Snackfood & Wholesale Bakery January 2012

BICAR® Sodium Bicarbonate and ISO 22000 Because she’s counting on us.

W

e know where our product goes. We know what’s at stake. Each of us at Solvay Chemicals understands the real world impact of our commitment to food safety.

How strong is our commitment? Strong enough to achieve certification of our Parachute, CO facility to the ISO 22000 Food Safety Management System Standard. We stand alone as the first North American sodium bicarbonate production facility to reach this milestone. Count on BICAR Sodium Bicarbonate to address the most critical food ingredient issue: safety. Count on Solvay Chemicals.

SAFE • Produced in North America’s first and only facility with an ISO 22000 Certified food safety management system • Production managed by a quality system built on a Hazard Analysis of Critical Control Points (HACCP) program and the FDA’s Good Manufacturing Practices (cGMP) LOCAL • Domestically manufactured in Parachute, CO, North America’s newest sodium bicarbonate production facility GLOBAL • Solvay Chemicals is a member of the Solvay Group, the world’s largest producer of sodium bicarbonate Solvay Chemicals. We make your choice an easy one.

Solvay Chemicals, Inc. 1.800.SOLVAY C (800.765.8292) www.solvaychemicals.us

Copyright 2011, Solvay Chemicals, Inc. All Rights Reserved.

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6 RECYCLABLE

Kwik Lok Is The Bag Closure Of Choice When It Comes To Function, The Environment And Consumer Convenience! Environment The Kwik Lok Bag Closure is designed to be reused and RECYCLED. The closure has earned a recyclable symbol of 6, making Kwik Lok a truly recyclable closure. Other closures, such as wire surrounded by paper or plastic, or polyvinyl and polypropylene tape with paper between the two ends, cannot be recycled. Wire and tape closures are typically thrown into the garbage each and every time, seldom ever reused. During our extruding process, no processed water is used or expelled into our city’s sewer system. Kwik Lok cools its extruders within a closed loop cooling system. Our new enhanced filtration system prohibits nearly all particulates from being expelled into the air. Kwik Lok is actively seeking to reduce our electrical demands by inventing and installing new, efficient closure manufacturing machinery. No hardeners or additives are added to our plastic. Newly developed additives such as PLA (Polyactide Acid), Polystarch or others are not used. Such additives, while claiming to make plastic degradable, present a couple of problems. (1) Recycling of products made with additives is problematic. The Biodegradable Products Institute concurs, “The recycling of plastic products made with these types of additives is poor, the plastic products have to end up in the landfill ... they cannot be recycled in their original form.” (2) The use of these additives creates methane gas which is 20 times more potent than carbon dioxide emissions! Every landfill has a different content, be it wet or dry, compost, or general waste, mixed with or without moisture and oxygen. Thus the process of degrading is highly dependent upon each landfill’s composition. Should the Kwik Lok closure be tossed into the garbage, its degradation process began at the moment the closure plastic left the extruder since no inhibitors or additives were added to the Kwik Lok. When you compare the choices, Kwik Lok, wire or tape ... Kwik Lok is the logical answer to your bag closing requirements.

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Convenience Kwik Lok is easy to remove. Many consumers have health issues such as arthritis, diabetes, and degenerative eye problems. For vision impaired customers and/or those with arthritis, the Kwik Lok is easy to remove. A person with totally impaired vision can remove a Kwik Lok closure. There is no guessing which way to untwist like you have with a wire closure. Attempt to find the ends of sticky tape and have the dexterity to separate the ends! It takes three hands to remove this closure, and it certainly is not reusable. The Kwik Lok Bag Closure is one of life’s little conveniences that plays an important function in packaging. It Closes the Bag Securely. It can carry Best Before Dating, or Country of Origin Labeling. It is manufactured with a low carbon output. It is degradable. It is recyclable. It’s Resealable, it’s Reusable, it’s REMARKABLE! Kwik Lok ... the Logical Choice ... Recyclable Bag Closure ... Convenient Bag Closure ... High Quality Dependable Bag Closing Machinery ... Date Coding on the Closure ... High Quality Custom Printed Closure Labels. Kwik Lok’s 893 Automatic Bag Closing Machine closes bags at 110 per minute and permits the packager to close bags with our standard Kwik Lok Closure or Closure-Labels.

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Contents Cover Story 18 | Turano Turns 50 Growing every day, Turano Baking Co., celebrates its 50th year in business in 2012, with automated artisan processes, a wealth of bread varieties and four U.S. production locations. We celebrate Turano’s 50th anniversary as the bakery smoothly transitions into its third generation of family owned and operated management.

Photos by Vito Palmisano

Plant Story 30 | Celebrating, Baking Bread Expanded several times, Turano Baking’s 185,000-sq.ft. headquarters plant in Berwyn, Ill., started out as a 2,000-sq.-ft. storefront; now it’s a sprawling dynamo of action, baking as many as 150 types of fresh products each day.

Columns 8 | Editor’s Note Editor-in-Chief Lauren R. Hartman looks at new beginnings for 2012 and introduces a few new columns to our monthly lineup.

14 | Industry Expert This month’s contributing columnist, Sylvia Melendez-Klinger, registered dietitian, member of the Grain Foods Foundation and owner/president of Hispanic Food Communications, finds new ways to understand the health and nutritional needs of Hispanic customers.

52 | The Nutritional Corner Contributing columnist and president of the Grain Foods Foundation (GFF), Judi Adams, provides a snapshot of the progress GFF is making with anti-grains issues.

96 | The Final Word Executive Editor Marina Mayer ponders the new year and notes what’s in store for bakeries and snack food companies, citing a report published by the International Dairy-Deli-Bakery Association (IDDBA).

76 | Insider Perspective This month, C. Thomas Harrington from Tennessee Bun Co. takes a football approach to a bakery’s ‘no-huddle offense.’

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 2012, 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].

4

Snack Food & Wholesale Bakery - January 2012

www.snackandbakery.com

Horizontal Flow Wrapping Experience the Bosch Advantage

Application experience is critical to successful flow wrapping What is the difference between a flow wrapper

Bosch technology minimizes downtime, speeding changeovers and cleaning

that efficiently packages products 24/7, year

Bosch’s flow wrappers incorporate industry

after year, and one that frequently jams and

leading technology built on decades of ex-

requires maintenance downtime? Often times

perience. Many changeover adjustments are

it is a result of the flow wrapper manufacture’s

accomplished simply by selecting a stored

experience with your application.

recipe, triggering independent servo motors

Pillow Packs

Multi-Packs

to make the needed changes. Changeover parts are replaced or adjusted within minutes without tools. Outstanding accessibility and a streamlined and sanitary design make the

Carrying Inserts

machine easy to clean.

Hand fed to fully automated wrappers and feeding solutions The manufacturer’s optimization of their

Bosch flow wrappers extend from the entry

standard machine to your application is critical

level Doboy Stratus, typically purchased by

to your success. That optimization is based

first time manufacturers looking for easy and

on their experience wrapping products with

flexible automation, to fully automated high

similar characteristics to yours and testing

speed wrappers. Feeding solutions range from

with your actual product. No company has

hand fed infeeds to completely automated

more flow wrapping experience across a broad

product handling systems including robotic

range of industries to draw upon than Bosch.

pick and place solutions.

Our associates work with you to understand

Whether you’re looking to produce standard

your operation and run tests using your

pillow packs, shrink packs, multi-packs with

product. They combine this with our unrivaled

support boards, or anything in between,

experience to deliver the most cost-effective

Bosch’s extensive flow wrapper and feeding

wrapping solution, ideally suited to your

portfolio ensures you receive the best solution

product and environment.

for your operation.

Stacked Products

On-Edge Slug Packaging

Shrink Packaging

Opening Aids

Download our free educational “Guide to Flow Wrapping” at www.boschpackaging.com/ nrd/guide Guide to Flow Wrapping

www.boschpackaging.com

Bosch Packaging Technology, Inc. Tel: 715-249-6511 [email protected] www.boschpackaging.com

Cartoning of Flow Wrapped Products

Contents Market Trends

Production, Technology & Product Development Solutions for a Changing Industry. January 2012 Vol. 101 No. 01

44 | Clean Labels for the New Year Many manufacturers are making headway with exciting new clean-label foods that prove to be tasty and satisfying.

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

New Products

John Schrei Publishing Director

50 | New Products Read about some of the most recently introduced products, such as weight loss bars made with fullness ingredients, chocolate pie donuts, ‘slimming’ blueberry bars and flavorful lentil crackers.

44

[email protected]

Tom Imbordino Group Publisher [email protected]

Jeff Heath Publisher [email protected] 224-554-9154

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

Marina Mayer Executive Editor

50

[email protected] 847-405-4008

Patty Catini Art Director

Advertising & Internet Sales

Special Report

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

56 | Dimensional Packaging Innovations

Suzanne Sarkesian Classified Sales

Check out the new dimensions in packaging, with extra features that allow snacks and baked goods to ‘do it all.’

[email protected] 248-786-1692

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

Support Services

56

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

Ingredient Technology 64 | Interesting Inclusions As more consumers scrutinize food ingredients, bakers and snack producers look to inclusions to create better-for-you products that deliver an irresistible taste.

Audience Development Kourtney Genereaux Audience Development Mgr. Stephanie Hunt Multimedia Mgr. Catherine M. Ronan Corporate Audience Audit Mgr. List Rental Postal contact: Kevin Collopy, Sr. Account Mgr. Ph: 845-731-2684; Toll Free: 800-223-2194 x684 [email protected]

64 Production Technology

Email contact: Michael Costantino, Sr. Account Mgr. Ph: 845-731-2748; Toll Free: 800-223-2194 x748 [email protected]

78

Single Copy Sales Ann Kalb Ph: 248-244-6499; Fax: 248-244-2925

78 | Belts and Conveyors With the Right Moves

[email protected]

Most bakers and snack producers want conveyors that are durable, versatile and easy to clean and maintain. Manufacturers are answering the call, with new equipment that has all the right moves.

John R. Schrei Publishing Rita M. Foumia Corporate Strategy Scott Krywko Information Technology Vincent M. Miconi Production Lisa L. Paulus Finance Michael T. Powell Creative Nikki Smith Directories Marlene J. Witthoft Human Resources Scott Wolters Events Beth A. Surowiec Clear Seas Research

Connect with Snack Food & Wholesale Bakery EEEA
Corporate Directors

BNP Media Helps People Succeed in Business with Superior Information

6

Snack Food & Wholesale Bakery - January 2012

www.snackandbakery.com

F

CUSTOM RMULATIONS Snack food manufacturers have come to rely on ADM Cocoa for consistency and quality. But what really sets us apart are the added extras you can’t get anywhere else. Like custom formulations. Our technical experts can help you create a one-of-a-kind, category-leading product your customers will crave. To find out more about how ADM’s technical expertise can give you an advantage, visit us at adm.com/ambrosia.

ADM. Chocolate…and so much more.

For customers around the world, ADM draws on its resources—its ts people, products, and market mar marke k t perspective perspectiv perspective—to —to help p them meet today’s consumer demands and envision tomorrow’s needs. © 2012 Archer Daniels Midland Company

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

Editor’s Note

New Beginnings, New Ideas +

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Snack Food & Wholesale Bakery - January 2012

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focus on family, food and simple pleasures. U œœ`ÊVœ˜ÃՓ«Ìˆœ˜Êˆ˜Ê>ÊL>`ÊiVœ˜œ“Þ°Ê œÊ“œÀiÊV>˜ÊLÀ>˜`ÃʍÕÃÌÊVœ>ÃÌʜ˜Ê«ÀœÛˆ`ˆ˜}ÆÊ̅iÞ½Ê…>ÛiÊ̜ÊëiVˆvÞʅœÜÊ̅iÞÊ «ÀœÛˆ`i]Ê܅ÞÊ̅iÞÊ«ÀœÛˆ`iÊ>˜`Ê܅>ÌÊ̅iÞÊ ÃÌ>˜`ÊvœÀÊ܅i˜Ê`œˆ˜}ÊÜ°Êi>ÀÃʜvÊ>Ê`œÕLi‡ `ˆ«ÊÀiViÃȜ˜Ê>˜`ÊÅ>œÜÊVœ˜ÃՓiÀÊVœ˜w`i˜ViÊ«ÀiÃÃÕÀiÊLˆ}ÊLÕȘiÃÃÊ̜Ê`œÊÜi° /…iÃiÊ>ÀiÊLÕÌÊ>ÊviÜʜvÊ̅iʜLÃiÀÛ>̈œ˜ÃÊ >˜`ÊvœÀiV>ÃÌÃÊvÀœ“Ê ÕÀœÊ,- °Ê"˜Ê̅iÊ vœœ`ÊÈ`i]Ê̅iʅˆ}…ÊÀ>ÌiʜvʜLiÈÌÞÊ>˜`Ê>˜Ê >}ˆ˜}Ê«œ«Õ>̈œ˜Êˆ˜Ê
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Տˆ˜>ÀÞÊ iÛiœ«“i˜ÌÊÃ>ÞÊi˜Ê9]Ê œœ“iÀÃÊ >˜`Êi˜Ê8iÀÃÊ>ÊÃii“Ê̜ÊÌÕÀ˜Ê̜Ê`ˆvviÀi˜ÌÊ vœœ`ÃÊvœÀÊVœ“vœÀÌ°ÊœÀiÊÌÀi˜`Ãʈ˜VÕ`iÊ̅iÊ i“iÀ}i˜ViʜvʓˆVÀœ«>̈ÃÃiÀˆiÃ]Ê>v>œÀiÃÊ ­-œÕ̅Ê
“iÀˆV>˜ÊVœœŽˆiÃʜÀÊVœ˜viV̈œ˜Ã®]Ê «ˆiÃ]Ê«œ«œÛiÀÃ]ÊëiVˆ>ÌÞÊvÀœâi˜Ê`iÃÃiÀÌÃ]Ê LiÌÌiÀÊL>Žˆ˜}ʓˆÝiÃ]ʓœÀiÊ«ÀiÌâiÃ]Ê}œL>Ê VՈȘi]ÊÜi˜iÃÃʈ˜}Ài`ˆi˜ÌÃ]ʓœÀiÊ
È>˜Ê ˆ˜yÕi˜ViÃÊ>˜`ʓœÀiÊ}ÕÌi˜qvÀiiʈ˜˜œÛ>̈œ˜Ã°Ê >ÀLiVÕiÊ>˜`Ê}Àˆi`Êy>ۜÀÃ]ÊÃÌÀiiÌÊ vœœ`Ã]Êvœœ`ÊÌÀÕVŽÊv>ۜÀˆÌiÃÊ>˜`ÊV…>˜}iÃʈ˜Ê Ø>VŽˆ˜}ʅ>LˆÌÃÊ>ÊÃii“Ê̜ÊLiʜ˜Ê̅iʅœÀˆâœ˜°Ê œÊ`œÕLÌ]ʈ̽ÃÊ}œˆ˜}Ê̜ÊLiÊ>˜ÊiÝVˆÌˆ˜}Ê Þi>À°Ê>««ÞÊ iÜÊ9i>ÀtÊÊSF&WB

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Business Briefs

suppliers

News Top Trends for 2012: Purity, Authenticity, Sustainability Lead the Way nnova Market Insights recently launched a webinar report, naming the Top 10 trends impacting the food and beverage market for 2012 and beyond. The top trends include purity, authenticity and sustainability, as consumers continue to look for products that have added value, despite the ongoing economic uncertainty. Other trends discussed: 1. “Pure” is the new natural. Natural products are becoming the rule rather than the exception in most western markets, despite ongoing issues with a clear definition of what “natural” encompasses. Innova reports a doubling in the number of products using the word “pure” between 2008-09, with a third added in 2010 and considerably more in 2011. 2. “Green” is a given. Corporate social responsibility and sustainability strategies have an increasingly important role. The focus is on reducing carbon emissions or packaging, or creating higher welfare or fair trade lines. 3. Location: The interest in where foods come from has never been higher among consumers. The drive is an interest in supporting local suppliers, a desire for ethnicstyle lines, concerns over the quality and safety of imported products, or the demand for authenticity in terms of products from a particular country or region. 4. Premium: Despite austerity measures topping the agenda from mid-2011, a premium position provides many benefits. Consumers still have to eat, and are likely to look increasingly to the extremes of discount or super-premium products, with center-ground brands squeezed. 5. Seniors: Companies are addressing the needs of an aging population, both in terms of packaging functionality and of general and specific health concerns. New EU regulations on labeling should also help seniors by improving the clarity and visibility of nutritional information. Various recent moves have been made in U.S. front-of-pack labeling. For more details, visit Innova Market Insights at www.innovadatabase.com.

I

people Tennessee Bun Co., Nashville Joe Waters is the new president, and comes to the company with an extensive background in acquisitions. An important part of the leadership team, Waters will focus on growing the company, fo increasing sales and adding new in customers. He has led several cu successful mergers and has su 30 years’ experience in plant, engineering, general manageen ment and executive leadership. m Joe Waters As vice president of manufacturing for the Fresh Bakery division of Sara Lee Corporation, he oversaw 40 plant operations

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Snack Food & Wholesale Bakery - January 2012

and was a member of the Fresh Bakery Leadership team and Sara Lee’s Global Leadership Team. Prior to his career at Sara Lee, Waters managed multiple plants for Anheuser-Busch, Thomas Industries and Continental Can Co. Nu-Tek Salt LLC, Minnetonka, Minn. Donald Mower becomes president/COO of Nu-Tek Salt, LLC, a Minnetonka, Minn.based company that develops sodium reduction technologies. Mower was previously acting COO and senior vice president of marketing, sales and corporate leadership for Ann’s House of Nuts.

