Contents Cover Story 10 | Tortilla Technology Galore Don Pancho Authentic Mexican Foods adds on to its state-of-the-art Halifax, N.C., plant to make room for an array of new better-for-you tortillas, wraps and chips.
Plant Story 18 | Four Lines, No Waiting
Photos by Vito Palmisano
Since Snack Food & Wholesale Bakery last visited Don Pancho East, the 85,000-sq.-ft., state-of-the-art facility added four new lines, chiller chambers and a host of other automated equipment to be able to shell out as much as 60,000 tortillas per hour, per line.
Columns 6 | Editor’s Note Editor-in-Chief Lauren R. Hartman attends the 4th Annual America’s Best Raisin Bread Contest. Learn more about the winners from the country’s only professional baking competition.
29 | The Nutritional Corner Contributing columnist and president of the Grain Foods Foundation, Judi Adams, offers up some healthy eating tips for the holidays.
43 | Engineering Management Contributing columnist and chairman of the American Society of Baking Jeff Dearduff encourages the industry to rise up and face the challenges that lie ahead.
56 | The Final Word Consumers tend to judge a package by its “cover,” so to speak. Executive Editor Marina Mayer unveils some hot packaging changes impacting the snack food and baked goods market.
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Snack Food & Wholesale Bakery - December 2011
SNACK FOOD & WHOLESALE BAKERY (ISSN 1096-4835) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or
[email protected].
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Contents 24 Market Trends
Production, Technology & Product Development Solutions for a Changing Industry. December 2011 Vol. 100 No. 12
24 | The Holidays Just Got Healthier Today’s cookie manufacturers have been busy little elves, creating new and exciting items for everyone on Santa Claus’ list.
For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail
[email protected] www.snackandbakery.com
New Products 28 | New Products
John Schrei Publishing Director
Read about some of the most recently introduced products, including snackable clusters, peppermint stick bars, protein-packed nutrition bars and a cracker and trail mix ready-to-eat snack.
[email protected]
Tom Imbordino Group Publisher
[email protected]
Jeff Heath Publisher
[email protected] 224-554-9154
Editorial
Special Report
Lauren R. Hartman Editor-in-Chief
30 | Package Handling with Care
[email protected] 847-405-4015
Check out what’s new in package handling equipment and systems to make manufacturing operations more productive.
Marina Mayer Executive Editor
[email protected] 847-405-4008
Patty Catini Art Director
30
Advertising & Internet Sales Barbara Szatko Senior Sales Manager
[email protected] 630-527-9927
Suzanne Sarkesian Classified Sales
[email protected] 248-786-1692
Jill L. DeVries Corporate Reprint Manager
[email protected] 248-244-1726
28
Support Services Liz Wright Marketing Coordinator
[email protected] 248-786-1652
Audience Development Kourtney Bell Audience Development Manager Stephanie Hunt Multimedia Specialist Carolyn M. Alexander Audience Audit Coordinator
Ingredient Technology 36 | Keeping Weight Management Real Many of today’s ingredient offerings deliver that heart-healthy, weight management solution consumers crave to stay fit without sacrificing foods they love.
List Rental Postal contact: Kevin Collopy at 800-223-2194 x684
[email protected]
Email contact: Michael Costantino at 800-223-2194 x748
Production Technology 44 | Built for Perfection Today’s laminators and sheeters are designed to deliver state-of-the-art attributes that meet operators’ needs and bakers’ demands.
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Snack Food & Wholesale Bakery - December 2011
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[email protected]
Corporate Directors 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 BNP Media Helps People Succeed in Business with Superior Information
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Whe n y o u r la be l s ay s “0 g t r an s -f a t” w o u l d n’t you l i k e t o rea l ly me a n i t ?
Editor’s Note
Baking Competition Winners Make the Most of Their Creativity T
he country’s only professional baking competition, the 4th Annual America’s Best Raisin Bread Contest, produced winners from a whopping 37 talented finalists this year. And from the looks of it, the judges had their work cut out for them. The contest, which took place Oct. 14-15 at the American Institute of Baking (AIB) in Manhattan, Kan., brought in many delectable entries, including sweet raisin- and walnutfilled pretzels, raisin whole wheat croissants, curry bagels and cream cheese-filled orange raisin brioche. More than 100 professional and student bakers submitted between one and three original formulas for the competition. Judges determined the finalists based on an initial blind test of both product formulas and photographs. Categories included artisan, commercial and Lauren R. Hartman breakfast, which
[email protected] consisted of rolls, pastries, scones, coffeecakes and more, all containing California raisins. The student category participants were especially creative. How often have you tasted barbecue raisin bread? “Our goal is to discover and reward the most creative and talented bakers in the country by challenging them to create raisin bread products in four categories: artisan, commercial, breakfast and student,” explains Larry Blagg, senior vice president of marketing for the California Raisin Marketing Board (CRMB), Fresno, Calif., the sponsor of the contest. “The competition has grown each year, and attracts the
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top bakers in America. This was our largest group yet.” The 12 winners are as follows:
Artisan: » Grand Prize–Gary Gottenbusch, Servatii Pastry Shop, Cincinnati, for California Raisin Walnut Pretzel » Judge’s Prize–Jory Downer, Bennison’s Bakery, Evanston, Ill., for Sweet City Loaf » Idea Prize–Monica Hoffberg, Bakery Nouveau, Seattle, Wash., for Raisin Rouleaux
Commercial: » Grand Prize–Rachel Crampsey, Tribeca Oven, Carlstadt, N.J., for Currant Seeduction Bread » Judge’s Prize–Angela Dodd, Cargill, Lake Oswego, Ore., for Cinnamon Raisin Apple Streusel Bread » Idea Prize–Nancy Sepe, Nancy’s Fancies, Providence, R.I., for Nonni’s Golden Raisin Sweet Bread
Breakfast: » Grand Prize–Phillippe Sanchez, Marriott International, Orlando, Fla., for Double California Raisin Whole Wheat Croissant » Judge’s Prize–Bill Hunter, Crestone Group Baking Cos., Grapevine, Texas, for » Sunrise Bagels » Idea Prize–Joanne Wilcox, Apple Crumbles, Utica, N.Y., for Marathon Mini Loaf
Student: » Artisan– Morgan Choi, the French Pastry School, Chicago, for Laminated Rosemary Raisin Epi » Commercial–Maddy Beck, Kansas State University, Manhattan, Kan., for Barbeque Raisin Bread » Breakfast–Nicole Barry, the French Pastry School, Chicago, for Muscat GrapeVanilla Cream Raisin Danish
Something special At the judges’ urging, due to the quality and originality of the finalists’ products,
the CRMB awarded one additional honor— The California Prize—in each of three categories. “These winners didn’t make the top three, but the quality was so good, the judges convinced us to award three additional prizes to bakers who were very deserving’” Blagg says. The California Prize went to: » Artisan—Daniel DiMuzio, La Brea Bakery, Inc., Greensboro, N.J., for Jumbo Raisin Fougasse with Toasted Walnuts » Commercial—Ron Guerrero, Caravan Ingredients, Lenexa, Kan., for Gluten-free Raisin Bread » Student—Julie Thompson, Johnson & Wales University Providence, R.I., for Sunny Side Up Orange Raisin Brioche During the competition, contestants produced at least six samples of their original product at the AIB kitchens, while the judges rated technique, formulations, efficiency and professionalism. Judges included Ciril Hitz, department chairman for baking and pastry at Johnson & Wales University, Providence, R.I.; Klaus Tenbergen, certified master baker and professor of culinology at California State University, Fresno, Calif.; Dominique Homo, president of Ecole du Pain, Montreal, Canada; David Guilfoyle, president of Half Baked Consultants, Inc., Abilene, Kan.; and Dan Malovany, executive editor of Baking & Snack, Kansas City, Mo. Chief judge and promoter of the contest was Theresa Cogswell, president of BakerCogs, Inc., Olathe, Kan. Congratulations to all of the winners and contestants—I wish you nothing but the best. The event also made me wonder: Why is this contest the only professional baking competition in the country? SF&WB
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Business Briefs
people
News Alpha Baking Tests Asset Tracking to Cut Bakery Tray Loss lpha Baking is testing a fully integrated asset-tracking system to determine its effectiveness in reducing bakery tray loss. The Chicago-based company partnered with The Kennedy Group, Willoughby, Ohio, and Orbis Corp., Oconomowoc, Wis., to conduct a nine-month pilot test using radio-frequency identification (RFID) tag technology to track trays and determine areas of tray loss within their supply chain. The first phase of the pilot test involved tagging and tracking a significant sampling of trays as they moved from Alpha Baking’s production plants to its individual ship points. The Kennedy Group supplied the RFID tags, installed the portals and created the read points for a realistic end-to-end experience. Future phases may include expanding the number of trays being tagged, as well as tracking trays at the depot and route levels. Alpha Baking has made reducing tray loss a company-wide priority, and employees and supply chain partners are collaborating to effectively manage Alpha Baking’s fleet of bakery trays.
A
Caravan Ingredients, Lenexa, Kan. Diane Carnell is named product category manager for emulsifiers, while Dave Pfefer is appointed D. Carnell product category manager for fortification. Both will have the primary responsibility of managing their product platforms to drive growth opportunities within the product portfolio by monitoring emerging consumer, competitive and market trends, key growth drivers and product line characteristics and D. Pfefer functionality.
supplier news Gold Coast Ingredients receives certification for International Food Standard (IFS), Version 5, a standard that is benchmarked against the Global Food Safety Initiative (GFSI). This certification provides evidence of the commitment of Gold Coast Ingredients to build and operate a management system capable of meeting these requirements. Heat and Control and Food Process Systems (FPS) form a global partnership to develop and market new technology for applying batters, breading and other coatings to a variety of food products. FPS designs and builds versatile applicators for coating bakery products, nuts and more. Heat and Control is a leading international manufacturer and supplier
of machinery systems and controls for food processing, seasoning application, conveying, inspection, weighing and packaging. Reading Bakery Systems is expanding its Robesonia, Pa., corporate headquarters. Phase 2 includes an expansion and renovation of existing space, such as human resources and accounting offices, conference rooms, lunch rooms and the machine shop area, and is expected to be completed in the spring of 2012. Reading also added more than 30 new staff mem-
bers, and is running two manufacturing shifts to keep up with customer demand. ADM Agri-Industries Co. receives the 2010-11 Gold Medal IPM Partner Award for its outstanding commitment to Integrated Pest Management (IPM) partnerships. The award was given by Orkin, LLC, Richmond, Va., the IPM Institute of North America, Madison, Wis., and NSF International, Ann Arbor, Mich. ADM utilizes Orkin’s Gold Medal Protection, a comprehensive IPM service that focuses on vigilant sanitation, prompt adherence to structural pest management recommendations, diligent record-keeping and staff participation in IPM training sessions.
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.
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Snack Food & Wholesale Bakery - December 2011
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TORTILLA TECHNOLOGY GALORE Don Pancho Authentic Mexican Foods’ state-of-the-art tortilla production facility in Halifax, N.C., is now fully onstream, paving the way for tortillas to become a weekly staple in the non-Hispanic market. Adding three more production lines at the Halifax location, the company is offering an array of new, better-for-you tortillas, wraps and chips that are helping make the most of its dynamic tortilla business. Lauren R. Hartman, Editor-in-Chief
T
o say that Don Pancho Authentic Mexican Foods, a Salem, Ore.-based tortilla manufacturer, has really grown in the last few years is an understatement. In business since 1979, the company is thriving, currently running three production facilities, an ever-expanding product line and state-of-the-art production capabilities. It was founded by past president George Puentes and his family members and named for his father, Francisco “Pancho” Puentes. Opening a high-tech tortilla facility and corporate office in Salem, Ore. in 1995, the company also has a plant in Salt Lake City and last year expanded to the East Coast in Halifax, N.C. Overall, the company now produces more than 100 million corn
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Snack Food & Wholesale Bakery - December 2011
and flour tortillas each year. Snack Food &Wholesale Bakery visited this newest Don Pancho production plant in Halifax—affectionately called Don Pancho East—last year when it was barely open. At that time, it operated on a limited basis, but today, the scrupulously clean, 85,000-sq.-ft. plant is a showcase for tortilla technology. The plant now features the latest in flour and corn tortilla mixing, sheeting, dividing, baking, counting/stacking inspection and packaging equipment. It’s also environmentally friendly, and incorporates various energysaving capabilties, including contained oven-heating discharges, sensor-activated lighting and materials recycling. Hearing about all of this, Snack
Food & Wholesale Bakery made a followup visit. “Part of our vision of becoming a national tortilla company dictated that we open a facility on the East Coast,” says Ricardo Baez, president of Don Pancho. The new Halifax facility is situated next to a salad plant owned by Don Pancho’s parent company, Reser’s Fine Foods, based in Beaverton, Ore. “So, it makes perfect sense in terms of synergies and transportation to be here,” he explains. “We’ll celebrate our one-year anniversary here very soon.”
