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full speed ahead Thanks to an increasing demand for tortillas and flatbreads, many of today’s equipment manufacturers are thinking—and creating—forward in a bigger, stronger and more versatile way. Marina Mayer, Executive Editor
F
or the past couple of years, the economic model of supply and demand has hit the equipment manufacturing community head-on. As tortilla and flatbread producers lowered their supply by scaling back on stock-keeping units, they also have lessened the ability to be innovative with their portfolios. And as they refurbished old equipment in hopes of making them last a bit longer, they simultaneously shied away from building, expanding or enhancing their facilities, even if it meant strengthening the bottom line. It’s almost as if tortilla and flatbread makers placed a bandage on their lines and walked away.
Now, they’re ripping off that Band-Aid with the help of their equipment suppliers by replacing old, tired equipment with new, state-of-the-art belts, dividers, rounders, sheeters, ovens, to name a few. The non-stick approach
One of the challenges that tortilla and flatbread producers face is creating a product that doesn’t stick to the equipment that bakes it. That’s why Taconic, Petersburgh, N.Y., developed a high-temperature, non-stick belt designed for pressing flour tortillas and flatbread. The A1127 belt lasts 25-30% longer than standard belts, according to Alberto Chavez, national sales manager, industrial Photo courtesy of Taconic products division, and it features a high-performance substrate with a proprietary polytetrafluoroethylene (PTFE)-based coating that is specifically engineered for abrasion- and punctureresistance. “Tortilla and flatbread manufacturers will continue to focus on the quality of their products,” Chavez says. “However, with the challenges of reducing costs and integrating sustainability programs, manufacturers will turn to higher-perform-
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ing and lower-cost equipment. Taconic offers longer-lasting belts, which reduce production downtime, leading to higher efficiencies and lower costs associated with belt changeovers. It also means less consumable items are entering landfills.” Running at full circle
To keep up with the ever-increasing demand for higher volumes, greater efficiencies, more advanced quality standards and ever-changing food safety concerns, J.C. Ford is continuously moving forward with new technologies, says Kyle Armstrong, sales manager. For starters, the La Habra, Calif., company introduced a new series of sheeters designed to improve weight control and thickness at higher speeds. “These new units are equipped with our new ‘cam force’ patent-pending weight control that provides much greater control at maintaining product weight,” Armstrong says. “With these high-speed lines controlling the weight of every tortilla to less than 0.2 g., customers can save more than $100,000 per year on product giveaway.” For both flour and corn tortillas, J.C. Ford released a 100% infrared (IR) burner oven that reduces energy needs by up to 30% and increases baking uniformity. “The flour tortilla lines have been equipped with our new ‘no-shim’ system,”
TORTILLA TRENDS
Photo courtesy of J.C. Ford
Illustration by J.C. Ford
Armstrong says. “Mounted over the top platen of the press is a series of adjusting knobs to make small changes in product sizing. This eliminates any need to drop plates or change shimming systems.” J.C. Ford also re-tooled its counter/ stacker with a new control system and a user-friendly touchscreen, Armstrong says, to provide more information at the touch of a button. “The control also includes a new auto reset for jams that keeps lines running and minimizes downtime. Because every packaging environment is unique, we have also increased engineering support for developing the most effective systems for each
TORTILLA TRENDS
customer,” Armstrong says. Meanwhile, companies such as Heat and Control, Hayward, Calif., provide an entire gamut of equipment specifically developed for tortilla and flatbread manufacturers. For corn tortillas, Heat and Control builds complete systems, including dry corn cookers, masa preparers, sheeters, ovens (and fryers for tostadas and taco shells), seasoning applicators, conveyors, checkweighers, metal detectors, x-ray and packaging equipment, says Caleb Reyes,
regional sales manager for processing systems. “Our recent developments emphasize producers’ needs for higher capacity, production flexibility and increased efficiency,” he says. For example, the company’s high-speed, high-capacity table tortilla systems are capable of producing up to 8,000 dozens per hour. Plus, Heat and Control’s Rotary Brander allows bakers to apply parallel grill marks to tortillas, sandwiches and more, Reyes says. “We also build directflame searers and infrared ovens that can produce unique surface finishes,” he adds. Appealing to the flatbread market
When all is said and done, the flatbread industry faces the same type of issues as others in the bakery market. That’s why Reiser launched a team of dividers and rounders that, “accurately divide over a wide range Continued on page TT-14
Photos courtesy of Heat and Control
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Continued from page TT-13
of absorbtions and viscosity. This gives the producers versatility as they develop new products,” says John McIsaac, vice president, strategic business development for the Canton, Mass.-based equipment manufacturer. Reiser’s Vemag dough divider, for instance, adds versatility, flexibility and accuracy to nearly any tortilla or flatbread production line. At the heart of the divider is the double-screw transport system, which enables positive displacement and exact-weight portions. Plus, it can handle up to 45-95% absorption rates. Additionally, Reiser’s Repak horizontal form/fill/seal packaging machines offer superior sanitary design, high production rates and maximum reliability. Made from heavy-duty stainless steel, they are engineered to meet the highest standards of hygiene and are designed for a quick and safe washdowns. And the rapid air forming
Photo courtesy of Reiser
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manufacturers are replacing old, tired equipment with new, stateof-the-art belts, dividers, rounders, sheeters, ovens, to name a few. system allows the use of thinner films while maintaining thickness in package corners, resulting in significant packaging material savings. Quality versus quantity
As far as the latest trends go, tortilla and flatbread machinery must come equipped with an assortment of hightech gadgets. “The future for tortilla and flatbread equipment is greater capacity systems that utilize automated controls to reduce human error and ensure consistent, quality products,” Armstrong says. “The next-generation equipment is being designed to not only reduce labor and scrap but also increase efficiencies and reduce the effects on the environment.” Corn tortilla producers are in search of higherquality products that deliver longer shelf life, while flour tortilla makers are churning out different types of ethnic-inspired products, Armstrong adds. “[For corn tortilla producers], it’s no longer just corn and water; today other ingredients are needed as well as improved baking
systems to provide softer more flexible products with extended shelf life,” Armstrong notes. “You walk down the bread section today and see Middle Eastern, Indian, Asian and other ethnic breads. Our systems are being designed to handle many types of flatbreads with one line giving the producer greater options.” Additionally, equipment must be versatile. “We are constantly working to keep our machines versatile with new dividing options and rounding techniques,” McIsaac says. “The producers will listen to their customers and develop what the market wants. We see all-natural and gluten-free as areas of growth. We also see specialty flavors that include inclusions such as pepper and onion.” Regardless of the bumps and bruises the tortilla and flatbread market endures, manufacturers continue to focus on the quality of their products, Chavez says. “The tortilla and flatbread markets will continue to grow in the coming years and flavor and quality will be the focus of this growth trend,” he adds. “It has been established that tortillas are a healthy, convenient and inexpensive food. Going forward, the winners will be those producers who present better flavor and higher quality in their products.” That’s why tortilla and flatbread equipment manufacturers are moving forward in a bigger, stronger and more versatile way.