Solazyme Roquette Nutritionals, a microalgae-derived food ingredients supplier, is opening a Phase II commercial production facility in Lestrem, France, to produce its lead microalgae-derived food ingredient—whole algalin flour. The 5,000-metric-ton facility is scheduled to be completed by the end of 2012. Bay State Milling opens an innovation and applications center in Quincy, Mass. Dedicated to the late Bernard Rothwell II, former president, the facility is known as the Rothwell Grainessentials Center: Where Grain Based Solutions Grow. The center is equipped an Bay State’s Rothwell experimental mill Grainessentials Center that allows for the development of products from conception to product application. Puratos is set to open a $42-million, state-of-the-art manufacturing facility in Pennsauken, N.J. The 171,000-sq.-ft. plant will produce more than 90,000 metric tons of bakery improvers, bases, mixes, bio-fermented sourdoughs and finishers, including icings, glazes and fruit and cream fillings. The new facility will become operational in the fall of 2012 and provide more than 190 local jobs for the community. It will offer an excellent working environment with the highest safety and quality standards, says Puratos. Nu-Tek Salt, Minnetonka, Minn. Says it has developed a patented technology that minimizes the metallic note of potassium chloride, giving it a similar perception to that of sodium chloride, or salt. Potassium chloride is frequently used as a replacement for sodium chloride in bakery applications, as food manufacturers focus on reducing salt levels in baked goods. Nu-Tek studies Continued on page 10

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“Now we can mix high viscosity emulsions 600% faster.” The Ross PreMax is the first batch rotor/stator mixer that delivers both ultra-high shear mixing quality and high-speed production. In side by side tests, the PreMax produces thickened dressings and sauces much faster than a traditional high shear mixer.

John Paterson PreMax Inventor Employee Owner

With a patented, high-flow rotor/stator design, the PreMax also handles viscosities far beyond the capacity of ordinary batch high shear mixers. In many applications, this can eliminate the need for supplemental agitation.

Contact Ross today to arrange a no-charge test in our laboratory. Call 1-800-243-ROSS Or visit mixers.com

The PreMax with a Delta generator operates with a tip speed of 5,000 fpm and handles viscosity up to 50,000 cP.

*Patent No. 6,000,840

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Business Briefs

supplier news Continued from page 10

show that its potassium chloride technology reduces sodium in bakery applications by 30%. The potassium chloride was tested against a control in yeast-leavened dough systems, showcasing double split, bran-dusted hamburger buns. Regular and 30%-reduced hamburger buns were produced having 675 mg./100 g. and 475 mg./100 g. of sodium, respectively. Samples were produced at a commercial bakery and sent to University of Nebraska, Lincoln, Neb., for sensory analysis. Packaging specialist tna, Sydney, unveils its newest manufacturing plant in Qingdao, China. Spanning 7,650 sq. meters, the plant incorporates two separate factories and office space. According to the company, the plant demonstrates tna’s commitment to the China and Asian markets by providing local, turnkey manufacturing

solutions to its customers. Huge growth in the Chinese sector is partly why the packaged food industry has seen up to 20% growth per annum in recent years, and the new plant demonstrates significant investment into growth in this sector, according to the company. “Investing in a market in which we are already active and which is predicted to enjoy double digit year-on-year growth for the foreseeable future wasn’t a difficult decision for tna,” says Michael Green, managing director of tna. Hearthside Food Solutions LLC, Downers Grove, Ill., acquires the Roskam Granola business unit of Roskam Baking Co., a former subsidiary of Hearthside. The acquisi-

tion includes manufacturing operations in Grand Rapids, Mich. Hearthside is a contract manufacturer of premium snack and convenience foods, including granola bars, popcorn and snack mixes. The Roskam unit produces granola base and a wide range of products, including bars, mixes and granola nut clusters. Copenhagen, Denmark-based Danisco, a producer of food ingredients, enzymes and bio-based solutions used in a variety of industries, including the bakery industry, has launched Danisco.com/health, a website designed to provide companies interested in developing dietary supplements for specific markets with useful information and advice. Site visitors can learn about Danisco’s product range, finished formats, service, licensing program and R&D expertise.

Editor’s Note: Go to www.snackandbakery.com to learn more about other news items relating to the snack food and wholesale bakery markets, or subscribe to Operations Weekly and receive news directly to your inbox every Wednesday.

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

Elizabeth Fujas, Rising Sun Farms founder

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Industry Expert

Health and Nutritional Needs of Hispanic Customers T he 2010 Census revealed that one in every six U.S. residents is Hispanic. The U.S. Hispanic population ranks second worldwide. Unfortunately, the growing Hispanic population experiences similar health issues as non-Hispanics but the prevalence may be higher. Hispanics have a higher prevalence of obesity than non-Hispanic whites. Also, Hispanics experience higher rates of obesityrelated diseases such as heart disease, hypertension, diabetes and cancer. Actually, heart disease is the leading cause of death among Hispanics. The good news is that Hispanics worry about their health, especially on behalf of their family. A life-threatening illness can affect their ability to provide for their family. They have a broad definition of health treatment that includes mainstream medicine, tradition, traditional healing and a strong religious component. You may be asking, if they worry so much about their health, then why is it that their health is in such critical condition? Let’s review some lifestyle and diet characteristics that make this transition difficult for most Hispanics: UÊAcceptance of over-eating, large portions UÊLack of exercise UÊCultural isolation often due to immigration status UÊAcceptance of larger body size UÊTraditional dishes are usually high in calories and fat UÊCultural celebrations are centered around food UÊPoor eating habits UÊLack of nutrition knowledge UÊConsume more fats and oils products UÊDiets tend to be less healthy, based on level of acculturation and time spent in the

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Snack Food & Wholesale Bakery - January 2012

United States. Overall, Hispanics spend a higher percentage of income on food compared to U.S. population as a whole. There is great diversity among Hispanics living in the United States, which results in different needs. When reaching your Hispanic customer, keep the following tips in mind: Acknowledge and embrace cultural differences. Learn about the diet and food habits of your Hispanic customers (ask them), and learn about the foods and brands preferred by Hispanics (high brand loyalty among Hispanics). Explore expanding the variety of brands you provide. Personalize messages to focus on their family lifestyle to include their children and extended family. Also, focus on the positives that can have an impact while maintaining cultural relevance. U>ŽiÊVՏÌÕÀ>Þ‡ÀiiÛ>˜ÌÊvœœ`ÃʜÀÊ recipes more healthful U,iVœ““i˜`ʏœÜÊv>ÌÊ`>ˆÀÞ]ʓˆŽÊ>˜`Ê yogurt UÊ,iVœ““i˜`ʏi>˜iÀÊVÕÌÃʜvʓi>ÌÊ>˜`Ê poultry and fish twice a week UÊ,iVœ““i˜`ʓœÀiÊvÀՈÌÃÊ>˜`ÊÛi}iÌ>Lià UÊ,iVœ““i˜`ÊLœÌ…Ê܅œiÊ>˜`Êi˜ÀˆV…i`Ê grains. Do the research. Learn about the goods and services that cater to Hispanic

Sylvia Meléndez-Klinger, MS, RD

tastes and preferences in cuisine and lifestyle, and embrace their culture by watching Spanish television, reading Hispanic magazines or reading and using their favorite cookbooks. Partner with local restaurants and health professionals who work with the Hispanic community. It’s not always easy for Hispanics to keep healthy habits, but there are some things they can do to stay fit that don’t take that much time or effort. I recommend starting with a healthy breakfast helps. A new survey from Kellogg’s found that although 9 out of 10 Hispanic moms want their kids to eat breakfast every day, 40% report that ̅iÊV…ˆ`Ài˜Ê`œ˜½ÌÊi>ÌÊLÀi>Žv>ÃÌÊ`>ˆÞ°ÊˆÃÃing this important meal is not ideal. Monitor food choices carefully. What you eat and how much you eat are critical factors in maintaining a healthy weight. Eat fewer calories by serving smaller portions and eating slowly helps. If you want to loose half a pound of weight in a week, you’ll need to burn up to 250 extra calories per day. Reduce fat intake. The Dietary Guidelines recommend consuming no more than 25 to 35% of calories from fat. Consume more fruits and vegetables. /…iʘi܏ÞÊÀii>Ãi`ÊÞ«>ÌiÊÀiVœ““i˜`ÃÊ filling half of the plate with fruits and vegetables. Think smaller. Pay attention to what you’re eating. Stop dieting. We love the idea of a quick fix, but the American Dietetic Association says fad diets don’t teach balanced eating habits necessary for a lifetime of weight management. Sylvia Meléndez-Klinger is a registered and licensed dietitian, a member of the Grain Foods Foundation and owner and president of Hispanic Food Communications.

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With one of the industry’s largest logistics networks,

ADM Milling works for you. It’s simple, really. You want the right product delivered to the right place at the right time. That’s how ADM works for you. As one of North America’s leading millers, we not only have one of the industry’s largest transportation and logistics networks, we have strategically placed production facilities throughout the country. And it’s all backed by a team of committed professionals working tirelessly on your behalf. That means an uninterrupted supply. No surprises. We’ll deliver on our promise, so you can deliver on yours. To learn more about how ADM Milling will work for you and your company, contact us at [email protected]. Or, visit us online at adm.com/milling.

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

800-422-1688 | [email protected] | www.adm.com/milling © 2011 Archer Daniels Midland Company

*Information is accurate as of October 2011, to the best of Archer Daniels Midland Company’s knowledge.

Intralox is a global manufacturer specializing in conveying technologies that solve conveyance problems, simplify processes, and save money for customers. For more than 30 years, we’ve been helping bakery and snack processors convey their products more efficiently and more profitably. The combination of our service infrastructure, industry expertise, innovative technology, and performance guarantees allows our customers to achieve extraordinary results. Intralox FoodSafe Solutions As food safety continues to be a focus issue in the food processing industry, the Intralox Food Safety Team researches and develops the most time-efficient and costeffective means of ensuring hygienic conveyance. Intralox’s

comprehensive approach to food-safe conveyance includes the right choice of belt and components, hygienic conveyance design guidelines, and thorough cleaning process management support. Hygienic Conveyor Belts ThermoDrive® belting is the ultimate hygienic conveying technology for a variety of food processing applications. ThermoDrive combines the best features of modular plastic and traditional flat belts, offering a smooth, continuous conveying surface and sprocket-driven operation. Optimal Spiral Performance Guaranteed We understand that the spiral is a vital part of your process and critical to your plant’s efficiency and profitability. The Intralox Spiral Optimization program is a comprehensive package of products and services that ensures your spiral always runs at peak performance. With high-performance Spiralox belting, a turnkey spiral retrofit, and regular followup inspections, choosing Spiral Optimization gives you the support, expertise, and guarantees that only Intralox can provide. ARB™ Technology Is Perfecting Plant Layouts Worldwide Intralox’s innovative, patented conveyance technology allows you to build state-of-the-art packaging lines with enhanced efficiency and flexibility. Our dedicated team of design engineers uses the latest

simulation models to optimize your line layouts. Whether you need to reduce overall system costs, save floor space, or reduce system controls and complexity, consult Intralox early on in your planning process. Award-winning ARB technology has simplified line layouts and enabled critical improvements for end users in over 2,500 installations worldwide.

Committed to quality and performance-driven results, Intralox offers customers global industry expertise and 24hr service. For country and industry-specific phone numbers, visit our website, www.intralox.com. Intralox, L.L.C. 301 Plantation Road. Harahan, LA 70123 US/Canada: 1.888.680.2358 Europe: +800.2253.7437 www.intralox.com customerservice.bakery@ intralox.com

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

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

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

Turano Turns 50 Maintaining traditional European bread baking processes using stone hearth ovens, European/Italian recipes, formulas and old-world flavor, Turano Baking Co., Berwyn, Ill., has been expanding its artisan-quality product line nationally. We celebrate the 50th anniversary of this growing company, which is smoothly transitioning into its third generation of family owned and operated management.

F

Lauren R. Hartman, Editor-in-Chief

or Turano Baking Co., Berwyn, Ill., its family namesake, Turano, and brand is a household word in the Chicago metropolitan area. Moving into its 50th year in 2012, the family-owned and operated bakery has very successfully sailed into the 21st century and into the national bakery scene. Its progressive style keeps its tasty Italian/European breads, sliced breads, buns, rolls, sandwich breads and specialties (such as its signature 2-lb. rustic round Pane Turano loaf) in the minds of the local community and now, in the national consciousness. Continuing to follow European traditions to bake the freshest, top-quality Ciabatta, Focaccia, Chicago-style French breads, hearth-baked peasant breads, sliced breads and rolls with artisan quality, the Turano family has grown, and man-

agement is carefully and thoughtfully “passing the torch” onto Generation Three. Practically raised in the bakery, the third generation knows what it’s doing. Sharing favorite family recipes from past generations, the company now operates four production facilities, distributes nationally and maintains authentic time-tested techniques to ensure that delicious, old-world flavor. Yet it does so with sophisticated, customized production equipment and high-speed technology. Turano Baking’s product line has grown extensively throughout the years. Its enormous line of 450 stock-keeping units (SKUs), including specialty breads and rolls, is delivered fresh daily throughout Chicagoland, southern Illinois, Wisconsin and northwest Indiana and parts of Iowa as well as across the United States on a frozen basis. Continued on page 20

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Snack Food & Wholesale Bakery - January 2012

www.snackandbakery.com

From left to right: Giancarlo Turano II, national sales manager; Joseph Turano, director of operations-Midwest; Anthony Turano, information systems director; Mario Turano, marketing director; and Lisa Turano, vice president, legal.

Photos by Vito Palmisano

www.snackandbakery.com

January 2012 - Snack Food & Wholesale Bakery

19

Continued from page 18

Today, 90% of the company’s business is devoted to foodservice bakery products and 10% is in retail. The local fresh delivery business breakdown comprises 75% in foodservice and retail comprises 25%. The Turanos have 90 truck routes in the Chicagoland area and 10 in the Milwaukee area. Products for national distribution are handled via food distributors, retailers and both large and small restaurant chains. Shelf life varies with the product; the fresh-baked bulk items have a one-day shelf life, the retail products have a five- to 10-day shelf life and the packaged foodservice products typically last five days. Beyond the Berwyn production facility headquarters, Turano Baking operates an additional frozen products plant in Bolingbrook, Ill., and recently opened facilities in Villa Rica, Ga., and Orlando, Fla. The Berwyn headquarters also incorporates Mamma Susi’s, a popular storefront bake shop, named after the family’s matriarch, where visitors can buy classic Italian pastries, cookies, freshly baked bread and other treats that are baked in-house and by hand. Some of Turano Baking’s newest products, introduced in the fall of 2011, consist of garlic bread and garlic parmesan bread in six-color printed bags; and croutons in Asiago cheese, Ciabatta, Pesto and Bruschetta varieties, packed in brightly printed 4.5-oz. standup bags.

Two of the three second-generation Turano brothers who carried on their father’s vision include Renato (Ron) Turano, chairman (left) and Umberto (Tony) Turano, president.

Partnerships back in the day Since 1962, the dynamic company has crafted up more and more varieties of fully-baked and now baked/frozen breads and rolls. Bakery founder Mariano Turano, born in Calabria, Italy, grew up in a community with a stone oven on which his family baked breads. He used his early baking skills to bake bread during World War II, and came to the United States for the first time in 1955. A few years later, he moved to this country, struggling to make a living, speak the new language and build

AT A GLANCE Company: Turano Baking Co. Headquarters/Location: Berwyn, Ill. Website: www.turano.com Plant Size: 185,000 sq. ft. No. of Lines: 6 No. of Employees: 407 Annual Sales Total: $200+ million Products: European artisan breads, hearth-baked peasant breads, Ciabatta, Focaccia, baguettes, buns and rolls, French rolls, sub/hoagie/ grinders, sliced pan and pullman breads Brands: Turano, Mamma Susi, Pane di Campagna

KEY PERSONNEL: Chairman: Renato “Ron” Turano President: Umberto “Tony” Turano Executive VP: Giancarlo Turano VP Sales: Ken Cotuno VP Operations: Les Messina VP Route Sales: Bill Carlson Midwest Region Operations Director: Joe Turano Southeast Region Operations Director: Leo Desrosiers Corp. Director of Quality Assurance: Michelle Rivera Director of Engineering: Frank Biernacki Marketing Director: Mario Turano National Sales Manager: Giancarlo Turano II

a future for his family, which includes sons Renato, Umberto and Giancarlo. He held various jobs, such as those in his brother’s grocery store, often baking in the store oven. His artisan-style bread became so popular that Mariano began delivering to homes, transporting the bread by car, developing a dedicated clientele and long list of loyal friends. The business kept growing and he was able to purchase an existing bakery in Chicago that had been called Campagna. He kept the name and opened for business as Campagna Bakery, Mario Turano and Sons. In 1965, he and his brothers opened a 2,000-sq.-ft. bakery in Berwyn, with a maximum output of 200 loaves of bread per day. “My grandfather initially opened with the intention to meet his then-current neighborhood demand,” explains Lisa Turano, vice president, legal. “He had tremendous foresight. Grandfather’s business was really relationship-based. People would literally come in to have coffee at the bake shop and buy a pound of cookies and two loaves of bread. He was really building many relationships.”

From coast to coast or ‘crust to crust’ In the 1970s, the Berwyn bakery expanded westbound and eastbound, and Mariano’s Continued on page 22

20

Snack Food & Wholesale Bakery - January 2012

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Continued from page 20

sons Renato, Umberto and Giancarlo, began managing the business, nurturing their father’s vision. The brothers then decided to take on the wholesale market and also launched Mamma Susi precooked, panned Focaacia pizzas. Customer demand

prompted the brothers to make their tempting breads available in neighborhood grocery stores. They also installed a pair of flour silos that can each hold 100,000 lb. of product, and in 1985, they enlarged the plant again to make par-baked breads for

Convey For Profit. Line efficiency, seasoning quality, breakage, stale product complaints, sales attainment, processing uptime, sanitation downtime, warehouse capacity, weigher accuracy: Are these issues reducing your profits? We understand and we can help! As the conveying technology leader, Heat and Control will work with you and create the product handling system that brings the profit back!