Built from scratch The multimillion-dollar Halifax plant was designed by the company’s tortilleros, or master tortilla makers, based on the successes and experiences of Don Pancho’s other manufacturing facilities. Don Pancho East now houses four main tortilla lines that are separated into two sides of the
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Photos by Vito Palmisano
Plant manager Steve Snyder (left), company president Ricardo Baez and Eastern division category manager Mark Haig share a laugh and a bite of some of the foods incorporating the company’s newest products. facility: A flour side; and a corn side. “We built this plant from scratch,” Baez explains. “The plant was specifically designed and equipped for producing tortillas. It was an empty lot a few years ago. We built it based on the plant in Salem and it improves upon the layout there. We gained a lot of great experience and put that into this facility. Production now has a better flow. I’d say that’s been our No. 1 change in the way we do things. We take into account the dimensions of our equipment, how the lines flow from front to back and how the product moves into packaging and into our warehouse.” The Halifax operation runs 24 hours a day, five days a week, as does the other Don Pancho facilities. “That’s the kind of volume we have, and that also factors into how we
design and build our plants,” Baez says. To maintain the smoothest production flow, the tortillas are produced on a straight line layout and packaged in-line with manufacturing. “We want that linear flow to our production equipment and plant layout because it reduces the chance of crosscontamination,” says Steve Snyder, who was with Reser’s for 23 years before he came over as the new plant manager of Don Pancho East. “Once ingredients leave the raw state and go into a dough state and the baking process, anything that would be contaminated is killed by the high oven temperatures. From that point forward, we want the least amount of [human] handling as possible. We also want the least amount of backflow from where the process begins.” Yet as a backup, the plant maintains a
manual packing area. “That way, we are prepared for anything,” Baez adds. “You can never really get away from hand packing. If something happens to the equipment at the high speeds we run at [the plant can run as much as 60,000 tortillas an hour], we can keep on packaging and keep running.” Baez predicates all of this on one thing: “For this plant to be successful, it really starts with our bakers. They ensure that we have consistent doughs, consistent recipes and start with baking product that’s consistent in size and weight so that it can stack correctly and can work with that equipment and the linear flow.” Like the other Don Pancho facilities, the Halifax plant produces corn, flour, homestyle flour tortillas and flavored wraps as well as gorditas and tortilla chips. These Continued on page 12
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Continued from page 11
are marketed to foodservice, the military and retail outlets, mostly under the Don Pancho brand as well as selected regional brands and Reser’s national Baja Café brand. The company serves independent restaurants, national and regional grocery stores and supermarkets as well as broadline distributors. Today, the products are distributed nationally in 45 states, which is up from 43 a year ago.
New flavors, better-for-you ingredients Roughly 60% of the tortilla products are made for foodservice while the other 40% is for retail customers. Everything is made fresh for distribution, and that freshness is a critical aspect of the business. “We take a lot of pride in baking our products fresh
AT A GLANCE
Company: Don Pancho East, Halifax, N.C., part of Don Pancho Authentic Mexican Foods Headquarters/Location: Salem, Ore. Website: www.donpancho.com Plant Size (in square feet): 85,000 sq. ft. No. of Lines: Four No. of Employees: 85 Products: Corn and flour tortillas, prefried chips, tostada shells, wraps Brands: Don Pancho, Reser’s Baja Café, La Burrita, Lynn Wilson, San Antonio KEY PERSONNEL: President: Ricardo Baez Tortilla Division GM: Catalino “Cuco” Quirarte Plant Mgr.: Steve Snyder Senior Hispanic Category Mgr.: Evan Jaqua National Foodservice Mgr.: Tom Hoffert Eastern Regional Category Mgr.: Mark Haig
and shipping them fresh,” Baez notes. “We want to create a national freshness. However, a small percentage of our customers do require their products be shipped frozen and we accommodate them.” Overall, the company produces about 400 stock-keeping units (SKUs), including gluten-free varieties. The top sellers remain traditional 6- to 10-in. tortillas and flavored wraps, though new flavors and tortillas with better-for-you ingredients have just been launched. Product shelf lives depend on the product and customer requests, but range from 10 days to 45 and 60 days, shelf-stable. “On the foodservice side of our business, the top sellers are our chips made from tortillas as well as our thick, table tortillas, enchiladas, fajitas and burritos,” Baez points out. “The large family-style packages of tortillas are designed mostly for Hispanic families that enjoy multiple tortillas at a time, so they’re also very popular,” he says. “This year, we had several new initiatives. We just introduced a lot of whole wheat products, and an extended line of flavored wraps to complement our traditional offerings. In corn tortillas, we launched a new blend of corn/flour tortillas to meet an emerging trend. We also developed a line of better-for-you products that we are extending as we speak.” Listening to consumers, customers and the market so that it can react quickly is what Don Pancho is all about. We’ve done a great job getting ahead of the curve,” Baez says. Colorful new packaging graphics have been designed for several of the products and callouts on the labels reflect the healthful benefits. The clear bags for the flat stacks of tortillas in several sizes are now resealable with a zipper closure. Wraps are available in new varieties, including Garlic Herb, Spinach, High Fiber/ Low Carb and Chile & Tomato, which
were launched only a few months ago. Don Pancho also introduced ready-to-grill tortillas. A big initiative being applied to all of the products is a sodium-reduction, fatreduction program, Baez adds. “We started to roll out lower-sodium products and those with a lower calorie, fat and sugar content. The launch has gone very well because these are the very same profiles we have in our existing products, delivered in a better-foryou formulation. We’re pleased with how well these products have been received.” There is also a deeper transformation within the tortilla market category, he says. “Tortillas are now emerging as a ‘transporter’ of great food from around the world. This has tremendous impact on our business. We need to stay ahead of this trend to ensure we’re relevant and a leader in our category. We’re trying to find out how to fuse a tortilla with some variation of Middle Eastern flatbread for use with Middle Eastern foods. That will be a breakthrough,” says Baez. “We try to keep our finger on the pulse of the trends, with the world population constantly changing.” But the company’s traditional 6-, 8- and 10-in. flour tortilla products are still in big demand, he mentions. “The top sellers in terms of shell diameter are constant, but it’s what goes into the shells to delivers a different experience—that’s what has changed.” As its business keeps evolving and changing, Don Pancho strives to keep a step ahead, says Mark Haig, category manager for the company’s Eastern division. “In the past five years, the influence of new flavors and applications for tortillas has played a significant role. The increased Continued on page 15
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Snack Food & Wholesale Bakery - December 2011
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SNAXPO brings together owners, executives and buyers from every segment of the industry. SNAXPO is the only place to go to see new equipment, technology and innovative ideas for the snack food industry. Not only does SNAXPO provide everything you need to succeed in creating a more profitable company, it also provides an excellent educational program and a chance to do plenty of networking and business in an intense and exciting marketplace.
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s State of the Industry Report
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s The Food Safety Modernization Act: What Snack Food Manufacturers Need to Know
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2012 0122 SNA NA AX AXP XPPPO X O EEX EXH XH X H HIB IBBBITOR ITTO IT O R LIS OR LLIIS ISSTT A. C. Horn & Co. ADI Systems Inc Alchemy Systems American Extrusion International ANEX Manufacturing Arizona Instrument LLC Azteca Milling L.P. BluePrint Automation, Inc. BMA Nederland BV Brother Mobile Solutions Bryce Corporation Buhler Aeroglide C. Cretors and Co. Carolina Ingredients Casa Herrera, Inc. Clextral Inc. Commercial Creamery Co.
Continental Ingredients C-P Flexible Packaging CPM Wolverine Proctor Dallas Group Douglas Machines Corp. Dow AgroSciences DSM Food Specialties Emsland Group Evans Food Group Ltd. F4F Polska sp. z o.o. Filtercorp Focke & Co., Inc. - General Packaging Formers By Ernie, Inc. Formers International Franz Haas Machinery of America, Inc. Fuchs North America Gamay
Genpak Heat and Control, Inc. INCALFER J.C. Ford Company J.R. SHORT JJ MARTIN GROUP, LLC. Kerry Ingredients & Flavors Kliklok-Woodman Kraft Food Ingredients Corp. Land O’Lakes Ingredient Solutions Leng D’Or Snack Foods USA Life Spice Ingredients Maddox Metal Works, Inc. MAFIN SPA MANE, Flavors & Seasonings Marioff North America Markem-Imaje
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Process Sensors Corporation Quality Fabrication & Design, LP Quickdraft Reading Bakery Systems Ross Computer Systems rtech laboratories Rudolph Foods Company Sani-Matic, Inc. Shick USA Sigmaplast/SIGMA Trading USA SK Food International Spray Dynamics, Ltd. Sunopta Grains & Foods Group (Sunrich) Symrise Taura Natural Ingredients
The Andersons, Inc. dba O’Malley Grain The Lanly Company Tiefenthaler Machinery Company, Inc. TNA North America, Inc. Tru-Vision Plastics Inc. Unique Solutions Urschel Laboratories Inc. UVA Packaging Viterra Canola Processing Wenger Manufacturing, Inc. Wire Belt Company of America Wixon, Inc. Wyandot, Inc. XPEDIUM (Numeric Computer Systems Inc.) Yamato Corporation
Continued from page 12
demand for a tortilla that has better ingredients and provides more health benefits has been huge,” he says.
The food safety factor Just as important to Don Pancho are the role of food safety and the impact of the updated Food Safety Modernization Act (FSMA), which has been an important piece in the development of the industry. “Besides adding state-of-the-art, high-tech production lines here in Halifax, we’ve also improved our good manufacturing practices (GMPs) by leaps and bounds,” attests Snyder. “We have strict sanitation standards and also implemented a hand-swabbing program for all employees who enter the plant,” he says. “This ensures that employees meet the standards, and we also make random quality assurance checks throughout the day for each shift. We have made a lot of food safety improvements. The FSMA has certainly had an impact on how we keep records and other things, but we’ve been practicing a lot of the required procedures all along.” Currently, Don Pancho East is in the process of becoming Safe Quality Food (SQF)-certified through the SQF Institute, Arlington, Va. “We just completed this certification at our plant in Salem, Ore.,” Baez explains. “At that plant, we scored a 99.1. We look forward to that process here.” The plant is also inspected by Cook & Thurber regularly, is audited by the military as well as by Silliker for certain customers. Several times a year, the plant is inspected internally and by select customers who conduct their own in-house inspection services.
Cost challenges While it appears as if Don Pancho is immune to the difficult economic pressures most companies face in the United States, one of the greatest challenges the company faces is high commodity costs. “The economy has been tough,” Baez admits. “Like all of our industry peers, we have the same pressures everyone else has in being able to keep up with increases in commodity costs. “We’re certainly not immune to it. From a commodities cost standpoint, it
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has been a very challenging year for our company as well as the industry,” he adds. “And the problem is that we don’t see a lot of relief in sight. As some of the larger population bases like China and India get more exposed to a westernized diet and
as more American- and Western-based restaurants open up in those places, their diets will change. So there will be incredible demands for some of the ingredients Continued on page 17
High expectations that set the standard. To us, it’s elementary.
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15
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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Ricardo cardo ardo B Baez, presi pres dent nt, t Don Pancho Pa Auth Authenti c Mexican xican F Foods s
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Peter Parthenis, Jr., president and CEO, standing, and Peter Parthenis, Sr., chairman and founder of Grecian Delight Foods
TORTILLA TECHNOLOGY GALORE
Milano Bakery, Inc., Wholesale Baker of the Year November
Grecian Delight Foods December
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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 Lau Lauren R. Hartman at
[email protected] [email protected] or 847-405-4015. 847-405-4015
Thank Yo You
Continued from page 15
and products we use. “This is a time where it’s most important to work in concert with our suppliers and purchasing departments to ensure we have a strong partnership in dealing with this situation. We have long-lasting partnerships as it is with our vendors, so it’s crucial to keep those strong.” However, Baez sees these tough times as an opportunity. “Since we last talked, we’re seeing a major increase in the awareness of the type of foods we eat and are moving into a world of information like never before,” he says. “We have been fortunate because we continue to add value for our customers in terms of baking a good, quality, consistent product every day. We really work with our team to maximize our efficiencies and try to cut out costs as much as possible throughout the system. What will keep our business going is to develop products that will meet current and future needs of our customers and consumers.”
one main strategic advantage Don Pancho has over its competitors, but he concludes with this: “What makes us a premier tortilla manufacture is our relentless pursuit of excellence in manufacturing tortillas and tortilla-related products. Our custom-
ers continue to share with us their views of providing them unparalleled quality, continued consistency and care we take in partnering with them. The feedback we receive is very rewarding.” SF&WB
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A passion for what we do While the company’s core customer base of Hispanic families has always been the most important group in its business, the core consumer is changing, Baez remarks. “Hispanic families have been with us from the start and now they have families and their kids have kids. We are thankful for this. But our core consumers are changing and we’re seeing newer generations experiment more with flour tortilla-based products and salty corn snacks. It’s interesting how more of our core is becoming the non-Hispanic customer. We try to target and educate new consumers about the multipurpose advantage of tortillas. They’re not just for eating enchiladas, tacos or fajitas. They can be used for sandwiches, pizzas and flatbread applications with Middle Eastern foods.” It’s clear that the team at Don Pancho East loves what it does. “And it’s a team effort,” affirms Haig. “We have our own tortilla team here, and we’re selective about who is on that team. We all have passion at the company and the team of people here has that same passion. Keeping that passion going is the main thing.” It’s difficult for Baez to point out any
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December 2011 - Snack Food & Wholesale Bakery
17
Four Lines, No Waiting Don Pancho East, Halifax, N.C., is brimming with a high-energy staff and high-tech tortilla production on four new lines that can each output as much as 60,000 tortillas per hour. Lauren R. Hartman, Editor-in-Chief
D
esigned by the company’s tortilleros, or master tortilla makers, Don Pancho Authentic Mexican Foods’ 85,000-sq.-ft., multimillion-dollar production plant in Halifax, N.C., or Don Pancho East as it is called by company employees, is based on the successes and experiences of the other Don Pancho tortilla manufacturing facilities. Don Pancho East now houses four main tortilla lines that are separated into two sides of the facility: A flour side; and a corn side. “We built this plant from scratch,” explains Ricardo Baez, company president. “It was an empty lot a few years ago,” he says. “We built it based on the plant in Salem, Ore. and it improves upon the layout there. We gained a lot of great experience and put that into this facility. Production now has a better flow. I’d say that’s been our No. 1 change in the way we do things. We take into account the dimensions of our equipment, how the lines flow from front to back and how the product moves into packaging and into our warehouse.” Able to produce as many as 60,000 tortillas an hour and 61 million lb. of corn
18
Snack Food & Wholesale Bakery - December 2011
and flour tortillas per year—up 100% from its initial estimates—the Halifax operation runs 24 hours a day, five days a week, with sanitation, as does the other Don Pancho facilities. Orders are filled on a just-in-time basis to ensure that customers are getting the freshest product possible. “That’s the kind of volume we have, and that also factors into how we design and build our plants,” Baez says. “Everything is made fresh for distribution. Freshness is a critical aspect of the business.” “We make and ship everything to order,” says Mark Haig, category manager for the Eastern division. “We put everything into our finished goods warehouse and transferred it out right away.” Product shelf life depends on the product and customer requests, but range from 10 days to 45 and 60 days, shelf-stable. “We want to create a national freshness,” Baez smiles, hinting at what could be the company’s national ad slogan. Most of Don Pancho’s 400 stock-keeping units (SKUs), including gluten-free tortillas, are made in Halifax. “The plant is HACCP-certified (Hazard Analysis Critical Control Point) annually,” adds plant manager Steve Snyder. “We have
internal meetings once a month to keep us up to standard. All of our incoming raw materials that are allergens are stored in a segregated area in an ingredients storage warehouse, and are also segregated in production. We currently have two 80,000-lb. bulk wheat flour storage silos, but may soon have to acquire another one.” Since Snack Food &Wholesale Bakery last visited Don Pancho East, the company has installed two more chiller chambers on the lines in its flour tortilla production room. All of the lines are programmable-logiccontrolled (PLC). In place following the huge multipass, straightline ovens on each line, the temperature-controlled chambers bring the flour tortillas down to a cooler at a more manageable temperature after baking so that they can be stacked and packaged. “We integrated the cooling chambers to minimize any variables associated with the tortillas before they’re packaged,” says Haig.
