Snack Food & Wholesale Bakery July 2011

FROM FORMULATION TO FINAL PRODUCT Look to ADM to increase your edge in the competitive baking segment. The ADM Bakery Platform is a network of R&D services designed to help our customers achieve maximum success. Think of us as your single point of contact for technology and resources that keep you on the cutting edge. Whether you’re looking to identify market trends, develop new products or enhance existing ones, we aim to exceed your expectations – quickly and efficiently.

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Contents

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12 | 2011 State of the Snack Industry Report: Overview

Production, Technology & Product Development Solutions for a Changing Industry. July 2011 Vol. 100 No. 7

Whether it’s a picnic, ballgame, festival or just lounging in the sun, the state of the snack industry proves that consumers are in for one wild, fun-filled, tasty ride.

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

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18 | Potato Chips

Potato chips have been around for ages and are a simple but fantastic idea in origin. But one thing’s certain: They’re as classic as a state fair.

John Schrei Publishing Director [email protected]

Tom Imbordino Group Publisher [email protected]

26 | Tortilla Chips

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Today’s tortilla chip makers prove that all it takes is a blend of bold flavors, zesty spices and some pizzazz in a bag in order to keep the fiesta goin’.

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

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

32 | Pretzels

Marina Mayer Executive Editor

Pretzels are evolving and taking on an action-packed Mad Mouse ride of bolder flavors, different spins on ‘tried-and-true’ recipes and sandwich fillings of sweet or savory varieties.

Patty Catini Art Director

[email protected] 847-405-4008

Advertising & Internet Sales Barbara Szatko Senior Sales Manager

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40 | Crackers

[email protected] 630-527-9927

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

Cracker producers have redefined what crackers represent to consumers—whether they’re a stand-alone item or a complementary piece to a larger snacking solution, they’re filling the void for fun-filled snacking occasions.

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

Support Services Nann Barkiewicz Production Manager

44 | Popcorn

[email protected]

Liz Wright Marketing Coordinator

Recent popcorn introductions offer up robust flavors, healthier formulations and convenience—an amusement park of ingredients for summertime snacking.

[email protected] 248-786-1652

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Kourtney Bell Audience Development Manager Stephanie Hunt Multimedia Specialist Carolyn M. Alexander Audience Audit Coordinator

48 | Nuts & Trail Mix Nuts, trail mixes and nut-and-fruit confections offer consumers convenient, flavorful pick-me-ups, as they try to get the most out of each summer day.

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List Rental Postal contact: Kevin Collopy at 800-223-2194 x684 [email protected]

54 | Jerky & Meat Snacks

Email contact: Michael Costantino at 800-223-2194 x748 [email protected]

Even though the temperature outside may be striking a new high, today’s jerky and meat snack manufacturers are still raising their own heat with hot flavorings and spicy offerings.

58 | Pork Rinds New varieties and larger portions give pork rind-loving consumers even more snacking options.

Audience Development

BNP Corporate

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

Continued on page 4

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Snack Food & Wholesale Bakery - July 2011

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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 ?

Contents Columns 6 | Editor’s Note

63 | Engineering Management

The Sweets & Snacks Expo was a festival of finger foods, says Editorin-Chief Lauren R. Hartman. Find out what new product introductions hit the show floor.

Contributing columnist, Jeff Dearduff, instills an old/new engineering concept to help manufacturers conceive ideas, design and implement processes and train employees.

60 | The Nutritional Corner

72 | The Final Word

The Grain Foods Foundation supports the new MyPlate icon, says contributing columnist Judi Adams. Find out how the newly revised graphic helps consumers eat more grains.

This year’s Dairy-Deli-Bake Seminar & Expo was a hit all around, according to Executive Editor Marina Mayer, thanks to high attendance, a bevy of new bakery products and, oh yeah, that Joe Montana guy.