SF&WB
TORTILLA TRENDS
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BatchPak™ delivery systems ensure consistency and control costs Liquid and dry preservative systems for all your tortilla needs Custom formulations and on-site technical service to meet your specific requirements Bake lab facilities and commercial grade tortilla manufacturing unit for continuous Quality Assurance and Product Development Innovative formulations, including clean label, trans fat free and organic Computer-aided dosing systems to ensure blending accuracy for critical ingredients
www.alliedblending.cOMs © 2011 Allied Blending & Ingredients. All rights reserved.
Market Trends Portion Control
Perfectly Portioned New single-serve and portion-controlled baked goods and snacks enable consumers to satisfy their cravings a little bit at a time. Romy Schafer, Contributing Writer
hen it comes to a favorite snack food, most people find it difficult to eat just the manufacturer’s recommended serving size. A dozen tasty potato chips or four chewy cookies quickly disappear when a person is snacking while watching television, at work or engaged in other activities. It’s easy to see how a 150-calorie treat can turn into a 1,500-calorie overload. Americans are now recognizing that when it comes to food, more isn’t always better. In fact, consumers are trying to be more cognizant of how much they eat—not just what they eat—and are seeking out foods, especially snacks, in single-serve and portion-controlled (usually 100-calorie) packages. Single-serve and portion-controlled baked goods and snacks offer consumers other benefits as well. A small bag of chips, cookies or freeze-dried fruit is more portable than a multi-serve bag and just the right size for a child’s lunchbox or an adult’s briefcase. Because people usually consume the entire contents of a single-serve bag, storage, freshness and waste aren’t issues. In addition, individual bags usually retail for
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$1-2, enabling consumers to inexpensively sample new flavors and products. Given all the advantages single-serve products have over their larger counterparts, it’s not surprising that more consumers are thinking small when buying snacks and baked goods. That’s why manufacturers are continuing to cater to consumers’ wants and needs by offering new treats in all snack categories. According to a Chicago-based Mintel study, “Diet Trends—U.S.—May 2010,” which is a report on diet and weight loss foods and trends, 63% of the 1,275
surveyed adults were interested in portioncontrol packaging. The percentages were even higher for respondents ages 18-24 (68%), 25-34 (68%) and 35-44 (69%), perhaps because people in these age groups often have children, therefore, are more likely to be interested in healthy eating.
For calorie counters Crumbly, cinnamon streusel topping and rich cinnamon filling will make calorie-counting consumers wonder if Weight Watchers coffee cakes really are a “better-for-you” alternative Continued on page 34
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Market Trends Continued from page 33
to their usual morning fare. Based on consumer feedback about the Weight Watchers product line and the sweet bakery category in general, Jackson, Mich.-based Dawn Food Products Inc., maker of Weight Watchers sweet baked goods, developed 120-calorie sweet treats. “Overall, consumers don’t want to compromise on taste to have a better-for-you treat,” says John Rzeszut, senior brand manager. Weight Watchers coffee cakes are individually wrapped and come four to a 5.5-oz. carton. “Wrapping products individually offers portion control, but also provides portability, allowing consumers to address a sweet craving without having to worry about sabotaging their weight-management plan when they’re away from home,” Rzeszut explained. The coffee cakes are sold at grocery stores and mass merchandisers nationwide at an average retail price of $3.49. Americans can be mindful of their caloric intake at lunchtime, too, by pairing their sandwich or soup with a singleserving size of baked potato chips, especially when they contain less fat and fewer calories than regular potato chips. Diamond Foods’ Kettle Brand now offers its 100-calorie bags
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of Kettle Brand baked potato chips in three varieties—Aged White Cheddar and Sea Salt & Vinegar, which were introduced in January, and Sea Salt. The Salem, Ore., snack producer developed the 100-calorie bags “to meet demand for healthier, convenient snacking options, which continues to increase significantly as more Americans seek healthier alternatives for snacking on the go,” says Julie Dunmire, marketing director. Kettle Brand’s all-natural baked chips are made with real, sliced potatoes, natural seasonings and all-natural oil. In addition, they contain no trans fats, MSG, artificial flavors or preservatives or genetically modified organisms (GMOs). The 100-calorie packs are available from Kettle Brand’s
online store in single-flavor 18-packs or 18-pack options, which retail for $15.99, or about 90 cents per bag. Consumers can also purchase them at in-store grocery delis, convenience stores, quick-serve restaurants and sandwich shops. Meanwhile, real kiwi slices and a hint of pure cane sugar are the only ingredients in Crispy Green Inc.’s FruitziO Kiwi freeze-dried fruit snacks, making them appealing to children and adults. Introduced in January, the crunchy, tart-yet-sweet treats join Strawberries and Applies, Apricots, Peaches and Strawberries. Unlike some 100-calorie snack packs, each 0.88-oz., resealable FruitziO bag contains about two and a half servings of product. “So even if [people] consume the whole bag in one go, it’s not a calorie overload,” says Angela Liu, founder and CEO of the Fairfield, N.J.-based company.
Individual FruitziO bags retail for $3.49, and can be found in supermarkets and stores that sell natural foods and on Amazon.com. For its part, Nature’s Own thin-sliced bagels and Nature’s Own Whitewheat sandwich rounds are great examples of portion-controlled bakery items, says Brent Bradshaw, brand manager for Flowers Foods Bakeries Group, Thomasville, Ga. “In our research, consumers told us that a regular-sized bagel was often too much for one serving, which led us to develop a thinner bagel,” Bradshaw says. “Unlike a
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Market Trends mini bagel, our thinner bagels are the same circumference as a regular bagel so they fit great in a toaster and can be used for sandwiches or mini pizzas. Nature’s Own thin-sliced bagels were first introduced in February 2010, but we improved both the formula and the packaging this time around.” These thin-sliced bagels are now thinner, lower in calories (110 calories each) and come in a convenient, resealable package. They also are available in Plain and 100% Whole Wheat with suggested retail price ranges from $2.89 to $3.09.
Let them eat cake “While research points to consumer interest in better-for-you products, we continue to see consumer interest in more indulgent snacks,” says Bradshaw. Shoppers who like to indulge in chocolaty treats, for example, will be eager to try two new items introduced under Flowers Foods’ Mrs Freshley’s and Blue Bird brands: Chocolate Bells, a crème-filled chocolate cake made with Hershey’s cocoa, and Chocolate Chip Muffins containing Hershey’s chocolate chips. “Partnering with one of the most recognizable brands in the confections industry was a great way to add excitement to our snack lineup and bring the great taste of Hershey’s to some of our chocolate snacks,” explained Bradshaw. Both products come in single-serve, two-count and six-count packs. Singleserve packs typically retail for 99 cents; multipacks sell for $2.99 to $3.19. Love and Quiches Desserts in Freeport, N.Y., a maker of chef-quality baked desserts, recently added two individuallywrapped products to its Gourmet Grab & Go line—L’il Lovers, which are moist, chocolaty brownies that come two to a pack with 100 calories per brown, and L&Q Blondie, a 3-oz. chocolate chip cookie bar, where one-half of the product constitutes a 180-calorie serving. “We don’t pretend to be anything other than decadent desserts,” says Andy Axelrod, president. “You can be healthy, work out and still indulge yourself.”
