SF&WB

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full speed ahead Thanks to an increasing demand for tortillas and flatbreads, many of today’s equipment manufacturers are thinking—and creating—forward in a bigger, stronger and more versatile way. Marina Mayer, Executive Editor

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or the past couple of years, the economic model of supply and demand has hit the equipment manufacturing community head-on. As tortilla and flatbread producers lowered their supply by scaling back on stock-keeping units, they also have lessened the ability to be innovative with their portfolios. And as they refurbished old equipment in hopes of making them last a bit longer, they simultaneously shied away from building, expanding or enhancing their facilities, even if it meant strengthening the bottom line. It’s almost as if tortilla and flatbread makers placed a bandage on their lines and walked away.

Now, they’re ripping off that Band-Aid with the help of their equipment suppliers by replacing old, tired equipment with new, state-of-the-art belts, dividers, rounders, sheeters, ovens, to name a few. The non-stick approach

One of the challenges that tortilla and flatbread producers face is creating a product that doesn’t stick to the equipment that bakes it. That’s why Taconic, Petersburgh, N.Y., developed a high-temperature, non-stick belt designed for pressing flour tortillas and flatbread. The A1127 belt lasts 25-30% longer than standard belts, according to Alberto Chavez, national sales manager, industrial Photo courtesy of Taconic products division, and it features a high-performance substrate with a proprietary polytetrafluoroethylene (PTFE)-based coating that is specifically engineered for abrasion- and punctureresistance. “Tortilla and flatbread manufacturers will continue to focus on the quality of their products,” Chavez says. “However, with the challenges of reducing costs and integrating sustainability programs, manufacturers will turn to higher-perform-

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Snack Food & Wholesale Bakery - April 2011

ing and lower-cost equipment. Taconic offers longer-lasting belts, which reduce production downtime, leading to higher efficiencies and lower costs associated with belt changeovers. It also means less consumable items are entering landfills.” Running at full circle

To keep up with the ever-increasing demand for higher volumes, greater efficiencies, more advanced quality standards and ever-changing food safety concerns, J.C. Ford is continuously moving forward with new technologies, says Kyle Armstrong, sales manager. For starters, the La Habra, Calif., company introduced a new series of sheeters designed to improve weight control and thickness at higher speeds. “These new units are equipped with our new ‘cam force’ patent-pending weight control that provides much greater control at maintaining product weight,” Armstrong says. “With these high-speed lines controlling the weight of every tortilla to less than 0.2 g., customers can save more than $100,000 per year on product giveaway.” For both flour and corn tortillas, J.C. Ford released a 100% infrared (IR) burner oven that reduces energy needs by up to 30% and increases baking uniformity. “The flour tortilla lines have been equipped with our new ‘no-shim’ system,”

TORTILLA TRENDS

Photo courtesy of J.C. Ford

Illustration by J.C. Ford

Armstrong says. “Mounted over the top platen of the press is a series of adjusting knobs to make small changes in product sizing. This eliminates any need to drop plates or change shimming systems.” J.C. Ford also re-tooled its counter/ stacker with a new control system and a user-friendly touchscreen, Armstrong says, to provide more information at the touch of a button. “The control also includes a new auto reset for jams that keeps lines running and minimizes downtime. Because every packaging environment is unique, we have also increased engineering support for developing the most effective systems for each

TORTILLA TRENDS

customer,” Armstrong says. Meanwhile, companies such as Heat and Control, Hayward, Calif., provide an entire gamut of equipment specifically developed for tortilla and flatbread manufacturers. For corn tortillas, Heat and Control builds complete systems, including dry corn cookers, masa preparers, sheeters, ovens (and fryers for tostadas and taco shells), seasoning applicators, conveyors, checkweighers, metal detectors, x-ray and packaging equipment, says Caleb Reyes,

regional sales manager for processing systems. “Our recent developments emphasize producers’ needs for higher capacity, production flexibility and increased efficiency,” he says. For example, the company’s high-speed, high-capacity table tortilla systems are capable of producing up to 8,000 dozens per hour. Plus, Heat and Control’s Rotary Brander allows bakers to apply parallel grill marks to tortillas, sandwiches and more, Reyes says. “We also build directflame searers and infrared ovens that can produce unique surface finishes,” he adds. Appealing to the flatbread market

When all is said and done, the flatbread industry faces the same type of issues as others in the bakery market. That’s why Reiser launched a team of dividers and rounders that, “accurately divide over a wide range Continued on page TT-14

Photos courtesy of Heat and Control

April 2011 - Snack Food & Wholesale Bakery

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Continued from page TT-13

of absorbtions and viscosity. This gives the producers versatility as they develop new products,” says John McIsaac, vice president, strategic business development for the Canton, Mass.-based equipment manufacturer. Reiser’s Vemag dough divider, for instance, adds versatility, flexibility and accuracy to nearly any tortilla or flatbread production line. At the heart of the divider is the double-screw transport system, which enables positive displacement and exact-weight portions. Plus, it can handle up to 45-95% absorption rates. Additionally, Reiser’s Repak horizontal form/fill/seal packaging machines offer superior sanitary design, high production rates and maximum reliability. Made from heavy-duty stainless steel, they are engineered to meet the highest standards of hygiene and are designed for a quick and safe washdowns. And the rapid air forming

Photo courtesy of Reiser

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Snack Food & Wholesale Bakery - April 2011

manufacturers are replacing old, tired equipment with new, stateof-the-art belts, dividers, rounders, sheeters, ovens, to name a few. system allows the use of thinner films while maintaining thickness in package corners, resulting in significant packaging material savings. Quality versus quantity

As far as the latest trends go, tortilla and flatbread machinery must come equipped with an assortment of hightech gadgets. “The future for tortilla and flatbread equipment is greater capacity systems that utilize automated controls to reduce human error and ensure consistent, quality products,” Armstrong says. “The next-generation equipment is being designed to not only reduce labor and scrap but also increase efficiencies and reduce the effects on the environment.” Corn tortilla producers are in search of higherquality products that deliver longer shelf life, while flour tortilla makers are churning out different types of ethnic-inspired products, Armstrong adds. “[For corn tortilla producers], it’s no longer just corn and water; today other ingredients are needed as well as improved baking

systems to provide softer more flexible products with extended shelf life,” Armstrong notes. “You walk down the bread section today and see Middle Eastern, Indian, Asian and other ethnic breads. Our systems are being designed to handle many types of flatbreads with one line giving the producer greater options.” Additionally, equipment must be versatile. “We are constantly working to keep our machines versatile with new dividing options and rounding techniques,” McIsaac says. “The producers will listen to their customers and develop what the market wants. We see all-natural and gluten-free as areas of growth. We also see specialty flavors that include inclusions such as pepper and onion.” Regardless of the bumps and bruises the tortilla and flatbread market endures, manufacturers continue to focus on the quality of their products, Chavez says. “The tortilla and flatbread markets will continue to grow in the coming years and flavor and quality will be the focus of this growth trend,” he adds. “It has been established that tortillas are a healthy, convenient and inexpensive food. Going forward, the winners will be those producers who present better flavor and higher quality in their products.” That’s why tortilla and flatbread equipment manufacturers are moving forward in a bigger, stronger and more versatile way.

SF&WB

TORTILLA TRENDS

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www.alliedblending.cOMs    © 2011 Allied Blending & Ingredients. All rights reserved.