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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Editor’s Note

Festival of Finger Foods went to the Sweets & Snacks Expo, May 24-26 in Chicago, for the first time, and enjoyed seeing all kinds of new products. Hosted by the National Confectioners Association (NCA), Washington, D.C., the show drew plenty of inspiration. There were thousands of new, exciting snack products from hundreds of exhibitors. I was thrilled that about 40% of the exhibits featured snacks, though there were more than enough candy, chocolate and other sweet confections too numerous to mention. According to the NCA, this year’s show experienced 13% growth in the number of exhibitors and was the largest in terms of both floor space and exhibitors in the event’s 15-year history. In fact, there were more than 14,000 visitors from across the globe and 545-plus exhibitors, including 160 new ones. “We have established a waiting list for exhibitors,” Lauren R. Hartman says Larry Graham, [email protected] president of NCA. “Our attendee registration count also tracked ahead of our record-breaking 2010 show counts, and 29% of our exhibitors were new to the 2011 event.” Fun new trends were everywhere, including a gourmet marketplace set up with hundreds of items on display, as well as a new product showcase that boggled the mind with automatic data scanning for more than 60 snacks and specialty treats. All natural played a big part in the introductions there, as consumers are looking for both healthy and indulgent products. Consumers want healthier snacks with quality, whole ingredients and no preservatives

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Snack Food & Wholesale Bakery - July 2011

without sacrificing taste, according to American Roland Food Corp., Hatfield Mass. The specialty food importer launched all-natural butter cookies made with a handful of delicious ingredients: Sables Shortbread Crisps, made from a combination of seven all-natural ingredients and real butter; and Galletes Shortbread Cookies, which hit the sweet spot between great taste and better-for-you. Americans are also developing more of an appetite for hummus, which is listed as one of the hot ingredients for 2011 by industry trend watcher Andrew Freeman. That’s why Simply 7 Snacks created plenty of buzz with its Hummus and Lentil Chips, which are all-natural chips that provide an ethnic twist for the health-conscious consumer. The Houston-based company insists that lentils aren’t just for soup and salad and hummus doesn’t have to be just a dip. “Imagine the first guy who thought to turn a potato into a potato chip,” says Simply 7 president Rashim Oberoi. “That’s us with new ingredients. And we’ve worked tirelessly to ensure that our chips taste authentic and are healthy, the way you’d expect.” Speaking of chips, Natural Snacks, LLC, Addison, Ill., showcased its Michael Season’s kettle-cooked potato chips in Lightly Salted, Sea Salt & Balsamic Vinegar, Honey BBQ, Jalapeño and Unsalted (which I truly applaud) varieties. Various snack makers featured retro themes, such as Natural Snacks with its retro Hot & Spicy Flavored tortilla chips. Freezedried fruit snacks in convenient stand-up pouches from Funky Monkey Snacks, Fishers, Ind., feature a better-for-you ingredients list, so those with food allergies can snack worry-free. For those computer and video game enthusiasts (and who isn’t?), stand-up pouches of Gamer Grub performance snacks (produced by Biosilo Foods, Inc., San Diego) boast no keyboard crumbs and no greasy fingers, though I doubt these

are in the healthy category. And Diamond Foods, Stockton, Calif., announced that its Emerald brand’s new Breakfast on the go! Nut & Granola Mix has joined Pop Secret in support of the Labels for Education program to nourish kids’ potential and energize back-to-school sales. Seasoned nuts in more exotic flavors are a big trend. Flavors from Sahale Snacks, Seattle, include Barbeque Almonds with Mild Chipotle & Ranch, Southwest Cashew with Chile & Cheddar and Tuscon Almonds with Parmesan & Herbs. Lord Nut Levington (made by Holy Cow LLC, Irving, Texas) is a new line of seasoned peanuts that come in five varieties—the Rebel Mary variety incorporates tomato and garlic powders mixed with traditional Bloody Mary ingredients. Corazonas Foods, Inc., Los Angeles, offers kettle-style potato chips in five new gourmet options with 40% less fat than most regular chips. Plus, they are gluten-free, have no trans fat and are said to have 0.4 g. of plant sterols per serving, which helps lower LDL cholesterol. Kernel Season’s, based in Elk Grove Village, Ill., unveiled bags of popcorn in several exciting kinds that are made with its popular seasoning. But the snacking doesn’t stop with that. This month, our annual State of the Snack Industry report is a festival of snacks, covering everything from trends and analysis to product performance and packaging initiatives. We start with an overview of the market, and move into potato chips, tortilla chips, pretzels, nuts and trail mix, jerky and meat snacks, popcorn and pork rinds. We uncovered interesting market share and product category reports and interviewed various snack industry product leaders, marketers, executives and plant managers. We’ll also tell you what’s in store in the snack food industry, acting as a carnival of information for producers and suppliers alike. We hope you enjoy, so grab your favorite beverage, a napkin and take a look. SF&WB