800 227 5980 / 510 259 0500 [email protected] www.heatandcontrol.com

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national distribution. It is these three second-generation brothers who developed the business into what today can be considered a baking empire, which has annual sales of approximately $200 million. The bakery continued to run out of space, so it was updated or expanded even further, points out Joe Turano, director of operations-Midwest. “We’ve had at least three major expansions here and there have been minor expansions as well,” he says. “The next major expansion was from 1999 to 2001, when we were able to expand the production facility east and westward, so we built a new building and added two more production lines, which doubled our total output and also doubled the size of our shipping dock. The biggest gain there was being able to have three transport dock doors for the large trailers so that we could easily accommodate deliveries and shipments in semi trucks.” Customers outside of Turano Baking’s daily delivery reach were also demanding more and more. So in the 1990s, Renato, Umberto and Giancarlo also added the Bolingbrook location (known within the company as Turano-Knead Dough Baking Co.) on 10 acres of land. Now a 220,000-sq.-ft facility, Bolingbrook has two production lines initially and plenty of cold-storage capacity and freezer space that allowed Turano Baking to move into the frozen business in a big way. Within five years, three more lines went into the Bolingbrook facility, which now provides full-baked products including bread sticks, premium hamburger buns and premium European baguettes, submarine rolls and dinner rolls. Approximately 95% of the product made in the Bolingbrook location is frozen and sold nationwide, so all frozen shipments, including those from Berwyn, originate out of Bolingbrook, says Joe Turano. Laughs Lisa Turano, “Our fathers have taken the business across the country, from crust-to-crust, so-to-speak. When my grandfather first purchased the bakery in Berwyn, he initially opened it with the intention of meeting the then-current neighborhood demand. He truly was a visionary. Continued on page 24

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But I don’t think he could have predicted what this bakery was going to become.”

Southern flavor Expansions outside of Illinois took place in 2008 and 2009, when the company

opened production plants in Georgia and Florida, respectively. Both of the expansion opportunities arose at the same time, says Giancarlo Turano II, national sales manager. “The Florida facility ended up opening a year later than Georgia,” he says.

Why have two plants in the South? “The thinking was customer-driven,” he says. “Georgia was an opportunity to not only serve a specific customer that really helped us grow into that facility but logically, it made sense to expand there and serve the Southeast and Southern portions of the United States. The Georgia facility really is a frozen extension of our Chicago plants.” Able to generate 100 million lb. of bread each year, the Villa Rica, Ga., plant provides another shipping point geographically, which was part of the plan. “We have two production lines there so far,” says Giancarlo Turano II. “The [bun] plant in Florida was also customer-driven, because there is a geographic need to be in Orlando. The plan was just to have one facility in the southeast, but two different opportunities arose. Orlando serves some major quick-service restaurants with one high-speed bun line, and McDonald’s is the anchor.” Turano Baking is gaining popularity in Georgia and the Southeast, especially with its artisan and European style of products, he points out. The area also welcomed a new site with the chance for more job openings. “We’re selling more and more product there each year,” Giancarlo Turano II mentions. “The customers have sophisticated palettes, and are looking for higher quality and unique breads.” Currently on a unit basis, the Berwyn location accommodates 30% of the total output, and Bolingbrook contributes about 25%, estimates Joe Turano. Georgia adds another 25% of total output and Florida 20%. “The southern facilities have allowed us to introduce high-speed pan breads, traditional and premium pan breads and highspeed hamburger buns for quick-service and retail outlets,” he says.

Growing by the minute Back to Berwyn. The headquarters location, also known as Campagna-Turano Bakery, now occupies 185,000 sq. ft. of production space. It houses six production lines that churn out 150 to 200 SKUs overall and produces 150 SKUs fresh daily. Continued on page 27

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Continued from page 24

Three of the lines are fully automated and three are semi-automated. All of the facility’s packaging is performed in-line with production. “We expanded this plant several times,” Joe Turano says. “We’ve been mass-producing the Pane Turano, which helped build the company, on a fully automated basis for 12 years,” explains Joe Turano. “Before that, it was made semi-automatically with some hand work involved for rack proofing and manually pressing of the dough. We built a fully automatic production line to produce here in Berwyn in 2000.” Staffed with 407 employees, the Berwyn location processes up to 1 million lb. of flour each week and nearly 1.5 millions lb. of dough each week. Operating seven days a week, 24 hours a day, with shutdown hours that vary throughout the week depending on what’s being produced, the plant and headquarters site primarily serves a seven-day fresh-delivery system, says Joe Turano. “In fact, all four facilities run at least five days a week. We service 50 states, one way or another with our lineup,” he points out. “We’re starting to grow the retail product line on a state-by-state basis. We ship product from Berwyn to the cold storage facility in Bolingbrook each day to freeze.” A fully functional kitchen at the Berwyn office also recently enjoyed an upgrade of appliances, marble counters and cabinet space. This is where corporate chef Paul Brigante makes lunches, tests new recipes and new products, produces videos for the company’s website featuring dishes he develops throughout the year, and teaches recipes so that the whole family will be coming back for seconds. A product innovator who has been with Turano Baking for nearly 20 years, Brigante assists restaurant customers in developing or improving menus. “Paul does a tremendous job of menu designing and consultation, so we bring customers in to meet him and he’s able to introduce our products in tandem with our route sales people and our local sales team,” Lisa Turano adds. Another advantage that Joe Turano points out is the company’s staff of employees. “Our

employees and management team are wonderful,” he says. “Our management team has been with the company for years and has grown with the company as we’ve grown. The employees are extensions of the family.”

Automating artisan Turano Baking is also blossoming with new technology, electronic processes, social media and other contemporary developments. For example, it’s creating some new artisan products on high-speed lines, says Joe Turano. “Perhaps the term ‘automated artisan’ is a better way to describe it,” he says. Technology is catching up with hand-crafted processes, and the company has been able to automate some of the things that could only be done by hand earlier. “It was a major goal to reproduce our original Pane Turano [2-lb.] automatically,” recalls Giancarlo Turano II. “The bread used to be processed by hand. Now, that’s automated. Artisan to me is a quality indicator—it isn’t a typical sub roll or hamburger bun—it takes old-world techniques and recipes and creates something unique, top quality. But it can be automated, because there’s no way you can create some products by hand in the kinds of volumes we need. We can make something special using automation.” The driving force behind strategies like this came from family patriarch and company owner Mariano Turano, he adds. “Our grandfather knew the company would be able to expand into a frozen basis, but the technology wasn’t there at the time. He knew it would catch up. One of our fathers’ and uncles’ goals was to invest in the technology to automate some of these processes so that we could maintain the quality of the product and make it available to the whole country.” In fact, Mariano Turano remained as the chairman of the board until he passed away in 1989, Lisa Turano remembers. “He was made chairman in 1984 and still came in to work every day, still held an office, still met with our fathers and had great ideas. It was their fortune to have Continued on page 28

Continued from page 27

him, and it’s ours to have them.”

Beyond bread The second-generation—Tony (Umberto), Ron (Renato) and Giancarlo—have artfully put a succession plan into place with the third generation, which includes a large lineup of cousins, brothers and sisters. “We’re implementing this plan gradually, and our fathers and uncles are very supportive of it,” Giancarlo Turano II explains. “They want to see it happen.” Generation Two has blended a brisk bakery business with family, tradition, quality and customer service, which will remain the foundations of the business, adds Joe Turano. “QSV² has always been our motto, which stands for Quality, Service, Value, Variety. The motto was created by our dads and uncles for the company’s 25th anniversary. Since then, we have been living and operating with that motto. Customers and family always come first, and we have the best role models you can imagine.” He says the management team takes its fathers’ and uncles’ advice and their guidance quite seriously and appreciates their patience. “They give us the space to make our own decisions,” Joe Turano says. “We lead our departments as we need to. We’re very fortunate that they’re working with us along the way, so that we can learn and take the opportunities.” Generation Three says their fathers and uncles have wonderful ideas and experience. “They drive a lot of our product development,” notes Joe Turano. “They have vision, just like our grandfather, and have developed the company to be ready for the marketplace today. We’re very fortunate to be in this position.” The second-generation brothers were ahead of their time with various product introductions. The second product they introduced at the retail market was Mamma Susi pizza, recalls Giancarlo Turano II. “They started growing that part of the business through grocery markets. But back then, they didn’t know that frozen pizza would become what it is today. They

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knew that a lot of our variety breads and submarine rolls would have a place in the market, but it was a matter of American tastes catching up to those of certain other parts of the world.” Some of the company’s new value-added products, such as the croutons, incorporate dramatic new bag graphics. The products aim to take the unique breads

Turano Baking is known for and use them in different ways. “We’re expanding beyond bread, into value-added product lines,” Giancarlo Turano II emphasizes. “It has been very successful so far. The retail market here in Chicago has accepted our brand for being a quality bread in general. Now, we’re offering another upgrade, with artisan

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croutons in three flavors that are made of our Ciabatta and Focaccia breads. The garlic breads are interpretations of what the sort of flavors we look for and the packaging is all new.”

Top trends Top sellers include the French breads, Ciabatta and peasant Italian breads, but hamburger buns are equally popular, as are the bakery’s premium hamburger buns and baguettes. Still, the third-generation Turano management team isn’t afraid to jump into new trends. It sees the need for lower-calorie products, pretzel breads, breads that lend themselves to more flavors and better-foryou, healthier products. “These are a few directions in which we see things going,” Giancarlo Turano II points out. “Just trying to add a bit of eye appeal and more value through unique flavor profiles is key.” There’s a need for lighter, airier prod-

ucts that are tender to the bite, continues Joe Turano. “We get a lot of requests for things that are lighter. People want to consume less per serving but still have their bread. They also want more whole grain, which is a trend in Europe, where European consumers accept more grains or whole wheat in a regular, standard product, without it being 100% whole wheat or 100% whole grain. And we’re also going to see a lot of hybrid-type products in the next five years. Our whole-wheat flour output is in double digit growth each year.” Now that it’s turning 50, Turano Baking will celebrate with its customers and employees all year-long. Product development and customer service have always been its focus, and the family has always supported product development. “It’s what drives the company,” concludes Joe Turano. We’ve developed versatile product categories for quick service, causal dining, fine dining restaurants and hotels. We have the dedica-

tion necessary for whatever that type of product is coming next, and our sales force is very multifaceted. For the future, we expect to keep producing the quality we always have, to continue to develop new products and drive our company. There are many opportunities with national distribution as it continues to grow.” Sharing a lot of amusing stories, the third generation of Turanos have fun together managing the bakery. “It has always been our life,” says Joe Turano. “We worked in different positions, and learned various jobs. What’s great is that no one forced or pushed us into working in this business. We were encouraged to do other things, but somehow, we all came back here.” Lisa Turano agrees: “Our dads raised us and gave us all wings. Alternatively, we all grew roots and stayed here because the nine of us all have something very different to contribute.” SF&WB

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January 2012 - Snack Food & Wholesale Bakery

29

Producing and Celebrating Bread Expanded several times, Turano Baking Co.’s Berwyn, Ill., headquarters production plant features three fully-automated makeup lines and three semi-automated lines that can produce some 200 stock-keeping units overall and generate as many as 150 types of fresh products each day. Starting out as a 2,000-sq.-ft. storefront in the early 1960s, the facility now is a 185,000-sq.-ft. dynamo of action.

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The bakery’s signature Pane Turano round bread emerges from the oven, above, and travels downstream to a tall racetrack spiral cooler before moving into the packaging department.

T

Lauren R. Hartman, Editor-in-Chief

urano Baking Co.’s Berwyn, Ill., headquarters location is a bustling, action-packed 185,000-sq.-ft. production complex, brimming with high-speed makeup lines as well as hand-crafting stations. Known by company personnel as Campagna-Turano, the plant is home to 407 employees and six production lines that process up to 1 million lb. of flour each week and approximately 1.5 millions lb. of dough each week. Customers have a need for so many different items that the lines in Berwyn alone churn out 150 to 200 of the company’s Continued on page 32

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Photos by Vito Palmisano

January 2012 - Snack Food & Wholesale Bakery

31

On the stress-free line, round Pane Turano loaves of bread exit the multizone hearth oven 12-across and convey toward a recently purchased racetrack cooler.

Continued from page 31

Stress-free, automatic and hand-crafted

stock-keeping units (SKU) overall and produce 150 fresh SKUs daily. There can be as many as 15 changeovers a day on four of the six lines. Some of the most sophisticated baking equipment in the world has found a home at the Turano Baking facility, as has some vintage machinery. Three of the production lines are fully automated and three are semi-automated. The newer lines have programmable logic controls, touchscreens and Ethernet capability so that the maintenance department can log in and check line efficiencies or diagnose any situation that may arise. All packaging is performed inline with production. “We expanded this plant several times,” observes Joe Turano, director of operationsMidwest and a member of the bakery’s third-generation management team. Operating seven days a week, 24 hours a day, with cleaning/maintenance shutdowns that vary throughout the week depending on what’s being produced, the plant primarily serves a seven-day fresh-delivery system.

In 2001, Turano Baking Co., Berwyn, Ill, installed a fully automated, stress-free line with a customized proofing system for its signature 2-lb. Pane Turano loaf, a rustic round Italian bread that was hand-made for many years. The line also generates various artisan breads, including aromatic Panini and Ciabatta and other Europeanstyle breads. At the heart of the line is a custom built, 108-ft.-long granite stone hearth tunnel oven with multiple zones that bake up the most aromatic loaves. New line additions include a fully automated racetrack cooling system and an automatic band slicer. “We duplicated the entire production line in our bakery in Villa Rica, Georgia,” Turano says, describing the line that runs the Pane Turano. “Stress-free means the dough is worked as little as possible to maintain the quality and integrity of its cell structure, and so that it has more absorption,” Turano explains. The large round loaves are produced at speeds of 1,500 an hour (25 a min.) while 3-lb. Panini bread is

made at 1,200 loaves per hour (20 a min). “The production lines in our three other production plants are all highspeed and fully automated for their given product categories,” he points out. “But here, production space is tight, so we upgrade and further automate as we’re able to.” The recently added racetrack cooler in Berwyn provides an additional hour of cooling time for the Pane Turano, which needs two hours to cool before slicing and packaging,” he says. “The product flows from the cooler automatically into a slicing unit and then to the packaging department.” In 2006, the bakery added another new fully automated line that runs French bread and rolls. Despite all of the speedy automation, the bakery still makes some products exclusively by hand, in a small area devoted to specialty and artisan breads. “We hand craft maybe five or 10 different breads for fine dining restaurants,” he adds. On the day of Snack Food & Wholesale Bakery’s visit, the fully-automatic stressfree line was running the 2-lb. Pane Turano bread while another of the fully-automatic lines was producing 8-in. French sandwich rolls for foodservice customers (the newer of the two lines at the plant that bakes French rolls). This French bread line runs long 1-lb. baguettes at up to 3,000 an hour (or 50 a min.). Both of the lines receive flour from a pair of outdoor silos that can each hold 100,000-lb. Water and shortening are pumped to the mixing stations from tanks. Additional “minor” ingredients such as dough conditioners, salt, sugar and block Continued on page 34

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yeast, are scaled manually from bags and other containers stored in a dedicated raw materials warehouse. Inclusions such as rosemary and other herbs, roasted garlic, cheeses, onion and many more are used in at least 15 to 20 of the items the plant produces.

Mixing, rolling and dividing Production on the line running the Pane Turano rounds starts with a three-bowl carousel spiral mixing station. Having a 1,000-lb. capacity, the system prepares the dough as the bowls rotate through the station, scaling flour, water and other ingredients and progressing to mixing and resting stations. After the dough is mixed, it’s deposited into a dough trough and is allowed to ferment anywhere from 30 to 120 minutes, depending on the type of dough running on the line. Then, the dough is transferred to a hopper on the stress-free Continued on page 36

French rolls emerge from the oven on one of three fully-automatic makeup lines at the Berwyn plant. They exit and make their way to a spiral cooler (background).

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about an hour. Leaving the proofer, the loaves relax a few minutes in an intermediate step halfway through the proofing process and then go back for a final proofing. Next, the proofed pieces are scored by hand and transferred into some proprietary sections of the line that create “just the right crust” on specially designed equipment that further shapes them into the proper dimensions. The loaves are automatically removed from the peel boards before being oriented and conveyed 12-across into the long, natural gas-fired hearth oven. The multizone, granite-stone oven bakes bread at temperatures ranging from 350-520°F for anywhere from 15-60 min., depending on the product running. There is a quality control check at the point where the loaves exit the oven and drop onto a return conveyor. Here, they travel to a tall, spiral racetrack cooler that brings them down to an ambient temperature, before


 


makeup line where it’s divided. As the dough drops into the divider, it’s formed into a continuous slab. Rails divide it into separate sections as cross rollers stretch the slab thinner and thinner. The line is equipped with several sheeting, gauging and dusting stations. In this case, the dough is dusted with flour. The separated portions of dough then travel to a scale system that checks the weight and portioning before the dough is guillotine-cut into individual pieces. A spraying system and topping applicators are also part of the line, though Turano says in this particular case, they’re bypassed. The dough then goes through a rounder and then the rounds are placed onto peel boards two-across, and are aligned by hand as peel boards convey underneath the line in a closed loop through the system. Proofing in a system that holds up to 1,200 dough pieces is next, as the dough pieces progress six-across on the peel boards and proof for

they exit onto a rack-style conveyor. This conveyor elevates them out of the main room and into the packaging department as they cool for another 50 to 60 min. The Pane Turano takes nearly two hours to cool before it’s sliced. As the conveyor lowers the round breads into the main floor of the packaging department, the loaves move single-file into the slicer and then are bagged in clear film bags printed with the Pane Turano logo, product details and the bakery logo. The bags are also automatically clipped closed and are sent through a metal detector before they’re tray-packed manually in counts of four. They also can be packed in eight-count corrugated cases for frozen distribution. The cases are sent through a tape sealer and are labeled, palletized manually and stretchwrapped on automatic equipment. From here, fresh loaves move to the shipping dock for delivery while the case loads are put into Continued on page 38

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the trucks. A shuttle system between the Berwyn plant and the plant in Bolingbrook, Ill., transports trailerloads of the product bound for frozen distribution to the Bolingbrook freezer. There are 10 refrigerated trailers that ship at least six truckloads each day to Bolingbrook to freeze. “Our new Villa Rica and Orlando plants are independent, where product is frozen onsite in the freezer attached to the bakery,” Turano notes.