Market Trends Portion Control

Perfectly Portioned New single-serve and portion-controlled baked goods and snacks enable consumers to satisfy their cravings a little bit at a time. Romy Schafer, Contributing Writer

hen it comes to a favorite snack food, most people find it difficult to eat just the manufacturer’s recommended serving size. A dozen tasty potato chips or four chewy cookies quickly disappear when a person is snacking while watching television, at work or engaged in other activities. It’s easy to see how a 150-calorie treat can turn into a 1,500-calorie overload. Americans are now recognizing that when it comes to food, more isn’t always better. In fact, consumers are trying to be more cognizant of how much they eat—not just what they eat—and are seeking out foods, especially snacks, in single-serve and portion-controlled (usually 100-calorie) packages. Single-serve and portion-controlled baked goods and snacks offer consumers other benefits as well. A small bag of chips, cookies or freeze-dried fruit is more portable than a multi-serve bag and just the right size for a child’s lunchbox or an adult’s briefcase. Because people usually consume the entire contents of a single-serve bag, storage, freshness and waste aren’t issues. In addition, individual bags usually retail for

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www.snackandbakery.com

$1-2, enabling consumers to inexpensively sample new flavors and products. Given all the advantages single-serve products have over their larger counterparts, it’s not surprising that more consumers are thinking small when buying snacks and baked goods. That’s why manufacturers are continuing to cater to consumers’ wants and needs by offering new treats in all snack categories. According to a Chicago-based Mintel study, “Diet Trends—U.S.—May 2010,” which is a report on diet and weight loss foods and trends, 63% of the 1,275

surveyed adults were interested in portioncontrol packaging. The percentages were even higher for respondents ages 18-24 (68%), 25-34 (68%) and 35-44 (69%), perhaps because people in these age groups often have children, therefore, are more likely to be interested in healthy eating.

For calorie counters Crumbly, cinnamon streusel topping and rich cinnamon filling will make calorie-counting consumers wonder if Weight Watchers coffee cakes really are a “better-for-you” alternative Continued on page 34

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Market Trends Continued from page 33

to their usual morning fare. Based on consumer feedback about the Weight Watchers product line and the sweet bakery category in general, Jackson, Mich.-based Dawn Food Products Inc., maker of Weight Watchers sweet baked goods, developed 120-calorie sweet treats. “Overall, consumers don’t want to compromise on taste to have a better-for-you treat,” says John Rzeszut, senior brand manager. Weight Watchers coffee cakes are individually wrapped and come four to a 5.5-oz. carton. “Wrapping products individually offers portion control, but also provides portability, allowing consumers to address a sweet craving without having to worry about sabotaging their weight-management plan when they’re away from home,” Rzeszut explained. The coffee cakes are sold at grocery stores and mass merchandisers nationwide at an average retail price of $3.49. Americans can be mindful of their caloric intake at lunchtime, too, by pairing their sandwich or soup with a singleserving size of baked potato chips, especially when they contain less fat and fewer calories than regular potato chips. Diamond Foods’ Kettle Brand now offers its 100-calorie bags

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Snack Food & Wholesale Bakery - April 2011

of Kettle Brand baked potato chips in three varieties—Aged White Cheddar and Sea Salt & Vinegar, which were introduced in January, and Sea Salt. The Salem, Ore., snack producer developed the 100-calorie bags “to meet demand for healthier, convenient snacking options, which continues to increase significantly as more Americans seek healthier alternatives for snacking on the go,” says Julie Dunmire, marketing director. Kettle Brand’s all-natural baked chips are made with real, sliced potatoes, natural seasonings and all-natural oil. In addition, they contain no trans fats, MSG, artificial flavors or preservatives or genetically modified organisms (GMOs). The 100-calorie packs are available from Kettle Brand’s

online store in single-flavor 18-packs or 18-pack options, which retail for $15.99, or about 90 cents per bag. Consumers can also purchase them at in-store grocery delis, convenience stores, quick-serve restaurants and sandwich shops. Meanwhile, real kiwi slices and a hint of pure cane sugar are the only ingredients in Crispy Green Inc.’s FruitziO Kiwi freeze-dried fruit snacks, making them appealing to children and adults. Introduced in January, the crunchy, tart-yet-sweet treats join Strawberries and Applies, Apricots, Peaches and Strawberries. Unlike some 100-calorie snack packs, each 0.88-oz., resealable FruitziO bag contains about two and a half servings of product. “So even if [people] consume the whole bag in one go, it’s not a calorie overload,” says Angela Liu, founder and CEO of the Fairfield, N.J.-based company.

Individual FruitziO bags retail for $3.49, and can be found in supermarkets and stores that sell natural foods and on Amazon.com. For its part, Nature’s Own thin-sliced bagels and Nature’s Own Whitewheat sandwich rounds are great examples of portion-controlled bakery items, says Brent Bradshaw, brand manager for Flowers Foods Bakeries Group, Thomasville, Ga. “In our research, consumers told us that a regular-sized bagel was often too much for one serving, which led us to develop a thinner bagel,” Bradshaw says. “Unlike a

www.snackandbakery.com

Market Trends mini bagel, our thinner bagels are the same circumference as a regular bagel so they fit great in a toaster and can be used for sandwiches or mini pizzas. Nature’s Own thin-sliced bagels were first introduced in February 2010, but we improved both the formula and the packaging this time around.” These thin-sliced bagels are now thinner, lower in calories (110 calories each) and come in a convenient, resealable package. They also are available in Plain and 100% Whole Wheat with suggested retail price ranges from $2.89 to $3.09.

Let them eat cake “While research points to consumer interest in better-for-you products, we continue to see consumer interest in more indulgent snacks,” says Bradshaw. Shoppers who like to indulge in chocolaty treats, for example, will be eager to try two new items introduced under Flowers Foods’ Mrs Freshley’s and Blue Bird brands: Chocolate Bells, a crème-filled chocolate cake made with Hershey’s cocoa, and Chocolate Chip Muffins containing Hershey’s chocolate chips. “Partnering with one of the most recognizable brands in the confections industry was a great way to add excitement to our snack lineup and bring the great taste of Hershey’s to some of our chocolate snacks,” explained Bradshaw. Both products come in single-serve, two-count and six-count packs. Singleserve packs typically retail for 99 cents; multipacks sell for $2.99 to $3.19. Love and Quiches Desserts in Freeport, N.Y., a maker of chef-quality baked desserts, recently added two individuallywrapped products to its Gourmet Grab & Go line—L’il Lovers, which are moist, chocolaty brownies that come two to a pack with 100 calories per brown, and L&Q Blondie, a 3-oz. chocolate chip cookie bar, where one-half of the product constitutes a 180-calorie serving. “We don’t pretend to be anything other than decadent desserts,” says Andy Axelrod, president. “You can be healthy, work out and still indulge yourself.”

www.snackandbakery.com

L’il Lovers and L&Q Blondie have a 60-day shelf life, although they contain no preservatives. Both retail for $1.39 to $1.79 per pack and are available in full-color merchandisers that hold 12 two-packs. Axelrod recommends retailers place the products by their cash registers or self-serve coffee stations. “Those are the places that really result in the big sales for us,” he says.

A little bit of heat

restaurants that offer spicy dishes and specialty markets that carry hot spices and condiments. These consumers are likely to look for snacks with robust flavors, too, wherever they shop. When it comes to snacks, most people have a weak spot for a particular type of treat, be it for salty, sweet, spicy, baked or fried. Single-serve and portion-control products enable consumers to engage in a little guilt-free snacking. SF&WB

Chocoholics and cake lovers aren’t the only ones who will be able to savor new snacks this year. Those who like it hot— as in spicy—can add a little heat to their lunch with a single-serve bag of Herr’s hot sauce-flavored potato chips, produced by Herr Foods, Inc. The Nottingham, Pa.-based snack manufacturer partnered with TW Garner Food Co. of Winston-Salem, N.C., which is renowned for its Texas Pete hot sauce, to create the zippy, rippled chip, which is available in small bags at convenience stores, mom-and-pop stores, supermarkets and other outlets that carry Herr’s products. “There’s an appeal, in some areas of the country, for foods that seem to favor more heat and spice,” says Daryl Thomas, senior vice president of sales and marketing. In urban areas with thriving ethnic communities, for instance, people are regularly exposed to—and seeking out—