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L’il Lovers and L&Q Blondie have a 60-day shelf life, although they contain no preservatives. Both retail for $1.39 to $1.79 per pack and are available in full-color merchandisers that hold 12 two-packs. Axelrod recommends retailers place the products by their cash registers or self-serve coffee stations. “Those are the places that really result in the big sales for us,” he says.
A little bit of heat
restaurants that offer spicy dishes and specialty markets that carry hot spices and condiments. These consumers are likely to look for snacks with robust flavors, too, wherever they shop. When it comes to snacks, most people have a weak spot for a particular type of treat, be it for salty, sweet, spicy, baked or fried. Single-serve and portion-control products enable consumers to engage in a little guilt-free snacking. SF&WB
Chocoholics and cake lovers aren’t the only ones who will be able to savor new snacks this year. Those who like it hot— as in spicy—can add a little heat to their lunch with a single-serve bag of Herr’s hot sauce-flavored potato chips, produced by Herr Foods, Inc. The Nottingham, Pa.-based snack manufacturer partnered with TW Garner Food Co. of Winston-Salem, N.C., which is renowned for its Texas Pete hot sauce, to create the zippy, rippled chip, which is available in small bags at convenience stores, mom-and-pop stores, supermarkets and other outlets that carry Herr’s products. “There’s an appeal, in some areas of the country, for foods that seem to favor more heat and spice,” says Daryl Thomas, senior vice president of sales and marketing. In urban areas with thriving ethnic communities, for instance, people are regularly exposed to—and seeking out—
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New Products 2
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3
Company: Ozery Bakery, Toronto, Canada Website: www.ozerybakery.com Introduced: February Distribution: National Company: Tumaro’s Gourmet Tortillas, Suggested Retail: $3.69 for a Providence, R.I. 12.7-oz. package Website: www.tumaros.com Product Snapshot: Morning Rounds are Introduced: February toastable fruit and grain buns made with Distribution: National a variety of healthy grains and enriched Suggested Retail: $2.99 to $3.99 for an ingredients, such as dried fruits, seeds 8.5-oz. package and muesli. Designed as an alternative Product Snapshot: Inspired by the Big to muffins, donuts and pastries, this Apple’s delis, Tumaro’s introduces New better-for-you breakfast option comes in York deli-style wraps, an alternative Cranberry Orange, Apple Cinnamon and to deli-style bread. These 10-in.-wide Muesli varieties. wraps are 96% fat-free and cholesterol- Ingredients (Apple Cinnamon): free, are high in fiber and deliver less Unbleached wheat flour (wheat flour, than 100 calories. They come in Rye, ascorbic acid [natural dough condiPumpernickel, Sour Dough, Everything tioner], niacin [vitamin B-3], iron [ferrous and Cracked Pepper. sulphate], thiamin mononitrate [vitamin Ingredients (Pumpernickel): Water, oat B-1], riboflavin [vitamin B-2], folic acid), fiber, whole wheat flour, rye flour, wheat filtered water, whole wheat flour, natural gluten, rye meal, sourdough base (wheat apples, antioxidant-containing raisins flour, salt, malt, fumaric acid, acetic acid, (raisins, vegetable oil), organic evapolactic acid), canola oil, caramel color, rated cane syrup, sourdough (organic cocoa powder, molasses, calcium prounbleached flour [wheat flour, ascorbic pionate, caraway seeds, salt, aluminum- acid {natural dough conditioner}, niacin free baking powder (corn starch, {vitamin B-3}, iron {ferrous sulphate}, sodium acid pyrophosphate, sodium thiamin mononitrate {vitamin B-1}, ribobicarbonate, monocalcium phosphate), flavin {vitamin B-2}, folic acid], filtered monodiglycerides, lecithin, potassium water, organic evaporated cane syrup, sorbate, fumaric acid, xanthan gum, yeast, sea salt, sunflower oil), yeast, sea guar gum, sodium bicarbonate, sodium salt, sunflower oil, antioxidant-containing metabisulfite (to maintain freshness). ground cinnamon, wheat germ, cultured Contains: wheat. wheat starch, citric acid, enzymes.
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Soft & Chewy Gluten-free Granola Bars
Company: Bakery On Main, Glastonbury, Conn. Website: www.bakeryonmain.com Introduced: April Distribution: National Suggested Retail: $5.49 for a five-count, 6-oz. box Product Snapshot: These soft and chewy, gluten-free granola bars are made with gluten-free certified oats (certified by the Gluten-Free Certification Organization [GFCO]), amaranth, quinoa, flaxseeds and chia seeds and are a great source of whole grains and omegas 3 and 6. They come in Peanut Butter & Jelly, Chocolate Almond and Apple Cinnamon varieties. Ingredients (Chocolate Almond): Certified gluten-free oats, brown rice syrup, evaporated cane juice, chocolate chips (sugar, chocolate liquor, cocoa butter, soy lecithin, vanilla extract), crisp rice (brown rice), expeller-pressed canola oil, almonds, flaxseed, quinoa, chia seed, amaranth, sea salt, natural flavors. Contains: tree nuts, soy.
Ozery Bakery Morning Rounds
Tumaro’s New York Deli-Style Wraps
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Hostess Pink Strawberry CupCakes
Company: Hostess Brands, Inc., Irving, Texas Website: www.hostessbrands.com Introduced: February Distribution: National Suggested Retail: $3.99 for a 15-oz. box Product Snapshot: The Hostess line of cupcakes turned pink with new pink strawberry cupcakes. Baked with a burst of fresh strawberries, filled with Hostess’ signature crème filling and topped with strawberry-flavored icing, these squiggle-topped snack cakes exert festive flavor. Ingredients: Sugar, enriched bleached wheat flour (flour, reduced iron, B vitamins [niacin, thiamin mononitrate {B1}, riboflavin {B2}, folic acid]), non-fat milk, corn syrup, partially hydrogenated vegetable and/or animal shortening (soybean, cottonseed and/or canola oil, beef fat), palm oil, egg whites, high-fructose corn syrup, strawberry puree, whole eggs, contains 2% or less of the following: modified corn starch, soy lecithin, corn starch, soybean oil, leavenings [sodium acid pyrophosphate, monocalcium phosphate, sodium bicarbonate], natural and artificial flavor (caramel color, wheat flour), whey, salt, soy flour, calcium dextrose, guar gum, cellulose gum, sorbic acid (to retain freshness), potassium sorbate, titanium dioxide (color), vegetable calcium caseinate, sodium caseinate, soy protein isolate, agar, red 40 lake, sodium phosphate, FD&C Red 40 lake. Contains: wheat, milk, egg, soy.
Edi tor ’s N ote: G o to w w w. s n a cka n d b a ke ry. c o m to re a d a b o u t mo re n e w p ro d u c ts .
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The Nutritional Corner Celebrating 70 Years of Enriched Grains in America his year marks the 70th anniversary of the establishment of the Food and Drug Administration’s (FDA) bread and flour enrichment programs in the United States. Inaugurated at a 1941 National Nutrition Conference for Defense in Washington, D.C., the enrichment of grain foods has been influential in improving the lives of millions of Americans. Prior to 1941, diseases related to malnutrition were rampant throughout the country. Pellagra, a condition associated with chronic deficiency of the B vitamin niacin, was among the Top 10 leading causes of death for people in Southern states throughout the late 1920s. Other common conditions related to malnutrition included iron-deficiency anemia and beriberi, the disease resulting from deficiency of the B vitamin thiamin. In response to the extensive presence of deficiency-related diseases, in 1938, the American Medical Association, Chicago, issued a statement declaring support for the fortification of staple foods such as flours.