www.snackandbakery.com

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Business Briefs

people

News

IN MEMORIUM

National Baking Week Kicks Off Aug. 29-Sept. 4 hare Our Strength, the Washington, D.C.-based nonprofit organization fighting to end child hunger in America, announces National Baking Week, Aug. 29Sept. 4, as part of its Great American Bake Sale fundraising program. National Baking Week encourages bakeries, restaurants and freestanding and supermarketbased delis to host bake sales, promotions or simply donate a percentage of sales from that week to help make sure no child in America goes hungry. “National Baking Week gives bakeries, restaurants, delis and supermarkets an avenue to support the Great American Bake Sale and help us put an end to childhood hunger,” says event director Amy Crowell. “It’s a unique way to rally employees behind a common cause, and it makes customers feel good about patronizing a business that gives back to the community it serves.” Individual bakery and deli businesses can develop their own promotions, which gives them added flexibility, according to Crowell. To access online promotion elements, visit the Bake Sale Resource Center at www. greatamericanbakesale.org.

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USDA Unveils New Food Icon n June 2, the U.S. Department of Agriculture (USDA) unveiled a replacement to its muchmaligned food pyramid, doing away with the rainbow-striped triangle with a staircase edge in favor of a simple circle designed to evoke a dinner plate, divided into four quadrants: Fruits; vegetables; grains; and protein (meat and beans). Dairy occupies a circle to the upper right of the plate. A plate symbol provides an easy-to-understand visual of how much of different types of foods Americans should be eating each day. The decades-old food pyramid was replaced with the plate-shaped icon, which experts say better depicts the balance of food groups recommended in a healthful

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diet. First Lady Michelle Obama and agriculture secretary Tom Vilsack presented the new healthy eating guide. The icon is part of a new initiative to stress habits such as eating less, filling up half your plate with fruits and vegetables and drinking more water. The USDA first introduced the food pyramid in 1992. So far, representatives from food industry trade groups are reacting positively to the change. The American Bakers Association, Washington, D.C., reported that it’s coordinating the joint response by a dozen groups representing the grain industry. This includes a joint press meeting with members of its nutrition advisory committee to discuss the impact of the new icon on grain foods.

Earl John “Bud” Gilmartin, Jr., Commercial Creamery Co. Earl John “Bud” Gilmartin, Jr., president of Commercial Creamery Co., Spokane, Wash., passed away recently. In 1933, Gilmartin purchased Gold Medal Dairies from Kraft Foods, and in 1948, purchased Commercial Creamery Co., where he became president and added manufacturing plants in Afton, Wyo. (1973); Jerome, Idaho (1977); and Louisville (1986). Gilmartin also started several other companies with partners including an egg business headquartered in Hong Kong and a flavor business headquartered in New York. He served on Gonzaga University Board of Regents, his alma mater, as well as many boards having to do with the food industry. In lieu of flowers, memorial contributions may be made to the Bud Gilmartin Fund at Gonzaga University, Attn: University Relations, 502 E. Boone Ave. Spokane WA 99258. To leave a condolence, go to www. hennesseyfuneralhomes.com.

MGP Ingredients Inc., Atchison, Kan. Ashley Gill has been named communications specialist, responsible for assisting with the execution of overall publicity and promotional projects, including internal communications programs and marketing communications ini- Ashley Gill tiatives. Meanwhile, Stephen Glaser was appointed plant manager at the Atchison, Kan., facility, responsible for the management of all operational activities and processes, including account- Stephen Glaser ability for plant performance, safety, environmental and quality objectives and the Continued on page 10

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Jodie Morgan has been appointed president and general manager, bringing more than 20 years experience in commercializing chemicals and food ingredients. Previously, she was president of SPI Foods, where she reorganized and repositioned the business, including negotiating long-term sup-

supplier news The Buhler Technology Group acquired Tijdhof Persmatrijzen, Oldenzaal, The Netherlands, and was integrated into the feed and biomass business unit. The management and the roughly 20 employees were retained by the company, which will be continued under the Buhler Tijdhof product brand. ENRECO obtained third-party verification of a five-log kill step for its flaxseed ingredient processing lines, reaffirming the company’s commitment to operate in accordance with the Global Food Safety Initiative. Delkor has been named as the exclusive distributor for HMPS, a leading Australian packaging machinery manufacturer. Delkor will provide cartoning equipment for HMPS’ Australia and New Zealand markets.