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New Products 2

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Company: Ozery Bakery, Toronto, Canada Website: www.ozerybakery.com Introduced: February Distribution: National Company: Tumaro’s Gourmet Tortillas, Suggested Retail: $3.69 for a Providence, R.I. 12.7-oz. package Website: www.tumaros.com Product Snapshot: Morning Rounds are Introduced: February toastable fruit and grain buns made with Distribution: National a variety of healthy grains and enriched Suggested Retail: $2.99 to $3.99 for an ingredients, such as dried fruits, seeds 8.5-oz. package and muesli. Designed as an alternative Product Snapshot: Inspired by the Big to muffins, donuts and pastries, this Apple’s delis, Tumaro’s introduces New better-for-you breakfast option comes in York deli-style wraps, an alternative Cranberry Orange, Apple Cinnamon and to deli-style bread. These 10-in.-wide Muesli varieties. wraps are 96% fat-free and cholesterol- Ingredients (Apple Cinnamon): free, are high in fiber and deliver less Unbleached wheat flour (wheat flour, than 100 calories. They come in Rye, ascorbic acid [natural dough condiPumpernickel, Sour Dough, Everything tioner], niacin [vitamin B-3], iron [ferrous and Cracked Pepper. sulphate], thiamin mononitrate [vitamin Ingredients (Pumpernickel): Water, oat B-1], riboflavin [vitamin B-2], folic acid), fiber, whole wheat flour, rye flour, wheat filtered water, whole wheat flour, natural gluten, rye meal, sourdough base (wheat apples, antioxidant-containing raisins flour, salt, malt, fumaric acid, acetic acid, (raisins, vegetable oil), organic evapolactic acid), canola oil, caramel color, rated cane syrup, sourdough (organic cocoa powder, molasses, calcium prounbleached flour [wheat flour, ascorbic pionate, caraway seeds, salt, aluminum- acid {natural dough conditioner}, niacin free baking powder (corn starch, {vitamin B-3}, iron {ferrous sulphate}, sodium acid pyrophosphate, sodium thiamin mononitrate {vitamin B-1}, ribobicarbonate, monocalcium phosphate), flavin {vitamin B-2}, folic acid], filtered monodiglycerides, lecithin, potassium water, organic evaporated cane syrup, sorbate, fumaric acid, xanthan gum, yeast, sea salt, sunflower oil), yeast, sea guar gum, sodium bicarbonate, sodium salt, sunflower oil, antioxidant-containing metabisulfite (to maintain freshness). ground cinnamon, wheat germ, cultured Contains: wheat. wheat starch, citric acid, enzymes.

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Soft & Chewy Gluten-free Granola Bars

Company: Bakery On Main, Glastonbury, Conn. Website: www.bakeryonmain.com Introduced: April Distribution: National Suggested Retail: $5.49 for a five-count, 6-oz. box Product Snapshot: These soft and chewy, gluten-free granola bars are made with gluten-free certified oats (certified by the Gluten-Free Certification Organization [GFCO]), amaranth, quinoa, flaxseeds and chia seeds and are a great source of whole grains and omegas 3 and 6. They come in Peanut Butter & Jelly, Chocolate Almond and Apple Cinnamon varieties. Ingredients (Chocolate Almond): Certified gluten-free oats, brown rice syrup, evaporated cane juice, chocolate chips (sugar, chocolate liquor, cocoa butter, soy lecithin, vanilla extract), crisp rice (brown rice), expeller-pressed canola oil, almonds, flaxseed, quinoa, chia seed, amaranth, sea salt, natural flavors. Contains: tree nuts, soy.

Ozery Bakery Morning Rounds

Tumaro’s New York Deli-Style Wraps

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Hostess Pink Strawberry CupCakes

Company: Hostess Brands, Inc., Irving, Texas Website: www.hostessbrands.com Introduced: February Distribution: National Suggested Retail: $3.99 for a 15-oz. box Product Snapshot: The Hostess line of cupcakes turned pink with new pink strawberry cupcakes. Baked with a burst of fresh strawberries, filled with Hostess’ signature crème filling and topped with strawberry-flavored icing, these squiggle-topped snack cakes exert festive flavor. Ingredients: Sugar, enriched bleached wheat flour (flour, reduced iron, B vitamins [niacin, thiamin mononitrate {B1}, riboflavin {B2}, folic acid]), non-fat milk, corn syrup, partially hydrogenated vegetable and/or animal shortening (soybean, cottonseed and/or canola oil, beef fat), palm oil, egg whites, high-fructose corn syrup, strawberry puree, whole eggs, contains 2% or less of the following: modified corn starch, soy lecithin, corn starch, soybean oil, leavenings [sodium acid pyrophosphate, monocalcium phosphate, sodium bicarbonate], natural and artificial flavor (caramel color, wheat flour), whey, salt, soy flour, calcium dextrose, guar gum, cellulose gum, sorbic acid (to retain freshness), potassium sorbate, titanium dioxide (color), vegetable calcium caseinate, sodium caseinate, soy protein isolate, agar, red 40 lake, sodium phosphate, FD&C Red 40 lake. Contains: wheat, milk, egg, soy.

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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The Nutritional Corner Celebrating 70 Years of Enriched Grains in America his year marks the 70th anniversary of the establishment of the Food and Drug Administration’s (FDA) bread and flour enrichment programs in the United States. Inaugurated at a 1941 National Nutrition Conference for Defense in Washington, D.C., the enrichment of grain foods has been influential in improving the lives of millions of Americans. Prior to 1941, diseases related to malnutrition were rampant throughout the country. Pellagra, a condition associated with chronic deficiency of the B vitamin niacin, was among the Top 10 leading causes of death for people in Southern states throughout the late 1920s. Other common conditions related to malnutrition included iron-deficiency anemia and beriberi, the disease resulting from deficiency of the B vitamin thiamin. In response to the extensive presence of deficiency-related diseases, in 1938, the American Medical Association, Chicago, issued a statement declaring support for the fortification of staple foods such as flours.

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Bakers throughout the country voluntarily began enriching bread with high-vitamin yeast and adding synthetic vitamins once the technology was available. But it wasn’t until 1941 that federal definitions were developed, standardizing the nutrient content of enriched and un-enriched flours. To this day, the FDA sets the standards for enriched grains by defining the levels of nutrients needed for grain products to be considered enriched; nutrients that must meet these standards include the B vitamins thiamin, niacin and riboflavin as well as iron and folic acid. Of these, folic acid is the most recent addition to the list of nutrients found in enriched grains, including white bread, bagels, pasta, tortillas and white rice. This fortification began in 1998 to increase folic acid intake in women of child-bearing age because of folic acid’s key role in the prevention of some birth defects (for more on this, check out Judi’s column in the January 2011 issue). As a member of the grains industry, I couldn’t be more proud of all the good

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

things that have come from the enrichment of grain foods. More than 150,000 lives have been spared and deficiency diseases such as pellagra and beriberi have been eradicated. And in the years since 1998, there have been 26% fewer cases of neural tube defects. That reduction translates to more than 15,000 cases of anencephaly and spina bifida prevented, for which we have the folic acid fortification of enriched grains to thank. In light of the 70th anniversary of enriching grains, I commend the milling and baking industry for their important contribution to the health of Americans. Grain foods remain a delicious, affordable and healthy staple in our population’s diets, and we at the Grain Foods Foundation, Ridgway, Colo., are committed to keeping it that way in all the years to come. Happy Anniversary. SF&WB

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Ingredient Technology Low-Sodium Formulation

Halting the Salt

Photo courtesy of Nu-Tek Salt LLC

Many of today’s ingredient suppliers are developing salt alternatives or replacements to help bakers and snack manufacturers create lower-sodium offerings. Marina Mayer, Executive Editor

he updated 2010 Dietary Guidelines for Americans pose a tremendous challenge for some bakers and snack manufacturers who scurry to reformulate certain product lines to meet the call for healthier products. Between lower-sodium offerings and stock-keeping units that boast fat-free label claims, these hot-button issues present a host of hurdles for the food manufacturing community. However, for many of today’s ingredient providers, offering a low-sodium option is just what they do. Companies such as Wixon Inc., for example, recognized the need to reduce sodium years ago, according to Leda Strand, director of technology applications and industrial ingredients, and have since created a host of low-sodium formulations that not only meet the revised guideline standards, but also open the door for better-tasting, better-quality products. “Recently, reducing sodium has moved

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from focusing only on salt to focusing on the entire flavor system of a product,” Strand says. “Salt substitutes should be used in conjunction with a re-balancing of a products’ flavor system, including spices, functional ingredients and other flavors. This allows developers to achieve the organoleptic properties that consumers expect.” As a result, last year, the Milwaukee, Wis.-based company launched KCLean

Salt, which is a blend of 50% salt and 50% potassium chloride and added taste modifiers to cover the undesirable metallic taste. “Consumers have had an interest in reducing sodium in their diets for many years, but now the push is also coming from grocery and retail chains, in addition to recent regulatory changes. This has moved sodium reduction from a ‘nice to have’ to a ‘must do,’” Strand notes. “ConContinued on page 40

Photo courtesy of Nu-Tek Salt LLC

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Ingredient Technology Photo courtesy of Danisco USA Inc.