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Bakers throughout the country voluntarily began enriching bread with high-vitamin yeast and adding synthetic vitamins once the technology was available. But it wasn’t until 1941 that federal definitions were developed, standardizing the nutrient content of enriched and un-enriched flours. To this day, the FDA sets the standards for enriched grains by defining the levels of nutrients needed for grain products to be considered enriched; nutrients that must meet these standards include the B vitamins thiamin, niacin and riboflavin as well as iron and folic acid. Of these, folic acid is the most recent addition to the list of nutrients found in enriched grains, including white bread, bagels, pasta, tortillas and white rice. This fortification began in 1998 to increase folic acid intake in women of child-bearing age because of folic acid’s key role in the prevention of some birth defects (for more on this, check out Judi’s column in the January 2011 issue). As a member of the grains industry, I couldn’t be more proud of all the good
Judi Adams, president, Grain Foods Foundation and the Wheat Foods Council
things that have come from the enrichment of grain foods. More than 150,000 lives have been spared and deficiency diseases such as pellagra and beriberi have been eradicated. And in the years since 1998, there have been 26% fewer cases of neural tube defects. That reduction translates to more than 15,000 cases of anencephaly and spina bifida prevented, for which we have the folic acid fortification of enriched grains to thank. In light of the 70th anniversary of enriching grains, I commend the milling and baking industry for their important contribution to the health of Americans. Grain foods remain a delicious, affordable and healthy staple in our population’s diets, and we at the Grain Foods Foundation, Ridgway, Colo., are committed to keeping it that way in all the years to come. Happy Anniversary. SF&WB
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Ingredient Technology Low-Sodium Formulation
Halting the Salt
Photo courtesy of Nu-Tek Salt LLC
Many of today’s ingredient suppliers are developing salt alternatives or replacements to help bakers and snack manufacturers create lower-sodium offerings. Marina Mayer, Executive Editor
he updated 2010 Dietary Guidelines for Americans pose a tremendous challenge for some bakers and snack manufacturers who scurry to reformulate certain product lines to meet the call for healthier products. Between lower-sodium offerings and stock-keeping units that boast fat-free label claims, these hot-button issues present a host of hurdles for the food manufacturing community. However, for many of today’s ingredient providers, offering a low-sodium option is just what they do. Companies such as Wixon Inc., for example, recognized the need to reduce sodium years ago, according to Leda Strand, director of technology applications and industrial ingredients, and have since created a host of low-sodium formulations that not only meet the revised guideline standards, but also open the door for better-tasting, better-quality products. “Recently, reducing sodium has moved
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from focusing only on salt to focusing on the entire flavor system of a product,” Strand says. “Salt substitutes should be used in conjunction with a re-balancing of a products’ flavor system, including spices, functional ingredients and other flavors. This allows developers to achieve the organoleptic properties that consumers expect.” As a result, last year, the Milwaukee, Wis.-based company launched KCLean
Salt, which is a blend of 50% salt and 50% potassium chloride and added taste modifiers to cover the undesirable metallic taste. “Consumers have had an interest in reducing sodium in their diets for many years, but now the push is also coming from grocery and retail chains, in addition to recent regulatory changes. This has moved sodium reduction from a ‘nice to have’ to a ‘must do,’” Strand notes. “ConContinued on page 40
Photo courtesy of Nu-Tek Salt LLC
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Ingredient Technology Photo courtesy of Danisco USA Inc.
Continued from page 38
sumers are no longer interested in choosing from two options: High-sodium/great taste; or reduced-sodium/less taste. They only want one option: Reduced-sodium plus great taste.” Sensient Flavors, Inc., Indianapolis, also offers a comprehensive portfolio of sodium-reduction flavor systems that are developed to reduce sodium by 25-35% or more per serving, says Emil Shemer, director, food solutions. “Sensient’s solutions take a whole systems approach to taste and functionality, and [they] are suitable for a variety of applications, including sweet and
savory baked goods, topical seasonings, bars and snack mixes, to name a few,” Shemer says. “Taste is the biggest challenge bakers and snack producers face in developing low-sodium formulations,” Shemer adds. “Producers are tasked with creating greattasting, lower-sodium products without sacrificing flavor. They also need to maintain a salty perception while keeping a clean ingredient statement.” For its part, Kikkoman Sales USA
launched a line of natural flavor enhancers (NFE) that allow 30-50% sodium reduction while improving the taste and flavor balance of lower-sodium products, says Joe Leslie, national industrial sales and marketing manager for the San Francisco company. The NFE line offers a neutral flavor combined with a strong umami effect for savory applications, such as breads, pizza dough, tortillas, crackers and snacks. It comes in one liquid version (NFE-L) and two dry ones (NFE-P and NFE-PY). “Kikkoman has always had lower-sodium options, but the 2010 Dietary Guidelines of Americans prove that we need to emphasize and expand our offering in this category,” Leslie says. “Kikkoman’s fermentation technology and history of producing low-cost, natural products places us in a strong position to help our customers in their sodium-reduction initiatives.” Likewise, Nu-Tek Salt LLC delivers reduced-sodium salt options that lower sodium content in bakery items up to 50%, without sacrificing flavor, notes Dustin Grossbier, director of quality and technology. The Minnetonka, Minn.-based company is also in the process of building a topical line that features higher salty flavor intensity products for use in snack food applications, Grossbier adds. Continued on page 42
While some companies introduce low-salt alternatives, others set out to replace salt entirely by mimicking its elements and eliminating its downfalls. Photo courtesy of Wixon Inc.
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Ignite Your Product Development Process! Prepared Foods’ 29th annual New Products Conference is the food & beverage industry’s premier event for gaining valuable insights into exciting global new products, culinary advances and emerging consumer trends. The New Products Conference provides R&D, Marketing, Product Developers, and Corporate Management executives like you, a dynamic forum to learn from world-class speakers, capture valuable new product & trend data, participate in an interactive culinary session, taste new products from around the globe, capitalize on incredible networking and ignite your creativity.