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Damien Perocheau has been named regional manager of the French operations, responsible for developing new and existing customer relationships and driving sales in the French market. He will work with current French customers, and focus on driving business growth, developing new relationships and boosting the company’s French sales.

Omega-9 Oils from Dow AgroSciences helped remove more than 1 billion lb. of saturated and trans fats from the North American diet, thanks to its new line of NEXERA canola and sunflower seeds. Blommer Chocolate is tripling capacity of its 85,000-sq.-ft. Campbellford, Ontario plant, which manufactures specialty and cocoa-based coatings and protein-forti-

fied products for the confectionery, snack and nutritional bar markets. The expansion is expected to be completed in the fourth quarter 2011. Loma Systems, an ITW co., created a strategic partnership with Dorner Manufacturing for the manufacture of conveyors for sanitary applications. This partnership allows both companies to offer proven, sanitary inspection solutions to a wide range of applications. Spraying Systems released a 72-page tank cleaning catalog called the “TankJet Tank Cleaning Products.” This catalog provides complete information on automated tank cleaning equipment and provides users on how they can increase production time and reduce labor costs without compromising cleaning effectiveness. The catalog also reviews key selection factors such as spray distance, impact, flow rate and coverage and offers guidelines, technical specifications and a list of tank cleaning accessories.

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. www.snackandbakery.com

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STATE OF THE SNACK INDUSTRY Snack Food & Wholesale Bakery chats with snack manufacturers to learn

more about new products, new packaging concepts and innovative ingredient solutions—all factors in developing a picnic of fun-filled fare. Potato Chips . . . . . . . . . . . . . . .18 Potato chips have been around for ages and are a simple but fantastic idea in origin. But one thing’s certain: They’re as classic as a state fair.

Tortilla Chips . . . . . . . . . . . . . . .26 Today’s tortilla chip makers prove that all it takes is a blend of bold flavors, zesty spices and some pizzazz in a bag in order to keep the fiesta goin’.

Pretzels . . . . . . . . . . . . . . . . . . .32 Pretzels are evolving and taking on an actionpacked Mad Mouse ride of bolder flavors, different spins on ‘tried-and-true’ recipes and sandwich fillings of sweet or savory varieties.

Crackers . . . . . . . . . . . . . . . . . .40 Cracker producers have redefined what crackers represent to consumers—whether they’re a stand-alone item or a complementary piece to a larger snacking solution, they’re filling the void for fun-filled snacking occasions.

Popcorn . . . . . . . . . . . . . . . . . . .44 Recent popcorn introductions offer up robust flavors, healthier formulations and convenience—an amusement park of ingredients for summertime snacking.

Nuts & Trail Mix. . . . . . . . . . . . .48 Nuts, trail mixes and nut-and-fruit confections offer consumers convenient, flavorful pickme-ups, as they try to get the most out of each summer day.

Jerky & Meat Snacks . . . . . . . .54 Even though the temps outside may be striking a new high, today’s jerky and meat snack manufacturers are still raising their own heat with hot flavorings and spicy offerings.

sponsored by

Pork Rinds . . . . . . . . . . . . . . . . .58 New varieties and larger portions give pork rind-loving consumers even more snacking options. www.snackandbakery.com

July 2011 - Snack Food & Wholesale Bakery

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S TAT E O F T H E I N D U S T RY Overview

Carnival of Snacks

Whether it’s a picnic, a ballgame, a county fair or just lounging in the sun, the state of the snack industry proves that consumers are in for one wild, fun-filled, tasty ride. Marina Mayer, Executive Editor

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oday’s snacks don’t need to don fancy costumes or hide behind magical face paint to garner attention. They also don’t require stunts, tricks or fictional characters parading around the plaza. That’s because many snacks maintain authenticity, originality, innovation and pizzazz. They are themselves, showing off their tried-and-true attributes, complete with hot and savory flavorings, convenient and easy-open packaging concepts and are on a mission to provide consumers the tastiest, yet healthiest snacks possible. Whether it’s a beef jerky stick laden with hot spices, crackers that put the fun in functional, chips that feature a bevy of shapes, sizes and textures, pretzels that

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garner a new twist or those hybrid items that don’t yet seem to have a specific home on the shelf, the snack aisles are sure to be set ablaze with fun-filled options.