French roll flair The French rolls are made in similar fashion on another of the three fully automatic lines, but with several differences. Two vertical mixers on this line work with straight dough and there’s no floor time after mixing. In addition, minor ingredients are added by hand. After mixing, the French roll dough is dumped into a dough trough, which is rolled over to a five-pocket divider. The divided dough then moves through a checkweigher and a rounder that forms the rolls. From the rounder, it transfers into an intermediate proofer and then after the proofer, the dough moves to a sheeter/roller that further manipulates it into a thinner sheet. It’s sheeted through curling belts and a pressure board and then back to proofing. Proofing for about 15 minutes takes place at ambient temperatures. The proofed rolls are then molded into 36-in.-long strings, and a reciprocating belt moves them onto peel boards holding five pieces each. After a dusting of corn meal, they’re automatically oriented form a horizontal to a vertical position on the boards. The boards make a U-turn on a conveyor leading to a main proofer, where they proof for another 60 minutes (baking temperatures and relative humidity are proprietary). After this final proofing, the rolls are scored and cut/perforated to size before they bake for 25 minutes in another multi-zone hearth oven. They exit the oven and convey to a second racetrack spiral cooler. After cooling, they progress overhead to the packaging room and follow the same procedures as the Pane Turano loaves, except that the line

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Snack Food & Wholesale Bakery - January 2012

After it’s sliced, the Pane Turano bread is bagged in clear film bags printed with the bakery and product logos before being clipped closed and sent through a metal detector. It takes nearly two hours for the 2-lb. rounds to cool. flow in the opposite direction from the Pane Turanos in order to save room. Next, the golden brown French rolls are sent through a bagger that loads them into six-count clear, wicketed bags with color-coded labels. The bags are then automatically clipped closed before they convey through a metal detector that checks them for any contaminants. Packaging efficiencies and other production information appear on computer touchscreens as line operators perform quality assurance checks periodi-

cally, monitoring product weight, dimensions, appearance, color and other variables. The bags are packed by hand into large black shipping trays that are manually palletized before the loads are whisked off to the shipping area.

Food safety first Food safety is a top priority at all four of Turano Baking’s production plants. “We keep track of all food safety regulations and are always on top of them,”

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Turano says. “We stay ahead of the curve on food safety. We’re Safe Quality Food (SQF)-certified at the plants in Georgia and Florida at a Level 2, and are working to certify the Bolingbrook plant and then work on Berwyn,” he continues. Each facility goes through at least six audits a year, depending on chain operator requests. Turano Baking is audited annually by the American Institute of Baking International (AIB), and has received a Superior rating in Berwyn for more than 12 years. “We’re always looking for equipment that has safe requirements,” he mentions. “For the most part, equipment manufacturers

have responded with food safety and easy maintenance in mind. We are looking at automating more with computer-aided manufacturing systems. But we always give our suppliers input and recommendations to fit our needs. Overall, they’re responding very well.” Each makeup line also conducts frequent quality control checks, regardless of the product running. And all of the lines at all four bakeries are equipped with metal detectors. But the Berwyn plant has become more process-controlled and automated in terms of quality data, Turano explains. “In fact, we will soon upgrade process control at all of our plants,” he says. “For a pilot, we installed touchscreens in our packaging areas to provide finished orders to the packaging operators so they know immediately what quantities of product they need to package. They enter data such as quality specifications, typical bread or bun Continued on page 40

 
    
   
 
 

   
 

























































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length, width and weight. These specs are checked every 15 minutes to review how the products are running. They also check product temperature and all scaling data are displayed on the screen. Our quality analyst gathers all of this data and can share it with our customers and plant personnel.” One initiative that began last year was to further automate the packaging lines company-wide, says Turano. There are opportunities to automate case-packaging functions on lines in the 220,000-sq.-ft. Bolingbrook complex and in the 107,000-sq.-ft. Villa Rica, Ga., facility. “We’re always looking for more efficient packaging equipment,” he adds. “We do not automatically palletize but we stretch wrap automatically in Berwyn. Being a fresh bakery primarily, the Berwyn plant has some space constraints the others don’t have. So to fully automate here—the way we have in the other bakeries—is a challenge.” Inventory handling is computerized in Villa Rica and at the 90,000-sq.-ft. bun

plant in Orlando, but Turano Baking would like to upgrade Berwyn’s inventory program, he adds. “We have computerized the inventory handling and processing in our newer plants,” he says. “The warehouses in Orlando and Villa Rica send micro ingredients automatically to the mixers there. From an inventory standpoint, they have real-time information of all ingredients and usage information is in real time. We’re working on upgrading to that kind of technology in Bolingbrook and Berwyn.” The degrading economy hasn’t steered clear of Turano Baking, but company management places a greater emphasis on new product development to stay on top of the competition. “We strive to be better and more efficient at what we do when planning projects and managing the company,” says Turano. “The situation has made every bakery in the country even more competitive. But it’s making us better so that when the markets

do turn around, we’re going to be much more prepared. It gives us an advantage for the future.”

Sustainability initiatives Reducing waste and energy usage and improving its sustainability is another Turano Baking goal. The company is evaluating the Energy Star program along with others and benchmarks its waste against all of the facilities. Improved lighting at all four locations is making things brighter in the plants and saving quite a bit of energy says Turano. A recycling program also is in place company-wide. Recycling bins are strategically located in each office and plant for separating plastics and paper. “We’ve cut our waste dramatically over the last few years since we implemented the program,” he says. “Continuous improvement is one of our mantras.” And it seems that Turano Baking’s mantra is working well. Happy 50th anniversary, Turano Baking. SF&WB

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    40

Snack Food & Wholesale Bakery - January 2012

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Squeeze it Feel the difference

New POWERFresh® Bread bakery enzymes with G+ Imagine with us Imagine you could keep your bread feeling significantly fresher for days longer1 than any other choice on the shelf. New POWERFresh® Bread with G+ technology makes it a reality. Developed together with the baking industry, POWERFresh® Bread and POWERFresh® Special bakery enzyme products are carefully tailored to make a difference that can be felt with a single squeeze. And that means more on-the-spot sales – plus customers who keep coming back for more. If you need to squeeze it twice, it probably wasn’t made with POWERFresh®. To learn more about POWERFresh® with G+ visit www.powerfresh.info

Telephone: (1) 800.255.6837 Fax: (1) 913.764.5407 www.danisco.com © 2010 Danisco USA, Inc.

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Market Trends Clean-Label Products

Clean Labels for the New Year Many clean-label manufacturers are making headway in snack and bakery segments by creating exciting new foods for consumers to enjoy, proving that clean-label foods can also be tasty and satisfying. Jen Roth, Contributing Writer

any New Year’s resolutions lead consumers to resolve to eat healthier, leaner and cleaner. With a variety of new clean-label products on the market, manufacturers are supplying their customers with more options than ever. “I believe consumers are looking for simple products that are minimally processed and claims that are meaningful and legitimate,” says Nicole Bernard Dawes, co-founder and CEO of Late July Organic Snacks. “Getting the public to understand and appreciate the difference between a certified organic product versus [a] conventional or all-natural [product is important].” All of the Barnstable, Mass.-based company’s products are certified organic by the U.S. Department of Agriculture (USDA). Late July’s new Cure for the Summertime Blues Organic Blue Corn Multigrain tortilla chips join the other creatively-named multigrain

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tortilla chips in the line, including Sea Salt by the Sea Shore, Mild Green Mojo, which boasts cheese, green chilies, and a hint of lime and Dude Ranch, a ranchflavored chip with a gang of sour cream and a variety of herbs and spices. How Sweet Potato It Is will be joining the rest of the multigrain chips in 2012. “These new chips have fun and interesting flavors the whole family will enjoy and healthy whole grains and seeds moms will want to give their kids,” states Bernard Dawes. Late July Organic Snacks enforces a clean-label billing on all of its packaging. “We have enhanced our new chip packaging to make the following statements more prominent when on the shelf: USDAorganic; certified gluten-free; 100% whole grains; multigrain snack chips,” states Bernard Dawes. “As we continue to develop new products and packaging, we make sure these messages are clear and visible for consumers.” Bernard Dawes also says that Late July Organic Snacks is creating innovative, organic and healthful snacks that offer the health and wellness shopper everything they want in one snack. Tortilla chips are prominent in the clean-label market. The Real Deal All Natural Snacks, Easton, Pa., creates a variety of organic tortilla chips for the clean-label consumer to enjoy. Earlier in 2011, the company launched its Organic Blue Corn

Tortilla Chips and Organic White Corn Tortilla Chips, which are made with nonGMO corn and boast 21 g. of whole grains per serving. The kosher and gluten-free chips were launched alongside the company’s Organic Multi-Grain Tortilla Chips, which come in Original and Baked options. “The Corriere family has 60 years of experience making every kind of corn-based snack,” says Deborah Crowe, vice president. “We’ve helped innovate some of the most unique and successful products in the natural foods market today.” One of The Real Deal Organic Snacks’ innovations includes utilizing unusual ingredients in its snacks. Its Real! Veggie Chips are made from corn, rice and peas. “Our Real! Veggie Chips are for moms who want to feed their kids healthy but good-tasting, kid-friendly snacks,” says Crowe. She adds that these snacks also are great for the weight-conscious consumer and offer more than one serving of vegetables in every ounce. The Real! Veggie Chips come in Original and Sriracha options, and boast 80% less fat than potato chips. Consumers can enjoy this snack on the go, launched in 100-calorie six-packs in 2012. Not only does the company offer a selection of tortilla and veggie chips, it also specializes in clean-label snack mixes. The Chili Lime and Original varieties both contain nacho tortilla chips, pretzels, corn Continued on page 46

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There’s only one Alberger brand salt. ®

© 2009 Cargill, Incorporated

It’s the shape that makes it great. Alberger® brand salt, exclusively from Cargill, is created from a process that starts with a hollow pyramid shape to form multi-faceted crystals. These unique crystals with a large surface area and low bulk density provide superior adherence, blendability and solubility compared to regular cube-shaped granulated salt. The rapid solubility also gives Alberger® salt its flavor burst when used in topical applications. To find out what else we can bring to the table, call 1-888-385-SALT or visit cargillsalt.com. collaborate

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Market Trends Clean-Label Products Continued from page 44

chips, BBQ corn chips and crunchy cheese curls, a consumer favorite. “Customers coast-to-coast have said that our cheese curls are the best they’ve tasted,” states Crowe. The company plans to launch the cheese curls as a standalone product in 2012.

“Customers should feel great about buying any bag of The Real Deal because we have perfected the art of the tortilla chip, corn chip and cheese curl and plan to continue to innovate with the best, most healthy ingredients without ever compromising great taste and texture,” says Crowe.

Another company manufacturing clean-label snack mixes is Healthient, Inc., Jupiter, Fla. It recently launched the LOLICRUNCH line under its SnackHealthy brand. The LOLICRUNCH line is entirely cholesterol-, dairy-, wheat-, and glutenfree. Both the Almond Crunch and Cashew Crunch varieties contain either almonds or cashews, peanuts and are sweetened with evaporated cane juice and brown rice syrup. They also come topped with a hint of sea salt. For consumers who aren’t nuts for just nuts, the Cranberry Nut Crunch option contains dried cranberries alongside almonds, peanuts and cashews. Consumers can imagine they’re snacking on a far away island with the Tropical Fruits and Nut Crunch variety, which offers dried mangoes, papayas and pineapples with almonds, peanuts and cashews. It also offers a little cayenne pepper kick in the seasoning blend. Clean label doesn’t apply only to snack products. Home Free, LLC of Windham, N.H., manufactures clean-label cookies for the sweet-toothed consumer. “Our name refers to the homemade feel of our products and to the cookies being free of most allergens, as well as of trans fat, cholesterol and anything artificial,” says Jill Robbins, president. “It also means that with our products, you are ‘home free’—you can relax because we took care of making sure the product is wholesome and allergen safe.” Home Free, LLC’s cookies come in a variety of shapes, sizes and flavors. “Some people like soft cookies, some like crunchy, some like big and some like mini,” states Robbins. “We offer all those options so everyone can enjoy their favorite kind of cookie.” Robbins adds that Chocolate Chip is one of the more popular selections the company provides. The favored cookie joins the Chocolate Chocolate Chip, Oatmeal, and Vanilla Continued on page 48

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With the resources you need to make the right choice,

ADM Milling works for you. As one of North America’s leading millers, ADM provides its customers with a little added something you don’t get everywhere else — expertise. Our technical experts are skilled at providing R&D teams with recommendations that give your products a competitive edge, all while keeping a close eye on your bottom line. It’s just one of the many ways we’re working for you. To learn more about how ADM Milling works for you, contact us at [email protected]. Or, visit us online at adm.com/milling.

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

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*Information is accurate as of October 2011, to the best of Archer Daniels Midland Company’s knowledge.

Market Trends Cookies Continued from page 46

varieties, which are all nut-free and made with whole grains. Home Free, LLC also offers gluten-free and organic versions of all its cookies for a consumer with a more specialized cleanlabel need.

“People with food allergies are already telling us that their bodies are sensitive and susceptible, so it seemed especially important with this population to keep the food clean,” says Robbins.

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Snack Food & Wholesale Bakery - January 2012

Another company making sweet snacks clean is Crispy Green of Fairfield, N.J. The company specializes in manufacturing freeze-dried fruits, making it easier for consumers to enjoy a sweet, healthy snack on the go. There are no worries about refrigeration, peels, cores, seeds or rinds with Crispy Green’s FruitziO products. The FruitziO line includes Strawberries, Peaches, Apricots, Apples and Strawberries and Kiwi options, the latter of which is the most recent offering to launch. All the FruitziO products have 100 calories per bag and contain no fat or cholesterol. The company’s flagship Crispy Green line offers a variety of fruit at 55 calories per serving including Apples, Mangoes, Asian Pears, Bananas, Canteloupes and Pinapples. The line comes in a singleserving six-pack, making it easy to eat on the go. Consumers can keep the packages in their cars, lunch boxes, desk drawers or briefcases for easy, clean-label snacking. Kashi Co. of La Jolla, Calif., has long been an advocate for cleanlabel food products. Recently, it launched a new variety of its TLC Layered Granola Bar line. The Peanutty Dark Chocolate Layered Bar offers a fruit and dark chocolate spread over a chewy peanut, peanut butter and granola bar base. Topped with chopped peanuts and chocolate chunks, the bar has 4 g. of protein and 7 g. of fiber. It joins the Pumpkin Pecan and Dark Chocolate Coconut to round out the company’s sweet and savory line. Clean-label food options are versatile, offering consumers plenty of snack and bakery options to satisfy anyone looking for a simple, healthful way to improve their diets. SF&WB

www.snackandbakery.com

Healthy trends are here to stay. Are you? GrainEssentials® t
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New Products 1 4 2

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Lentil Crackers

Company: Mediterranean Snack Food

1

thinkThin Fruit and Nut Bars

Company: thinkproducts, Ventura, Calif. Website: www.thinkproducts.com Introduced: January Distribution: National Suggested Retail: $1.69-1.99 for a 1.41-oz. bar or a 14.11-oz. box Product Snapshot: The thinkThin lineup now includes Fruit and Nut Crunch bars, which offer two times more protein and 60% less sugar than leading fruit and nut bars. These gluten-free, vegan-friendly bars come in Blueberry, Cherry and Cranberry Apple varieties. Ingredients (Blueberry): Peanuts, almonds, brown rice syrup, soy crisps (soy protein isolate, tapioca starch), chicory fiber, cashews, currants, dextrose, natural flavors, blueberries (blueberries, apple juice concentrate, sunflower oil), soy lecithin, sea salt. Contains: peanuts, soy, almonds, cashews.

Co., Boonton, N.J. Website: www.mediterraneansnackfoods. com Introduced: May Distribution: National Suggested Retail: $3.49-$3.99 for a 4.-5 oz. box Product Snapshot: Mediterranean Snack Food Co.’s all natural Lentil Crackers are a line extension to the company’s Baked Lentil Chips, which are the first to feature the super food benefits of lentils. The Lentil Crackers are available in three naturally gluten-free flavors (Sea Salt, Rosemary Herb and Cracked Pepper) and offer a great taste, satisfying crunch and 5 g. of protein with only 110 calories, the company says. Ingredients (Rosemary Herb): Lentil flour, corn flour, potato starch, vegetable oil (olive oil and/or sunflower oil and/or palm fruit oil) milk protein, sugar, milk cream, sea salt, rosemary, leavening. Allergen Information: Manufactured in a facility that also processes product containing egg yolk. Contains: Dairy.

3

Fullbar

Company: Fullbar, LLC, Greenwood Village, Colo. Website: www.fullbar.com Introduced: January Distribution: National Suggested Retail: $5.99 to $11.99 for a 9.54-oz. box Product Snapshot: Fullbars are clinically proven weight loss bars made with Slendesta, a fullness ingredient. Similar to bariatric surgery, Fullbar works with consumers’ “wiring” to stimulate a complex neural and hormonal feedback loop that fills up and promotes fewer eating occasions. The bars come in Chocolate Caramel and Chocolate Peanut Butter varities. Ingredients (Chocolate Peanut Butter): Brown rice syrup, puffed wheat cereal (durum wheat, ferric orthophosphate, niacinamide, thiamine, mononitrate, riboflavin), peanut butter (peanuts), soy protein concentrate, honey, glycerin, agave syrup, gum Arabic, dry roasted peanuts, canola oil, salt, natural flavors. Contains: wheat, peanut, soy.