Featured Speakers Include: > Family Brand Dynamics: Decoding The Drivers of Family Brand Success Speaker: Laurie Klein, Vice President, The Family Room What’s behind the success of the country’s most iconic family brands? How does your brand measure up? > Truly Global Strategies? Speaker: J. André de Barros Teixeira, Recent Vice President, International R&D, Campbell Soup Company, Belgium, Formerly, President and General Manager, Coca-Cola, Russia Discover the changes affecting consumers and companies, new ways to look at demographics and how to avoid commonplace behavior in market research.
discover new products
> A Call to Innovation and Action: A Professional Call to Arms Speaker: Christopher W. Miller, PhD, NPDP, Founder and CEO, Innovation Focus The companies represented at the conference have substantial influence over the diet of the American population. Through our creativity we can create a healthier more vibrant society. > On the Foodservice Horizon: Expanding Boundaries and Opportunities into Retail Speaker: Kevin Higar, Director of Operator Product Development, Technomic Kevin will explore the food, beverage, and overall menu strategies of tomorrow's successful restaurants. Not surprisingly, these more successful trends will morph into the retail marketplace as well. > Innovation That Could Change the (CPG) World Speakers: Lynn Dornblaser and David Jago, Directors, Custom Solutions Group, Mintel International We'll take a brief look backward at a few proven examples of innovation that changed everything, and offer our own picks of innovative thinking that may change things in the future. > Mintel New Product Showcase and Tasting Session After you've heard about some of the most innovative recent product introductions, you'll have the chance to see and taste them as well. > Product Development Innovation Workshop Upgraded Speaker: Ron DeSantis, Director, Continuing Education’s Industry Solutions Group, The Culinary Institute of America CIA Master Chef DeSantis will guide teams through the innovation process — from ideation through development — and explain the concept of structured culinary innovation.
network
Save the Date – September 11-14, 2011 Make a commitment today to invest in your career, revitalize your creativity, and network with the industry’s top new product development leaders, while enjoying the warm weather at The Ritz-Carlton in Naples, Florida
For more information, contact Marge Whalen, Senior Event Manager at 847-405-4071 or
[email protected].
www.PreparedFoods.com/npc
new product trends
Ingredient Technology Photo courtesy of Wixon Inc.
Continued from page 40
“We see the health and wellness trend continuing to skyrocket, and low-sodium formulations are on the forefront of them,” he notes. “The general public has become much savvier in reading product labels. Having great-tasting products that are lower in sodium than their counterparts will be a competitive advantage.”
De-salting by default While some companies introduce low-salt alternatives, others set out to replace salt entirely by mimicking its elements and eliminating its downfalls. For instance, Innophos, Inc., Cranbury,
N.J., released Cal-Rise, a sodium-free leavening that replaces SAPP 28 (a mediumacting leavening powder) on a 1:1 basis, yet still decreases sodium content by an average of 28%, says John Brodie, technical service manager—baking. “Cal-Rise can be used in most formulas that currently use SAPP 28. This includes cake-type formulas, muffins, biscuits, flour tortillas, pancakes and baking powders,” he adds. Innophos also developed Dough-Rise, a reduced-sodium leavening agent designed to replace SALP (sodium aluminum phosphate) in commercial applications where long holding times are needed, such as in cake and donut formulas. “The use of
these leavenings will help you formulate low- and reducedsodium baked goods without changing flavor or texture,” Brodie adds. “These leavenings will also significantly increase calcium contents.” Meanwhile, Danisco USA Inc., New Century, Kan., introduced its SaltPro line, “which allows bakers to reduce their sodium content by 25-30% in breads, buns, rolls and sweet goods,” says Helle Tornas, industry manager. SaltPro is a sodium replacer that retains the characteristics of a full-salt product and delivers the sensory attributes of salt, yet delivers a similar mouthfeel, texture and palatability, all without the high-sodium levels. “We have seen successful use of this line of ingredients in yeast-raised products such as breads and buns and then in sweet goods such as cookies,” Tornas says. Despite the changes in consumer preference and government recommendations, today’s ingredient suppliers are halting the salt so bakers and snack manufacturers can create lower-sodium offerings with bigger and better taste. SF&WB
Photos courtesy of Innophos
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Ingredient Briefs
SensoryEffects Flavor Systems introduces Choco-Flakes, a line of compound coating inclusions designed to have a melting point of around 80°F, making them suitable for use in frozen dessert systems. They are available in dark, milk and white chocolate, and can be made into other customized chocolate-based flavors such as chocolate cherry or raspberry white chocolate. Choco-Flakes is said to provide a superior mouthfeel, flavor delivery and improved tolerance in application. SensoryEffects Flavor Systems Bridgeton, Mo. 800-422-5444 www.sensoryeffects.com
Van Drunen Farms introduces individually quick frozen (IQF) organic herbs for an added-value spice in frozen pizza, salsas, frozen entrees and more. The lineup of herbs includes basil, cilantro, parsley, green onion, chives, collards, dill, kale, lemongrass, oregano, sage and thyme. IQF organic herbs are domestically grown and produced by spreading freshly harvested herbs in a single layer on a slow-moving conveyer through sub-zero air, resulting in a free-flowing IQF product that can easily be handled. This process creates a convenient, micro-ready ingredient that comes in multiple forms or sizes. Van Drunen Farms Momence, Ill. 815-472-3100 www.vandrunenfarms.com
Caravan Ingredients develops Tortilla Suave, a conditioner that combines the latest in extended-shelf-life and antistick technology to improve softness and rollability and allows for the removal of hydrogenated fats and trans fat from labels. Tortilla Suave is made to be easily applied to existing formulations without a disruption to current formulas or processes. Caravan Ingredients Lenexa, Kan. 800-669-4092 www.caravaningredients.com
Puratos launches its new and improved S500 bread improver range. Based on patentpending enzyme technology and freshness enzymes, the new S500 delivers superior dough tolerance, outstanding volume and improves the fresh characteristics of the final bread. The new S500 can be used in a wider range of bread applications such as crusty bread, rolls, loaf breads, whole meal, soft breads and sweet goods and in more processes, such as retarded fermentation and short freezing. The range includes S500 Red, which gives volume and extreme tolerance in any baking condition; S500 Ultra, a high-quality multipurpose improver; S500 Blue, which is designed especially for automated lines; and S500 Green, the clean label variety. Puratos Corp. Cherry Hill, N.J. 856-428-4300 www.puratos.us
SF&WBtv
Glanbia Nutritionals launches OptiSol 5000, a natural, flax-based ingredient designed to improve the texture of pizza doughs by enhancing extensibility and workability. OptiSol 5000 functions as a moisture management tool. It develops dough texture through enhanced moisture retention, creating a softer and less chewy texture. This is especially evident in whole wheat crusts where the result can be tough and unpleasant for more health-conscious consumers. Moisture retention also maintains product quality over a longer shelf-life, increases surface area by up to 5% and cuts costs for manufacturers. OptiSol 5000 also is high in fiber and rich in ALA Omega-3. Glanbia Nutritionals Fitchburg, Wis. 800-336-2183 www.glanbianutritionals.com
Watson debuts gluten-free mixes created to shorten time-to-market, reduce R&D efforts and material testing costs and eliminate the need to audit multiple vendors. Developed specifically for bread and muffins, these gluten-free mixes meet the standards of the Celiac Sprue Association. Watson Inc. West Haven, Conn. 800-388-3481 www.watson-inc.com
View videos demonstrating the newest bakery & snack food ingredients by visiting
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Engineering Management