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Photos by Vito Palmisano
The lines sparkle with stainless-steel equipment and shiny floors. Above, a roller cuts the tortillas while a counter/stacker, right, readies the baked tortillas for packaging.
Environmentally friendly Sparkling with new shining stainless-steel equipment and floors, the immaculate facility is equally environmentally friendly, incorporating various energy-saving and recycling capabilities, including contained oven-heating discharges, sensor-activated lighting and materials recycling, thanks to a neighboring materials recycler. “We bring all of our recyclable plastic and paperboard materials to the recycling company right behind this building, and they handle it,” Snyder points out, proudly. “Any extra tortilla waste goes into a trailer that’s shipped up the road to be recycled as chicken feed. We have very little waste.” On the day of Snack Food & Wholesale Bakery’s visit, the facility was shelling out 10-in. flour tortillas for foodservice and 6-in. white (table) corn tortillas for retail sales that are packed into 18-count bags and yellow corn tortilla “thins” that are later made into thin, fried chips. This line can generate about 5,000 dozen tortillas an hour. The other corn line ran 12-packs of corn tortillas that eventually were packed into 160-count shipments for foodservice distribution. “We make table corn on one of the two corn lines,” explains Haig. “Table corn is
thicker and has more moisture in it. We have a four-row corn line (which makes four tortillas across) and a six-row corn line, on which we make chips. We store corn and flour tortilla products and the raw ingredients for them in completely separate rooms. We have an allergen segregation program.”
Fine-tuned for efficiency In the corn room, the required amount of ingredients is added automatically to the mixers at the front of the two tortilla lines via PLC. There are various ways operators can deliver the corn masa to the lines. Today, flour is added by the 50-lb. bag. “We’re working with different corn masas, but preservatives and other ingredients are metered into the mix automatically,” Snyder points out. Batches range in size from 200-300 lb. The bags of masa are dumped into a hopper of a system that uses paddles to work the dough. “All of the flour goes through a metal detector/magnet to make sure it’s free of contaminants,” Snyder adds. Water, preservatives and other ingredients are automatically premetered into the system. The dough is then dumped into a presheeter, where it is thinned to specifications of about ¼ in. thick. Next, it moves into a sheeter, where it is thinned yet again
to further specifications. There’s some fine tuning that takes place at the presheeting/sheeting station in order to achieve the proper thickness of the corn tortilla chip, thanks to the bulk cutters used, Haig notes. When the dough collects on the sheeter head, a cutter runs across the back side and cuts the shapes of the tortilla out of the sheet. “This presheeting/sheeting system is stateof-the-art” observes Haig. “The old way of sheeting was with a masa feeder and an auger. A vertical auger would then force the mix into flutes that would lead it to a sheeter head. The masa dough is a dry dough, so it can put tremendous stress on an auger and wear it out. The presheeter saves us so much downtime and really increases throughput. It also makes us better operators, and we don’t put so much stress on the product and we get a more efficient flow.” As a white roller cuts the tortillas, the round tortillas emerge on the conveyor, four across, and progress toward the oven, Continued on page 20
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December 2011 - Snack Food & Wholesale Bakery
19
Bags of corn tortillas, left, which feature handy zipper closures, pass through a metal detector. Above, the printed bags accumulate prior to case packing.
The flour side
Continued from page 19
which has a 34-sec. dwell time and is 20 ft. long. Scraps are filtered back into the mixing system to be reused. “The tortillas move at about 1,000 per minute here,” Snyder says. The three-stage multizone straightline oven bakes the tortillas for 32-34 sec. at 450-600°F, depending on the zone. “The ovens are conveyorized inside, so the tortillas make three passes on the conveyor belt,” Haig explains. “The corn tortillas run at very high temperatures, and we need the oven to be long so actually instead of 20 ft., it’s like we have 60 ft. of cooking space inside with the three passes,” he says. “The tortillas pass through it three times and we do the same thing in the cooling process.” Once baked, the tortillas exit the oven and progress to a new seven-pass (multilane) cooling conveyor chamber. In about 4.5 min., the tortillas are brought down to an ambient temperature and are ready for stacking. They transfer onto a belt where they’re automatically counted and stacked into retail packs (18 count). The stacks of corn tortillas are then bagged in printed clear film bags with zippered closures, heat-sealed and transferred to a metal detector and ink-jet coder that applies production information and a date code. The bags are then case-packed and the cases are imprinted with production information and product identification, tape-sealed and palletized.
In the flour tortilla room, similar production line processes occur, with a few exceptions. Unlike the corn lines, the flour lines are equipped with proofers. Flour is pumped into the storage hoppers near the mixing area from a pair of silos in back of the plant that each hold 80,000 lb. The flour is weighed and added to the mixer, which uses a counter-rotation method to make dough with a perfect consistency. The mega tortilla line measures 130 ft. long, and is capable of producing four tortillas across at rates of about 29,000-30,000 tortillas an hour. “Actually, what we have on the flour lines are not mixers but more of a kneader,” Haig explains. “There are rollers that manipulate the dough instead of mixing it, and it can be mixed in the dough cart, which removes a step. On top of that, the cart locks into the meter system and the counter-rotation of the rollers against each other increases the action or kneading of the dough. This helps develop the dough faster. So instead of mixing for 12 min. the old way, this line is able to make a 300-lb. batch in seven min.” One of the flour lines was working with 200- to 300-lb. batches. The mixed dough travels into a ball mixer, up an elevator and is dumped into a hopper. The dough then heads to a rounder where dough balls form using an oscillating drum. The balls go up an elevator and move into the proofer. As the dough balls are made, they drop through four long cylinders into a proofing
system where they remain for about 7-8 min. at 70-80°F. After proofing, the dough enters a presser while a PLC monitors conveyor belt speed and the press station. The tortillas are pressed into a flat 8-in. size, and next enter a four-up, conveyorized three-pass straightline oven to bake at 450-550°F for 26-30 sec. “There are particular toast points required for the flour tortillas, and the different temperature zones in the oven provide that carmelization and add flavor,” Snyder explains. “That’s one of the differences between the corn and flour tortillas.” As the baked tortillas emerge from the oven, the conveyor elevates them into an enclosed chilling chamber—there are chill chambers on both flour lines—where they cool down for about 2.5-3 min. to a temperature of about 70°F. The chambers are about 30 ft. long and take the tortillas through 22 passes, says Haig. This is done to cool them evenly in a shorter period of time. Exiting the chiller, the tortillas progress to a visual inspection system that checks for size, shape and holes or defects and contaminants. If it spots any problems, an air blast kicks the tortilla offline into a bin. Automatic counting and stacking is next as another station automatically counts off the appropriate amount of tortillas for a stack and then layers them and then pushes them through a belt system that readies the stacks for bagging. They get tamped slightly and are stacked in groups of 10. At this point, the stacks of 8-in. tortillas are grouped and bagged by hand, dependContinued on page 22
20
Snack Food & Wholesale Bakery - December 2011
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ing on their specifications, but the majority are sent through an automatic bagger/ sealer with PLC control. Baez notes that the production lines are equipped with “the traditional manual backup,” as he calls it, as an insurance policy. However, the automatic packaging process has increased throughput by about 25%, says Haig. The stacks are staged or grouped for bagging in clear film bags. The stacks also pass through a metal detector that rejects any foreign materials. The bags are heatsealed before passing an ink-jet date coder and then the bag codes are inspected. Next, the bags are sorted and manually placed into 12-count shipping cases that are erected by a semi-automatic case former. The cases are then sent through a tape sealer and are palletized. The palletized loads are then sent into holding in the 20,000-sq.-ft. dry-storage warehouse before being loaded onto trucks. The lines each generate as many as 60,000 tortillas or more an hour. “We can
change the equipment over several times or not frequently, depending on demand. We try to maintain one size of tortilla through a shift,” says Snyder.
Special features Adjacent to one production room is a quality assurance lab, where research and development take place and products are tested to determine moisture, preservative, pH levels and other variables. It’s also where some of the new recipes are created. With the data gathered, the company can provide product characteristic and test results information to customers, Snyder explains. “We test each batch in this lab,” he says. “We retain something from each batch and lot we make. This is a QA sticker that indicates what time the product was made, a product code, temperature levels, pH levels, what line it ran on, the expiration date and we keep these samples through their expiration date. We also do random sensory testing after the end of a product’s shelf life to ensure that everything is what is should be.” Snyder discusses more evidence that Don Pancho East is focused on energy efficiency. “We have a high-efficiency quick-water system that heats water instantly as our
demand requires, and it only runs during our sanitation shift.” The facility is air conditioned but the ovens generate an immense amount of heat. To contain the heat, the company added a wall-like divider in both production rooms at the discharge of the high-heat ovens. “This keeps the heat on this side of the facility, so that we don’t have to battle the heat in the rest of the plant,” Haig says. “The heat dividers contain the heat in one area of the room, so it’s very efficient.” Quality assurance (QA) is also performed throughout production, Haig adds. “We test hourly for metal detection, ph and moisture content at the time that the dough is being fed to the final product stage. We take retention samples for customers in our lab and perform shelf life checks from July—we’re looking at a sample to see how long things last. Another part of our QA system involves raw materials that are checked before they even get into the building.” There are also established track-and-trace procedures, Snyder says. “There’s full lot accountability from point of inception for each ingredient and each component throughout the entire system. Once product is shipped, we can trace it back to who received what ingredients, what ingredients went into the product, what the lot numbers are and we do
In the flour room, left, mixed dough travels to a ball mixer. The dough balls form using an oscillating drum. Flour is added to a gigantic mixer, right, which makes dough using a counter-rotation/kneading process.
22
Snack Food & Wholesale Bakery - December 2011
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mock recalls several times a year with different variables, ingredients and products.”
What’s next? Currently, Don Pancho East is in the process of becoming Safe Quality Food (SQF)-certified through the SQF Institute, Arlington, Va. “We just completed this certification at our plant in Salem, Ore.,” Baez explains. “We scored a 99.1 at that plant. We look forward to that process here.” Don Pancho East is also inspected regularly by Cook & Thurber, and is audited by the military as well as by Silliker for certain customers. Several times a year, the plant is inspected internally and by select customers who conduct their own in-house inspection services. Baez agrees, an expansion in some way could be on the horizon. “We are probably going to expand further,” he says. “Our goal is to provide national freshness to our existing and future customers and make sure we deliver. We’re always looking to grow and one target would be to expand our coverage. Adding another facility could be on the horizon.” There is plenty of room at Don Pancho East for additional production lines in either the corn or the flour rooms, Haig says. “We built this plant to grow. Being a part of Reser’s Fine Foods, when we build a plant, we take what we have learned from other plants and apply it to the new one. And the new plant is always better. We build big because it’s less expensive to add equipment to a large space than to knock down a wall five years later. It gives us the freedom to make changes in the future. Having said that, we could expand this building because we have the land here to do so. This entire complex is designed to handle a 320,000-sq.-ft. facility, so in the future, it could be expanded.” Says Baez, “That’s why we also try to standardize the equipment and training at all of our plants. We have very established partnerships with vendors and suppliers. We are looking to explore any and all opportunities to expand Don Pancho and continue to be that national brand we have become. We have room here for at least two more corn lines and a frying line. So we could probably add maybe three more lines.” Baez is very excited about the future.