Krispy Kreme Glazed and Dipped Donuts

Company: Krispy Kreme, Winston-Salem, N.C. Website: www.krispykreme.com Introduced: November 2011 Distribution: National Suggested Retail: $1.09 for a 4-oz. package of Glazed Chocolate Pie; $4.29 for a 14.9-oz. box of Dipped Cake Product Snapshot: Krispy Kreme is expanding its product lineup with new chocolate-flavored donut offerings. For instance, the Glazed Chocolate Pie option consists of a smooth chocolate filling and Krispy Kreme’s Original Glazetopped crust and comes in a microwavefriendly box. The Dipped Cake version features a donut fully immersed in chocolate-flavored dip. Ingredients (Glazed Chocolate Pie): Enriched flour (wheat flour, niacin, reduced iron, thiamine mononitrate, riboflavin, folic acid), high-fructose corn syrup, water, palm oil, fractionated palm oil, sugar. Contains less than 2% of the following: vegetable shortening (palm oil, fractionated palm oil, mono- and diglycerides, polysorbate 60), food starch (modified), cocoa, vegetable shortening (interestified soybean oil, hydrogenated cottonseed oil), corn starch, salt, cocoa processed with alkali, sodium propionate preservative, corn syrup, soybean oil, dextrose, wheat flour, malted barley, vegetable shortening (palm oil, fractionated palm oil, soy lecithin), titanium dioxide color, chocolate liquor, potassium sorbate preservative, xanthan gum, glucono delta lactone, sodium stearoyl lactylate, artificial flavor, sodium benzoate preservative, sodium alginate, calcium carbonate, corn syrup solids, citric acid, yellow 5, yellow 6, agar-agar, maltodextrin, wheat starch, propylene glycol, mono- and diglycerides, soy lecithin, sorbitan monostearate, baking soda. Contains: wheat, soybeans.

E d i t o r ’s No t e : Go t o w w w. sn a c k a n d b a k e r y. c o m t o r e a d a b o u t m o r e n e w p r o d u c t s.

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Thought for food. At Viterra our best ideas go into every product we provide. Our research and development specialists work closely with our customers to ensure that we deliver the exact formula and profile to meet their food ingredient needs. We’ve got the people, the expertise and the technology to create the highest standard of nutrition, texture and flavor in a wide range of products. We deliver innovative essential ingredients and we are dedicated to our customer’s success. Visit us at viterra.com or reach us at [email protected]

21C Oats, Inc., a subsidiary of Viterra Inc.

The Nutritional Corner

A Rapid Response Program Update ast year, I provided you with a snapshot of the Grain Foods Foundation’s efforts to share positive messages about the health benefits of bread and grains to the media through our rapid response program. As we kick off the new year, I am happy to share the tremendous progress we’ve made in this area during the past few months. It’s discouraging to acknowledge that the health of Americans has been on a significant decline in the last decade and an already booming weight loss industry thrives because of it. More often than not, carbohydrates, particularly grains, are vilified and misrepresented in these diets “du jour.” At a time when one fad diet after another is released, it’s crucial that we maintain a strong voice for our industry, reinforcing the facts about grains to influencers and consumers alike. This is the purpose of our rapid response program. Since September, the Grain Foods Foundation (GFF) has issued some two-dozen letters to top-tier media outlets, including The Chicago Tribune, MacLean’s, Glamour, and Fox and Friends. Most of the letters educate reporters on a variety of topics. Yet one of the most significant issues we faced this fall was the anti-grains rhetoric from cardiologist Dr. William Davis in his fad diet book, Wheat Belly: Lose the Wheat, Lose the Weight, and Find Your Path Back to Health. In it, Davis asserts that wheat consumption is solely responsible for Americans’ health ills, and that cutting wheat from our diets is the cure-all solution to conditions such as obesity, diabetes, celiac disease and rheumatoid arthritis. Through both traditional and social media channels, we have been working closely with our scientific advisory board to point out that this book is just another low-carb

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Snack Food & Wholesale Bakery - January 2012

diet book with a catchy title (it restricts grains, potatoes and most fruits and vegetables) while highlighting the sound science supporting the important role wheat plays in a healthful diet. Another ongoing issue for GFF has been the spreading of misinformation by physician and talk show host, Dr. Mehemet Oz. Known for his extreme positions on carbohydrates. Dr. Oz has discouraged consumption of bread and grains during multiple show segments throughout the years. During that time, GFF has sent the host and show producers numerous letters correcting this misinformation. As a result of our ongoing response efforts, including a video rebuttal on YouTube, Dr. Glenn Gaesser, chairman of our scientific advisory board, was invited to appear on a recent segment of The Dr. Oz Show. The segment aired on November 28, and in a point-by-point discussion, Dr. Gaesser challenged the host on topics ranging from eating right to the best indicator of good health. As professor and director of the Healthy Lifestyles Research Center and the Exercise and Wellness Program at Arizona State University, Dr. Gaesser highlighted the large body of scientific evidence supporting carbohydrates’ role in maintaining a healthy weight. In fact, he shared data from peer-reviewed journals indicating an inverse relationship between

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

carbohydrate intake and weight. The Dr. Oz show reaches approximately 4.35 million viewers across the country each day. He is one of the most powerful influencers in the media and we couldn’t be more pleased with how well Dr. Gaesser held his own and so clearly represented GFF’s messages on the show. While we are thrilled about this media success, there is still work to be done. Although these are only two examples of

our efforts, they demonstrate the need for constant vigilance, which is the cornerstone of our rapid response program. Furthermore, these situations show that influencer engagement often isn’t a matter of instant gratification. Only with consistent interaction were we able to develop a connection with Dr. Oz and establish GFF and Dr. Gaesser’s position as a credible resource in the minds of the show producers. We look forward to future opportunities for growing the industry’s reputation, and most of all, keeping the facts straight in today’s overwhelming media environment. SF&WB

www.snackandbakery.com

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Special Report Packaging Innovations

New Packaging Dimensions It doesn’t take 3D glasses to see the new develop– ments and trends in snack and bakery packaging. Bob Garrison, Contributing Writer

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hat do consumers want? It doesn’t take special glasses to see these trend lines. With 3D theater movies, 3D televisions, 3G and 4G smartphones, it’s clear consumers want added dimensions and extra features. They want to more closely connect with a momentary diversion, to create more of a custom experience. They also want to feel better about how their purchase impacts the environment. Experts agree that new products and packaging carry those themes right into the snack and bakery food categories. “Increased competition, an uncertain

global economy and growing sustainability demands are driving packaging developments across all categories, including snack foods and bakery,” says Timothy Bohrer, CPP, a packaging materials expert and owner of Pac Advantage Consulting LLC, Chicago. “These trends have companies working harder to differentiate themselves when it comes to how consumers perceive their product quality, convenience and value. The familiar equation of ‘cheaper, better, faster—choose any two,’ no longer creates success. Today, consumers and retailers demand all three product attributes.” A 25-year industry observer, Rick Lingle is Editor-in-Chief of BNP Media’s Food & Beverage Packaging magazine. “Convenience, paired with product differentiation, is a potent combination,” says Lingle. “We see continued snack and bakery interest in convenience. This includes zipper resealability or easy-open techniques such as full, top-of-pack peel and reseal features for cookies. Meanwhile, every company is chasing sustainability, often as one component within a larger Corporate Social Responsibility initiative.”

Form and function Courtesy of ConAgra Foods

Architects used to say, that “forms follows function.” Although that phrase may be

Courtesy of Jolly Time Homemade Pop Corn

lost to the past, packaging engineers are keeping it alive in new products as different as soup to nuts—or, perhaps, biscotti to nuts. What are consumers’ “functional” food needs? On some levels, it’s clear they’re looking for snacks that do it all: Either satisfy individual needs or create a “sharing” experience for two or more. Among those tapping the latter trend are American Pop Corn Co., Sioux City, Iowa, and ConAgra Foods, Omaha, Neb. Last year saw American Pop Corn roll out a Jolly Time microwave bag that, with the pull of a string, turns into an “Insta-Bowl” for sharing. Similarly, ConAgra launched its own Pop Up Bowl, which includes a transparent lid so that consumers can watch their popcorn pop. Not everyone shares the same tastes? That’s okay, too. ConAgra came back last September with Orville Redenbacher’s Flavors, individual 3.24-oz. popcorn bags, each with a separate seasoning packet. Flavors seasonings include White Cheddar, Extra Cheese or Sea Salt and Vinegar. Continued on page 58

56

Snack Food & Wholesale Bakery - January 2012

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Special Report Packaging Innovations

And the award goes to …

S

nack foods and bakery products earned top honors in 2011 competitions hosted by the Flexible Packaging Association (FPA) and the Paperboard Packaging Council (PPC). Flexible Packaging Achievement Awards: Weaver Popcorn Co., Inc., Van Buren, Ind., earned a silver award for environmental and sustainability achievement for a new Trail’s End caramel corn bag developed by Danafilms Inc. and Plastic Packaging Technologies Inc. FPA credited Weaver and its suppliers for a “dramatic” packaging conversion from historical rigid tins and pails. Of-

ficials said the in-line Quad Seal Bag provides improved shelf presence, a three-ply barrier film combination and Inno-Lok zipper. Say FPA contest judges: “This package provides a compelling case study for marketers to convert to flexible packaging for an improved package at a lower cost, while reducing disposable waste by 80 to 85 percent.” National Paperboard Packaging Competition: ConAgra Foods’ Slim Jim 16-Count Snack Sticks package (provided by Graphic Packaging) earned an “Eco” Excellence Award. PepsiCo’s Quaker Oats unit earned a Gold award (general category) for new Quaker Life Soft Baked Bars (Graphic Packaging). Where there’s smoke … There’s fire. Want to know who’s hot

in private-label new products and packaging? Snack and bakery products earned as many as eight awards in the Private Label Manufacturers Association’s (PLMA) 2011 annual “Salute to Excellence” new product competition. PLMA showcased winners during the PLMA show last November in Chicago. Snack and bakery product honorees included Delhaize America (parent to Hannaford Bros. Markets, Food Lion and others) for its Home360 Baby Strawberry-Apple Little Puffs. Visit www.plma.org to see all “Salute to Excellence” winners.

Continued from page 56

Jesse Spungin is ConAgra’s vice president and general manager for the Orville Redenbacher’s brand. “We’ve found consumers more than ever want to control the flavor of their food, and the flavor packet in Orville Redenbacher’s Flavors allows popcorn lovers to sprinkle on the preferred amount of seasoning to control the flavor intensity.”

Courtesy of ConAgra Foods

Of course ConAgra isn’t the only one easy for travel. Officials say they developed thinking small (packaging) to creatively a flexible, durable new bag that bends and deliver big flavor. Still more interesting new folds effortlessly. offerings include PB2, a powdered snack in “In order for us to better service our 0.85-oz. glossy, multi-colored packets. Bell consumers, we wanted to find out what we Plantation Inc., Tifton, Ga., tells consumcould do better to enhance their experiers they simply need to add ence with our product,” says water and stir to make a marketing director Matt quick snack using PB2 peaDuffy. “Biscotti Bites are an nut butter or PB2 peanut easy solution for consumbutter with chocolate. ers who want to snack on Others use packaging gourmet cookies on-the-go; it to facilitate eating expericommunicates a less ‘fancy’ ences. One of those is and more ‘every-day’ biscotti. Nonni’s Foods LLC, Tulsa, The easy- to-use bag makes Okla. In conjunction with biscotti snacking effortless its summertime launch of and convenient; just open and Biscotti Bites, Nonni’s says wrap back up for another it wanted complementary biscotti break.” packaging to make its biteAlso targeting new usage Courtesy of Nonni’s Foods LLC size snack less messy and occasions is John B. SanContinued on page 60

58

Snack Food & Wholesale Bakery - January 2012

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means on the football field but did you know the Slipstick Conveyor’s horizontal motion gently glides your product along the conveyor so degradation is reduced or eliminated, delivering the product intact, retaining any added seasonings or coatings. Call 1.800.527.2116 today or visit www.sssdynamics.com to see how the Slipstick can safely simplify your operation and increase your profits.

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Special Report Package Handling Systems Continued from page 58

filippo & Son, Inc., the Elgin, Ill., marketer of Fisher nuts.

Courtesy of John B. Sanfilippo & Son, Inc.

“Consumer research led us to reinvent the baking nut category and create the Fisher Freshness Seal Bag,” says Howard Brandeisky, vice president of John B. Sanfilippo’s global marketing, innovation and customer solutions. “After opening, this

new bag offers a pressto-seal closure that locks in the flavor and crunch of the nuts. The upright design also makes it easier to scoop right out of the bag, into the mixing bowl and store after use.” Many food processors hope their packaging literally clicks with consumers in other ways. One of those companies is Jack Link’s Beef Jerky, Minong, Wis. When the company recast its MATADOR beef jerky communications and packaging design last fall, it used the opporCourtesy of Jack Link’s Beef Jerky tunity to take packaging

just a little bit further to reach MATADOR’s millennial target consumer. “As part of MATADOR’s new, unique and vibrant package design, the brand has incorporated a QR (Quick Response) code to bring the latest news and happenings from MATADOR directly to its fans,” says Mark Catlin, direcContinued on page 62

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Special Report Packaging Innovations Continued from page 60

tor of marketing for the brand. “When scanned with a smart phone, the twodimensional barcode will connect fans directly to MATADOR’s Facebook page,

and provide elements like event sponsorship videos and product special offers. The QR code will also be used across many of MATADOR’s marketing and sales ele-

ments, such as in-store point-of-purchase, on MATADOR mobile marketing trucks, integrated into trade show activations and for field training.”

    

 
   



 


 
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Because green is good With the introduction of Freschetta Simply…Inspired Pizza, The Schwan Food Co., Marshall, Minn., took a fresh look at the product packaging. Officials say that each of the eight new varieties of Freschetta Simply…Inspired pizzas is wrapped in new Fresch-Taste Seal packaging to lock in the flavor while using 30% less packaging by weight than a traditional pizza carton. By removing the outer paperboard carton, Schwan estimates that Freschetta Simply…Inspired pizza saves 1,378 tons of paperboard, which adds up to 23,433 trees saved each year. This new package design also sets Freschetta Simply… Inspired pizzas apart within the retailer’s frozen pizza section. SF&WB

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Want to learn more about snack and bakery packaging material trends? Visit www.snackandbakery.com for an exclusive interview with Tim Bohrer, CPP, Pac Advantage Consulting, LLC, Chicago. Bohrer has more than 30 years of packaging industry experience from executive posts at American Can, Fort James, James River and Ivex.

www.snackandbakery.com

Exclusive website details from Tim Bohrer

Special Report Package Handling Systems

Because we’re living in a materials world Snack Food & Wholesale Bakery talks packaging trends with Timothy Bohrer, CPP, president of Pac Advantage Consulting LLC, Chicago. SF&WB: What factors are driving today’s food packaging trends? Timothy Bohrer: Increased competition, an uncertain global economy and growing sustainability demands are driving packaging developments across all categories, including snack and bakery. These trends have companies working harder to differentiate themselves when it comes to how consumers perceive their product quality, convenience and value. The familiar equation of ‘cheaper, better, faster – choose any two,’ no longer creates success. Today, consumers and retailers demand all three product attributes.” SF&WB: You follow numerous product sectors. What have you observed in snack and bakery food packaging? Bohrer: Specifically, we see snack and bakery food manufacturers – and their suppliers – upgrading graphics. It’s clear that they’re striving to simplify printing press changeovers, increase productivity and reduce costs. We see increased use of sophisticated seven- and eight-color systems to eliminate spot colors. This creates new benefits for both package converters and users. SF&WB: What’s happening in food packaging graphics? Bohrer: Packages need high-impact graphics to convey brand confidence and “newness” in the fraction of a second while consumers scan store shelves. PACK EXPO Las Vegas had an interesting exhibit sponsored by Clemson University’s Sonoco Institute of Packaging Design and Graphics. The institute is using state-of-the-art “eyetracking” technology to study the reaction of real consumers to real package designs – in a realistic mini-mart setting. Later, suppliers and manufacturers will be able to leverage results from these studies and create even more “bang” for a company’s graphic design buck. SF&WB: How are manufacturers and suppliers making packages more convenient? Bohrer: Consumer convenience and package reliability improvements dominate package upgrades. You see re-closeable stand-up

pouches continuing to make inroads and now they’re evolving to more “dump-fill” product formats. New technologies include … … Toray’s TreaTear™ directional-tear PP sealant films. Here, Toray is trying to address and consumer complaints about tear notches that don’t provide predictable results; … Ampac’s E-Z Zip® pull-tab opening feature retains the package header and its messaging after opening. It also streamlines [in-plant] filling by not exposing zipper elements to product until the package is opened; … an EASY-LOCK® micro-hook closure system. France’s Aplix is addressing the problem of zipper misalignment on reclose. Known for its hook-and-loop closure systems, Aplix has introduced and patented this product, which closes securely without requiring perfect alignment. … Zip-Pak’s Zip360™ system, which applies zipper reclosure to the full width of a gusseted pouch or bag. This greatly increases the consumer’s access to the product as well as his or dispensing options. … a joint venture between T.H.E.M. and Zip-Pak. These two suppliers have developed a new product that combines the rigidity and barrier of a laminated folding carton – with the reclose of zipper technology in the Zipbox® package. Liner elimination offers the potential to deliver simple, cost effective opening and reclosure. SF&WB: How is sustainability impacting package material development? Bohrer: Package materials and formats are always competing and these advances drive cost savings and convenience improvements for manufacturers. Now, sustainability represents a new battleground. The packaging industry always has delivered source reduction (to package users) as technology progressed. Today, however, this topic has become more sophisticated in regard to how you measure the parameters of sustainability. It’s become a much more complex playing field for those who specify packaging. Now we’re talking about everything from simple calculations of weight reduction and related transportation energy savings – all the way to comprehensive lifecycle analyses. The entire packaging value chain

is experimenting at the moment to identify the most practical and economically viable packaging solutions to reduce environmental impact. SF&WB: How are these trends playing out in snacks and bakery foods? Bohrer: Renewably sourced raw materials are receiving increased attention, with the North American market placing greater emphasis on bio-derived vs. biodegradable attributes. Officials are still questioning the conversion of traditional food producing acreage to bio-energy or biochemical end uses. Meanwhile, researchers also are looking at ways to increase the efficiency of bio-sources from perennial plants on marginal lands. Cellulose film – one of the earliest clear films used to package bakery and snack foods – has reemerged as a highly desirable component in laminations, with multiple metallized and barrier coated grades available. Several U.S. suppliers now offer biaxially oriented corn-based PLA and are incorporating into snack packaging. You can see that the stakes are high; Frito-Lay is involved in lawsuits in both the United Kingdom and the United States in regard to ownership of two patents covering biodegradable bag materials. These trends should continue into and through 2012 because there is much more room to grow in performance improvements. You’ll see suppliers and manufacturers applying this knowledge to the next generation of sustainable packages. About Timothy Bohrer A 30-year-plus packaging industry veteran, Bohrer works with both flexible and rigid structures in plastic, paper and composite packaging and the materials that form the foundation of these package types. Bohrer has also led R&D efforts at American Can, James River, Fort James and Ivex Packaging. SF&WB readers can reach Bohrer by visiting www.pacadv.com, calling (773) 268-2232 or emailing him at [email protected].