Figures don’t lie According to Chicago-based SymphonyIRI Group, the salty snack arena remains the highest grossing segment in the snack industry, with $13 billion in 2010. Categories such as potato chips, tortilla/tostada chips and cheese snacks garnered a majority of the winnings, raking in $4.8, $3 and $1.2 billion, respectively. The cracker category roped in $4.4 billion in sales, with all other crackers (excluding breadsticks, graham crackers, matzah, saltines and those with fillings) accounting

for $3.1 billion in sales. Snack nuts experienced $2.7 billion in sales while dried meat snacks saw $1.3 bil-

www.snackandbakery.com

S TAT E O F T H E I N D U S T RY

lion. Miscellaneous snacks, such as apple chips, carob-, yogurtand chocolate-covered snacks, nutritional snacks and trail mix took in $606.8 million in sales.

Snackscapade “[The snack category] is a great place to be,” says Jeff LeFever, director of marketing for Jack Link’s Beef Jerky, Minong, Wis. “The trend toward snacking as a behavior is only getting stronger. If the industry listens to consumers and stays ahead of changing wants and needs, the future is going to be very, very bright.” Trends such as better-for-you, unique flavor combinations, spicy and ethnic flavors and all-natural top the charts, says Steve Sklar, senior vice president of marketing for Inventure Foods, Phoenix, Ariz. To stay on trend, in July 2010, Inventure Foods debuted Boulder Canyon brand Hummus & Sesame chips, which are lightly

salted with hummus and sesame seeds and are a good source of fiber. Inventure Foods also expanded its TGI Friday’s line of snack items to include Jalapeño Cheddar Crunchy Cheddar Bites. These zero-trans-fat snacks blend jalapeño spices and cheddar cheese to deliver crunch and spice in every bite. Also hopping on the hummus ride is Houston-based Simply 7 Snacks, which in February introduced hummus- and lentil-flavored chips. The hummus chips come in Sea Salt, Tomato Basil and Spice Chili Pepper options, while the lentil ones are available in Sea Salt, Bruschetta and Creamy Dill. “Our products match up well with the trend toward more ethnic and Mediterranean foods, especially the growing interest in hummus among American consumers,” says Paul Albrecht, brand manager. “The very introduction of our products is a competition in a new category. The salted snack arena is dominated by potato chips, and while there has been great innovation in the methods to process and cook potatoes,

there hasn’t been a lot of innovation away from potatoes in different ingredients. We are trying to challenge the potato chip dominance by offering a better-for-you alternative made from unique ingredients. Hummus chips and lentil chips are creating a brand new category within the salty snack aisle.” For companies such as FunkyChunky, Inc., St. Edina, Minn., finding just one snack arena to participate in isn’t good enough. That’s why it nixed the traditional segments and blended sweet with salty to create the ultimate party of snacks. FunkyChunky’s newest creation, ChipZel-Pop, blends crisp potato chips, crunchy pretzel sticks and buttery caramel corn and with caramel and milk, Continued on page 14

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S TAT E O F T H E I N D U S T RY Overview Furthermore, Crips Snacks, based in Derbyshire, London, created Crips 99Cals, which are crunchy, oven-baked wheat and potato snacks that offer 70% less fat than traditional fried potato chips and deliver just 99 calories per pack. They come in Thai Sweet Chilli, Sea Salt & Balsamic Vinegar and Mature Cheddar Spring & Spring Onion varieties in 0.79-oz. bags. “The new packs are designed to offer something low in calories and fat, but without sacrificing the crunch, taste and eating experience of more traditional snacks,” says Gareth Smith, managing director.