Continued from page 38

sumers are no longer interested in choosing from two options: High-sodium/great taste; or reduced-sodium/less taste. They only want one option: Reduced-sodium plus great taste.” Sensient Flavors, Inc., Indianapolis, also offers a comprehensive portfolio of sodium-reduction flavor systems that are developed to reduce sodium by 25-35% or more per serving, says Emil Shemer, director, food solutions. “Sensient’s solutions take a whole systems approach to taste and functionality, and [they] are suitable for a variety of applications, including sweet and

savory baked goods, topical seasonings, bars and snack mixes, to name a few,” Shemer says. “Taste is the biggest challenge bakers and snack producers face in developing low-sodium formulations,” Shemer adds. “Producers are tasked with creating greattasting, lower-sodium products without sacrificing flavor. They also need to maintain a salty perception while keeping a clean ingredient statement.” For its part, Kikkoman Sales USA

launched a line of natural flavor enhancers (NFE) that allow 30-50% sodium reduction while improving the taste and flavor balance of lower-sodium products, says Joe Leslie, national industrial sales and marketing manager for the San Francisco company. The NFE line offers a neutral flavor combined with a strong umami effect for savory applications, such as breads, pizza dough, tortillas, crackers and snacks. It comes in one liquid version (NFE-L) and two dry ones (NFE-P and NFE-PY). “Kikkoman has always had lower-sodium options, but the 2010 Dietary Guidelines of Americans prove that we need to emphasize and expand our offering in this category,” Leslie says. “Kikkoman’s fermentation technology and history of producing low-cost, natural products places us in a strong position to help our customers in their sodium-reduction initiatives.” Likewise, Nu-Tek Salt LLC delivers reduced-sodium salt options that lower sodium content in bakery items up to 50%, without sacrificing flavor, notes Dustin Grossbier, director of quality and technology. The Minnetonka, Minn.-based company is also in the process of building a topical line that features higher salty flavor intensity products for use in snack food applications, Grossbier adds. Continued on page 42

While some companies introduce low-salt alternatives, others set out to replace salt entirely by mimicking its elements and eliminating its downfalls. Photo courtesy of Wixon Inc.

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Ignite Your Product Development Process! Prepared Foods’ 29th annual New Products Conference is the food & beverage industry’s premier event for gaining valuable insights into exciting global new products, culinary advances and emerging consumer trends. The New Products Conference provides R&D, Marketing, Product Developers, and Corporate Management executives like you, a dynamic forum to learn from world-class speakers, capture valuable new product & trend data, participate in an interactive culinary session, taste new products from around the globe, capitalize on incredible networking and ignite your creativity.

Featured Speakers Include: > Family Brand Dynamics: Decoding The Drivers of Family Brand Success Speaker: Laurie Klein, Vice President, The Family Room What’s behind the success of the country’s most iconic family brands? How does your brand measure up? > Truly Global Strategies? Speaker: J. André de Barros Teixeira, Recent Vice President, International R&D, Campbell Soup Company, Belgium, Formerly, President and General Manager, Coca-Cola, Russia Discover the changes affecting consumers and companies, new ways to look at demographics and how to avoid commonplace behavior in market research.

discover new products

> A Call to Innovation and Action: A Professional Call to Arms Speaker: Christopher W. Miller, PhD, NPDP, Founder and CEO, Innovation Focus The companies represented at the conference have substantial influence over the diet of the American population. Through our creativity we can create a healthier more vibrant society. > On the Foodservice Horizon: Expanding Boundaries and Opportunities into Retail Speaker: Kevin Higar, Director of Operator Product Development, Technomic Kevin will explore the food, beverage, and overall menu strategies of tomorrow's successful restaurants. Not surprisingly, these more successful trends will morph into the retail marketplace as well. > Innovation That Could Change the (CPG) World Speakers: Lynn Dornblaser and David Jago, Directors, Custom Solutions Group, Mintel International We'll take a brief look backward at a few proven examples of innovation that changed everything, and offer our own picks of innovative thinking that may change things in the future. > Mintel New Product Showcase and Tasting Session After you've heard about some of the most innovative recent product introductions, you'll have the chance to see and taste them as well. > Product Development Innovation Workshop Upgraded Speaker: Ron DeSantis, Director, Continuing Education’s Industry Solutions Group, The Culinary Institute of America CIA Master Chef DeSantis will guide teams through the innovation process — from ideation through development — and explain the concept of structured culinary innovation.

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Save the Date – September 11-14, 2011 Make a commitment today to invest in your career, revitalize your creativity, and network with the industry’s top new product development leaders, while enjoying the warm weather at The Ritz-Carlton in Naples, Florida

For more information, contact Marge Whalen, Senior Event Manager at 847-405-4071 or [email protected].

www.PreparedFoods.com/npc

new product trends

Ingredient Technology Photo courtesy of Wixon Inc.

Continued from page 40

“We see the health and wellness trend continuing to skyrocket, and low-sodium formulations are on the forefront of them,” he notes. “The general public has become much savvier in reading product labels. Having great-tasting products that are lower in sodium than their counterparts will be a competitive advantage.”

De-salting by default While some companies introduce low-salt alternatives, others set out to replace salt entirely by mimicking its elements and eliminating its downfalls. For instance, Innophos, Inc., Cranbury,

N.J., released Cal-Rise, a sodium-free leavening that replaces SAPP 28 (a mediumacting leavening powder) on a 1:1 basis, yet still decreases sodium content by an average of 28%, says John Brodie, technical service manager—baking. “Cal-Rise can be used in most formulas that currently use SAPP 28. This includes cake-type formulas, muffins, biscuits, flour tortillas, pancakes and baking powders,” he adds. Innophos also developed Dough-Rise, a reduced-sodium leavening agent designed to replace SALP (sodium aluminum phosphate) in commercial applications where long holding times are needed, such as in cake and donut formulas. “The use of

these leavenings will help you formulate low- and reducedsodium baked goods without changing flavor or texture,” Brodie adds. “These leavenings will also significantly increase calcium contents.” Meanwhile, Danisco USA Inc., New Century, Kan., introduced its SaltPro line, “which allows bakers to reduce their sodium content by 25-30% in breads, buns, rolls and sweet goods,” says Helle Tornas, industry manager. SaltPro is a sodium replacer that retains the characteristics of a full-salt product and delivers the sensory attributes of salt, yet delivers a similar mouthfeel, texture and palatability, all without the high-sodium levels. “We have seen successful use of this line of ingredients in yeast-raised products such as breads and buns and then in sweet goods such as cookies,” Tornas says. Despite the changes in consumer preference and government recommendations, today’s ingredient suppliers are halting the salt so bakers and snack manufacturers can create lower-sodium offerings with bigger and better taste. SF&WB

Photos courtesy of Innophos

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Ingredient Briefs

SensoryEffects Flavor Systems introduces Choco-Flakes, a line of compound coating inclusions designed to have a melting point of around 80°F, making them suitable for use in frozen dessert systems. They are available in dark, milk and white chocolate, and can be made into other customized chocolate-based flavors such as chocolate cherry or raspberry white chocolate. Choco-Flakes is said to provide a superior mouthfeel, flavor delivery and improved tolerance in application. SensoryEffects Flavor Systems Bridgeton, Mo. 800-422-5444 www.sensoryeffects.com

Van Drunen Farms introduces individually quick frozen (IQF) organic herbs for an added-value spice in frozen pizza, salsas, frozen entrees and more. The lineup of herbs includes basil, cilantro, parsley, green onion, chives, collards, dill, kale, lemongrass, oregano, sage and thyme. IQF organic herbs are domestically grown and produced by spreading freshly harvested herbs in a single layer on a slow-moving conveyer through sub-zero air, resulting in a free-flowing IQF product that can easily be handled. This process creates a convenient, micro-ready ingredient that comes in multiple forms or sizes. Van Drunen Farms Momence, Ill. 815-472-3100 www.vandrunenfarms.com