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“Things are really coming together,” he says. “Every successful operation really starts on the inside. It’s the baking that really allows our team to flourish. And the star is the tortilla. If we can make products the way we promise, then we’re successful. Every baker who’s successful has a great,
consistent high-quality product that stands the test of time. We see great consistency with Steve and his team. We’re meeting the goals we set for this plant. Steve and Mark have met and exceeded the initial first-year goals, with months to spare. They’ve done a great job.” SF&WB
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December 2011 - Snack Food & Wholesale Bakery
23
Market Trends Cookies
The Holidays Just Got Healthier Ho ho ho! It’s time to set out a plate of cookies and milk for Santa because cookie manufacturers have been busy little elves, creating new and exciting items for everyone on Santa Claus’ list. Jen Roth, Contributing Writer
nlike previous years where children left out the same old plate of chocolate chip cookies for Santa, today, they’ll have plenty to set out, as manufacturers are churning up a whole list of items that all consumers—yes, even the naughty ones—can enjoy. For example, Mary’s Gone Crackers, Gridley, Calif., created a line of gluten-free cookies called love. “Consumers want to know that they
are eating healthful ingredients more and more. There is also a desire to eat real food and not “nutraceuticals.” And of course, the markets for gluten-free and organic are still growing steadily,” states Mary Waldner, chairman and co-founder. “Mary’s Gone Crackers’ love cookies fill all of those needs, and the most important need—great taste.” Launched in February 2010, the love cookies come in Chocolate Chip, Ginger
U
THE TOP
Cookies
10
(For the latest 52 weeks ending Oct. 2, 2011)
Rank
Brands
Dollar Sales
% Change vs. Previous Year (in millions)
Dollar Share
Unit Sales (in millions)
Unit Sales % Previous Year
1. Private Label
$667.9
-0.4
14.1
304.7
-2.6
2. Nabisco Oreo
$354.6
+10.4
7.5
134.0
+13.2
3. Nabisco Chips Ahoy!
$347.5
+4.0
7.4
137.2
+10.2
4. Nabisco Oreo Double Stuf
$155.0
-5.6
3.3
51.7
-3.8
5. Little Debbie
$139.5
+0.2
3.0
125.8
+4.2
6. Lofthouse
$138.1
+2.3
2.9
41.5
+9.4
7. Nabisco Newtons
$108.5
+5.2
2.3
45.7
+9.4
8. Pepperidge Farm
$97.1
-2.6
2.1
32.9
-2.7
9. Pepperidge Farm Milano
$95.1
+0.9
2.0
33.8
+1.4
$94.8
+3.0
2.0
74.0
+2.5
$4,730.2
+2.9
100.0
2,214.8
+2.9
10. Little Debbie Nutty Bar Total*:
*Includes brands not shown Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
Snaps and N’Oatmeal Raisin, the latter bringing the familiar taste and texture of grandma’s soft oatmeal raisin cookies, but without the oats and a substitute organic currants for raisins. A Double Chocolate option made its debut in March. “All of our cookies are gluten-free, organic and vegan, sweetened with coconut palm sugar and contain chia seeds, which are high in Omega 3s and other healthful ingredients,” Waldner says. The cartons and corrugated shipping cases for these cookies are also made of 100%-recycled fiberboard and incorporate soy-based inks, Waldner adds. Mary’s Gone Crackers’ love line is not only a great option for those who are gluten-intolerant, but it’s also a better-foryou alternative that moms can feel good about giving to their kids. “Once we decided not to use eggs or dairy products in our cookies (in addiContinued on page 26
24
Snack Food & Wholesale Bakery - December 2011
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Market Trends Cookies Continued from page 24
tion to being gluten-free and organic), my challenge was to find ingredients that worked to create delicious, familiar-tasting cookies,” states Waldner. “Sneaking whole grains and other nutritious ingredients into tasty, organic cookies with less sugar is going to be well received.” Meanwhile, Fabe’s All Natural Bakery, San Fernando, Calif., introduced glutenfree, vegan, 1-in.-diameter round mini cookies. Made with all-natural ingredients and sweetened with palm fruit oil and natural syrups, the Organic Macaroon, Dark Chocolate, Cranberry Orange and Ginger Snap options are said to be a great addition to any lunchbox or snacking occasion. Fabe’s also launched whole grain mini cookies that are Sweetened By Nature, which means they’re packed with fruits, vegetables and grains. They come in Chocolate Chip, Oatmeal Raisin, Peanut Butter, Coconut Chip and Double Chocolate Chip varieties. For consumers looking to pump some iron during the holidays, Lenny & Larry’s offers the “complete cookie package,” with Muscle Cookies, a power-packed cookie that offers 20 g. of whey protein and 5 g. of fiber. “We aren’t coming ‘late to the party,’ trying to capitalize on a trend. We arrived very early,” states Barry Turner, CEO and founder of the Northridge, Calif., company. There are a lot of all-natural cookies in the market—some vegan cookies and some cookies with high fiber—but we have been able to hit the mark on these entire trends, plus with added protein. The ‘complete cookie’ is the trend.” Set to hit store shelves in the first quarter of 2012, Muscle Cookies will be available in Chocolate Chip, Peanut Butter, Oatmeal Raisin and Double Chocolate Chip varieties, all of which contain no sugar alcohols and no high-fructose corn syrup, the company says. Lenny & Larry’s is also working on a mini version of The Complete Cookie along with a lower sugar variety. If Santa is in a hurry, running from one house to the other and doesn’t have time to grab a cookie on his way up the chimney,
26
Snack Food & Wholesale Bakery - December 2011
he’s in luck. That’s because Old Colony Baking Co., Spring Valley, Ill., has created a 5-oz. package of its co-branded bag cookie line, which contains the company’s Diamond Walnut Shortbread, Musselman’s Apple Sauce/Oatmeal and ReaLemon Lemon cookies. “As single-serve items, our cookies are perfect for the on-the-go consumer,” states Jeffrey Kaufman, president.“We are seeing more and more micro markets popping up, which gives the normal vend consumer a considerably large selection of products resulting in healthier choices.”
Cookies and wine? In some households, the holidays bring on traditional gatherings, parties and even cookie and wine pairings. To spruce up the holiday spirit, Cookies & Corks, Falls Church, Va., created a line of sweet and savory cookies that are meant to be paired with the perfect pinot. “Consumers are really enjoying savory or salty flavors mixed with sweet flavors,” says Laura Englander, vice president of sales and marketing. “We have a Sea Salt Chocolate Oatmeal cookie that always evokes a head nod followed by something like, ‘oh, I love salt and chocolate together.’ We’ve got a sweet and savory Apricot Sage cookie that pleases both palates,” In May, Cookies & Corks launched single packs of Apricot Sage, Ginger
Molasses, Zesty Lemon, Sea Salt Chocolate Oatmeal, Espresso Chocolate Peanut Butter and White Cheddar Rosemary options to be included in a Red Wine Pairing box, complete with red, white and sparkling wine. “Each of the boxes has a cookie and wine pairing guide (on the side of the box) so that consumers will have an easy time making a selection of wine to pair. We did this because we know how intimidating wine pairing can be,” Englander says. “We crafted our cookies for enhanced wine pairing by lowering the sugar level in some of the cookies, adding a little more vanilla in others and we use kosher salt. The result is a cookie that does not taste like a packaged cookie.” In July, Cookies & Corks revealed single flavor boxes of cookies, along with a wine pairing guide that offers up recommendations such as Zesty Lemon with Pinot Grigio, Sauvignon Blanc, Brut sparkling wine, Prosecco or Demi-Sec sparkling wine, Pinot Noir and Merlot, she adds. “Our packaging is intended to attract customers by the bright colorful design, ease decision-making fatigue by telling them which wines will be good pairings and inform them that they are making a healthy decision buying these cookies without artificial preservatives, flavors, partially hydrogenated oils or trans-fats,” Englander adds. Salem Baking Co. also is chucking the crackers-with-wine forté in favor of
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Market Trends Cookies Iced Gingerbread Man. Also included are Wedding Cake, Cashew Nougat and Pfeffernusse, a German-inspired cookie made with holiday spices and molasses and topped with powdered sugar.
cookies. In fact, the Winston-Salem, N.C., company offered a variety of suggestions in using its thin Morovian cookies for sweet and savory appetizers. Both the Spicy Ginger and Artisan Blend Chocolate kinds can be topped with a soft goat cheese and either a spicy jelly or a sweet orange honey. The lineup also includes Brown Sugar and Cinnamon, Sugar with Vanilla Bean, Meyer Lemon with Lemon Zest, Pomegranate Lime with a Hint of Sea Salt, Cinnamon with Brown Sugar and Toasted Coconut.
Making the list As long as companies are creating lowercalorie, non-fat, gluten-free and organic versions of their favorite cookie, there will always be another item on the shelf that goes above and beyond consumers’ wildest dreams. Northfield, Ill.-based Kraft Foods’ fulfilled this dream by reimagining America’s favorite sandwich cookie, the Oreo. Introduced this summer, the Triple Double Oreo boasts not two, but three chocolate wafers surrounding a dollop of the famed vanilla cream filling and a bonus helping of chocolate cream filling. At 4.5 g. of fat per cookie, one single-serving of this 100-calorie sinful sweet is bound to give anyone a super-charged sugar rush. When filling the platter for Santa’s visit, one should not neglect the holiday favorites. Fortunately, Ashland, Ohiobased Archway Bakeries, Co., a division of Snyder’s-Lance of Charlotte, N.C., is bringing back its traditional Archway holiday cookie line beginning Nov. 1. The line offers consumer favorites such as Bells and Stars, Gingerbread Man and
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Regardless of whether you’re naughty or nice, today’s cookie manufacturers are creating new and innovative varieties of the indulgent baked goods that can satiate any kind of sweet, savory or guilt-free craving. SF&WB
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New Products
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Clif Peppermint Stick Bars
Company: Clif Bar & Co., Emeryville, Calif. Website: www.clifbar.com Introduced: October Distribution: National Suggested Retail: $1.39 for a 2.4-oz. bar Product Snapshot: New to the Clif lineup of winter favorites is Peppermint Stick. Made with certified-organic ingredients, this ice cold-flavored bar maintains 23 vitamins and minerals and is a good source of protein and fiber. It joins the other seasonal varieties—Spiced Pumpkin Pie and Iced Gingerbread— and 1% of net sales benefit the Winter Wildlands Alliance, a national non-profit organization promoting and preserving winter wildlands. Ingredients: Organic brown rice syrup, ClifPro (soy rice crisps [soy protein isolate, rice flour, barley malt extract], organic roasted soybeans, organic soy flour), organic evaporated cane juice, organic rolled oats, organic toasted oats (organic oats, organic evaporated cane juice), ClifCrunch (organic oat fiber, psyllium, inulin [chicory extract], organic milled flaxseed), soy white chocolate (organic evaporated cane juice, cocoa butter, soy flour, soy lecithin, natural flavors), organic soy butter (organic roasted soybeans, organic soybean oil, salt), peppermint candy (evaporated cane juice, rice syrup, coconut oil, colored with vegetable and fruit juice concentrates, soy lecithin, natural flavors, citric acid), organic date paste, sea salt, natural flavors.
Company: Abbott Nutrition, Columbus, Ohio Website: www.abbottnutrition.com Introduced: October Distribution: National Suggested Retail: $5.49 for a 5.6-oz. box of four bars Product Snapshot: Abbott Nutrition responds to the growing diabetes and obesity epidemic with Glucerna Hunger Smart nutrition bars for consumers with diabetes. Each bar offers 140150 calories with 10 g. of protein and contains CARB STEADY, a carbohydrate blend of slowly digestible carbohydrates, designed to help minimize blood sugar spikes. They come in Chocolate Peanut Butter Crisp and Chocolate Chip Crisp varieties.
Sunbutter + Cracker Ready-to-Eat Snacks
Company: Enjoy Life Foods, Schiller Park, Ill. Website: www.enjoylifefoods.com Introduced: October Distribution: National Suggested Retail: $4.99 for a 3.5-oz. box Product Snapshot: Sunbutter + Crackers is the latest ready-to-eat snack choice to hit the GoPicnic brand of all-natural, gluten-free products. It features a creamy sunflower seed spread, multigrain crackers, fruit and seed trail mix, tropical fruit bites and a double chocolate chip cookie. Ingredients: Sunbutter Spread: Sunflower seed, sugar, monodyglycerides (to prevent separation), salt, natural mixed tocopherols (to preserve freshness). Multigrain Crackers: Brown rice flour, whole grain yellow corn, potato starch, safflower oil, oat fiber, evaporated cane juice, sesame seeds, flaxseeds, millet, sea salt, quinoa seeds. Seed and Fruit Trail Mix: Raw sunflower kernels, roasted hulled pumpkin seeds (sunflower oil [sunflower oil, citric acid], salt), raisins, dried apples, chocolate chips (evaporated cane juice, natural chocolate liquor [non-alcoholic], non-dairy cocoa butter), cranberries. Tropical Fruit Bites: Apple puree concentrate (contains ascorbic acid), apple juice concentrate, mango juice concentrate, pineapple juice concentrate, natural flavor and color, pectin, glazing agent. Double Chocolate Chip Cookie: Flour mix (white rice flour, buckwheat flour, millet flour), chocolate chips (evaporated cane juice, chocolate liquor, non-dairy cocoa butter), palm oil, brown pure cane sugar, evaporated cane juice, natural process cocoa powder, natural flavors, vanilla, salt, baking soda, sodium acid pyrophosphate, xanthan gum, rosemary extract.
Glucerna Hunger Smart Nutrition Bars
Ingredients (Chocolate Chip Crisp):
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KIND Healthy Grains Snackable Clusters
Company: KIND Healthy Snacks, New York
Website: www.kindsnacks.com Introduced: October Distribution: National Suggested Retail: $5.99 for an 11-oz. bag
Product Snapshot: KIND Healthy Grains is a new line of snackable clusters made from an artisanal blend of whole grains such as amaranth, quinoa and buckwheat and superfoods, including blueberries, walnuts, chia seeds and flaxseed. They come in Peanut Butter Whole Grain, Vanilla Blueberry with Flax Seeds, Cinnamon Oat with Flax Seeds, Maple Walnut with Chia & Quinoa, Dark Chocolate & Cranberry and Oats & Honey with Toasted Coconut varieties.
Ingredients (Vanilla Blueberry with Flax Seeds): Whole grains (gluten-free oats, brown rice, gluten-free oat flour, buckwheat, amaranth, millet, quinoa), evaporated cane juice, flaxseeds, chicory root fiber, canola oil, vanilla extract, molasses, blueberry puree, apple puree, plum puree, apple juice, glycerine, sea salt, vitamin E (D-Alpha tocopheryl acetate), citrus fiber, citrus pectin.