Time to U.P.G.R.A.D.E. o get to the next level in your management skills, you must upgrade. You must improve policies, advance procedures and raise the bar. You must enhance the way you do business in order to continue doing business. Here, I have taken the term, “upgrade,” and tweaked to relate it to our industry and discipline. For instance, the “U” stands for Understanding. In order to increase our knowledge of this business, the people and the tasks at hand, we need to spend more time trying to understand the important stuff and let the small stuff go. Find ways to learn something new today. So many times we get caught up chasing what turns out to be insignificant items and old junk, and sometimes we’re just chasing ghosts. We need to find ways to spend some quality time learning the next best way to do, say or explain something better. When understanding becomes sharing to those around you, you will be regarded as a better manager and communicator. The “P” stands for Plus, which means “what can you bring to the situation that adds value?” You know what you know, but sometimes others don’t. When you see something happening around you, find a way to insert yourself in a helpful way so that the situation becomes less of a problem to those around you. You must be careful not to come off as a know-it-all, but it’s possible to help without turning people off. It’s all about delivery. The “G” stands for Give. You can be a go-getter or a go-giver. In our workplace, there are so many people who need help learning the next new thing. As a manager, it is your responsibility to be the giver. Don’t be selfish with your knowledge. Pay it forward by sharing your knowledge upfront and allowing people to absorb, apply and eventually re-teach. Andrew Carnegie, a Scottish-American industrialist, businessman, entrepreneur and philanthro-
T
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pist, said people can “get rich by making others rich.” How can you implement that philosophy with a giving spirit? The “R” stands for Relate. This is all about relationships. As a manager, mentor or leader in some other capacity, you gain more ground when you make the relationship with a colleague or direct report a high priority. We sometimes face situations where we have to work with someone who has a work ethic or talent level that doesn’t quite meet our personal standards. We can’t let that get in the way of making progress on the task at hand; we are all being paid to complete it, no matter how large or small it may be. The “R” can also stand for Respect, because when you have this in mutuality, you can be more productive and successful. The “A” stands for Adjust. Nothing in this world successfully happens without some level of adjustment during the course of the deployment of a task. Peyton Manning, the quarterback for the Indianapolis Colts, is the ultimate plan adjuster. What has become the norm in Colts football is actually the constant execution of adjustment, or “calling the audible” as they say. He never comes to the line and runs the play exactly as called in the huddle. He looks over the defense and then steps back and adjusts the play, sometimes slightly and other times completely. Their winning record proves that adjustments work. In your line of work, don’t be afraid to step back, survey the situation and make slight or complete changes to ensure the task will be successful. The “D” stands for Discipline. No, not handing out punishment, rather this definition of discipline means the ability to control one’s self and their actions in times
Jeff Dearduff
[email protected] of stressful situations. Having the discipline to follow-through on the commitment when everything around you seems to be in turmoil is the mark of a true professional. If you let the stress get to you, you can make poor decisions that can cause a bad situation to become worse. Sometimes acquiring the internal discipline to handle stressful situations requires a person to go outside their comfort zones and seek help on organizing thoughts, making decisions and controlling tempers. If you want to go to the next level in your management development, you must find a way to have the discipline to handle any situation that comes up. The “E” stands for Execute. Now we can bring this all home. Execution is one of the easier things to understand and sometimes the toughest to carry out. Everything requires execution to get positive results. You can’t understand something better if you don’t reach out and give a wholehearted try. You can’t add value to a situation if you stand back and watch. You can’t be a giver if all you want to do is receive. You won’t have a team if you don’t relate to others. If you stick to your guns and are not willing to shift course, you could shoot yourself in the foot, and if you don’t have the internal discipline to handle the stresses of the daily workload, you could actually get physically sick. On this Transatlantic flight we call our careers, we will land at our destination in better health, mind and spirit when we spend a little extra time upfront and U.P.G.R.A.D.E. SF&WB
Understanding Plus Give Relate Adjust Discipline Execute
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New Markets • New Technologies • New Opportunities
JUNE 7-9, 2011 Westin Beach Resort, Fort Lauderdale, FL KEYNOTE ADDRESS Latest Trends & Technologies in Pouch Packaging & Machinery Dennis Calamusa, President, AlliedFlex Technologies One of the industry’s leading influencers will explore the latest pouch packaging trends and technologies solving today’s most challenging applications.
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Equipment Briefs are electro-polished to simplify cleaning. A full-length hood covers the kettle for safety and retains heat for high-energy efficiency. It also has steam blanketing to purge oxygen and prolong oil life, lower exhaust volume and a clean-in-place system to reduce sanitation labor. Heat and Control, Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com Charles Ross & Son offers three sizes of its V-Blenders, which are designed for the intimate, dry blending of free-flowing solids that vary in bulk density and percentage of total mixture. All Ross V-Blenders are supplied with intensifier bars to permit de-lumping and de-agglomeration as needed. In addition, they are manually operated via butterfly discharge valves and come equipped with safety railings, stainless-steel support stands and fully-integrated motors and controls. Charles Ross & Son Co. Hauppauge, N.Y. 800-243-7677 www.mixers.com
Heat and Control’s new MasterTherm Kettle Fryer (MTKF) can produce 500 finished lb. of batch fried potato chips per hour. Cooking oil is heated gently and uniformly throughout the fryer by a thermal fluid heat exchanger, which is immersed in the oil. Generous spacing between the heating tubes facilitates cleaning and eliminates areas where fines can accumulate. Each tube expands independently, greatly reducing damage caused by thermal stress. Tubes
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Lantech presents a patent-pending Load Seeking Clamp 4.0, designed to reduce film breaks by holding onto the film, preventing film breaks and releases at the clamp. At the beginning of the wrapping cycle, the clamp goes out to the edge of the load, creating clamp-to-load contact regardless of the width of the load. This eliminates sagging issues and maximizes containment at the bottom of the load. Lantech Louisville, Ky. 800-866-0322 www.lantech.com
Banner-Day introduces SmartSpark, a revolutionary conveyor oven ignitor/sensor that provides highly reliable burner
ignition and flame sensing when used in a conveyor oven. This stainless-steel ignitor/sensor enables precision control of conveyor oven burners while offering ease of installation. And it can be used independently and integrated into overall total oven control systems. Banner-Day Saginaw, Mich. 877-837-0584 www.banner-day.com
Douglas Machines introduces TriVex, a fully automatic top-loading case packer that erects, loads and seals cases. TriVex operates at 15 cases per minute depending on case size, and is fully integrated, which means less product handling, case handling, maintenance of additional equipment and floor space. It comes with an application-specific loader, end effector and infeed solutions for an array of products such as flexible bags and pouches, semirigid and/or rigid trays, tubs, cups, cartons and over-wrapped products. Douglas Machines Corp. Clearwater, Fla. 800-331-6870 www.dougmac.com
Designed specifically for sanitary processing operations, the Quick-Clean Series of
View videos demonstrating the newest bakery & snack food equipment by visiting www.snackandbakery.com
Snack Food & Wholesale Bakery - April 2011