Caravan Ingredients develops Tortilla Suave, a conditioner that combines the latest in extended-shelf-life and antistick technology to improve softness and rollability and allows for the removal of hydrogenated fats and trans fat from labels. Tortilla Suave is made to be easily applied to existing formulations without a disruption to current formulas or processes. Caravan Ingredients Lenexa, Kan. 800-669-4092 www.caravaningredients.com

Puratos launches its new and improved S500 bread improver range. Based on patentpending enzyme technology and freshness enzymes, the new S500 delivers superior dough tolerance, outstanding volume and improves the fresh characteristics of the final bread. The new S500 can be used in a wider range of bread applications such as crusty bread, rolls, loaf breads, whole meal, soft breads and sweet goods and in more processes, such as retarded fermentation and short freezing. The range includes S500 Red, which gives volume and extreme tolerance in any baking condition; S500 Ultra, a high-quality multipurpose improver; S500 Blue, which is designed especially for automated lines; and S500 Green, the clean label variety. Puratos Corp. Cherry Hill, N.J. 856-428-4300 www.puratos.us

SF&WBtv

Glanbia Nutritionals launches OptiSol 5000, a natural, flax-based ingredient designed to improve the texture of pizza doughs by enhancing extensibility and workability. OptiSol 5000 functions as a moisture management tool. It develops dough texture through enhanced moisture retention, creating a softer and less chewy texture. This is especially evident in whole wheat crusts where the result can be tough and unpleasant for more health-conscious consumers. Moisture retention also maintains product quality over a longer shelf-life, increases surface area by up to 5% and cuts costs for manufacturers. OptiSol 5000 also is high in fiber and rich in ALA Omega-3. Glanbia Nutritionals Fitchburg, Wis. 800-336-2183 www.glanbianutritionals.com

Watson debuts gluten-free mixes created to shorten time-to-market, reduce R&D efforts and material testing costs and eliminate the need to audit multiple vendors. Developed specifically for bread and muffins, these gluten-free mixes meet the standards of the Celiac Sprue Association. Watson Inc. West Haven, Conn. 800-388-3481 www.watson-inc.com

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

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Engineering Management

Time to U.P.G.R.A.D.E. o get to the next level in your management skills, you must upgrade. You must improve policies, advance procedures and raise the bar. You must enhance the way you do business in order to continue doing business. Here, I have taken the term, “upgrade,” and tweaked to relate it to our industry and discipline. For instance, the “U” stands for Understanding. In order to increase our knowledge of this business, the people and the tasks at hand, we need to spend more time trying to understand the important stuff and let the small stuff go. Find ways to learn something new today. So many times we get caught up chasing what turns out to be insignificant items and old junk, and sometimes we’re just chasing ghosts. We need to find ways to spend some quality time learning the next best way to do, say or explain something better. When understanding becomes sharing to those around you, you will be regarded as a better manager and communicator. The “P” stands for Plus, which means “what can you bring to the situation that adds value?” You know what you know, but sometimes others don’t. When you see something happening around you, find a way to insert yourself in a helpful way so that the situation becomes less of a problem to those around you. You must be careful not to come off as a know-it-all, but it’s possible to help without turning people off. It’s all about delivery. The “G” stands for Give. You can be a go-getter or a go-giver. In our workplace, there are so many people who need help learning the next new thing. As a manager, it is your responsibility to be the giver. Don’t be selfish with your knowledge. Pay it forward by sharing your knowledge upfront and allowing people to absorb, apply and eventually re-teach. Andrew Carnegie, a Scottish-American industrialist, businessman, entrepreneur and philanthro-

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pist, said people can “get rich by making others rich.” How can you implement that philosophy with a giving spirit? The “R” stands for Relate. This is all about relationships. As a manager, mentor or leader in some other capacity, you gain more ground when you make the relationship with a colleague or direct report a high priority. We sometimes face situations where we have to work with someone who has a work ethic or talent level that doesn’t quite meet our personal standards. We can’t let that get in the way of making progress on the task at hand; we are all being paid to complete it, no matter how large or small it may be. The “R” can also stand for Respect, because when you have this in mutuality, you can be more productive and successful. The “A” stands for Adjust. Nothing in this world successfully happens without some level of adjustment during the course of the deployment of a task. Peyton Manning, the quarterback for the Indianapolis Colts, is the ultimate plan adjuster. What has become the norm in Colts football is actually the constant execution of adjustment, or “calling the audible” as they say. He never comes to the line and runs the play exactly as called in the huddle. He looks over the defense and then steps back and adjusts the play, sometimes slightly and other times completely. Their winning record proves that adjustments work. In your line of work, don’t be afraid to step back, survey the situation and make slight or complete changes to ensure the task will be successful. The “D” stands for Discipline. No, not handing out punishment, rather this definition of discipline means the ability to control one’s self and their actions in times

Jeff Dearduff [email protected]

of stressful situations. Having the discipline to follow-through on the commitment when everything around you seems to be in turmoil is the mark of a true professional. If you let the stress get to you, you can make poor decisions that can cause a bad situation to become worse. Sometimes acquiring the internal discipline to handle stressful situations requires a person to go outside their comfort zones and seek help on organizing thoughts, making decisions and controlling tempers. If you want to go to the next level in your management development, you must find a way to have the discipline to handle any situation that comes up. The “E” stands for Execute. Now we can bring this all home. Execution is one of the easier things to understand and sometimes the toughest to carry out. Everything requires execution to get positive results. You can’t understand something better if you don’t reach out and give a wholehearted try. You can’t add value to a situation if you stand back and watch. You can’t be a giver if all you want to do is receive. You won’t have a team if you don’t relate to others. If you stick to your guns and are not willing to shift course, you could shoot yourself in the foot, and if you don’t have the internal discipline to handle the stresses of the daily workload, you could actually get physically sick. On this Transatlantic flight we call our careers, we will land at our destination in better health, mind and spirit when we spend a little extra time upfront and U.P.G.R.A.D.E. SF&WB

Understanding Plus Give Relate Adjust Discipline Execute

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New Markets • New Technologies • New Opportunities

JUNE 7-9, 2011 Westin Beach Resort, Fort Lauderdale, FL KEYNOTE ADDRESS Latest Trends & Technologies in Pouch Packaging & Machinery Dennis Calamusa, President, AlliedFlex Technologies One of the industry’s leading influencers will explore the latest pouch packaging trends and technologies solving today’s most challenging applications.

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Equipment Briefs are electro-polished to simplify cleaning. A full-length hood covers the kettle for safety and retains heat for high-energy efficiency. It also has steam blanketing to purge oxygen and prolong oil life, lower exhaust volume and a clean-in-place system to reduce sanitation labor. Heat and Control, Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com Charles Ross & Son offers three sizes of its V-Blenders, which are designed for the intimate, dry blending of free-flowing solids that vary in bulk density and percentage of total mixture. All Ross V-Blenders are supplied with intensifier bars to permit de-lumping and de-agglomeration as needed. In addition, they are manually operated via butterfly discharge valves and come equipped with safety railings, stainless-steel support stands and fully-integrated motors and controls. Charles Ross & Son Co. Hauppauge, N.Y. 800-243-7677 www.mixers.com

Heat and Control’s new MasterTherm Kettle Fryer (MTKF) can produce 500 finished lb. of batch fried potato chips per hour. Cooking oil is heated gently and uniformly throughout the fryer by a thermal fluid heat exchanger, which is immersed in the oil. Generous spacing between the heating tubes facilitates cleaning and eliminates areas where fines can accumulate. Each tube expands independently, greatly reducing damage caused by thermal stress. Tubes

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Lantech presents a patent-pending Load Seeking Clamp 4.0, designed to reduce film breaks by holding onto the film, preventing film breaks and releases at the clamp. At the beginning of the wrapping cycle, the clamp goes out to the edge of the load, creating clamp-to-load contact regardless of the width of the load. This eliminates sagging issues and maximizes containment at the bottom of the load. Lantech Louisville, Ky. 800-866-0322 www.lantech.com