Soy protein crisps (isolated soy protein, tapioca starch, rice flour, cocoa [processed with alkali], salt, calcium carbonate, barley malt), chocolate-flavored coating (lactitol, fractionated palm kernel oil, polydextrose, cocoa, artificial flavor, soy lecithin, monoglycerides, vanilla, acesulfame K), fruit juice and grain dextrins, marshmallow binder (maltitol syrup, fractionated palm kernel oil, water, corn maltodextrin, glycerine, egg white powder, titanium dioxide, soy lecithin, salt, natural and artificial flavors), fructose liquid, chocolate-flavored chips (maltitol, chocolate liquor [processed with alkali], cocoa butter, sorbitan tristearate, soy lecithin, vanilla), soy protein isolate, corn maltodextrin, short-chain fructooligosaccharides, glycerine, high-oleic safflower oil, chocolate layer (maltitol syrup, sorbitol, palm kernel oil, milk protein concentrate, cocoa [processed with alkali], chocolate liquor, natural flavors, soy lecithin, salt, gum Arabic, xanthan gum, locust bean gum, tetrasodium pyrophosphate). Contains less than 2% of the following: cocoa fructose liquid (fructose, water, corn maltodextrin, Dutched and natural cocoas [processed with alkali], salt, carrageenan, natural flavors, tocopherol, ascorbic acid), calcium phosphate, cellulose guar gum, rolled oats, natural and artificial flavors, dl-Alpha-tocopheryl acetate, salt, ascorbic acid, sucralose, beta-carotene, chromium chloride. Contains: egg, milk, soy and wheat ingredients.
Edi tor ’s N ote: G o to w w w. s n a cka n d b a ke ry. c o m to re a d a b o u t mo re n e w p ro d u c ts .
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The Nutritional Corner
Happy and Healthy Holiday Eating t’s that time of year again—the holiday season is in full swing. As my family and I gathered around the Thanksgiving table not too long ago, one thing we were unanimously thankful for was our health. Looking forward to what will surely be a whirlwind of holiday parties, indulgent dinners and decadent desserts over the next month, it can be hard to prioritize the very thing for which we were grateful for. This time of year makes me think of research published a few years back in the New England Journal of Medicine, examining the effects of holiday weight gain on Americans. The study revealed that, on average, Americans gain one pound between Thanksgiving and the New Year. Although this may seem like a drop in a bucket, what was most notable about the
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study is that people didn’t lose that extra pound in the following months. In other words, the weight gained during this time is being carried over from year to year, and we all know that weight gain over time can have a huge impact on health. Because it can be so easy to overindulge, here are some tips for keeping this holiday season the healthiest ever. For starters, consider this fact—hunger and thirst are two sensations that can often be confused. To help monitor hunger this holiday season, be sure to stay hydrated. Next time you find yourself reaching for that second slice of pie, first try having a glass of water or some water-rich food, such as a piece of fruit. Drinking plenty of calorie-free
Judi Adams, president, Grain Foods Foundation and the Wheat Foods Council
beverages, like water or seltzer, can help keep hunger at bay and reduce overindulging. Another important pitfall to avoid is skipping meals. When gearing up for big holiday feasts, people often think it’s a good idea to skip breakfast to save calories for later in the day. But, by skipping the most important meal of the day, you set yourself up for failure. Not only will it slow down your metabolism (your body’s ability to burn calories), it often drives unconscious overeating. Last, keep in mind that the holidays are a special time of year, and celebrations with friends and family call for special treats. Your festivities don’t have to be all or nothing when it comes to these treats—just remember portion size and frequency of your indulgences is most Mini Pumpkin Cheesecakes PXIßQWLQZLWKIRLOFXSFDNHVW\OH important. When you’re liners. Place cooled bread circles in the planning what to eat at bottom of each foil liner. In a medium Ingredients holiday gatherings, survey bowl, beat light cream cheese and 1.5 tsp. pumpkin pie 3 slices whole grain spice bread the offerings first and select a sugar with an electric mixer on medium 1 tsp. vanilla Vegetable oil spray small portion of your favorspeed until mixture is combined, 2 whole eggs 1/2 tsp. cinnamon ite indulgence. Then fill the approximately 2-3 min. Add canned 12 oz. light cream cheese Light whipped topping and freshly grated 1/2 cup sugar remainder of your plate with pumpkin, pumpkin pie spice and vanilla 3/4 cup canned pumpkin nutmeg for garnish healthier fare. Don’t forget, and beat for 1-2 min. on medium speed celebrations don’t have to until mixture is combined. Add eggs, Instructions revolve solely around food— one at a time, and beat on mediumPreheat oven to 350°F. Flatten bread you can enjoy more active low speed until combined (do not slices with a rolling pin. Using a 2-in. time with your loved ones by over-mix after adding eggs or the mini size biscuit cutter, cut four circle taking a walk, going sledding cheesecakes may crack when cooled). shapes from each slice. Place bread or playing in the backyard. Pour cheesecake batter into foil circles on a non-stick baking sheet, And, for you holiday hosts liners. Bake at 350°F for 25-30 min. or sprayed with vegetable oil spray. Lightly out there, do everyone a favor XQWLOFHQWHUVDUHVHW3ODFHPXIßQWLQ spray tops of bread circles with and serve up lighter, healthier on a cooling rack for 30 min. Remove vegetable oil spray and sprinkle with fare for all to enjoy. Try this FKHHVHFDNHVIURPPXIßQWLQ&RYHU cinnamon. Bake for 8-10 min. or until healthy holiday recipe (left) and refrigerate for one hour prior to bread is golden brown. at your next gathering. Your serving. Garnish with light whipped Place toasted bread circles on a guests—and their waistlines— topping and nutmeg if desired. cooling rack for 5-10 min. Line a 12-cup will thank you later! Happy Holidays! SF&WB Recipe courtesy of Mrs. Baird’s Bakeries, a division of Bimbo Bakeries USA, Horsham, Pa.
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Special Report Package Handling Systems
Package Handling with Care A critical aspect on any production line, the package handling function may require one conveyor section, multiple lanes or hundreds of integrated material handling accumulators, elevators, lowerators, robotics, controllers and more. We asked several manufacturers what’s new in package handling equipment and systems to make your manufacturing operation more productive. Lauren R. Hartman, Editor-in-Chief
everal trends in package handling systems are driving sales and impacting bakers, snack food manufacturers and other food processors. Despite the slow economy, packaging equipment has experienced a real growth curve the last 18-24 months. As companies look to increase output, add items, change processes and reduce costs, they often turn to automation. And cost is one of the most critical aspects involved with packaging handling equipment. At Delkor Systems, Circle Pines, Minn., today’s key drivers are retail-ready/shelfready packaging concepts and machine versatility. “Another factor is fast, repeatable changeover due to product variety demands,” reports Mike Wilcox, vice president of sales, marketing and aftermarket sales. “Delkor has developed and launched eight new machines over the last 18 months that already account for almost 40% of new machine sales. These machines incorporate ideas that address the aforementioned trends and have allowed us to grow our business.” Many cutting-edge developments position Delkor to provide attractive packaging, enabling the company to better serve customer needs, Wilcox adds. In addition, tool-less changeovers have been a customer desire for some time. “But also minimizing the changeover time requirement is
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equally important,” Wilcox points out. “The third element of this trend is fast startup. A fast changeover is quickly negated if continual adjustments are necessary for optimum performance.” Clearly, demands call for more equipment sanitation and higher performance. “The new standards for cleanliness and sanitary design are a fact of machine design today,” he says. “Dry-product operations are using sanitary design elements formerly found in dairy and meat operations, while the latter industries require higher levels of sanitary design than before.” Delkor’s Trayfecta carton-and-case forming machine line is at the top of its product sales today. The machines form cartons, cases and trays in either paperboard or corrugated materials. The Trayfecta M series of mechanical formers incorporates many safety and reliability features for which Delkor packaging machines are respected. Trayfecta S Series formers apply servodrive controls to critical machine functions, thereby increasing speed and flexibility, while retaining traditional safety and reliability attributes. Its Spot-Pak machine line is also innovative for secondary packaging applications because it not only eliminates a corrugated case, but the corrugated trays as well. The machinery can load primary product containers onto flat pads.
Photo courtesy of Delkor Systems
A critical factor in designing new package handling systems today that Delkor faces includes the ability to maintain line operation while sorting and removing damaged or unsalable product to prevent downtime and bad product getting to the pallet, according to Wilcox. “Also, minimized material content and overall utilization places a significant demand on product and package handling machines. Low-height trays, simple corrugated pads, shrinkbundled products and lightweight materials require more precise machine movement and accurate repeatable setup. Our customers would also like to see precision package forming, managing damaged product out of the line, minimizing product rework and lower operating costs. Creating flexibility in machine design is also important to readily
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Special Report Package Handling Systems Photo courtesy of Lantech
adapt to a variety of material and package options. But, delivering higher standards of operation while remaining cost effective is another key element.” Despite poor economic reports though, Wilcox sees package machine sales to be very good for many companies at this time.
Costs are an issue When it comes to costs, everyone is trying to control them, admits Derek Jones, senior marketing product manager at Lantech, Louisville, Ky. Jones says his firm experienced a downturn in sales back in 2008 like everyone else in the industry. Some bakers and snack producers are taking advantage of the current economy by upgrading and/or retrofitting existing equipment with the latest innovations. “Many understand that the return on investment with recent innovations will have a short payback period,” says Jones. “But 2011 has been a banner year for sales. With that in mind, one of the best ways to keep tabs on costs is to make sure that shipping charges are correct. By weighing every load you ship for quality and freight costs, you are able to ensure that you’re being charged correctly.” In addition, he says that understanding customer’s needs help his firm continue to be the leader in innovation in the industry. “Customers want peak performance,” Jones states. “They also want all-in-one weighing and stretch-wrapping machines that have a small footprint, are durable and keep operators safe. But it’s a challenge sometimes in educating our audience that all stretch wrappers are not [created] equal.” Lantech’s EZ Weigh integrated scale with semi-automatic stretch wrapper, which was launched at September’s Pack Expo Las Vegas, meets those demands, he points out. “EZ Weigh weighs every load to optimize load quality and freight costs. The machine saves space and has a new, tilted skirt turntable design. The turntable resists impacts from fork trucks and pallet
jacks. The weighing system is integrated under the turntable instead of with the entire machine. This helps improves weight accuracy as items only on the turntable are weighed.” Improvements in containing loads is one of the greatest opportunities for growth in the package handling equipment market, Jones
points out. “It’s critical to ensure that every load shipped meets ‘good load’ criteria. Good loads are bonded to a pallet to prevent shifting during transit. The stretch film used must be evenly applied to the load, without long or dragging film tails that could get caught on downstream equipment.”
expect higher performance and some of it focuses on cleaning. “They want to minimize planned downtime and, if possible, eliminate unplanned downtime,” he points out. “Designing equipment with features that make cleaning easier and more effective reduces planned downtime for sanitation or allergen washes. Designs on our equipment like tip-up tails, belt lifters and clean-out windows address these requirements. Customers are able to access these components, to clean the inside of the conveyor frame in seconds without tools.” He believes that sanitary equipment is evolving every day. “Each time a piece of equipment is manufactured, suppliers and customers work on ways to make the equipment more sanitary.” Dorner continues to invest in “smart” conveyance. “Smart” features go beyond sanitation and into conveyors that are easier to implement, communicate and
Hygienic design counts Dorner Manufacturing Corp., Hartland, Wis., agrees that the focus is not only equipment’s material construction but also hygienic design. “Customers are of the mindset that they will own this equipment for a long time,” says John Kuhnz, director of marketing. “Paying attention to equipment design and construction leads to a lower cost of ownership over the life of the equipment. This is a direct result of changes in overall cleaning practices in terms of increased frequency and to include areas in the facility that otherwise are not considered. In addition, the packaging lines in some applications are in closer proximity to the production areas, so customers opt for stainless steel and other corrosionresistant materials. This is driving sales of sanitary designed and constructed equipment. It’s also impacting accessories often used with the equipment.” Kuhnz says that customers indeed
Photo courtesy of Dorner Manufacturing Corp.
interface with emerging technologies and packaging, Kuhnz says. The company offers a diverse range of conveyors and unithandling solutions to meet these trends. There are conveyors for dry areas as well as wipedown and washdown platforms, available in both aluminum and stainless steel. “Each conveyor platform has hygienic design features required for a targeted environment within the food production facility,” Kuhnz reports. “And each platform has a set of conveyor features or accessories that allows for tailoring to each customer’s application.” Where Dorner’s washdown systems are concerned, the most popular feature is the Continued on page 32
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Special Report Package Handling Systems Photo courtesy of Dorner Manufacturing Corp.
sions are taking place on each system design as companies look for greater ROI from packaging equipment automation. But for our role in package handling systems, I’d like conveyors to lead the way in hygienic design and sanitation features,” says Kuhnz. “Sanitary equipment is evolving every day.”
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tip-up tails, which allow for quick access to internal frames for sanitation. On its dry conveyor platforms, the SmartSlot creates a smooth side on the exterior but still allows for the fast attachment of automation components. “In other words, there are no T-slots that could catch product debris,” he says. The AquaPruf sanitary conveyor line is also designed for fast, effective sanitation that allows production lines to start running again quickly. “This is a real dollar saver,” Kuhnz points out. Another trend that Dorner sees is the increased use of flexible package and pouches. “They bring new challenges with respect to their handling,” Kuhns acknowledges. “Another trend is future needs planning with package handling systems. Can a system be designed for a larger package, a smaller package or accept a 50% increase in volume? These discus-
Robots get a grip Weldon Solutions, York, Pa., builds robotic palletizing systems that it considers are the most flexible way to load multiple pallets of different products at the same time. “This requires that the robot’s end-of-arm tool (EOAT) be flexible enough to securely handle a variety of items,” notes Charles Gales, manager of automation sales at Weldon. “Our UniGripper has a matrix of valves that create a vacuum across the surface, and is capable of picking up one or multiple cases,” he says. “The compliant face of the UniGripper only creates a vacuum where cases are present. That allows for handling of different case sizes with no changeover. This is particularly helpful for CPG companies that change case sizes frequently during the production day or over time. The UniGripper can also automatically adapt to new case sizes. Once a new product or product size is programmed into the robot,
that new information is ready to be handled by the UniGripper.”