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Equipment Briefs rotary airlock valves from ACS Valves aids in regulatory standard and practice compliance, reduces cleaning and sanitizing time and simplifies inspection. The tool-less, clean-in-place design enables full access to the rotor and all internal surfaces of the housing without time-consuming disassembly of the endplate, or the concern for accurate rotor re-alignment during re-assembly. Plus, the 8-vane rotor design eliminates excess pressure loss through the system, ensures cost-efficient upstream and downstream material management and reduces process energy consumption. ACS Valves Ontario, Canada 800-655-3447 www.acsvalves.com
A new 18-in. diameter Centrifugal Impact Mill Model CIM-18-SS from Munson Machinery provides coarse to fine (400 mesh) grinding of friable materials into controlled particle sizes, as well as de-agglomerating and conditioning of dry solids. A direct-drive system reduces the unit’s footprint to about half of that required by a belt-driven machine, allowing installations in restricted areas. High-speed rotation of the inner disc creates centrifugal force that accelerates bulk material entering the central inlet of the opposing stationary
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disc. As material travels from the center to the periphery of the discs at high speed, it passes through a “treacherous path” of five intermeshing rows of rotating and stationary pins with the desired tight particle size distribution obtained by controlling the rotor speed. It also provides high throughput rates per horsepower relative to machines employing screens, hammers, knives or rolls, depending on application. Munson Machinery Co., Inc. Utica, N.Y. 800-944-6644 www.munsonmachinery.com
American Fabric Filter debuts a portable reclaim sifter for sifting small batches of dry powders. This versatile sifter is capable of batch-sifting up to 600 lb. an hour and may be operated sitting atop a drum or using the optional adjustable height-rolling base for easy relocation around the plant. It also comes with one framed screen, motor speed controller and a sliding shut-off door. American Fabric Filter Co. Wesley Chapel, Fla. 800-367-3591 www.americanfabricfilter.com A new Vibroscreen Flo-Thru low-profile screener from Kason Corp. classifies bulk material into three fractions at high rates. It employs two screening decks and two unbalanced-weight gyratory motors mounted on opposing exterior sidewalls of
the unit instead of one motor positioned beneath the screening chamber, significantly reducing minimum height requirements. The design also allows vertical alignment of the top inlet and bottom outlet, allowing the smallest fraction to descend through the screener in a straight-through path at high rates; the larger fractions are ejected through spouts at the peripheries of the coarse-mesh upper screen and fine-mesh bottom screen. Kason Corp. Milburn, N.J. 973-467-8140 www.kason.com Spiroflow Systems introduced “CABLEflow” tubular cable drag conveyors, designed for applications requiring gentle handling or for those requiring conveying both to and from multiple points in a circuit. CABLEflow conveyors transfer friable bulk products from single or multiple infeed points to single or multiple discharge points with little or no damage. Other benefits include totally enclosed dust- and contamination-free handling, operation in three planes to allow for complex circuits and the elimination of transfer points using only a single drive, metered or flood-fed capability. They also handle hot, cold, wet, dry, hygroscopic or temperature-sensitive materials, minimum product attrition due to gentle conveying action, minimum material residence and build-up due to round construction and operation under pressure differential or insert purge. Spiroflow Systems, Inc. Monroe, N.C. 704-291-9595 www.spiroflowsystems.com Continued on page 48
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Equipment Briefs Continued from page 47
saving vertical design, a large, angled top opening for easy filling, first-in-first-out sliding divider shelf for proper lot rotation and ability to use on a rack or louvered panel or mounted on a wall or workstation. Akro-Mils, division of Myers Industries, Inc. Akron, Ohio 800-253-2467 www.akro-mils.com
Akro-Mils introduces a smaller size bin and new rack design for its innovative easy-flow gravity hopper system. The new smaller, lighter 31620BLUE hopper has a 6-gallon holding capacity, assisting end users in material handling and 5S processes. It also features a compact and space-
Sensor Products offers the Tactilus electronic pressure-mapping system, designed to allow measurement of contact pressures between two mating surfaces. This system reveals critical pressure distribution problems that can compromise package integrity. Applications include quality control monitoring for uniform pressure across sealing dies in heat seal and sealing ma-
chinery and characterization of nip impression pressures in the nip between rollers in converting machinery. Pressure readings are captured as the sealing surfaces make contact, and the software analyzes the data from the sensors within a pad, enabling the engineer to view data on a computer screen and make adjustments to the heat-sealing equipment. Sensor Products Inc. Madison, N.J. 973-884-1755 www.sensorprod.com
Producing Rolls for over 45 Years Our team of experts help select the right equipment for your production, but we don’t stop there. We will work with you to improve product quality and maximize your profitability. Our 24-hour customer service hotline and fully stocked US parts warehouses add to the positive Koenig experience.
Growing Your Business through Superior Automation EQUIPMENT • INSTALLATION • PARTS • SERVICE Exclusive East Coast Distributor
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Rich Breeswine, National Sales Manager Koenig Bakery Systems 6207 Settler Road, Richmond, VA 23231 1-804-564-3997
[email protected] www.koenigusa.com www.snackandbakery.com
Production Technology Lubrication
Pushing the Limits Many of today’s lubricants and systems allow customers to operate around the clock with efficiency, flexibility and ease. Marina Mayer, Executive Editor Photos courtesy of Klüber Lubrication North America L.P.
t used to be that bakers and snack manufacturers ran their production lines on a routine, five-day schedule, shutting down for two days of cleaning, sanitation and maintenance. And if a part broke down or a line became inoperable, companies would just replace them and move on. That was then—this is now. Today, companies are aiming to stretch the limits and operate around the clock in an efficient, flexible and sanitary manner in order to produce more product and fulfill more orders. Now, the stakes are raised and every minute counts. That’s why suppliers are developing dependable lubricants to help their customers do the job right the first time. Choosing the correct lubricant is only half the battle, says Kimberly Eldridge, North American market manager, food, beverage and pharmaceutical industry, for Klüber Lubrication North America L.P.— using the lubricant correctly is the other half. That’s why the Londonderry, N.H., company offers guidance to those sorting through the method behind the madness, so-to-speak. “How a lubricant is applied can be a key indicator in predicting how well the lubricant will perform,” Eldridge says. “How can the user best apply the product to ensure that it achieves the performance and protection they expect? And how can they do it safely?” Klüber’s lubricants allow for the use of single-point applicators in hard-to-reach areas, which helps reduce potential safety risks for operators, Eldridge adds. In addition, a lubricant reservoir that pumps
I
product through lines to various application points can be viewed as a safety measure. “It may allow the lubrication of points that would otherwise require a machine shutdown to be performed safely,” she adds. Another key factor is being able to lubricate without contaminating food, says Don Schaefer, regional sales manager for Bijur Delimon International (BDI), a partner of Lubrication Engineers, Inc., Morrisville, N.C. “Due to the nature of the food plant, we often supply a ‘lube-in-a-lockbox’ solution,” he adds. “This approach allows only qualified people to make adjustments to the program. Only the person with the
key can change volume and frequency. Replenishing the reservoir is accomplished with an external fill coupler to ensure the mating fill pump has the correct oil or grease and is clean. Central systems can be automatically filled to keep flour, gluten Continued on page 50
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Production Technology
Photo courtesy of Lubrication Engineers, Inc.