Banner-Day introduces SmartSpark, a revolutionary conveyor oven ignitor/sensor that provides highly reliable burner

ignition and flame sensing when used in a conveyor oven. This stainless-steel ignitor/sensor enables precision control of conveyor oven burners while offering ease of installation. And it can be used independently and integrated into overall total oven control systems. Banner-Day Saginaw, Mich. 877-837-0584 www.banner-day.com

Douglas Machines introduces TriVex, a fully automatic top-loading case packer that erects, loads and seals cases. TriVex operates at 15 cases per minute depending on case size, and is fully integrated, which means less product handling, case handling, maintenance of additional equipment and floor space. It comes with an application-specific loader, end effector and infeed solutions for an array of products such as flexible bags and pouches, semirigid and/or rigid trays, tubs, cups, cartons and over-wrapped products. Douglas Machines Corp. Clearwater, Fla. 800-331-6870 www.dougmac.com

Designed specifically for sanitary processing operations, the Quick-Clean Series of

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Equipment Briefs rotary airlock valves from ACS Valves aids in regulatory standard and practice compliance, reduces cleaning and sanitizing time and simplifies inspection. The tool-less, clean-in-place design enables full access to the rotor and all internal surfaces of the housing without time-consuming disassembly of the endplate, or the concern for accurate rotor re-alignment during re-assembly. Plus, the 8-vane rotor design eliminates excess pressure loss through the system, ensures cost-efficient upstream and downstream material management and reduces process energy consumption. ACS Valves Ontario, Canada 800-655-3447 www.acsvalves.com

A new 18-in. diameter Centrifugal Impact Mill Model CIM-18-SS from Munson Machinery provides coarse to fine (400 mesh) grinding of friable materials into controlled particle sizes, as well as de-agglomerating and conditioning of dry solids. A direct-drive system reduces the unit’s footprint to about half of that required by a belt-driven machine, allowing installations in restricted areas. High-speed rotation of the inner disc creates centrifugal force that accelerates bulk material entering the central inlet of the opposing stationary

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disc. As material travels from the center to the periphery of the discs at high speed, it passes through a “treacherous path” of five intermeshing rows of rotating and stationary pins with the desired tight particle size distribution obtained by controlling the rotor speed. It also provides high throughput rates per horsepower relative to machines employing screens, hammers, knives or rolls, depending on application. Munson Machinery Co., Inc. Utica, N.Y. 800-944-6644 www.munsonmachinery.com

American Fabric Filter debuts a portable reclaim sifter for sifting small batches of dry powders. This versatile sifter is capable of batch-sifting up to 600 lb. an hour and may be operated sitting atop a drum or using the optional adjustable height-rolling base for easy relocation around the plant. It also comes with one framed screen, motor speed controller and a sliding shut-off door. American Fabric Filter Co. Wesley Chapel, Fla. 800-367-3591 www.americanfabricfilter.com A new Vibroscreen Flo-Thru low-profile screener from Kason Corp. classifies bulk material into three fractions at high rates. It employs two screening decks and two unbalanced-weight gyratory motors mounted on opposing exterior sidewalls of

the unit instead of one motor positioned beneath the screening chamber, significantly reducing minimum height requirements. The design also allows vertical alignment of the top inlet and bottom outlet, allowing the smallest fraction to descend through the screener in a straight-through path at high rates; the larger fractions are ejected through spouts at the peripheries of the coarse-mesh upper screen and fine-mesh bottom screen. Kason Corp. Milburn, N.J. 973-467-8140 www.kason.com Spiroflow Systems introduced “CABLEflow” tubular cable drag conveyors, designed for applications requiring gentle handling or for those requiring conveying both to and from multiple points in a circuit. CABLEflow conveyors transfer friable bulk products from single or multiple infeed points to single or multiple discharge points with little or no damage. Other benefits include totally enclosed dust- and contamination-free handling, operation in three planes to allow for complex circuits and the elimination of transfer points using only a single drive, metered or flood-fed capability. They also handle hot, cold, wet, dry, hygroscopic or temperature-sensitive materials, minimum product attrition due to gentle conveying action, minimum material residence and build-up due to round construction and operation under pressure differential or insert purge. Spiroflow Systems, Inc. Monroe, N.C. 704-291-9595 www.spiroflowsystems.com Continued on page 48

April 2011 - Snack Food & Wholesale Bakery

47

Equipment Briefs Continued from page 47

saving vertical design, a large, angled top opening for easy filling, first-in-first-out sliding divider shelf for proper lot rotation and ability to use on a rack or louvered panel or mounted on a wall or workstation. Akro-Mils, division of Myers Industries, Inc. Akron, Ohio 800-253-2467 www.akro-mils.com

Akro-Mils introduces a smaller size bin and new rack design for its innovative easy-flow gravity hopper system. The new smaller, lighter 31620BLUE hopper has a 6-gallon holding capacity, assisting end users in material handling and 5S processes. It also features a compact and space-

Sensor Products offers the Tactilus electronic pressure-mapping system, designed to allow measurement of contact pressures between two mating surfaces. This system reveals critical pressure distribution problems that can compromise package integrity. Applications include quality control monitoring for uniform pressure across sealing dies in heat seal and sealing ma-

chinery and characterization of nip impression pressures in the nip between rollers in converting machinery. Pressure readings are captured as the sealing surfaces make contact, and the software analyzes the data from the sensors within a pad, enabling the engineer to view data on a computer screen and make adjustments to the heat-sealing equipment. Sensor Products Inc. Madison, N.J. 973-884-1755 www.sensorprod.com

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.

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Snack Food & Wholesale Bakery - April 2011

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

Production Technology Lubrication

Pushing the Limits Many of today’s lubricants and systems allow customers to operate around the clock with efficiency, flexibility and ease. Marina Mayer, Executive Editor Photos courtesy of Klüber Lubrication North America L.P.

t used to be that bakers and snack manufacturers ran their production lines on a routine, five-day schedule, shutting down for two days of cleaning, sanitation and maintenance. And if a part broke down or a line became inoperable, companies would just replace them and move on. That was then—this is now. Today, companies are aiming to stretch the limits and operate around the clock in an efficient, flexible and sanitary manner in order to produce more product and fulfill more orders. Now, the stakes are raised and every minute counts. That’s why suppliers are developing dependable lubricants to help their customers do the job right the first time. Choosing the correct lubricant is only half the battle, says Kimberly Eldridge, North American market manager, food, beverage and pharmaceutical industry, for Klüber Lubrication North America L.P.— using the lubricant correctly is the other half. That’s why the Londonderry, N.H., company offers guidance to those sorting through the method behind the madness, so-to-speak. “How a lubricant is applied can be a key indicator in predicting how well the lubricant will perform,” Eldridge says. “How can the user best apply the product to ensure that it achieves the performance and protection they expect? And how can they do it safely?” Klüber’s lubricants allow for the use of single-point applicators in hard-to-reach areas, which helps reduce potential safety risks for operators, Eldridge adds. In addition, a lubricant reservoir that pumps

I

product through lines to various application points can be viewed as a safety measure. “It may allow the lubrication of points that would otherwise require a machine shutdown to be performed safely,” she adds. Another key factor is being able to lubricate without contaminating food, says Don Schaefer, regional sales manager for Bijur Delimon International (BDI), a partner of Lubrication Engineers, Inc., Morrisville, N.C. “Due to the nature of the food plant, we often supply a ‘lube-in-a-lockbox’ solution,” he adds. “This approach allows only qualified people to make adjustments to the program. Only the person with the

key can change volume and frequency. Replenishing the reservoir is accomplished with an external fill coupler to ensure the mating fill pump has the correct oil or grease and is clean. Central systems can be automatically filled to keep flour, gluten Continued on page 50

www.snackandbakery.com

April 2011 - Snack Food & Wholesale Bakery

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Production Technology

Photo courtesy of Lubrication Engineers, Inc.