The fruits of the carnival

Continued from page 13

white and dark chocolate drizzles. This funfilled snack attack is hand-crafted in small, made-to-order batches, is OU-dairy certified kosher and comes in 8- and 20-oz. canisters. “The salty/sweet combination continues to be a big hit in our business mix,” says Ronni Feuer, founder of FunkyChunky. While some consumers are craving for the sweet and salty mix, others are opting for a more baked version. Case in point: Last year, Snikiddy, LLC received so much positive feedback from its Snikiddy Baked Fries that it added Barbeque and Sea Salt Baked Fries to the mix. “Americans love their French fries, but not necessarily the guilt that comes with eating them,” says Mary Schulman, cofounder and vice president of marketing of the Boulder, Colo.based snack producer. “Now they can fulfill

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their craving with a healthy version of fries. These two new flavors are our first dairyfree/vegan options.” In May, MARS Chocolate North America, Hackettstown, N.J., expanded its Combos team of baked snacks to include a Buffalo Blue Cheese Pretzel variety. “This new flavor features the zesty combination of Buffalo wing sauce and blue cheese surrounded by a crunchy pretzel exterior,” says Tim Quinn, vice president of trade development. “This cheesy, crunchy snack is made with real cheese and is oven baked to create a hearty snack that satisfies hunger.” Late last year, MARS also introduced revamped the packaging, complete with brighter colors and eye-catching graphics that add “hunger appeal” to each bite. “Each bag includes a photo of the food representing the Combos snack flavor from a slice of mouth-watering pizza to a bowl of zesty salsa,” Quinn adds.

Whether it’s fun in the sun or a lounge in the shade, sometimes even the healthiest snacks don’t curb that sweet tooth. That’s why some snack manufacturers turned to fruit to liven up their portfolio and offer consumers something sweet, healthy and tasty in a fruit-filled way. For instance, Peeled Snacks added organic Cherry-go-round to its Fruit Picks line of grab-and-go snacks. These gluten-, dairyand wheat-free snacks are sourced from all-natural cherries picked from small farms and deliver fiber and vitamin C. “We source Continued on page 16

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organic ingredients whenever possible, and we are dedicated to providing the healthiest snacks possible for a market of consumers demanding nourishing and tasty snacks,” says Noha Waibsnaider, chief executive officer of the Brooklyn, N.Y., company. Meanwhile, Healthient, Inc., Jupiter, Fla., debuted Crispy Fruit, a line of freeze-dried fruit snacks that are made from 100% fruit and contain no added sugar, preservatives, fat or cholesterol. This on-the-go snack comes in a 20-serving, 0.35-oz. variety pack of Pineapple, Banana and Fuji Apple varieties, which dole out 34, 61 and 47 calories, respectively. The 100-calorie FruitziO product line, produced by Crispy Green Inc., Fairfield, N.J., now includes freeze-dried kiwi options. Made with the finest freeze-dried kiwi fruit slices and a hint of pure cane sugar, this snack delivers a sweet and tart taste.

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As with any seasonal festivity, once the ride is over, the carnival packs up and leaves town until next year. However, the snack industry is here to stay year-round. “The snack food industry is growing every day,” Albrecht says. “New innovations, creativity and variety in snacks and brands continue to appear in rapid succession. We try to stay at the forefront of this activity

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hen it comes to picnics, carnival rides and barbeques, making sure that snacks are safe and healthy for young kids tends to be a top priority. That’s why Plum Organics, Emeryville, Calif., is urging babies to “eat your colors” with Super Puffs, babyfriendly snacks made with real organic fruits and vegetables and are fortified with vitamins and minerals. Touted as “super yummy,” these USDA-certified organic snacks come in 100% BPA-free containers that can be recycled or repurposed for storage, arts and crafts and more. These wheat-free puffs are available in Super Yellows (Banana and Peach), Super Purples (Blueberry and Purple Sweet Potato), Super Reds (Strawberry and Beet), Super Oranges (Mango and Sweet Potato) and Super Greens (Spinach and Apple) varieties.