Continued from page 49
and debris out of the lubricant.” BDI provides uptime solutions using centralized lubrication equipment to automatically lubricate food processing
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Attaining higher standards “Much like the surface of your skin, a very low volume of oil applied evenly to a sticky surface can provide adequate lubrication,”
Photos courtesy of JAX, Inc.
machinery, Schaefer notes, and the system itself consists of a central pump, reservoir and metering devices. “In a food plant, systems are remotelymounted in an enclosure with a clear plastic viewing window. The lube system includes an alarm for low-level, low-pressure or monitored performance. A beacon to alert the operator and automatic refilling from central storage are popular options,” he adds. BDI’s lubrication systems also reduce contamination and save money by eliminating the traditional oil can and grease gun. “Most manual devices are not kept clean and dedicated to the lubricant; the result is debris and mixed lubricants that are injected into the bearing,” Schaefer says.
says Shaun Beauchamp, director of operation for XACT Fluid Solutions, a whollyowned subsidiary of JAX, Inc. That’s why the Menomonee Falls, Wis.-based companies jointly created JAX food-grade mold release, a NSF 3H-registered release agent that promotes release and product separation by modifying the interface between the food and grills, loaf pans, boning Continued on page 52
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Production Technology Continued from page 50
benches, chopping blocks and other hard surfaces. “Sanitation processes are becoming more aggressive to handle cleanliness during increased production schedules,” Beauchamp says. “Stainless-steel systems [such as the food-grade mold release] with solid-state components and a long cycle life are imperative in this environment. You want to reduce downtime, which implies ensuring the automated solution does not become a maintenance concern. We pride ourselves on innovative, reliable, flexible solutions that solve problems.” In addition, XACT concocted the flat-pattern spray-bar system, which is a turnkey spray system that sprays onto conveying surfaces such as molds, belts and conveyors. It comes with a control cabinet, pumps, solenoids, logic controls, a lowlevel switched reservoir, a system stand and status light. The system is designed to last a minimum of 100 million cycles.
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Photo courtesy of Dayton Progress Corp.
“Our systems micro dose lubricants into all applications, which is specifically critical in oven applications,” Beauchamp says. “JAX supplies lubricants for baking with a significant margin of safety for flash point. XACT produces our systems for longevity in high-temperature applications. If a typical oven runs at 550°F, we have no concern, as our fluids operate well at these temps, and we build our dispensing systems to handle 900°F. The combination
of a fluid with low volatility and a positive displacement dispensing system that accurately controls lubricant volumes provides protection against typical baking fears.” Meanwhile, Dayton Progress Corp., Dayton, Ohio, launched DAYLube, a high-performance lubricant that uses nanoceramic particles to provide continuous lubrication to steel surfaces. Available in 5-gal. pails, DayLube is NSF-H1 food-grade certified, provides 10 times the normal life and features high load-bearing properties, such as water, steam, acid and chemical resistance. Plus, it is ideal for high-volume applications and protects bearings, bushings cables, cams, chains, conveyors, gears, lifters, machine parts, robotics, slides, wear plates and more. Pushing the limits is what many of today’s companies do to stay in the game, and they do so with the help of some flexible and dependable lubricants and systems. SF&WB
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Lubrication: The secret ingredient in your recipe for productivity Partner with Klüber Lubrication to get more from your operation. We’ve developed a broad line of kosher, halal and ISO 21469 certified lubricants to meet the extreme demands of the food industry. Our NSF H1 lubricants boost efficiency, save energy, reduce lubricant waste and extend relubrication intervals — all while meeting your food-grade requirements. Klüber Lubrication promotes a healthy production line and a healthy bottom line. Talk to one of our specialists to find your secret ingredient. Klüber Lubrication North America L.P.
[email protected] / www.klueber.com
your global specialist
Supplier Standpoint Distribution: The Last Bastion of Significant Savings?
F
or an industry that produces products woven into the core fabric of life for which there will always be plenty of demand, the fresh baking industry seems to perpetually be under a lot of pressure. Not a day goes by without reports of ingredients reaching record high prices, or a new low/no-grain diet announced. Not to mention the fiercely competitive nature of the industry itself, heightened by the increased power of retailers, the introduction of in-store bakeries and the rise in production of artisan bread. It becomes increasingly difficult to make a decent buck selling commercially baked bread.
The margin is determined by the price the customer is willing to pay minus the costs of getting the product to that customer. Price is always under pressure from ever-increasing buying power of the food retailers and competition. Of course, quality and choice of ingredients and new, innovative products allow for some differentiation, and thus, price flexibility. But cost is the place manufacturers most commonly look to increase profitability. The main “buckets” that make up the
Photos courtesy of pcdata Inc.
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modernization and continuous improvements? Is it because many don’t feel technology can be flexible enough to deal with the dynamic nature of order fulfillment and bread distribution? Or is it because companies don’t think the potential “real” opportunities to affect and improve the business aren’t there? Whatever the reason, many organizations are not taking the time to look at what can truly Courtesy of pcdata Inc. be accomplished to improve business in cost of a loaf of bread are ingredients, the distribution side of the plant. production costs (including overhead) and Getting the product to the end customer is the costs involved in getting the bread to the probably the area that still has the most popaying customer or distribution costs. tential for savings, and technology is the key One of the downsides to the globalized to unlocking them. Paper-based order-fulfillworld is not that ingredient prices today are ment processes are very error prone; they are set at the will of forces out of the manualso really inadequate to deal with the highly facturer’s control, but rather the result of a dynamic nature of fulfilling large numbers myriad of events, such a weather phenomena, of ever-changing orders and matching them crop predictions and demands playing out in against ever-changing production volumes. parts of the world such as China and India. Computer-based solutions can adjust Generally speaking, ingredient prices do product allocation dynamically based on priwhatever they want. orities set by the user. No paper adjustments The focus of the industry has been and need to be made; the process happens quickly continues to be on reducing production and accurately. costs of bread. Huge production efficiency Another benefit of today’s systems is increases and reductions of production waste traceability. Each time a product is handled, have been realized over the past 20 years. the warehouse operator has to confirm this Production lines are extensively automated. in the system. These “checks” improve order Walking through any modern production fulfillment accuracy, which improves customer facility today, one can’t help but be amazed service levels, eliminates the need for extra at the limited amount of personnel on the truck runs and reduces “unaccounted for’s” to production floor as the products roll off the nearly zero. Some distribution solutions even line by the thousands. offer automatic scanning of product onto the The ongoing market consolidation that delivery trucks and product scanning when it has been taking place for decades is another is received by the end customer or depot. It is result of the efforts to lower production costs. very common to see a savings of up to 30% Market consolidation increases production in warehouse and distribution costs when volume in the remaining factories and allows these new systems are installed and incorpofor greater economies of scale. rated in the daily business process. Payback Interesting to note is that with most periods of 12-18 months are the norm. For wholesale bakeries, bread is still being these reasons and others, it truly makes good distributed just as it was 100 years ago, usbusiness sense to evaluate the positive effect ing pen and paper and a lot of labor. There modern distribution systems can have on the are tremendous opportunities to affect the bottom line. Distribution may be one of the bottom line and improve the quality offered last bastions and unknown areas of signifito the end customer on the other side of the cant savings opportunities in this industry. production wall. Editor’s Note: Marc Braun is the president at pcdata Why is it then that this is an often overInc., East Granby, Conn. For more information, go to looked aspect of the business in regard to www.pcdatainc.com.
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Snack Food & Wholesale Bakery - April 2011
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April 2011 - Snack Food & Wholesale Bakery
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Snack Food & Wholesale Bakery - April 2011
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