Continued from page 49

and debris out of the lubricant.” BDI provides uptime solutions using centralized lubrication equipment to automatically lubricate food processing

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Snack Food & Wholesale Bakery - April 2011

Attaining higher standards “Much like the surface of your skin, a very low volume of oil applied evenly to a sticky surface can provide adequate lubrication,”

Photos courtesy of JAX, Inc.

machinery, Schaefer notes, and the system itself consists of a central pump, reservoir and metering devices. “In a food plant, systems are remotelymounted in an enclosure with a clear plastic viewing window. The lube system includes an alarm for low-level, low-pressure or monitored performance. A beacon to alert the operator and automatic refilling from central storage are popular options,” he adds. BDI’s lubrication systems also reduce contamination and save money by eliminating the traditional oil can and grease gun. “Most manual devices are not kept clean and dedicated to the lubricant; the result is debris and mixed lubricants that are injected into the bearing,” Schaefer says.

says Shaun Beauchamp, director of operation for XACT Fluid Solutions, a whollyowned subsidiary of JAX, Inc. That’s why the Menomonee Falls, Wis.-based companies jointly created JAX food-grade mold release, a NSF 3H-registered release agent that promotes release and product separation by modifying the interface between the food and grills, loaf pans, boning Continued on page 52

www.snackandbakery.com

Production Technology Continued from page 50

benches, chopping blocks and other hard surfaces. “Sanitation processes are becoming more aggressive to handle cleanliness during increased production schedules,” Beauchamp says. “Stainless-steel systems [such as the food-grade mold release] with solid-state components and a long cycle life are imperative in this environment. You want to reduce downtime, which implies ensuring the automated solution does not become a maintenance concern. We pride ourselves on innovative, reliable, flexible solutions that solve problems.” In addition, XACT concocted the flat-pattern spray-bar system, which is a turnkey spray system that sprays onto conveying surfaces such as molds, belts and conveyors. It comes with a control cabinet, pumps, solenoids, logic controls, a lowlevel switched reservoir, a system stand and status light. The system is designed to last a minimum of 100 million cycles.

52

Snack Food & Wholesale Bakery - April 2011

Photo courtesy of Dayton Progress Corp.

“Our systems micro dose lubricants into all applications, which is specifically critical in oven applications,” Beauchamp says. “JAX supplies lubricants for baking with a significant margin of safety for flash point. XACT produces our systems for longevity in high-temperature applications. If a typical oven runs at 550°F, we have no concern, as our fluids operate well at these temps, and we build our dispensing systems to handle 900°F. The combination

of a fluid with low volatility and a positive displacement dispensing system that accurately controls lubricant volumes provides protection against typical baking fears.” Meanwhile, Dayton Progress Corp., Dayton, Ohio, launched DAYLube, a high-performance lubricant that uses nanoceramic particles to provide continuous lubrication to steel surfaces. Available in 5-gal. pails, DayLube is NSF-H1 food-grade certified, provides 10 times the normal life and features high load-bearing properties, such as water, steam, acid and chemical resistance. Plus, it is ideal for high-volume applications and protects bearings, bushings cables, cams, chains, conveyors, gears, lifters, machine parts, robotics, slides, wear plates and more. Pushing the limits is what many of today’s companies do to stay in the game, and they do so with the help of some flexible and dependable lubricants and systems. SF&WB

www.snackandbakery.com

Lubrication: The secret ingredient in your recipe for productivity Partner with Klüber Lubrication to get more from your operation. We’ve developed a broad line of kosher, halal and ISO 21469 certified lubricants to meet the extreme demands of the food industry. Our NSF H1 lubricants boost efficiency, save energy, reduce lubricant waste and extend relubrication intervals — all while meeting your food-grade requirements. Klüber Lubrication promotes a healthy production line and a healthy bottom line. Talk to one of our specialists to find your secret ingredient. Klüber Lubrication North America L.P. [email protected] / www.klueber.com

your global specialist

Supplier Standpoint Distribution: The Last Bastion of Significant Savings?

F

or an industry that produces products woven into the core fabric of life for which there will always be plenty of demand, the fresh baking industry seems to perpetually be under a lot of pressure. Not a day goes by without reports of ingredients reaching record high prices, or a new low/no-grain diet announced. Not to mention the fiercely competitive nature of the industry itself, heightened by the increased power of retailers, the introduction of in-store bakeries and the rise in production of artisan bread. It becomes increasingly difficult to make a decent buck selling commercially baked bread.

The margin is determined by the price the customer is willing to pay minus the costs of getting the product to that customer. Price is always under pressure from ever-increasing buying power of the food retailers and competition. Of course, quality and choice of ingredients and new, innovative products allow for some differentiation, and thus, price flexibility. But cost is the place manufacturers most commonly look to increase profitability. The main “buckets” that make up the

Photos courtesy of pcdata Inc.

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Snack Food & Wholesale Bakery - April 2011

modernization and continuous improvements? Is it because many don’t feel technology can be flexible enough to deal with the dynamic nature of order fulfillment and bread distribution? Or is it because companies don’t think the potential “real” opportunities to affect and improve the business aren’t there? Whatever the reason, many organizations are not taking the time to look at what can truly Courtesy of pcdata Inc. be accomplished to improve business in cost of a loaf of bread are ingredients, the distribution side of the plant. production costs (including overhead) and Getting the product to the end customer is the costs involved in getting the bread to the probably the area that still has the most popaying customer or distribution costs. tential for savings, and technology is the key One of the downsides to the globalized to unlocking them. Paper-based order-fulfillworld is not that ingredient prices today are ment processes are very error prone; they are set at the will of forces out of the manualso really inadequate to deal with the highly facturer’s control, but rather the result of a dynamic nature of fulfilling large numbers myriad of events, such a weather phenomena, of ever-changing orders and matching them crop predictions and demands playing out in against ever-changing production volumes. parts of the world such as China and India. Computer-based solutions can adjust Generally speaking, ingredient prices do product allocation dynamically based on priwhatever they want. orities set by the user. No paper adjustments The focus of the industry has been and need to be made; the process happens quickly continues to be on reducing production and accurately. costs of bread. Huge production efficiency Another benefit of today’s systems is increases and reductions of production waste traceability. Each time a product is handled, have been realized over the past 20 years. the warehouse operator has to confirm this Production lines are extensively automated. in the system. These “checks” improve order Walking through any modern production fulfillment accuracy, which improves customer facility today, one can’t help but be amazed service levels, eliminates the need for extra at the limited amount of personnel on the truck runs and reduces “unaccounted for’s” to production floor as the products roll off the nearly zero. Some distribution solutions even line by the thousands. offer automatic scanning of product onto the The ongoing market consolidation that delivery trucks and product scanning when it has been taking place for decades is another is received by the end customer or depot. It is result of the efforts to lower production costs. very common to see a savings of up to 30% Market consolidation increases production in warehouse and distribution costs when volume in the remaining factories and allows these new systems are installed and incorpofor greater economies of scale. rated in the daily business process. Payback Interesting to note is that with most periods of 12-18 months are the norm. For wholesale bakeries, bread is still being these reasons and others, it truly makes good distributed just as it was 100 years ago, usbusiness sense to evaluate the positive effect ing pen and paper and a lot of labor. There modern distribution systems can have on the are tremendous opportunities to affect the bottom line. Distribution may be one of the bottom line and improve the quality offered last bastions and unknown areas of signifito the end customer on the other side of the cant savings opportunities in this industry. production wall. Editor’s Note: Marc Braun is the president at pcdata Why is it then that this is an often overInc., East Granby, Conn. For more information, go to looked aspect of the business in regard to www.pcdatainc.com.

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

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Snack Food & Wholesale Bakery - April 2011

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Snackandbakery.com

Brochures Go Digital

I

t seems as though everything is going digital these days, and brochures and press kits are no exception to the rule. Go to www.snackandbakery.com to visit Snack Food & Wholesale Bakery’s “Digital Brochures” section and find a bevy of supplier sell sheets promoting the latest in equipment and ingredients for the snack and bakery markets. For example, users can pull up literature about Banner-Day’s SmartSpark, a revolutionary conveyor oven ignitor/sensor, or read up on a multitude of manufacturing models from FoodTools. Are you handing out brochures at a tradeshow? If so, send us the pdf and we’ll publish online.