Lowering cost of ownership Dynamic Conveyor Corp., Muskegon, Mich., launched a new line of conveyors to the food processing and food packaging industries at PackExpo Las Vegas 2011, says Jill Bartka, president. “In addition to being quick and easy to clean, which saves time and money, the new line offers a unique benefit of reconfiguring the conveyor layout when the needs of the processor change.” The company’s DynaClean conveyors are eco-friendly and sustainable, she points out, and reducing the ecological footprint is becoming a priority for many food companies. “Lowering the total cost of ownership is typically even more important to processors as costs continue to rise and it becomes more and more difficult to make a profit,” she says. “The DynaClean line is a response to these needs by allowing the end user to quickly and easily clean the conveyor, saving time and labor and other resources. This also saves changing the conveyor configuration with new segments of a different length or angle, preventing the conveyors from sitting unused and forcing the processor to purchase a new conveyor.” Bartka says that when her firm designs a new package handling systems today, one of the most critical factors is that time is money. “Customers need conveyors that are quick and easy to clean. We design systems to include optional belt lifters that allow for access within three seconds to the underside of the belt and the internal conveyor components. The ability to remove the belt, belt supports, the motor and the return within in a few minutes without tools gives easy and very quick access for a thorough cleaning and sanitation. The conveyor can be reassembled after cleaning almost as easily as taking it apart.” While the snack food and bakery markets are relatively new to Dynamic Conveyor, Bartka says there are great opportunities. “Educating processors on these new options in conveying that weren’t available just a few months ago is exciting for us and the processors. We’re
Photos courtesy of Weldon Solutions
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Special Report Package Handling Systems eager to educate them on the fact that they can reduce their costs of conveyor ownership with a quick and easy-to-clean system that’s reconfigurable.” Partnering with Intralox, Harahan, La., Dynamic Conveyor will soon offer an option for Intralox’s ThermoDrive belts on DynaClean conveyors. “An innovative, patented technology, ThermoDrive is the first to combine the best features of modular plastic and traditional flat belts.”
Solving denesting difficulties Customers are also looking for solutions to difficult denesting tasks brought on by the need to reduce shipping costs. Because tray and clamshell package manufacturers are asked to reduce the size and weight of their denesting features, trays now nest closer together, making them even more difficult to separate, states Paul Grieger, inside sales for Axis Automation, Hartland, Wis. “Tray and clamshell manufac-
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turers need to be toms. “Trays can now have ridges able to make trays across the entire surface below with much smaller the product, which translates into denesting features, less product breakage and better or possibly even presentation,” he says. “Cookies none at all,” Griegor crackers can stay nested in the er says. “We’re seetray. And the denester’s design ing a sharp increase works well with trays that have in demand for our much smaller denesting features or AXIS denester, in some cases, none at all. Smaller which doesn’t denesting features means that trays use conventional nest closer together. That’s ultidenesting methods.” mately better for the environment. Launched in Less space between trays means the spring, the fuel savings because there are AXIS denester was fewer cases to ship for the same developed to answer quantity of trays or clamshells.” Photo courtesy of Axis Automation the call of rising Grieger agrees that sanitation is fuel surcharges, increasing labor costs and always an issue. “A stainless-steel construca demonstrated need to perform without tion makes cleaning and sanitation much suction cups. It denests difficult containers easier. And easier changeovers are also very such as certain foam structures. Because important. High performance is always a of this, trays don’t need to have flat botContinued on page 35
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Special Report Package Handling Systems Continued from page 33
requirement as well. A denester can be well built, easy to clean and a real bargain, but if the machine isn’t up to the task at hand, it’s going to be moved to a dark corner where it will sit and gather dust.”
Display-worthy and enviro-friendly
Display-ready packaging that significantly reduces labor costs when stocking shelves is also seeing big demand at Eagle Packaging Machinery, Miami. “Another trend we see is packaging that’s environmentally friendly—using less packaging to reduce the overall packaging footprint,” says John Brown, sales and marketing coordinator for Eagle. “Our POLOK tray former uses no glue or tape, which facilitates recycling. Customers also look for machines that can pack or form different tray sizes and are fast and easy to change over. The flexibility of the POLOK tray former allows us to accommodate various tray-size ranges unique
to each customer.” all functions are controlled with The former crea PLC color touchscreen. Also ates one- and twousing vacuum technology is Eagle’s tuck, multi-tuck and Z.ZAG palletizer, which automatiintricate trays, with cally picks up one or two cases and or without a lid, in places them on a pallet. The system small and large-size can be used with several producformats. “Secondtion lines. ary packaging that “There’s another trend in doesn’t touch the the industry to lighten the conproduct directly, tainer board without sacrificing productivity is the required strength and integrity paramount,” Brown needed, all of which will influence Photo courtesy of Eagle Packaging Machinery the future designs of equipment,” adds. In addition, the Boxxer Auto Lock case Brown points out. “Today, we see more need erector uses no tape or glue when erecting for equipment that’s simpler for operators to RSC/HSC-style cases with auto-locking botlearn and use and for maintenance staff to toms. Built with a low maintenance mechani- service.” cal drive, a heavy-duty welded steel frame Regardless of what’s being packaged and interlocked safety gates and doors, the and shipped, this and many other package Auto Lock provides quick-size changeovers handling systems are being designed to fill in a compact footprint. Venturi vacuum the bill on baker and snack manufacturer technology is used to erect the trays, and needs. SF&WB
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Ingredient Technology Heart Healthy & Weight Management
Keeping Weight Management Real Many ingredient suppliers are stepping up with heart-healthy, weightmanagement solutions that allow consumers to indulge without the guilt. Marina Mayer, Executive Editor
hese days, maintaining a heart-healthy diet is top of mind for most consumers. Whether it be a routine of vitamins and antioxidants, a clean-label, low-sodium product or protein options that also serve as weight-management tools, many of today’s ingredient suppliers are “keeping it real” through a host of better-for-you introductions. “Consumers want nutritious, natural, minimally processed foods that pack a huge punch of healthy and an equally impressive dose of delicious,” says Philippe Caillat, senior director of marketing for Solazyme Roquette Nutritionals (SR Nutritionals). “Bakers and snack manufacturers continue to look for innovative ingredients that can help decrease the use of saturated fats, eggs, milk and other high-calorie,
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high-cholesterol ingredients often found in today’s packaged foods.” That’s why in January 2012, the South San Francisco, Calif., company will introduce a whole algalin flour that contains 50% healthy lipid with high-oleic content (similar to olive oil), natural phospholipids (similar to eggs), fiber and protein, Caillat adds. “The truly remarkable characteristic of this ingredient is its ability to function as more fat than it is, making it an outstanding solution for improving nutritional profiles in baked goods and snacks,” he adds. “For example, when formulators use whole algalin flour, they are able to make good-tasting finished products that contain 40-50% less fat without taste compromise. The finished product is significantly
Photo courtesy of Solazyme Roquette Nutritionals
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reduced in calories, saturated fat and cholesterol and retains exceptional taste, texture and functionality.” In July 2012, SR Nutritionals will launch a highly digestible whole algalin protein that contains 50% protein along with fiber, healthy lipid, micronutrients and a unique amino acid profile. “These characteristics combine to offer an innovative new source of vegetable protein that is so much more than just protein,” Caillat adds. Danisco USA’s PinVita phytosterols help to substantially reduce and control cholesterol, as well as act as a food and dietary supplement that’s suitable for allergen- and GMO-free items. PinVita, which is derived from a sustainable pine source, is available in free or esterified form for bars and other baked goods. Meanwhile, Danisco’s ActivK range of vitamins K2 MK-7 can be formulated into dietary supplements, come in powder and oil-based formats and are good for bars, bread and other bakery products. “Both PinVita and ActivK are backed up by a large body of research showing they are effective at improving health,” says Cathy Dorko, industry manager of bakery, fats and oils for Danisco, New Century, Kan. “Both products are extracted from natural sources, but the extraction process and downstream processing may preclude labeling as natural.” Whey protein is also an excellent source of protein, and is an all-natural solution that also helps to reduce fats in a variety of food applications, says Jeff Banes, applied Continued on page 38
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Ingredient Technology Heart Healthy & Weight Management Continued from page 38
cakes, cookies and muffins, Banes adds. “In a recent kitchen test, Grande Bravo was used to replace 50% of the cream cheese in a cheesecake application. In this trial, calories and fat decreased by 12% and 41%, respectively, while protein was increased by 150%. In a single-serving portion, fat grams were reduced from 17 g. to 10 g., while calories dropped from 227 to 199. At the same time, protein was increased from 4 g. to 6 g.,” he adds.
Skinny cooks actually can be trusted
Photo courtesy of Danisco USA
Continued from page 36
technology manager for Grande Custom Ingredients Group (GCIG), Lomira, Wis. For example, the Grande Bravo line of functional whey protein concentrates can be used to reduce the amount of high-fat ingredients, such as butter, eggs, cream cheese, cream and other dairy ingredients in cheesecake, cream/pastry fillings, frostings,
Ever hear that saying, “skinny cooks can’t be trusted?” Well, now they can. No longer are consumers left with the unruly task of managing their weight. That’s because many of today’s ingredient solutions do that automatically. So says Corn Products International, Inc./National Starch Food Innovation. “When it comes to snack crackers and chips, consumers are looking for good-foryou options with better eating sensations and flavors without compromising taste and texture,” says Patrick O’Brien, marketing manager, bakery for Corn Products/ National Starch. “They also want better
choices in healthy snacks, like reduced-fat, fiber-fortified and whole-grain options— for themselves and their children.” Corn Products/National Starch’s HOMECRAFT Create 765 is a clean-label, specialty wheat flour derived from a unique variety of waxy wheat that allows for the reduction of costly fat ingredients in indulgent baked goods, says O’Brien. “HOMECRAFT Create 765 can help improve nutritional profile by reducing total calories, calories from fat and grams of fat per serving,” he adds. “For example, in a standard industry brownie formulation, a 25% reduction in fat led to a decrease in total calories and calories from fat to 6 g. on a 28-g. serving.” The Westchester, Ill.-based company also helps bakers and snack manufacturers achieve low-fat, low-calorie claims that mimic full-fat, full-calorie counterparts through its Dial-In Texture Technology and Texicon food texture language. Under this technology, consumers can translate what they like and dislike about food texture into scientific attributes. For example, “creamy” is actually a multifaceted texture experience that results from differing intensities of at least 15 sensory and rheology attributes, such as mouth-coating, meltaway and oral viscosity. However, manufacturers face challenges in developing better-for-you products, which can vary depending upon the nutritional targets and desired finished product, says Cheryl Borders, technical service, edible beans for Archer Daniels Midland Co. (ADM), Decatur, Ill. That’s why ADM developed VegeFull, a line of cooked ground bean powders used in extruded and sheeted snacks, crackers, cookies, nutritional bars, tortillas and baked goods. This clean-label powder is also minimally processed using a solvent-free approach, making it an ideal solution to maintaining a healthy weight and preventing obesity, diabetes and heart disease. “ADM’s VegeFull line of cooked ground bean powders and ingredients can be incorporated into snacks and baked goods to provide several better-for-you
Photo courtesy of Grande Custom Ingredients Group
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Photo courtesy of Archer Daniels Midland Co.
choices,” Borders says. “Compared to traditional cereal grains, beans contain more protein and fiber. Protein and fiber can help in slowing digestion and providing energy over a longer period of time, which may help in reducing overall caloric intake and in weight management.” Walnuts are also a recommended weight-management aid, as they are said to be a good source of antioxidants, vitamins, fiber and protein, according to Jennifer Getz Olmstead, marketing director, domestic for the California Walnut Board and California Walnut Commission, Folsom, Calif. “[Walnuts are] the only nut that provides a significant amount of the plant-based Omega 3 fatty acid alpha-linolenic acid (ALA),” she adds. “Walnuts can help in weight management. Due to their delicious flavor and satiating effect, individuals who consume walnuts regularly do not exhibit weight gain and report feeling content.” Plus, the American Heart Association, Dallas, recently announced Continued on page 40
Photo courtesy of California Walnut Board
Ingredient Technology Heart Healthy & Weight Management Continued from page 39
its certification of walnuts as a heart-healthy food that can easily be identified with the heart-check mark, says Getz Olmstead. “The heart-check mark identifies foods that meet the nutritional standards set by the American Heart Association and provides consumers a quick and reliable way to identify heart-healthy foods,” she adds. When it comes to snacking, almonds are said to be a consumer favorite, according to Harbinder Maan, manager, North America ingredient and category marketing for the Almond Board of California. In fact, the Modesto, Calif., company “works with research chefs to develop and maintain an extensive database of almond recipe solutions for almost any product formulation, particularly in the key categories of cereal, snacking and chocolate,” Maan adds.
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Photo courtesy of Almond Board of California
Case in point: A 1-oz. portion of almonds provides 6 g. of protein, 13 g. of fat, only 1 g. of saturated fat and 3.5 g. of fiber—elements that are known to give people that “full” feeling they crave, she notes. Thankfully, the future is bright for products that offer heart-healthy and
weight-management benefits, such as those items rich in whole grains and fiber, says Brian Sorenson, director of manufacturing operations for Dakota Specialty Milling Inc., Fargo, N.D. “There is a continuous stream of reports of nutritional studies that inform the consumer of the health benefits of a diet rich in whole grains and high in fiber,” he adds. “The development of countless new products in this segment reflects the commitment of food companies in providing healthy products, not only in the retail grocery, but also for restaurant, foodservice, military and school lunch programs.” Regardless if it’s a sweet and savory snack or a succulent slice of cheesecake, many of today’s ingredient offerings deliver that heart-healthy, weight management solution consumers crave to stay fit without sacrificing foods they love. SF&WB
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Ingredient Briefs
Glanbia Nutritionals unveils OptiSol 2000, a binding system that reduces sugar by up to 50%, providing a highly desirable alternative to lecithin and other binders for bars, the company says. OptiSol 2000 is also said to maintain high-performance emulsification properties without the costs associated with alternative emulsifying agents that contain high levels of sugar. Glanbia Nutritionals Fitchburg, Wis. 800-336-2183 www.glanbianutritionals.com
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Kemin’s Shield brand antimicrobial system is a mold inhibitor specifically designed for tortilla products. This liquid, concentrated, non-corrosive preservative keeps products looking great, tasting delicious and staying fresher longer. Kemin Food Technologies, division of Kemin Industries Des Moines, Iowa 866-253-9579 www.kemin.com
TIC Gums introduces the Ticaloid GR 5420 blend of gums, which completely replaces guar in bakery products such as cake, bread, bagels and muffins. This proprietary blend delivers the same texture benefits as guar gum, but without the threat of supply interruptions or price instability. Ticaloid GR 5420 can be used in amounts of 2-5 oz. per 100 lb. of flour. TIC Gums White Marsh, Md. 800-899-3953 www.ticgums.com
View videos demonstrating the newest bakery & snack food ingredients by visiting
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Supplier Standpoint
Creating Connections Through Consumer Insights onsumers are bombarded with hundreds of product messages every day. How do businesses ensure that their products are reaching the right target audience with a relevant message? Without knowing the consumer and what their motivations and needs are, valuable time and money are wasted. In our current economy, this is not something most businesses can afford. Identifying what matters most to the consumer can build a bridge between a product and the consumer, ultimately increasing sales. Caravan Ingredients creates this connection for the consumer, which can be achieved through consumer insights.
during the shopping occasion. The good news is that more retailers and suppliers are starting to understand the value of consumer insights. Businesses that focus their efforts on the consumer will likely be the big winners.