62a

Thank hank You

Snack ck Food & Wholesale Bakery has a big “Thank You” for the bakers and snack ck food companies that have invited us into their plants in 2011. Thanks so much to the corporate and plant management teams. January

Gonnella Baking Co. February

Shearer’s Foods, Inc., Snack Manufacturer of the Year March

Gabby’s Bagels, Inc.

April

Highland Baking Co. May

Old Colony Baking August

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TORTILLA TECHNOLOGY GALORE

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Is your company a leader in bakery or snack food innovations? You should be here in 2012 or beyond. We are looking for bakers, snack food producers, and packagers to showcase in future issues. Contact Editor-in-Chief Lauren Lau R. Hartman at [email protected] [email protected] or 847-405-4015 847-405-4015.

Thank Yo You

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

21C Oats, Inc., a subsidiary of Viterra Inc.

Ingredient Technology Inclusions

Inventive, Creative Inclusions As more consumers scrutinize ingredients in the foods they buy, bakers and snack producers are turning to inclusions to create better-for-you products that deliver irresistible taste. Romy Schafer, Contributing Writer

akers and snack producers have been using inclusions for years to create tasty treats that appeal to consumers. These include nuts, dried fruit, crunchy grain clusters, moist fillings, sugar-coated chocolate disks and other items. Inclusions add flavor, color and texture to everything from cookies and snack bars to granola mixes and tortilla chips. Despite the many inclusions available to them, bakers and snack producers are always looking for new ingredients to help

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Photos courtesy of Georgia Nut Co.

them expand or improve their product lines, so they can meet changing consumer demands and differentiate themselves. Today, this means seeking out inclusions that will help create baked goods and snacks

for health-conscious consumers who want products that are made with all-natural ingredients, contain less sugar and unhealthy fats and are fortified with vitamins and minerals. Not surprisingly, inclusion suppliers are ready to deliver. Georgia Nut Co., for instance, has been receiving many requests for products with added protein and calcium, all-natural flavors and colors, and reduced sugar, says vice president of sales and marketing Kurt Thorsen. The Skokie, Ill.-based company’s wholesale offerings include fruits, nuts, seeds and yogurt-covered pretzel, carob and sugar-coated choclate pieces. “We’ve being doing a lot of all-natural, GMO-free Gems, which is our sugarshelled version of an M&M,” Thorsen says. “We refine a lot of calcium-fortified Photo courtesy of Quali Tech Inc.

64

Snack Food & Wholesale Bakery - January 2012

Continued on page 66

www.snackandbakery.com

Ingredient Technology Inclusions

“Consumers seem to be a lot more concerned about where their food is coming from. They’re also trying to eat well, so that’s driving things like systems that allow for reduced sodium and reduced fat.” – Stan Tinsley, sales manager, QualiTech Inc., Chaska, Minn. Continued from page 64

products, so we can make our own coatings and enhance [them] with calcium.” The company uses the calcium-enriched coatings on a variety of products, including its yogurt-covered raisins and Gems, which are popular inclusions for cookies, muffins and granola mixes. Thorsen says Georgia Nut’s “tremendous processing capability” enables it to create innovative and new products not currently on the marketplace. “We do a lot of Gems, and sugar shelling is our single largest product line,” he says. “So we asked ourselves what we could do that’s different from everyone else. We [now] form our own lentils and refine our own coatings. We can add protein and other

inclusions to the center of the Gems. There are so many different things that we can do that we haven’t necessarily leveraged in the past that we’re working on now.” In addition to developing items on its own, the company routinely works with its customers to create new products. “We try to understand, directionally, where they want to go, along with showing them things we believe are relevant for the marketplace and might be a good addition to their line,” he explains. “So, it’s really a two-way street. We’re taking direction from them, and we’re also suggesting ideas that we have that they might not have thought of or understood that we can make.” QualiTech Inc., a Chaska, Minn.-based

Photo courtesy of QualiTech Inc.

66

Snack Food & Wholesale Bakery - January 2012

company that specializes in particulates, inclusions and savory blends that add flavor, function, mouthfeel and visual appeal to foods, also is seeing more consumers interested in their health and wellness. “Consumers seem to be a lot more concerned about where their food is coming from,” says Sales Manager Stan Tinsley. “They’re also trying to eat well, so that’s driving things like systems that allow for reduced sodium and reduced fat.” It’s not surprising, therefore, that QualiTech is also seeing more interest on the part of food processors in systems that can deliver nutritional ingredients, such as fiber, protein, fruit content and nutraceuticals. “Inclusions have typically been points of color, flavor and texture,” says Tinsley. “What we’re seeing now is their potential to add things like Omega 3s. They make it easy for manufacturers to add such supplements.” QualiTech’s lineup of standard and customizable food inclusions and particulates includes Pell-ettes, a carbohydrate-based, uniformly sized berry alternative; FlavorLites, round, flavor-coated, grain-based crisps; Season-ettes, unflavored, cerealbased pellets and granules that mimic spices and dry seasoning blends; Flavor Islands, which are soft, colorful particulates for wet and dry applications; FlavR-Grain, a 100% natural, stabilized corn germ; and Flavor-ettes, which are sweet or savory particulates that can carry nutritional supplements. A recent Flavor-ettes introduction demonstrates, however, that inclusions also can help bakers and snack producers create more nutritional products by what they don’t bring to the table. QualiTech’s new Cheese Flavor-ettes “is a big breakthrough for us,” says Tinsley. “It provides significant advantages to our customers over real cheese” because it doesn’t melt at high temperatures, yet delivers a rich cheese flavor into systems where real dairy products won’t work.” In addition, the company designed Cheese Flavor-ettes to offer “significant nuContinued on page 68

www.snackandbakery.com

Bulk material from A to B. Technology from A to Z. We understand that the efficient handling and processing of raw materials has a decisive impact on the cost-effectiveness of production in industrial bakeries. As a result, Bühler works with you to develop and implement solutions for every stage of the process: secure product intake, careful storage, exact dispensing, and precise weighing. System controls allow for customized recipes, and can easily be integrated into your production planning system. Bühler, providing the speed and precision you demand. Visit us at the 2012 BakingTech Conference March 4th - 7th, 2012; Chicago, IL. Bühler Inc., PO Box 9497, Minneapolis, MN 55440, 763-847-9900 [email protected]

Innovations for a better world.

Ingredient Technology Inclusions Continued from page 66

tritional value over real cheese,” explains Tinsley. “Real cheese or cheese sauce is typically very in high fat and has a lot of sodium in it. We developed a product that has significantly less sodium and fat, but provides the eating experience of, say, a cheese dipping sauce.”

Tinsley says QualiTech typically works directly with its customers to develop inclusions for products on which they are working, rather than rolling out a product across the board. “Our value proposition is customization,” he says. “We have a standard list of

products that we can offer as samples on a fast turnaround, but we also turn around samples designed to meet a customer’s objectives quickly. We have a process for identifying a customer’s key requirements, so that we can make sure that we are sending them the right items the first time.” Tinsley continues, “We also understand that the needs and limitations of bakery and snack R&D. Many times, our customers have to do their testing on their production equipment. Our manufacturing process is very scalable. We can make production runs as small as 400 lbs. of a custom item. This way, a customer knows that the material they are testing with in their facility is what they can expect when they roll out a new item in full production. We work to understand the complete journey their product is going to make, from

Photo courtesy ofViterra Inc./21st Century Grain Processing Co.

conception to physical process to market.” Viterra Inc./21st Century Grain Processing Co., a global food ingredient company, develops grain-based inclusions with proprietary ingredients for customers who use them to create healthy or indulgent snacks, baked and chewy granola bars, energy and nutritional bars, baked goods, tortillas and more. “They can be based on textural differentiation, flavor-release uniqueness and targeted nutrition,” says Bill Bonner, senior technical adviser based at the company’s Kansas City, Mo., operations. Currently, Viterra Inc./21st Century Grain Processing is developing several new ingredients for use in future inclusions, including high-fiber oats and beta glucan concentrates from specific oat varieties. “These provide beta glucan in support of the [Food and Drug Administration] health claim for potential cholesterol claim reducContinued on page 70

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Ingredient Technology

Photo courtesy ofViterra Inc./21st Century Grain Processing Co.

Inclusions Continued from page 68

tion,” explains Bonner. Like QualiTech and Georgia Nut, Viterra interacts directly with the R&D staffs of consumer product companies when developing new products for them. “Our sales, technical service and product developers are in constant contact with

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customers to identify project solutions and new market concepts,” Bonner explains. “Our own consumer product development experience results in our development team understanding key parameters in the process allowing extremely quick identification of issues and solving them.”

Material issues As for most food processors, the makers of inclusions have seen their costs for raw materials increase, especially for all-natural ingredients, which often aren’t as plentiful or as accessible as regular inclusions. Cocoa, cocoa butter, fats, oils, sugar and peanuts are just a few of the items whose prices have gone up significantly, according to Thorsen. “It’s almost universal, I’d say, from a raw materials standpoint,” he says. “I’ve been doing this for 25 years, and I’ve never seen anything like this before.” Still, Thorsen says his company tries not to pass higher ingredient costs onto its customers. “It’s something we can manage,” he says. “We try to look at ways to reduce [product] costs, while still delivering the taste and flavor profile.” Tinsley concurs: “We’re looking at new ways of formulating ingredients to mitigate that cost effect. The cost of grains, grain products and sugar has gone up, but not at the same relative level. So there’s an opportunity to look at, for example, more intense sweeteners—Stevia or something like that—that allow you to reduce the impact of the cost of sugar.” The company is also continuing to look for new sources for natural ingredients, particularly colors. “We have found some really great natural sources for reds and greens,” says Tinsley, “as well as purples, which are more important for vegetable and fruit [products]. We’ve had really good luck, but they’re just inherently more expensive, which is something consumers may not always understand.” What consumers are starting to realize, however, is that a product can be both better-for-you and an indulgent treat. “Indulgence is still king,” says Thorsen. “[A product] still has to taste good. We try to deliver the functionality of indulgence and taste, but with that good-for-you twist.” SF&WB www.snackandbakery.com

Ingredient Briefs

Givaudan expands its TasteSolutions Sweetness program to help bakers achieve sugar reduction goals. Developed from botanical sources and biotechnology, these GRAS-certified modifiers provide sensorially-balanced profiles for both naturally and artificially sweetened low- and zero-calorie products by enhancing their sweetness characteristics while masking undesirable notes and improving flavor. Givaudan Vernier, Switzerland +41 (22) 780 9111 www.givaudan.com

Caravan Ingredients introduces a donut frying oil under the Trancendim line, which delivers a clean mouthfeel. This oil allows for a better-for-you nutritional panel with 0 g. trans-fat, a reduction in saturated fat and the elimination of hydrogenation from the ingredient declaration. Caravan Ingredients Lenexa, Kan. 800-669-4092 www.caravaningredients.com

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Food Ingredient Solutions develops the FISclear line of transparent, stable micro-emulsion colors, extracts and oils made from paprika, beta carotene, carotenal, lycopene, carrot oil, palm carotene and canthaxanthin. These colors and extracts provide a wide range of shades, from pale to greenish yellow to various peach, orange and pink tones to a rich, deep red, ideal for confectionery items. FISclear employs GMO-free emulsifiers and produces particle sizes of 50-100 mm with unparalleled clarity, stability and shelf life. Food Ingredient Solutions, LLC Teterboro, N.J. 201-440-4377 www.foodcolor.com

Symrise’s consumer health business unit consolidates its botanical extracts under the Actiplants brand. This plant extract contains biofunctional ingredients that help strengthen the cardiovascular and immune system and ensure mental fitness. The Actiplants Bilberry, a standardized extract of Vaccinium myrtillus (bilberry), is said to contain antioxidant properties, support the function of capillaries and positively influence ocular health. Symrise Inc. Teterboro, N.J. 201-288-3200 www.symrise.com

Kalsec evaluates the stability of a variety of edible oils, comparing its line of natural antioxidants to a commonly used synthetic equivalent. The ingredient supplier compared peroxide values and oxidative stability instrument (OSI) induction times of TBHQ to Kalsec Duralox oxidation management system AN-110, XT. In both comparisons, Duralox met or exceeded the performance of TBHQ. Kalsec, Inc. Kalamazoo, Mich. 800-323-9320 www.kalsec.com

Nordic Naturals launches Omega-3 Fortify, a food- and water-soluble Omega powder with zero hints of fish. Omega-3 Fortify contains micro-encapsulated cod liver oil in powder form and is designed as an alternative to soft gels and liquids. This neutral-flavored formula can be used as a topping on virtually any snack and baked good. Each single-serving stick-pack contains 500 mg. of EPA+DHA. Nordic Naturals, Inc. Watsonville, Calif. 800-662-2544 www.nordicnaturals.com

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Ingredient Briefs Continued from page 72

Cherries Jubilee from Truitt Bros. consists of real Pacific Northwest cherries that add an elegant, decadent touch to a variety of desserts, muffins and cheesecake and work as a filling for crepes and pastries. They’re infused with brandy and nonalcoholic cognac, and come in an easy-tostore, shelf-stable pouch. Truitt Bros., Inc. Salem, Ore. 800-547-8712 www.truittbros.com

McIlhenny Co., the makers of Tabasco brand products, introduces Tabasco brand Pepper Paste, specially created for cakes and other baked applications. Tabasco brand Pepper Paste is an intermediate moisture ingredient prepared by combining Original Tabasco Pepper Sauce and Tabasco Processor’s Blend, which are both derived from aged red peppers, fermented with salt and mixed with vinegar. Tabasco Pepper Paste also provides texture, flavor enhancement and heat. McIlhenny Co. Avery Island, La. 337-373-6105 www.tabascoingredients.com

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Penford Food Ingredients introduces PenFibe RS, a potato-based resistant starch, designed for breads, cakes, muffins, pastries, cookies, crackers, tortillas, sheeted baked and extruded snacks, nutrition bars and gluten-free foods. PenFibe RS contains about 85% dietary fiber on a dry solids basis, maintains a low water-holding capacity—which allows for increased solids/bulk without affecting product quality—and provides a good recovery of fiber content level after manufacturing. Penford Food Ingredients Co. Centennial, Colo. 800-652-4732 www.penfordfoods.com

QualiTech’s Flav-R-Grain PBE is an allnatural, allergen-free, cost-effective solution that helps value-added products better utilize peanuts and peanut-based ingredients. This stabilized corn germ adds a nutty, whole grain flavor, emulates fried/toasted applications and is good for breads, cookies, bars and baked goods. QualiTech, Inc. Chaska, Minn. 952-448-5151 www.qualitechco.com

Z Trim is a multi-functional cellulose ingredient derived from natural sources such as oat bran or corn bran. Produced by Z Trim Ingredients, this cellulose ingredient contributes multifunctional attributes such as moisture management, texture and appearance quality, fat and calorie reduction, clean labeling and cost control for baked goods, fillings and toppings. Typical usage levels range from 0.5-2%, and its superior water binding capabilities help hold other liquids and ingredients in place to prevent pooling, weeping, separation and settling in an emulsified system. Z Trim Ingredients Mundelein, Ill. 847-549-6002 www.ztrim.com

Dawn Foods launched Dawn Mi Panadería, a line of authentic Latino bakery items, including a variety of mixes, ready-to-finish frozen churros and fillings. Included in the line are products for seasonal bakery events. This line is developed to help bakers prepare authentic Latino products. Dawn Food Products, Inc. Jackson, Mich. 800-248-1144 www.dawnfoods.com

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Insider Perspective

A Bakery’s No-Huddle Offense T his is the greatest time of year! New Year’s resolutions are made and perhaps already broken. But this is pro football playoff time, and college football championship bowl time. Watching football reminds me that we can learn something from anything. Meaning that the best teams employ what they hope is a winning football strategy. There are many strategies. Certainly, one of the most exciting is the no-huddle offense. About 99% of the time, after the referee whistles a play is over, the offense forms a huddle to call the next play. After a lot of scratching, spitting and trash-talking, the coach uses some fancy electronics to tell the quarterback about the next play and the quarterback relays the play to the team. In perfect unison, the team members slap their hands and slowly trot to the line of scrimmage with high expectations that the next play will surely be the one that scores a touchdown. This very slow process must take no more than 40 seconds, which may not seem long, but there are many things that can get accomplished in this short 40 seconds—not the least of which is watching a repeat of the last play about a dozen times at many different speeds and from many different points of view. Once in a while, the offensive team uses a no-huddle offense, a speedy, high-risk strategy whereby as soon as the last play has ended, the offense immediately approaches the line of scrimmage while the quarterback screams the next play; rather than taking the time—some 30 seconds— to huddle. Maybe one second after the team is set, the next play is started. There’s no time for huddling, trotting slowly, instant replays, or even a lot of hoping. The next play is running right after the last play ended—almost continuous action. Think about this concept for a second. Can a team win a lot of football games with this strategy? Can football teams sustain this type of strategy for a whole game? Some do—albeit very few.