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Snack Food & Wholesale Bakery - April 2011

While on our site, go to our “White Papers” section to get detailed reports on distribution centers, moulders, baker’s yeast or learn how to improve production efficiency. Feel free to send us your white paper. 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].

www.snackandbakery.com

Ad Index Company Website

Page

Company Website

Page

Company Website

Page

21st Century Grain Processing . . . . . . . . . . 7 www.AllAboutClusters.com

FooDesign . . . . . . . . . . . . . . . . . . . . . . . . . 24 www.foodesign.con

National Confectioners Association . . . . . 25 www.sweetsandsnacks.com

ALIT SRL . . . . . . . . . . . . . . . . . . . . . . . . . . 21 www.alit.it

FoodTools . . . . . . . . . . . . . . . . . . . . . . . . . . 31 www.foodtools.com

National Starch Food Innovation . . . . 18, 19 www.foodinnovation.com/bakery

Allied Blending & Ingredients, Inc.. . . TT-BC www.alliedblending.com

Global Pouch Forum . . . . . . . . . . . . . . . . . 45 www.GlobalPouchForum.com

New Products Conference . . . . . . . . . . . . 41 [email protected]

Arr-Tech, Inc. . . . . . . . . . . . . . . . . . . . . . . . TT-5 www.arr-tech.com

Harpak-ULMA Packaging . . . . . . . . . . . . . 23 www.harpak-ulma.com

North Dakota Mill . . . . . . . . . . . . . . . . . . . . 50 www.ndmill.com

Ashworth Bros., Inc. . . . . . . . . . . . . . . . . . 15 www.ashworth.com

Heat and Control Inc. . . . . . . . . . . . . . . TT-IBC www.heatandcontrol.com/s4

Petrochem, Inc. . . . . . . . . . . . . . . . . . . . . . 51 www.petrochem1.com/freesample

Brolite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 www.bakewithbrolite.com

Kikkoman Sales USA, Inc. . . . . . . . . . . . . . 39 www.kikkomanusa.com/foodmanufacturers

Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC www.reiser.com

California Raisins Marketing Board . . . 10-11 www.LoveYourRaisins.com

Kluber Lubrication North America L.P. . . . 53 www.klueber.com

Spraying Systems Co. . . . . . . . . . . . . . . . . 30 www.spray.com/freecoatingtest

Caravan Ingredients . . . . . . . . . . . . . . TT-IFC www.caravaningredients.com

Koenig Bakery Systems . . . . . . . . . . . . . . 48 www.koenigusa.com

Taconic . . . . . . . . . . . . . . . . . . . . . . . . . . TT-11 www.4taconic.com

Clear Seas Research . . . . . . . . . . . . . . . . . 55 www.clearseasresearch.com

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

Tortilla Industry Association / TIA . . . . . . TT-3 www.tortilla-info.com

Corn Products International . . . . . . . . . . . . 5 www.cornproducts.com/trends/yogurt

MINSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC www.minsa.com

United Soybean Board . . . . . . . . . . . . . . . . 3 www.SoyConnection.com/QUALISOY

FPSA / Process Expo . . . . . . . . . . . . . . . . . . 9 www.myprocessexpo.com

Moline Machinery LLC. . . . . . . . . . . . . . . . 52 www.moline.com

Wire Belt Company of America . . . . . . . TT-7 www.wirebelt.com

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

www.snackandbakery.com

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

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

BNP Media 155 Pfingsten Road, Suite 205, Deerfield, IL 60015 Phone: (847) 405-4000 Fax: (847) 405-4100 Reaching a total qualified circulation of 14,000 copies. Source: Dec 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 Number 40813549. Canada Postmaster: Send address changes to: Ascend Media, PO Box 456, Niagara Falls, ON L2E 6S8.

April 2011 - Snack Food & Wholesale Bakery

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The Final Word

A Guaranteed Good Time E ver since college, I associated the Spring Solstice with the National Collegiate Athletic Association (NCAA) brackets. Regardless of how well I thought I knew what I was doing, or believed in my “system” of picking the winning teams, I usually ended up having to bow out by the time Sweet 16 rolled around. Thankfully, I don’t have to endure that pain anymore because nowadays, I peg springtime as SNAXPO time—a time when I roam the aisles to learn about the latest and greatest in ingredients, equipment and, well, snacks. It’s a show where I pack light because I know I’m coming home with cookies from Ellison Bakery, Fort Wayne, Ind., snacks from Rudolph Foods, Lima, Ohio, and an assortment of pens, bags, mugs and literature from all the fun and innovative exhibits showing new things in the snack industry. It’s also a time when I run into wonderful friends, such as Michael Season, president of Addison, Ill.-based Natural Snacks, LLC, the maker of Michael Season’s and Mexi-Snax branded snacks and the recipient of Snack Food & Wholesale Bakery’s 2010 Snack Manufacturer of the Year award. And who can forget the picture-andautograph session with the folks from Shearer’s Foods, Inc., Brewster, Ohio, the producer of Tangos, Shapers, Shearer’s and Riceworks brands and the receiver of Snack Food & Wholesale Bakery’s 2011 Snack Manufacturer of the Year award (okay, maybe Bob Shearer, chairman, co-founder and CEO of Shearer’s, didn’t sign autographs, but he was stopped a few times on the way to our booth to talk shop)? And oh yes, there was a make-yourown-chili buffet, complete with cheesecake

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Snack Food & Wholesale Bakery - April 2011

and lemonade—anything to quench that 90-degree Orlando heat. SNAXPO is just one of those shows where you know you’re going to have a guaranteed good time. This year’s SNAXPO, which is sponsored by the Snack Food Association (SFA), Arlington, Va., and took place March 20-23 in Orlando, was no different. In fact, more than 1,100 attendees networked, exchanged ideas and experienced what I call the SNAXPO buzz. The ingredient suppliers showed up with some tasty prototypes that delivered exotic, hot and savory flavors. For example, Marc Green, senior manager, marketing communications for National Starch Food Innovation, Bridgewater, N.J., treated me and my sales staff to a demo of crispy, crunchy and “crinchy” chips and crackers. Wixon, St. Francis, Wis., showcased its Global Street Food BBQ Tastes campaign, which includes Kansas City BBQ potato chips, Argentinean Asado sweet potato chips, Korean Kalbi crunchy snacks, South African Braai corn puffs and Russian Shashlik potato balls, all made with the company’s KCLean Salt, which reduces sodium by 50%. Companies such as Technology Crops International, Winston-Salem, N.C.; Pioneer Hi-Bred International, Inc., Johnston, Iowa; and Oilseeds International Ltd., San Francisco, displayed an assortment of new fats and oils designed to offer functionality, taste and performance. (to learn more about these and other fat/oil companies, look for the Ingredient Technology section of Snack Food & Wholesale Bakery’s August 2011 issue). In the packaging arena, folks at the Print-

Marina Mayer, executive editor [email protected]

pack booth handed out samples of Zip-Pak’s Zip360, a package that features a multi-align zipper, a 360-degree opening for easy access and pour-spout functionality in a stand-up format, suitable for snack applications. Other highlights included the State of the Snack Industry report, presented by Sally Lyons Wyatt, senior vice president of Chicago-based SymphonyIRI Group. In this session, Lyons Wyatt provided statistics on consumer spending habits (42% of shoppers are cutting spending on snacks) and explained how confidence is returning despite economical concerns. She also touched on how sustainability remains a growth opportunity for the snack market (20% of consumers say they are trying to eat more natural and organic products) and how many shoppers are turning to brand name products that come with reasonable price tags (salty snacks increased 0.4% since last year). Learn more about the state of the industry for your snack market in Snack Food & Wholesale Bakery’s July 2011 special report. Meanwhile, the late Earl Wise, Sr., founder of Wise Foods, Inc., Berwick, Pa., received SFA’s 2011 Circle of Honor award, which recognizes the achievements of snack food industry executives who have been leaders in the association. Whether it’s a new product, ingredient or equipment, making the trek out to SNAXPO is a better gamble than some silly basketball bracket. That’s because it’s always a guaranteed good time. SF&WB

www.snackandbakery.com

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