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Understanding the consumer All shoppers are not equal. In order to begin identifying strategic growth areas, consumer groups must be identified. Understanding the consumer and shopper is the first step in solving problems and identifying strategies. Four key questions to ask are: 1. What is the value of each consumer segment? 2. What are the demographics and lifestyle elements of these consumers? 3. How are they different from other consumers? 4. What are the key motivations for purchase? Developing a deep understanding of the consumer is an ongoing process. Businesses need to immerse themselves in their consumer’s lives whenever possible. Because consumers often verbalize how they want to shop and/or purchase in a category, immersion with the core consumer helps to better identify stated behaviors versus actual purchase behaviors. Ultimately, a deeper understanding of this consumer will cut to the core what matters most to the consumer. This knowledge will enable a business to identify opportunity areas and develop and position their products more effectively.
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Applying insights to your business
The why behind the buy Data alone is not an insight. Leveraging data to understand consumers’ needs and providing a solution to that need is the objective. There are numerous syndicated data sources available to identify market trends and individual product performance. However, to truly begin to understand the consumer in a specific region, primary or proprietary research is a must. For example, pick up any paper today and it will mention health and wellness in the United States. Syndicated data can confirm this trend, but the “why behind the buy” is only discovered by engaging with consumers through primary research. Knowing that health and wellness is an overall trend is important, but being able to dig deeper and to identify what that means for a business’ core consumer will help to identify potential areas for new opportunities.
Supplier input with consumer insights In a consumer-centric economy, retailers and suppliers must be willing to discuss and share consumer insights. By using these insights, suppliers and retailers can work together to create the optimal product assortment and a captivating shopping experience. Suppliers must create and provide products that meet a consumer need, and retailers must create the best overall consumer experience by having the right products available at the right time, with the right value
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When a business incorrectly identifies their consumer, it greatly impacts their potential business. Imagine that a business based on previous experience identified its core consumer as families with a female head of household, age 35-44 years old. This same business could discover through use of syndicated household panel data that their consumer is actually a one- to two-person household with an age greater than 60 years old. Just by discovering this fact alone, a business can identify products that would have stronger appeal to a smaller household with older consumers versus the products they originally offered. This serves as a reminder that just like consumers, manufacturers, suppliers and retailers are getting hit with numerous inputs on a daily basis. It is important to stay objective and leverage consumer insights not only to inspire product development but to also validate marketplace actions. Many suppliers are in a position to help their customers obtain the valuable information that consumer insights bring to the table. Businesses are encouraged to reach out to their suppliers for help in understanding the current and future state of the market and to confirm who their core consumer really is. In doing so, businesses can feel certain that they are selling the right product, at the right time, to the right consumer. Marge O’Brien is the consumer insight manager for Caravan Ingredients, Lenexa, Kan., and is certified through the Category Management Association. O’Brien can be reached at
[email protected].
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Engineering Management
Another One Bites the Dust nother year, that is. We are beginning to bring down the curtain on another challenging season for our country and our industry. The economics of our world are still on a roller coaster ride, and the housing market makes it tough for anyone to make a move. And here we go again with another batch of presidential promises from a gang of “not-so-ready-for-primetime” candidates. Next year should be fun. Over the past 12 months, our industry has seen its share of interesting moves and shakes. We’ve seen the big guys get bigger and the small guys continue to hang on, despite of the big guys’ power. This has happened on the bakery side as well as the original equipment manufacturers (OEM) and allieds side. This year has been a year where positioning for the future has been taken very seriously. When thinking about the workplace, the challenges continue to be finding creative ways to automate processes that reduces headcount, finding people who will work hard and strive to grow and searching for even stronger manufacturing efficiencies that reduce cost inputs, so that the price of products can still be tolerable to the buying public and so that companies can remain competitive. On the automation piece, we’ve seen advancements and developments from the equipment manufacturers for many years. We always get a closer look at these next greatest ideas at IBIE every three years, and we occasionally implement what we find, only to see the next step in progress three years later. Part of the challenge for bakers is that while they can see their way to investing in automation once in a while, they can’t see doing it every third year. While a company might have their process up to automation standards three years ago, the company that waited and implemented is now three years ahead and possibly more competitive. Equipment manufacturers design and
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build equipment and bakers bake. The day that an OEM brings a baker into their ideation sessions, the better they will be in reading the minds of the dough side of the industry. As an organization, BEMA, Overland Park, Kan., has touched on this with its Baking Industry Forum, but there is a ways to go. Working together will do two things. First, it will keep mechanical automation ideas relevant to the needs of the bakers, and second, it will help the ingredient operations develop better ways for a baker to handle and use their products. The “people factor” still seems to be an issue where challenges continue to slow overall progress. Whether we are talking about production workers, supervisors or managers, finding the right people for the job is difficult. Developing current people to modernize ideas has also seemed to take a back-burner approach. In the past, companies would give bakers and mechanics additional training, but there continue to be roadblocks, such as not having backup for such individuals during training and the cost of training. Folks at the American Institute of Baking, Manhattan, Kan., will tell you that the ratio of foreign students to U.S. students is very troubling. If bakers don’t find ways to develop the talent they have, companies may find themselves stuck in old-fashioned ways. The only way you can take an experienced person in an operation and improve their ways is to get them out of the house so they can see what’s going on in the outside world. To accomplish this, you must bring the outside world to them in the form of hiring teachers or consultants who can teach development tactics in-house. The final piece of the equation is the production efficiencies that drive cost avoidance and price reduction. It’s tough enough to have products on the shelf in just the right place, but if they have the wrong price, you have a double negative hit. The automation challenge, coupled
Jeff Dearduff
[email protected]
with the people challenge, can often create an efficiency challenge. Inefficient equipment operated in oldfashioned ways doesn’t equal the level of competitive pricing that comes with that ever-welcomed element called profit. Plant efficiency really depends on that combination of the appropriate level of automation and the right people who are developed. Going into 2012, the industry has opportunities for everyone to get up on their feet and make a change. As chairman of the American Society of Baking, Swedesboro, N.J., I would like to take a minute to remind everyone that the annual BakingTech conference is being held March 4-7, 2012. This conference will touch on many of the ideas discussed in this article. We will double the number of breakout education and information sessions, keynote speakers will supply methods and strategies for workplace improvement and we’ll again offer the Marketplace, where bakers can mingle with OEM’s and allied’s, sharing ideas that bring efficiency to the forefront. The theme for the conference is “Rise Up, in Community, in Industry, in Workplace and in Self,” and I encourage you to rise up and find your way to the meeting. I personally look forward to seeing you there. SF&WB
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Production Technology Laminators & Sheeters
Built for Perfection Today’s laminators and sheeters are designed to deliver state-of-the-art attributes that meet operators’ needs and bakers’ demands. Marina Mayer, Executive Editor
roducing the perfect puff pastry takes a lot of skill, patience and operator knowhow. It also takes a premium formula, precise measurements and stateof-the-art equipment that delivers accuracy, flexibility and automation. In addition, today’s laminating systems have to be able to perform multiple tasks, be stress-free and be able to grow with future needs, says Rich Breeswine, general manager of Koenig Technology, Inc., Richmond, Va. “In the past, you would have one system to do yeast-raised donuts, another for puff pastries and Danish and then a different line for flatbreads, baguettes, pizza, etc.,” he says. “This would mean a multitude of lines in different rooms and a larger production staff needed for each product.”
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That’s why Koenig created the Menes line of laminators and sheeters for loaf bread, baguettes, ciabatta, pizza, donuts, sheet cakes, croissants, strudel, pita and flatbread. “The core feature of the Menes [line] is represented by the so-called ‘Twin Sat,’ which grants a minimum stress and force to the dough belt while being reduced in thickness,” says Breeswine. “In combination with several other modules, the Koenig Menes line offers the highest weight accuracy along with perfect artisanal and stress-free product quality.” Meanwhile, Rademaker USA installed new methods of continuous laminating for highspeed applications and dough capacities up to 25,000 lb. per hour, says Eric Riggle, vice president of the Hudson, Ohio, company.
Photo courtesy of Koenig Technology, Inc.
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Many of today’s laminators and sheeters come equipped with stateof-the-art features that meet operators’ needs and bakers’ demands. “Some laminating systems utilize a stop-and-start method to create the laminations. These are discontinuous styles of laminating, where the dough sheet is stopped during the pull-back or retraction,” he adds. “With high speeds or soft dough applications, the loop of dough that is created cannot often be pulled out when the conveyor starts moving again, causing production and quality issues. We have corrected this with a continuous running buffering system that does not stop and start the dough sheet.” Furthermore, Canton, Mass.-based Reiser’s Vemag line now encompasses a single-lane sheeting system that combines a Vemag portioner with a rotary sheeter attachment to reduce hand labor and automate production lines. “The rotary sheeter can be used to extrude all types of portioned doughs, fats, toppings and batter for panning applications,” says John McIsaac, vice president, Continued on page 46
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EFFICIENT EQUIPMENT FOR BISCUIT PRODUCTION
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Depositing, Extruding and Wire-Cutting System V60 The new V60 system is designed for single, twin or triple depositing as well as for wire cutting and extruding. modified extrusion head allows to process both semi-liquid batters, soft deposited dough, very stiff dough, chocolate fillings for pralines and even low fat products very short distances between feed roller and pumps ensure gentle dough handling and improved weight accuracy across the entire working width brand new pneumatic fixing system for easier operation and shorter downtimes www.haas-meincke.com
Production Technology Laminators & Sheeters Photo courtesy of Rademaker USA Photo courtesy of Reiser
Continued from page 44
strategic business development. “It can also extrude continuous sheets of product onto makeup lines.” The rotary sheeter can also be used for margarine sheeting, McIsaac adds. “Extruding continuous, precise and
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consistent sheets of margarine or other shortening onto moving lines is easily accomplished,” he says. “The fat/ dough ratio remains constant, resulting in uniform quality and achieving exact calorie counts.” Reiser also introduced a small diameter pumping system that offers precise flow of shortening and margarine on lamination lines. This helps keep calorie counts accurate and brings consistency to the process, McIsaac says. “From our perspective, the application of the shortening or margarine must be accurate. Calorie counts are so important today and must be accurate for nutritional fact labeling,” McIsaac says. “Also, the system must be versatile enough to handle different fats and be easily adjustable. The Vemag easily handles all type of products
and viscosities. With just the push of a button, the pre-programmed Vemag can easily switch over from one product recipe to another.” Creating the perfect product doesn’t have to be a grueling process. Many of today’s laminators and sheeters come equipped with state-of-the-art features that meet operators’ needs and bakers’ demands. SF&WB
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Equipment Briefs 3M’s industrial adhesives and tapes division presents 3M water-activated tapes and tape dispensers. Available in white
A-B-C introduces Model 450, a high-speed case erector that seals with a new soybased adhesive for a sustainable alternative to traditional petroleum-based hot melt. Designed for speeds to 55 cases per minute, reliable mechanical operation and a servooperated sealing ram, this case erector helps packagers increase productivity while the new Liquamelt adhesive from H.B. Fuller, St. Paul, Minn., reduces costs. A-B-C Packaging Machine Corp. Tarpon Springs, Fla. 800-237-5975 www.abcpackaging.com Charles Ross dual-shaft mixers are suitable for processing pastes, gels, suspensions, slurries and other viscous formulations. The highspeed disperser draws powders into a liquid batch through a powerful vortex and rapidly disperses any lumps and agglomerates. The low-speed anchor agitator promotes bulk flow and uniform batch temperature, “feeding” the disperser blade with fresh product while constantly scraping vessel surfaces. Charles Ross & Son Co. Hauppauge, N.Y. 800-243-7677 www.mixers.com Hinds-Bock’s servo-driven pump fillers are designed for high-speed accurate
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spreading of products, as well as depositing and filling applications. Custom spouts are used to match the spread width and length for the application. A single machine can run up to 160 units per minute, depending on the product and application. Machines are available in single- or multiple-lane versions. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com
and kraft colors, this tape is designed to create a secure bond when the moistened adhesive interacts with porous surfaces. The tape forms a tamper-resistant seal that shreds if pulled off before delivery. The coreless rolls reduce waste and simplify roll changes. 3M St. Paul, Minn. 800-362-3550 www.3m.com/packaging
Unifiller’s spot depositor features a userfriendly design that deposits directly from the bowl and delivers simple and accurate portioning. This versatile machine also allows quick cleanup for changeover of various products. Unifiller Systems, Inc. Delta, B.C., Canada 604-940-2233 www.unifiller.com
tna debuts the intelli-scan 2 comprehensive date-code assurance system, designed to process images through its camera to ensure that the date code is printed, complete and legible. This system is suitable for a range of print requirements, can handle both light and dark texts and produces exposure times of less than 0.5 ms and speeds up to 200 bpm. Also, the new intelli-read 3 integrated bar-code scanning system automatically scans a bar code on film and cross checks to verify that the correct product is being processed. tna North America Coppell, Texas 972-462-6500 www.tnasolutions.com
View videos demonstrating the newest bakery & snack food equipment by visiting www.snackandbakery.com
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Snack Food Today Jerky Makers Release All-Natural Formulas ith products made from all-natural ingredients being the talk of the food industry circuit, it’s no surprise that some snack manufacturers hopped on board to deliver better-foryou items. Thanasi Foods, LLC, is no exception to the rule. That’s because the Boulder, Colo.-based jerky maker announced the conversion of its DUKE’S brand of beef jerky, steak strips and beef brisket strips to include all-natural ingredients. The switch also includes the removal of hydrolyzed soy protein, MSG, erythorbate and sodium nitrites. This revamped recipe will be available starting first
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quarter of 2012. “We are making a better-for-you product that carries delicious flavor from ingredients found in America’s kitchens,” says Justin Havlick, president and founder. “This initiative keeps up with DUKE’S small-batch promise to make jerky the way it should be made—in small batches with simple and clean ingredients.” Meanwhile, Oberto Brands launched an allnatural jerky line under its Oh Boy, Oberto! brand that’s made from simple, all-natural ingredients and is free of preservatives and artificial ingredients “Jerky has long been a
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Snack Food & Wholesale Bakery - December 2011
popular high-protein snack, but most products on the market contain a lot of artificial ingredients—the main ones being hydrolyzed vegetable protein and corn syrup—so they really weren’t all that good for you,” says Tom Ennis, chief executive officer of Oberto Brands, Kent, Wash. “It’s simple—when you use more pure, wholesome ingredients, you get a better product with better taste.”