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Like very few football teams, bakeries need a no-huddle offense every hour of the day and every day of the week. Even 40-second meetings aren’t allowed. We produce some products at 1,000 to 1,800 pieces a minute. If we take 40 seconds to talk and trot around, 1,200 biscuits wind up in the trash. It’s continuous action. A bakery no-huddle offense is a winner strategy for the same reasons it is for football—to get a competitive advantage and to be as effective as possible with the short amount of time available. We accept the high risks of continuous action in order to score “financial touchdowns.” Few football teams are successful at a no-huddle offense—even with big payoff—because of its high risks and strict requirements. The strict requirements for high-speed flawless execution for football teams are the same as for us. Here are a few key elements: Planning is paramount. Failing to spend at least 30% of the time planning can result in disaster. Planning needs to include not only the overall plan but all the details too. Just as coaches who have many plays scripted ahead of time can call them quickly, we need to have our detailed game plan established considering, for instance, each product’s quality requirements and each customer’s specific needs. We don’t score financial touchdowns if products aren’t just right and customers aren’t happy. The team’s coaches—bakery managers and supervisors—aren’t the only personnel who need to be informed of the overall game plan. The quarterback—the forepersons and leads—also need to know the plan. Directives can be relayed quickly and seamlessly if forepersons know the overall plan. What happens if an audible—changing the play at the line of scrimmage (at the last minute)—needs to be called because of changing conditions? Easy to execute if the floor personnel are involved in the plan. Communication must be crisp, accurate and easily understood if the no-huddle is to

C. Thomas Harrington

be effective. This will involve full advance communication of the plan, with all aspects of its execution details. “Players” will have many questions that need to be answered in such a way as to build an effective language about the detailed process that everyone understands. Football teams use practice sessions to build a universal language that results in full and immediate understanding through repeated interaction among players. We use extensive training sessions and buddy systems for on-the-job training, training manuals and pictures to accomplish the same thing: Seamless communication. Obviously, the final key element is flawless execution. Without players who routinely pay careful attention to the special requirements of their job—and can execute on those requirements—a football team using the no-huddle goes nowhere. It’s the same thing at the plant. Training sessions and training aids are great, but careful, patient and detailed coaching allows a staff to understand the job’s special aspects. Paying careful attention to detail results in the kind of financial touchdowns that make customers—and stockholders—smile. See, watching championship football is actually an opportunity to see how the great teams function. So the next time you see the no-huddle executed to perfection and marvel at the coordination necessary, think about your plant. How’s your nohuddle? Are you ready to score financial touchdowns? SF&WB C. Thomas Harrington is the chief financial officer and chief operating officer of Tennesee Bun Co. (The Bun Companies), Nashville, Tenn. Tom has more than 30 years of experience assisting businesses in all stages of development with strategic financial decisions. A graduate of Millikin University, Tom managed his own regional public accounting firm for years. Tom has been instrumental in the financial decisions concerning bakeries since 1996.

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Process. Package. Prosper!

Get more machinery, for more applications, from one source you can always rely on. Heat and Control will help you profit with efficient machinery for all types of snacks, corn products, nuts, and even donuts, muffins, and baked products. We supply equipment designed specifically for your products, operations, and sustainability. And we support you from start to future with sales, installation, service, parts, and training. Contact Heat and Control today to discuss your next project and see demonstrations of our latest equipment. • Raw product unloading, storage & preparation • Batch & continuous fryers • Spiral & linear ovens • Seasoning applicators • Ishida multihead weighers • Ishida snack bagmakers • Ishida checkweighers, X-ray inspection, seal checkers • CEIA metal detectors • Conveyors, accumulators, distribution systems • Container fillers, tray sealers • Packaging platforms • Real-time line management & control systems

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Production Technology Conveyors & Belts

All the Right Moves Bakery and snack producers want durable conveyors that are easy to clean, maintain and versatile for current and future production needs. Manufacturers say new equipment designs address these objectives. Romy Schafer, Contributing Writer

urchasing a conveyor system is a major capital expense for most bakers and snack producers, so they want to be sure they choose one that meets their current and future production needs. They want durability and equipment that’s easy to maintain and clean. They also want a system they can retrofit to accommodate new product lines and future technologies. Recent equipment introductions by leading conveyor manufacturers meet all of these requirements and more. Undoubtedly, sanitation is one of the most important considerations for today’s bakers and snack producers. Unsanitary food-processing conditions can lead to a host of problems for food processors,

P

Photo courtesy of Intralox L.L.C. U.S.A.

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including product recalls, fines and a loss of consumer confidence. “More and more people are paying attention to the whole idea of food safety,” says Don Osborne, team leader at Intralox L.L.C. U.S.A. in Harahan, La., which offers a variety of conveyor belts. “Bakers didn’t use to worry much about it because they have these big ovens that literally kill anything that’s on a product. Now, they’re becoming more aware of the issue.” Intralox recently introduced several products designed for hygienic food-processing applications, including bakery. Its new ThermoDrive belts are made from homogeneous thermoplastic, with a flexible, 100%-closed surface, and are positively driven using sprockets, so they don’t creep or stretch. These tight-transfer belts also allow for smaller radii at the end of conveyors, making it easy for food processors to efficiently transfer small products, such as cupcakes or cookies. Intralox’s modular plastic belting, meanwhile, consists of modules designed to interlock into a brick-like pattern, with full-length hinge rods. The plastic material is easy to clean and helps prevent bacterial growth. “The hygienic design of a conveyor belt is a paramount concern among [food] processors,” says Jamie Card, marketing specialist at Wire Belt Co. of America. The Londonderry, N.H., company offers stainless-steel belts (Flat-Flex, C-CureEdge, TC-327, EYE-Flex, EZSplice and speciality) and CarrySmart conveyors, a made-to-order line of sanitary conveyors (Flex-Turn, Flat-Flex Straight and Flat-Flex Shuttle and Spreader/Converger specialty conveyors). All of the company’s Flat-

Photo courtesy of Wire Belt Co. of America

Flex belting products are accepted by the U.S. Department of Agriculture (USDA) National Sanitation Foundation/ANSI/3-A hygiene standards. So is Wire Belt’s new Compact Grid conveyor belt. Intended for smaller, more delicate products, such as those in the baking and snack industry, the stainlesssteel belt has a 70%-open surface area that makes it easy to clean and keep clean, and it has no concealed spaces in which pathogens and allergens can hide. Compact Grid is suitable for processes in which product coatings, drainage and liquids or air circulation are factors, says Card. The belt’s 10-mm.-sq. openings also provide enough support for doughy products, such as warm cookies, so they don’t deform into the belt during transfer. Wire Belt says all its products are designed for clean-in-place (CIP) applications, and can be cleaned with a food processor’s existing equipment, saving time, money and energy. Dallas-based Triple/S Dynamics Inc., is enhancing its line of all stainless-steel, Continued on page 80

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Cleaning is hard work.

Steel belts from Berndorf Band make it easy! In the food processing industry the smooth surface of steel belts eliminates ¿bers or fat remnants from lodging within the gaps during processing, helping maintain hygienic requirements. Steel belts from Berndorf Band meet the strictest hygienic requirements and are easy to clean. Due to the smooth surface a limited amount of aggressive chemicals is required and the cleaning area is easily accessible. Comprehensive technical customer service, development of special tools and a wide range of training courses all ensure that our customers receive the very best support.

BERNDORF BELT TECHNOLOGY 2525 Bath Road Elgin, IL 60124 Phone: 847.931.5264 Fax: 847.931.5299 [email protected] www.berndorf-usa.com

Production Technology Conveyors & Belts Beyond sanitation

Photo courtesy of Triple/S Dynamics Inc.

Continued from page 78

sanitary slat conveyors to incorporate such features as CIP belt washing and drying systems and continuously welded lifting flights for elevating applications. The conveyors use a proprietary, overlapping stainless-steel conveyor slat with continuously welded traveling side guides to eliminate crevices in the food stream. The slats are attached to stainless-steel chains that ride on ultra-high-molecularweight (UHMW) guiderails. The conveyors’ formed stainless-steel frames have openings that provide access between the belts for cleaning. According to Blake Svejkovsky, manager of product handling systems at Heat and Control Inc., Hayward, Calif., the company’s FastBack horizontal motion conveyors reduce product breakage by up to 60%, compared with vibratory conveyors, and prevent the loss of product coatings, eliminating unplanned downtime required to clean coatings from the conveyor pan. In addition, Heat and Control’s Revolution distribution conveyors feature rotary gates that eliminate pinch points and product breakage while providing proportional product distribution without the risk of cross contamination and allergen migration.

While cleanability and sanitation are top of mind for bakers and snack producers when purchasing a conveyor system, conveyor manufacturers know that factors such as reconfigurability, improved production throughput and product handling also influence buying decisions. That’s why they also incorporate these capabilities into their product designs. “Our DynaClean system is unique,” says Jill Batka, president of Dynamic Conveyor Corp., Muskegon, Mich. “Most of the [conveyor] options out there for snack and bakery are stainless-steel. Our conveyor is plastic-sided with stainless-steel components. In using plastic sidewalls instead of stainless-steel versions, we’re able to give customers the option to reconfigure or repurpose their conveyors when their needs change. It’s very economical to reconfigure a conveyor they already own.” The custom-designed conveyor is built to meet National Sanitation Foundation (NSF), Food and Drug Administration (FDA) and USDA standards, and is quick and easy to clean and sanitize without using tools. “It’s also blue, which is a favorite color in food processing because most foods are not blue,” says Batka. “From a safety and a cleanliness standpoint, it’s easy to see food product or areas that need to be cleaned.” Batka adds that Dynamic Conveyor has partnered with Intralox for many years, and plans to add Intralox’s ThermoDrive belt to its belt options. Although Wire Belt is very focused on cleanability, Card says the company also is focused on key processing elements like Photo courtesy of Dynamic Conveyor Corp.

product orientation, product placement and improved production throughput. “The conveyors we design now are more focused on adding value to a product as it flows through a process, rather than just moving a product from point A to point B,” she says. “While that trend is becoming more prevalent in the food-processing business today, Wire Belt has been focused on the value proposition for decades.” Intralox’s Activated Roller Belt (ARB)

Photo courtesy of Intralox L.L.C. U.S.A.

technology, which was recently introduced to the baking industry, also offers bakers and snack producers increased throughput, as well as greater product handling flexibility. ARB-equipped conveyors transport products via free-spinning angled rollers that extend above and below the belt surface. Because conveyed products can be moved selectively, ARB conveyors can change the direction, alignment, location and speed of an item independently, without using rails or mechanical controls. Heat and Control says its FastBack product-blending system, meanwhile, lets food processors accurately mix multiple snack, cereal and other ingredients and maintains the blend all the way to packaging. According to Svejkovsky, the horizontal motion conveyor’s gentle slow-forward, Continued on page 83

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Increase product yields and Improve your bottom line.

Use Compact Grid™ conveyor belting… only from Wire Belt. t 70% open area allows for efficient heating and cooling of your product.

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t Excellent product support for smaller, delicate products such as tortilla chips.

t Belt joining is simple and fast. t Low energy requirement for driving the belt. t Excellent belt tracking. t Easy to retrofit on your conveyor. Wire Belt Company
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fast-back motion reduces product damage, coating loss and unscheduled cleaning. ClimbBack, a new version of the FastBack horizontal motion conveyor, has

Photo courtesy of Heat & Control

a unique pan design capable of conveying product uphill as much as 8%, operates more cleanly than belt conveyors and reduces equipment stack-up problems.

Purchasing considerations While experienced food processors know what they need and want in a conveyor system for their operation, industry newcomers often only have a general understanding of such things as sanitation, production throughput and configuration flexibility. Conveyor manufacturers can provide useful information about these issues and others that can help bakers and snack producers in their purchasing decision. For instance, a conveyor system that’s easy to clean and inspect is a must for a food-processing company. Knowing how a conveyor must be cleaned (with caustic cleaners, for instance) may dictate the material from which the unit must be constructed (stainless steel rather than plastic or a 316 stainless-steel instead of 304 stainless-steel) and where it can be cleaned. Also, the cleaning process for conveyors having parts that must be soaked in cleanout-of-place (COP) tanks may be costlier,

longer and less ecofriendly. Knowing very specifically how a conveyor will be used and the type and size of the product it will transfer is essential to choosing a unit for maximum production efficiency. Reliability and sustainability also are important purchasing considerations, say the suppliers. Conveyors and belts made by established manufacturers and from durable, high-quality components and materials typically last longer than their less costly counterparts. In addition to being built to last, well-made conveyors are typically designed so that they can be retrofitted to meet a manufacturer’s changing product needs, a less costly and more eco-friendly option. Bakers and snack producers planning to buy a new conveyor system or retrofitting an existing system will find plenty of options for their specific needs, thanks to conveyor manufacturers dedicated to helping their customers move in the right direction. SF&WB

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Equipment Briefs Standard-Knapp’s Tritium multipacker is equipped with the RoboWrap system and features the Robo-Wand multi-axis pro-

Hinds-Bock’s fully automatic batter and injection line is suitable for applications such as muffins, mini cheesecakes and snack cakes with fruit- or cheese-filled centers. The line features a servo-driven dual chain conveyor with an optional paper cup placer, a batter depositor, a second diving bridge injection depositor, a recipe control unit that’s accessed through an Allen Bradley PLC and simple tool-free adjustments for pan-to-pan product changeover. The conveyor can also be lengthened for additional options. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com

grammable path wrapping section, which can be positioned at any point above the conveyor to package a particular desired pack pattern. Designed for versatility, ease of changeover and finished product quality, this multipacker adapts to packaging sustainability issues and reduces material used in packaging and waste. Standard-Knapp, Inc. Portland, Conn. 860-342-1100 www.standard-knapp.com

Focus Works’ new SQF Sentinel is a PCbased software package that automates the collection of plant data, thus eliminating problems associated with paper-based data collection and manual data analysis for food safety protocol. The SQF Sentinel can be directly attached to PLC-based control systems and wireless, hand-held devices used by plant floor personnel to enter data. After the data is collected, it is stored in the “data dashboard”—a centralized database that the company says is customized to keep tabs on the level of various data points collected by the product. Focus Works, Inc. Patchogue, N.Y. 631-758-3629 www.focus-works.com

Clysar’s Clysar LTCH polyolefin shrink film is designed for high-speed static seal applications, such as frozen pizza and fresh bakery items, at 80 packages per minute. Clysar LTCL is a “soft” shrink film with a low shrink force that can replace film up to twice as thick to create packages without bending or distortion. Both Clysar LTC films allow for more available shrink for crisp, tight wraps with excellent cleanup, better balanced shrink to conform evenly to a range of products, superior film strength for process efficiency and package integrity, superior tear resistance to minimize film tearing and rips, better clarity, shine and gloss for attractive

package appearance and shelf appeal and wider operating windows for faster line speeds. Clysar, division of Bemis Co. Oshkosh, Wis. 920-527-7800 www.clysar.com

ITW Muller presents the Octopus SideKick, a second carriage that can be added to almost any new or existing Octopus machine. The SideKick operates as an independent film carriage that will automatically rotate into primary wrapping position upon the film being depleted or breaking. Because the Octopus can now run two rolls of film before needing attention, the operator only needs to address the machine half as often. In addition, one carriage can be removed for maintenance while the second one continues to wrap. ITW Muller Div., Illiinois Tool Works Arlington Heights, Ill. 800-628-6787 www.itwmuller.com Uniformly apply coatings with Heat and Control’s FPS coating applicators. The tumble breader, for instance, uses a vibratory conveyor to tumble, coat and convey product at high transfer rates. Finished product can then be spread, aligned or laned to suit downstream inspection, cooking and freezing equipment. The compact breader uniformly applies a wide variety of coatings, Continued on page 86

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January 2012 - Snack Food & Wholesale Bakery

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Equipment Briefs Continued from page 85

from pre-dust to final pass. The applicators require less line length than traditional applicators and can be rolled to different locations. Heat and Control, Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com

Powered by energy-efficient regenerative blowers, WindJet air knives are said to provide excellent performance in drying and blow-off operations and eliminate the need for costly compressed air. Produced by Spraying Systems, these air knives help reduce operating costs by as much as 95% when used for a wide range of operations such as debris and dust blowoff, removal of excess water and moving products. Spraying Systems Co. Wheaton, Ill. 800-957-7729 www.spray.com The Bug Blocker overhead screen door system from Rasco Industries is added to an existing overhead door system to let cool breezes in but keep pests and insects out of the plant. Using the existing door’s vertical tracks, the door is attached with a switch mechanism, a second set of horizontal tracks and a screen door with stainless-steel mesh. The doors are AIB-, ASI-, HACCP- and IPM-certified

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and comply with Homeland Security programs. Rasco Industries, Inc. Loretto, Minn. 800-537-3802 www.bugblocker.com The Comtec Model 2200 pie and pastry crust press from Comtec Industries is said to be one of the first presses that combines top and bottom pie crust production in one operation. This press creates consistent crust that’s exact to size without the need for dusting flour or special formula, skill or strength. It forms up to 350 covered pies per hour with two-man operation and up to 700 uniform bottom crusts per hour with one operator. This machine is also applicable for tarts and cheesecake. Comtec Industries Ltd. Woodridge, Ill. 630-759-9000 www.comtecindustriesltd.com

Bosch Packaging Technology introduces the Pack 301 IN inverted horizontal flow wrapper, designed to gently transport snacks, baked goods and confectionery items by carrying them on top of the film from the former through the cutting head, thus minimizing jams and ensuring superior package appearance. The Pack 301 IN has a modular film backstand that can be located in various positions relative to

the infeed and wrapper, allowing users to optimize the film path while enhancing the package appearance, resulting in minimal film waste and fewer rejects. Bosch Packaging Technology, Inc. New Richmond, Va. 715-246-6511 www.boschpackaging.com Klüber Lubrication introduces Klübersynth MR 96-31, a light grease that utilizes a polyalkylene glycol-base oil and a unique mix of solid substances to reduce vibration, dampen noise and produce smooth motion of different plastic materials. It is compatible with elastomers and plastics that range from -40°C to 120°C, is water-resistant and helps protect against copper corrosion. Klüber Lubrication North America L.P. Londonderry, N.H. 603-647-4104 www.kluber.com The Cryovac technology CT-301 shrink wrapper from Sealed Air wraps up to 14-in. tortillas at speeds of 40 ppm. This patent-pending, multi-layered machine is will not compromise on flavor and performance, and provides a 70% or greater packaging material source reduction. In combination with the Shanklin F-1DA wrapper with vacuum and indexing infeed, this shrink wrapper provides a more efficient, effective and greener solution for the tortilla industry. Sealed Air Corp., Cryovac Food Packaging Systems Duncan, S.C. 800-845-3456 www.cryovac.com

www.snackandbakery.com

If leading edge manufacturing and automation technologies are your priorities, save the date for the food industry’s PREMIER CONFERENCE in 2012.

SAVE THE DATE APRIL 22–25, 2012

Sanibel Harbour Marriott, Ft. Myers, Florida

WHO SHOULD ATTEND: ) Vice Presidents of Operations ) Plant Managers ) Vice Presidents of Engineering ) Plant Maintenance Managers ) Plant Engineers ) Directors of Engineering ) Owners and Presidents ) Directors of QA/QC

ALL NEW AGENDA FOR 2012 TO INCLUDE Food Safety Modernization Act: What You Need to Know Now Speaker: Kurt Deibel, Vice President, Quality & Food Safety, HJ Heinz

Creating a No-compromise Operations & Manufacturing Culture Speaker: Neil Ducoff, Founder and CEO, Strategies

Engineering Keynote: Manufacturing Innovation for Today’s Leaders Speaker: Dave Haft, Senior Vice President, Sustainability, Productivity and Quality, Frito-Lay

Social Responsibility: Addressing Customer and Consumer Concerns Speaker: Leigh Ann Johnston, CPEA, EHS Training, Communication, & Sustainability Manager, Tyson Foods, Inc

Best Practices in Automated CIP Speaker: Pete Duessel, Project Engineer, Coca-Cola Refreshments North America

Robotics vs. Continuous Motion Speaker: Terrence Southern, Senior Engineer, Flexible Automation, Frito-Lay North America, Inc.

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Speaker: William L. Ramsey, Director of Corporate Security, McCormick & Company, Inc.

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Snack Food Today La Tortilla Factory names family member new CEO am Tamayo has been promoted to chief executive officer of La Tortilla Factory, making him the third generation of the family to run the Santa Rosa, Calif., company. Tamayo, 36, succeeds current CEO Stan Mead, carrying out a long-planned succession in the family business. “I’m honored to be granted this opportunity to carry on this family business,” says Tamayo. “It’s something I’ve been preparing myself for for years. I had the opportunity to learn from a lot of talented people, not only in our family, but the people we have in our business.” Mead says he appreciates of the opportunities he had at the company and now plans to retire. “Their willingness to let me participate shows

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tremendous courage on their behalf,” he notes. “To let an outsider participate on a high level has been both an honor and a privilege.” Under Mead’s leadership since 2008, the company grew from 175 to nearly 300 employees, and annual revenues more than doubled to $50 million. The company’s product can be found in grocery stores nationwide. Tamayo takes on the role as CEO on Jan. 28, and says he doesn’t plan any drastic changes. La Tortilla Factory was founded by the Tamayo family in 1977. It distributes products under the La Tortilla Factory, Smart & Delicious and Sonoma brands, and offers glutenfree, 100-calorie and low-carbohydrate options.

ConAgra Buys National Pretzel Co. onAgra Foods, Omaha, Neb., says that it has agreed to acquire National Pretzel Co., a Lancaster, Pa., private-label manufacturer, from Brookstone Holdings. National Pretzel makes private-label pretzels in a variety of forms, including rods, sticks, braids and twists for a variety of customers, such as many of the top grocery retailers in America. Terms of the transaction, expected to close within 30 days, are subject to customary closing conditions. National Pretzel reportedly has total net sales approaching $200 million. The company also has a leading position in the supply of private-label pretzel items, and also posts sales under the HK Anderson and Shultz labels, both of which are included in the agreement. The agreement also includes three bak-

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eries in Lancaster, Pa., Hanover, Pa. and Visalia, Calif. More than 700 National Pretzel employees are expected to join ConAgra Foods when the transaction closes. “Acquiring National Pretzel Co. is consistent with our strategies for growth, which include expanding our private label footprint and growing in strategic adjacencies,” notes Gary Rodkin, chief executive officer of ConAgra Foods. “National Pretzel is a leading private-label manufacturer, with a strong team in an attractive category,” Rodkin says. We’re excited about its future growth potential and are confident we can profitably leverage our innovation and supply chain capabilities as we integrate our businesses after close of the transaction.”

Snack Food & Wholesale Bakery - January 2012

Snyder’s-Lance Cuts Sodium Across Multiple SKUs nyder’s-Lance, Inc. is in position to comply with the National Salt Reduction Initiative guidelines by 2012. That’s because the Charlotte, N.C., company says it voluntarily reduced the sodium of multiple stock-keeping units (SKUs) from a number of its brands, including Snyder’s of Hanover, Lance, Krunchers, Cape Cod, EatSmart Naturals, Jays, Grande, Tom’s, Archway, OKe-Doke and Stella D’oro. To reduce sodium levels without altering the taste profile of its products, Snyder’s-Lance conducted extensive testing to ensure that consumers would not perceive any difference between the current and the new lower-sodium product. Due to consumer perceptions that reduced-sodium products are less flavorful, Snyder’s-Lance will not promote the lower sodium levels on its packaging. Snyder’s-Lance also removed transfats and high-fructose corn syrup from its products and says it remains committed to reducing the sodium in its unflavored chips.

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European Snacks Association Stages Snacks Production Course “Chips & Snacks: Raw Materials to Formed Products” is a three-day savory snacks production course sponsored by the European Snacks Association (ESA), London, that will take place in London, April, 12-16, 2012. The course covers production of potato chips and savory snacks—from raw materials to formed products. Topics include an introduction to the European market for savory snacks; trends and drivers; raw material and process choices; manufacturing processes for potato chips, extruded, pellet and sheeted snacks; maximizing product quality and consistency and the optimization of energy management. For more information, contact the ESA at [email protected].

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CONSULTING

T&T Consulting and its GREEN work: T&T Recycles Older Baking Ovens by updating its controls with the latest technology. • Ask us about remanufacturing your older baking oven, thus improving its energy efÀciency and overall baking performance. • Ask us about savings of 50% against a new tunnel oven with a T&T remanufactured oven. • Ask us about improving your oven’s steam distribution, quality and efÀciency.

Being GREEN with T&T SAVES THE ENVIRONMENT and SAVES YOU MONEY! T&T Consulting & Engineering, Inc. Tel: 1.847.288.9809 Fax: 1.847.288.9709 www.tandtce.com [email protected] EQUIPMENT FOR SALE

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Check Out Our All-New Website V isit our all-new snackandbakery.com website, which has been redesigned for a faster, easier online experience. We’ve made navigation easier and faster, to access features, webcasts and web exclusive articles quickly. Now, you can easily “retweet” or “like” any article, and find articles and events results with an advanced keyword search; or narrow by date, author, issue and more. A “Most Popular” tab has also been added, so you can see what others in the industry are reading. A comprehensive events calendar also presents and sorts what’s happening tomorrow—today. There’s also a way to register for total access to your favorite Snack Food & Wholesale Bakery content, such as our

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Snack Food & Wholesale Bakery - January 2012

annual State of the Industry reports, Top 50 Bakers and Snack Producers, our digital editions, monthly feature articles and our exciting 100th Anniversary special in April. Plus, there are RSS options for receiving updated news on any mobile device. Simply go to www.snackandbakery.com for more information. Also, we encourage you to become a fan of Snack Food & Wholesale Bakery through Facebook, www.facebook.com/ snackandbakery, or follow us on Twitter at 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. You can also log onto our site and subscribe to 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

ADM . . . . . . . . . . . . . . . . . . . . . . . 7, OBC www.adm.com

Danisco USA Inc. . . . . . . . . . . . . . 9, 41 www.danisco.com

QualiTech . . . . . . . . . . . . . . . . . . . . . . 69 www.qualitechco.com

ADM . . . . . . . . . . . . . . . . . . . . . . . 15, 47 www.adm.com/milling

Food Automation & Manufacturing Conference and Expo 2012 . . . . . . 87 www.foodautomationconference.com

Quickdraft . . . . . . . . . . . . . . . . . . . . . . 62 www.quickdraft.com

American Bakers Association 2012 Convention . . . . . . . . . . . . . . . 84 www.americanbakers.org American Society of Baking BakingTech 2012 . . . . . . . . . . . . . . . 82 www.asbe.org

Food Safety Summit Expo & Conference . . . . . . . . . . . . . . . . . . . 61 www.foodsafetysummit.com FooDesign . . . . . . . . . . . . . . . . . . . . . 34 www.foodesign.com

Reiser . . . . . . . . . . . . . . . . . . . . . . . . . 37 www.reiser.com Ross, Charles & Son Company . . .11, 13 www.mixers.com

Ashworth Bros., Inc. . . . . . . . . . . . . . 33 www.ashworth.com

Gemini KB Systems . . . . . . . . 21, 46, 70 www.kbsystemsinc.com

Schaaf Technologie GmbH . . . . . . . . 39 www.foodextrusion.com

Bay State Milling . . . . . . . . . . . . . . . . 49 www.baystatemilling.com

Gertrude Hawk Ingredients . . . . . . . . 65 www.gertrudehawkchocolates.com

SensoryEffects . . . . . . . . . . . . . . . . . . 73 www.sensoryeffects.com

Berndorf Belt Technology . . . . . . . . . 79 www.berndorf-usa.com

Harpak-ULMA Packaging . . . . . . 25, 57 www.harpak-ulma.com

BluePrint Automation . . . . . . . . . 12, 83 www.bpa-flexolutions.com

Heat and Control . . . . . . . . . . 22, 48, 77 www.heatandcontrol.com

Bosch Packaging Technology, Inc.. . . . 5 www.boschpackaging.com

Hinds-Bock Corporation . . . . . . . .54-55 www.hinds-bock.com

Brolite . . . . . . . . . . . . . . . . . . . . . . . . 23 www.bakewithbrolite.com

International Bakers Services, Inc. . . 27 www.internationalbakers.com

Brother Mobile Solutions, Inc. . . .42-43 www.brothermobilesolutions.com

Intralox . . . . . . . . . . . . . . . . . . . . . .16-17 www.intralox.com

Buhler Inc. . . . . . . . . . . . . . . . . . . . . . 67 www.buhlergroup.com

Key Technology . . . . . . . . . . . . . . . . . 29 www.key.net

ToolBox Bakery Solutions . . . . . . 24, 68 +1-800-488-1741

California Raisin Marketing Board . . . . . . . . . . . . . . . . . . . . . 53, 71 www.LoveYourRaisins.com

Koenig Bakery Systems . . . . . . . . . . 36 www.koenigusa.com

Triple/S Dynamics, Inc. . . . . . . . 59, IBC www.sssdynamics.com

Kwik Lok . . . . . . . . . . . . . . . . . . . . . . .2-3 www.kwiklok.com

Viterra . . . . . . . . . . . . . . . . . . . . . 51, 63 www.viterra.com

Caravan Ingredients . . . . . . . . . . . . . 75 www.caravaningredients.com Cargill Salt Division . . . . . . . . . . . . . . 45 www.cargillsalt.com

Packaging Strategies Structural Packaging Summit . . . . . . . . . . . . . 60 www.structuralpackagingsummit.com

Shurtape . . . . . . . . . . . . . . . . . . . . . . . 35 www.Shurtape.com/GoodToTheCore SK Food International . . . . . . . . . . . . 40 www.skfood.com SnackandBakery.com . . . . . . . . . . . . 26 www.snackandbakery.com Solvay Chemicals, Inc. . . . . . . . . . IFC-1 www.solvaychemicals.us

Wire Belt Company . . . . . . . . . . . . . . 81 www.wirebelt.com

Reader & Marketing Services LETTERS Lauren R. Hartman Snack Food & Wholesale Bakery 155 Pfingsten Road, Suite 205 Deerfield, IL 60015 [email protected] SINGLE COPY SALES Ann Kalb [email protected] Ph: 248-244-6499 Fax: 248-244-2925 CUSTOM MEDIA Chris Wilson [email protected] Ph: 248-244-8264

REPRINTS Jill DeVries [email protected] Ph: 248-244-1726 LIST RENTAL Postal contact: Kevin Collopy [email protected] Ph: 845-731-2684 Toll free: 800-223-2194 x684 Email contact: Michael Costantino at [email protected] Ph: 845-731-2748 Toll free: 800-223-2194 x748

www.snackandbakery.com

PRINT & INTERNET ADVERTISING Jeff Heath [email protected] (224) 554-9154 Barbara Szatko [email protected] (630) 527-9927 CLASSIFIED ADVERTISING Suzanne Sarkesian [email protected] (248) 786-1692

BNP Media 155 Pfingsten Road, Suite 205, Deerfield, IL 60015 Phone: (847) 405-4000 Fax: (847) 405-4100 Also publishers of: Beverage Industry, BrandPackaging, Candy Industry, Dairy Foods, Flexible Packaging, Food & Beverage Packaging, Food Engineering, Food Master, Industria Alimenticia, Prepared Foods, Private Label Buyer, Refrigerated & Frozen Foods, The National Provisioner January 2012 - Snack Food & Wholesale Bakery

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The Final Word

Is 2012 Really the End or Just the Beginning?

Marina Mayer, executive editor [email protected]

hhh, a new year—a time to start over, cross those to-dos off U.S. Bakery Department Category Contribution the list and make the wrongs right. It’s a time to flip the calendar, '*&#   !'+'& #) #'&  "#  look ahead, plan ahead and move    

forward with unfinished business. !% (#% +  In the event that the world 

),& doesn’t end in 2012 (anyone see 
the movie?), the new year appears $  $+ # to offer that hope and promise 
 "#  
$   we’ve all been looking for. $+ *




'' 2012 also projects to be both a 
profitable and innovative year, as '&)   '%% indicated in the “What’s in Store 
 
2012” report, published by the ''$#  International Dairy-Deli-Bake As

'%% sociation (IDDBA), Madison, Wis.  
For instance, pies are the next “it” dessert, as most pie makers are integrating seasonal and Source: Perishables Group FreshFacts, Powered by Nielsen, 52 weeks ending June 25, 2011, www.perishablesgroup.com. savory ingredients and offer a “welcome blend of nostalgia and comfort food.” (For more pies, The new report also says that as of March check out “The Final Word” in the FebruMuffin sales rose 2.7% with regular 2011, 5,000 products in 22 countries ary 2012 issue). muffins stealing 52.7% share of the total donned the Whole Grain Stamp (developed muffin market (gourmet/jumbo, mini and In-store bakery (ISB) sales are projected by the Whole Grains Council, Boston), a to surpass $11.5 billion, the report says. tops/crowns followed with 32.4%, 13.8% 25% increase since July 2010. In 2010, 47% of sales were powered by and 1.2% of market share, respectively). The wheat versus white bread debate desserts (cakes, cookies, pies, brownies and Sales of rolls climbed 1.8%, with pretzel continues to rank top-of-mind within the dessert bars), as indicated in the Perishrolls making an appearance in the market. industry. In 2010, whole wheat bread took ables Group FreshFacts study, produced by Bagels grew 1.4%, contributing to Perishables Group, West Dundee, Ill. These over, penetrating 52.5% of U.S. house2.9% of total bakery sales. holds, whereas white bread ruled most are included in IDDBA’s trends report. Fortunately for many bakers, 2012 often in 38.8% of U.S. households. Breads and rolls comprised roughly 30% isn’t the end of the world—it’s just the Other noteworthy growth records of ISB sales. beginning. SF&WB include: Meanwhile, the whole grain and highSweet goods sales jumped 4.7% from last fiber foods market is poised to reach $24 To check out the “What’s in Store 2012” report or to year and contributed to 6.9% of ISB sales. billion by 2015, the IDDBA study states. review other charts, go to www.iddba.org.

A

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You know what it means on the football field.

But did you know that the

Slipstick Conveyor can be your sanitary wide receiver to accumulate product upstream of a packaging distribution system. The Slipstick provides gentle sanitary on-line storage of products with no mechanisms or moving parts in the food zone, greatly reducing the risk of cross contamination that commonly occurs when using a belt-storage unit. The gentle horizontal motion of the Slipstick is uniquely suited for the storage and discharge of even the most fragile products. Call 1.800.527.2116 today or email SALES SSSDYNAMICSCOM to add the Slipstick “Wide Receiver” to your processing lineup.

When food safety matters, the Slipstick Accumulator is the sanitary alternative. www.sssdynamics.com 1.800.527.2116 0/"OXs$ALLAS 48 

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

ADM. Chocolate…and so much more.

For customers around the world, ADM draws on its resources—its people, products, and market perspective—to help them meet today’s consumer demands and envision tomorrow’s needs. © 2012 Archer Daniels Midland Company

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