Nobody Likes Kettle Brand Chips, They Love Them iamond Foods, Inc. is launching a new marketing campaign to expand national awareness of its Kettle Brand potato chips. “For almost 30 years, Kettle Brand growth has been fueled by word-of-mouth advocacy,” says Craig Tokusato, vice president of marketing. That’s until the Stockton, Calif., company devised the “Nobody Likes Kettle Chips. They Love Them.” campaign, which kicked off with 15- and 30-second national TV spots, print advertisements, public relations, in-store marketing and digital advertisements. “This campaign is about the unique passion and love people feel for Kettle Brand chips,” Tokusato says. “We were inspired by real consumers describing the extraordinary lengths they go to during ordinary moments to get, save and enjoy their favorite Kettle Brand chips.” In conjunction with the campaign, Diamond Foods is giving away 30,000 bags of Kettle Brand chips to honor its upcoming 30-year anniversary. Fans who register at Kettle Brands’ Facebook page, www.facebook.com/KettleBrandChips, will receive a coupon in the mail for a free bag, while supplies last.
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EQUIPMENT FOR SALE
S PREVENT PRODUCT RECALL 3 P PRODUCTS, R O D U CTS, 1 SOLUTION Switching to Plastic Pallets ·
Improved hygiene, cleaning and sanitizing for WIP areas
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Chemical & blood resistant
PlasticPallet.com
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Non-porous
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Substantially longer life compared to wood pallets
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Improves efficiency in handling
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Transfer raw ingredients and packaging materials to a hygienic pallet for in house use.
Pallet Inverter ·
Simple 180 degree inversion to recover damaged bags for Good Housekeeping and GNP.
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Straighten poorly stacked or tilted loads which can become a safety hazard.
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Exchange finished product from in-house pallets to rental pallets or slip sheets.
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Cleans wood, plastic & aluminum pallets, totes, containers and freezer spacers
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Minimizes the risk of introducing Salmonella, E-coli, Listeria, Allergens, dust, dirt and other contaminants
PalletInverter.com
Pallet Washing System
#HERRYgS )NDUSTRIAL %QUIPMENT #ORP s 600 Morse Ave., Elk Grove Village, IL 60007
800.350.0011 s www.Material-Handling.com
PalletWasher.com
Designed to dissolve solids or semisolids where time, temperature and complete hydration are important. Ideal for: • Salad Dressings • Ice Cream mixes • Candies • Reconstituted products
• Canned condiments • Sauces • Fillings • and more
Process stabilizing gums, emulsifiers, flours, cocoas, yeast, powdered eggs, starches, condiments, caseinates, juice concentrates, food purees, whey solids, frozen products, cheese slurries and more in just a few minutes even at high concentrations.
a division of
1230 Taney North Kansas City, MO 64116
[email protected] • www.breddo.com
800-669-4092
www.snackandbakery.com
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EQUIPMENT FOR SALE
CUSTOM TANKS & PRESSURE VESSELS In Stock!
Empty Pan Dollies Durable galvanized steel with heavy-duty 5” dia. casters.
EPD 1826-200
s s s s
3HIPS 503 %ASILY ASSEMBLED %RGONOMICALLY MOVE AND 3TORE 0ANS 6IEW /N /UR 7EBSITE
EPD EP PD 1826-100 182
Vessels, reactors and storage tanks designed to meet your special requirements! • 2 ASME Certified plants in the USA • USFDA, BISSC, ABS, API and UL code requirements • 316 and 304 stainless steel, and many alloys Call Ross today!
1-800-524-ROSS www.storagevessels.com
www. 1-800-834-8125 www.shopcraftracks.com
SnackandBakery .com
USED WALK-IN-COOLER-FREEZERS REFRIGERATION SYSTEMS – EQUIPMENT HUGE INVENTORY, ALL SIZES Buy Sell - Nationwide - Wholesale Prices
Tel. 216-426-8882 www.awrco.com
[email protected]
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Snack Food & Wholesale Bakery - December 2011
www.snackandbakery.com
EQUIPMENT FOR SALE
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] www.snackandbakery.com
December 2011 - Snack Food & Wholesale Bakery
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EMPLOYMENT
Direct leadership of 2nd shift operations - 125 employees. Responsible for meeting customer orders, at standard cost or better, while protecting the safety of our employees and product. Demonstrable leadership skills, 5+ Years commercial bakery experience, degree preferred, six sigma, lean manufacturing, or continuous improvement skills desired. Qualified applicants send resume to
[email protected]. Please, no recruiters. Professional search fees will NOT be honored.
TO THE TOP " !
SUZANNE SARKESIAN @
[email protected] or call 248.786.1692
Snackandbakery.com
Check Out ‘Our Views’ Missed our columns in print? No worries. You can beat the presses by reading Snack Food & Wholesale Bakery’s columns online in the “Our Views” section of www. snackandbakery.com. Between front-of-pack labeling and gluten-free products, editor-inchief Lauren R. Hartman covers all of the hot topics pertaining to the snack and bakery markets in her “Editor’s Note.” Meanwhile, executive editor Marina Mayer’s “The Final Word” comments on the state of the industry, sometimes from a consumer standpoint. Contributing columnist and chairman of the American Society of Baking, Jeff Dearduff, gets down and dirty with “Engineering Management,” tapping
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Snack Food & Wholesale Bakery - December 2011
into dozens of practical, problem-solving tips and suggestions from a working bakery engineer’s point of view. Also, contributing columnist Judi Adams, president of the Grain Foods Foundation and the Whole Wheat Council, offers news on grain-related issues. While on our site, users can sift through an assortment of new products, breaking news items or read the latest in production and ingredient technology. And don’t forget to subscribe to the site’s RSS feeds, so you can remain on top of the news at all times. To advertise with Snack Food & Wholesale Bakery, on its website or in the free e-newsletter, Operations Weekly, please contact publisher Jeff Heath at
[email protected] or sales manager Barb Szatko at
[email protected].
www.snackandbakery.com
Ad Index Company Website
Page
Company Website
Page
Company Website
Page
AAF International . . . . . . . . . . . . . . . 33 www.AAFINTL.COM
Koenig Bakery Systems . . . . . . . . . . 35 www.koenigusa.com
Puratos . . . . . . . . . . . . . . belly band, 13
ALIT SRL . . . . . . . . . . . . . . . . . . . . . . 41 www.alit.com
Kwik Lok . . . . . . . . . . . . . . . . . . . . . . IFC www.kwiklok.com
QualiTech . . . . . . . . . . . . . . . . . . . . OBC
Almond Board of California . . . . . . . 37 www.AlmondBoard.com
LeMatic Innovation . . . . . . . . . . . . . . 39 www.lematic.com
Rademaker USA, Inc. . . . . . . . . . . . . 21
www.puratos.us
www.qualitechco.com
www.rademaker.com American Society of Baking BakingTech 2012 . . . . . . . . . . . . . . 34 www.asbe.org Blue Diamond Growers . . . . . . . . . . . 7 www.bluediamond.com Ford Commercial Trucks . . . . . . . . . . . 9 www.ford.com/commercial-trucks
Loders Croklaan . . . . . . . . . . . . . . . . . 5 www.croklaan.com
Reiser . . . . . . . . . . . . . . . . . . . . . . . . . 25 www.reiser.com
MINSA . . . . . . . . . . . . . . . . . . . . . . . . . 1 www.minsa.com Shurtape . . . . . . . . . . . . . . . . . . . . . . 27 Moline Machinery LLC . . . . . . . . . . . 40 www.moline.com
www.shurtape.com
Snack Food Association
Haas-Meincke . . . . . . . . . . . . . . . . . . 45 www.haas-meincke.com
Northwest Food Processors Association Expo . . . . . . . . . . . . . . 46 www.nwfpa.org
Intralox . . . . . . . . . . . . . . . . . . . . . . . . . 3 www.intralox.com
Novozymes . . . . . . . . . . . . . . . . . . . . . .IBC www.acrylaway.com
J.C. Ford Company . . . . . . . . . . . . . . 23 www.jcford.com
Pendleton Flour Mills . . . . . . . . . . . . 48 www.pfmills.com
SNAXPO 2012 . . . . . . . . . . . . . . . . 14 WWW.SNAXPO.COM
Tate & Lyle . . . . . . . . . . . . . . . . . . . . . 15 www.splendasucralose.com
Tate & Lyle . . . . . . . . . . . . . . . . . . . . . 17 www.tateandlyle.com
Reader & Marketing Services LETTERS
REPRINTS
PRINT & INTERNET
Lauren R. Hartman
Jill DeVries
ADVERTISING
Snack Food & Wholesale Bakery
E-mail: devriesj@
Jeff Heath
155 Pfingsten Road, Suite 205
bnpmedia.com
E-mail: heathj@
Deerfield, IL 60015
T: (248) 244-1726
bnpmedia.com
E-mail: hartmanl@ bnpmedia.com SINGLE COPY SALES/BACK ISSUES Ann Kalb T: (248) 244-6499
T: (224) 554-9154 LIST RENTAL Postal contact:
Barbara Szatko
Kevin Collopy
E-mail:
[email protected]
800-223-2194 x684;
T: (630) 527-9927
BNP Media 155 Pfingsten Road, Suite 205, Deerfield, IL 60015 Phone: (847) 405-4000 Fax: (847) 405-4100
[email protected]
E-mail:
[email protected]
CLASSIFIED ADVERTISING
CUSTOM MEDIA
Email contact:
Suzanne Sarkesian
Chris Wilson
Michael Costantino at
E-mail: sarkesians@
E-mail:
[email protected]
800-223-2194 x748;
bnpmedia.com
T: (248) 244-8264
[email protected]
T: (248) 786-1692
www.snackandbakery.com
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
December 2011 - Snack Food & Wholesale Bakery
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The Final Word
More Than Meets the Eye or years, packaging innovations have taken a backseat to new product development and plant enhancements. However, more and more bakers and snack producers are learning that consumers tend to judge a package by its “cover,” so to speak. That’s why they’re creating packaging concepts that “talk” to consumers; that convey a “please pick me up” message. The new packaging for MATADOR beef jerky, for instance, incorporates a “reinvented communication and design strat-
F
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Snack Food & Wholesale Bakery - December 2011
egy, built to better resonate with our millennial target consumer,” says Mark Catlin, director of marketing for the MATADOR brand. Produced by Jack Link’s Beef Jerky, Minong, Wis., the MATADOR brand comes in eye-catching packaging that incorporates an on-pack quick response (QR) code, allowing consumers to access fresh, engaging and relevant content. “MATADOR beef jerky was launched by Jack Link’s with the idea of offering a truly differentiated product (tender jerky) to a differentiated meat snack consumer (millennials),” Catlin says. “Our target consumer research and initial sales results confirm that the new package design clearly meets our objectives with a 3:1 preference over previous design, an 89% purchase intent score, an 85% uniqueness score and strong initial sales performance.” Meanwhile, ConAgra Foods, Inc., Omaha, Neb., introduced two primary packaging differences for its Orville Redenbacher’s popcorn line. “The popcorn bag now comes with a separate seasoning packet, which allows consumers to control the flavor intensity of their popcorn,” says Jesse Spungin, vice president and general manager. “Also, on the individually wrapped 3.24-oz. single bags, the creative design is featured on the bag’s cellophane wrapper rather than an exterior box.” This packaging makeover came about because consumers voiced concern over wanting to control the flavor of their popcorn. “The flavor packet in Orville Reden-
Marina Mayer, executive editor
[email protected]
bacher’s flavors allows popcorn lovers to sprinkle on the preferred amount of seasoning to control the flavor intensity,” says Spungin. In October, John B. Sanfilippo & Son Inc., Elgin, Ill., owner of the Fisher nuts brand, introduced the Fisher Freshness Seal bag, which features a stand-up design and press-to-seal closure that locks in freshness and preserves the flavor and crunch of the nuts after opening, says Howard Brandeisky, vice president, global marketing, innovation and customer solutions. The stand-up bag consists of a flat, expandable bottom and a wide open top, making it easier and more convenient to scoop out nuts. Whether it’s inviting colors and graphics, an easy-to-open container or words that spell out ingredients, health benefits and more, the food industry is taking note—and taking shape—with new packaging innovations. SF&WB For more on these and other new packaging concepts introduced within the snack and bakery market, look for our special report on packaging innovation in Snack Food & Wholesale Bakery’s January 2012 issue.
www.snackandbakery.com
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