S TAT E O F T H E I N D U S T RY Overview and create products that no one has seen before while sticking to our core values of a simpler, healthier snack.” That’s why brands must continue to provide quality ingredients with flavors consumers love, Quinn adds. “The key to producing a fun-filled product is continuing to answer consumers’ taste for great flavors that are on-trend,” he notes. “There is tremendous opportunity in anticipating consumer trends and responding to them in a nimble manner. We have found that ‘getting closer to our consumers’ offers the greatest opportunities for growth. And in challenging economic times, offering value to the consumer is another enduring opportunity.” From chips to pretzels to beef jerky and nuts, today’s snacks don’t need any fancy gimmicks to woo consumers—they just need to be their fun-filled, better-for-you selves. SF&WB

Pump Up the Volume

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verything pops with Pringles, but this time, the coveted brand produced by Cincinnati-based Procter & Gamble is pumping up the volume. Now through Oct. 31, consumers can send in their receipt from any four Super Stack cans of Pringles and receive a free Pringles-branded speaker device. “Pringles is about unexpected fun and good times,” says Kristin Herrmann-Ratz, brand manger for Pringles. “The new Pringles’ speaker is just one more way to make good times even better wherever you are.” The device is designed to fit on the top of any empty Pringles can, using the emptiness to amplify the sound when attached to an MP3 player.

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S TAT E O F T H E I N D U S T RY Potato Chips sponsored by

Potato Chip Playground Potato chips have been around for ages and are a simple but fantastic idea in origin. Still, one of the industry’s most beloved snack foods, they run a Tilt-a-Whirl of flavors with shelf appeal, shapes and varieties. But one thing’s certain: They’re as classic as a state fair. Lauren R. Hartman, Editor-in-Chief

M

ost of the stories about potato chips involve their invention pegged around 1853 by a cook named George Crum, who resided somewhere along the East Coast (many websites reference New York). The stories involve Crum’s fried potatoes being returned to the kitchen because they weren’t crunchy enough, so he ended up dumping

the slices into hot grease and the rest, as they say, is history. It’s obvious that potato chips are evolving and will continue to do so for many generations to come, with new yet familiar tastes, spicy flavorings and premium ingredients. Healthier, less “bad-for-you” options are already surfacing. In these difficult times, as

Potato Chips

THE TOP

10

(For the latest 52 weeks ending Mar. 20, 2011) Rank

Dollar Sales (in millions)

Brands

1

Lay’s

2 3

% Change vs. Previous Year

Dollar Share

Unit Sales (in millions)

Unit Sales % Previous Year

$1,270.1

4.5

26.6

730.2

+0.3

Ruffles

$547.6

+14.9

11.5

273.2

+20.4

Wavy Lay’s

$327.8

-6.3

6.9

125.0

-4.6

4

Pringles

$320.6

+1.1

6.7

200.8

+2.2

5

Private Label

$270.9

-2.4

5.7

166.4

-3.6

6

Lay’s Natural

$207.8

+2,029.9

4.4

75.2

+2,820.7

7

Utz

$173.5

+1.1

3.6

105.9

+2.1

8

Lay’s Kettle Cooked

$146.6

-21.2

3.1

66.7

-15.7

9

Baked Lay’s

$131.0

-8.0

2.7

53.2

-6.5

$124.8

+11.2

2.6

51.6

+17.9

$4,774.0

+3.3

100.0

2,495.

+4.5

10

Kettle 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)

Chicago-based market research firm SymphonyIRI Group’s research indicates, consumers may not be snacking as much as they have in the past, still troubled with the economy and rising food prices. About 42% of the consumers surveyed by SymphonyIRI said they are spending less right now on snacks overall, while 30% are trying to make snacks last longer and are snacking less frequently. Another 25% are eliminating impulse snack purchases at the supermarket. Snack manufacturers are feeling the pinch, too. The Snack Food Association, Arlington, Va., reports that more than 40 snack food executives met with members of Congress and key staff members in May, asking for help with soaring commodity costs as part of the association’s 2011 Legislative Summit. Yet the potato chips sector grew 22%, claims a new report from Mintel, which also says that smaller segments like popcorn and cheese snacks showed the growth of 17% and 20%, respectively. “People bought more chips during the recession because they’re a good value,” says Chris Haack, senior analyst at Mintel, Chicago. “As the economy gets stronger, we expect annual sales increases to slow, but we don’t expect markets to contract. New product innovations and the changed eating habits of many Americans will keep shoppers headed towards the snack aisle.” Continued on page 20

18

Snack Food & Wholesale Bakery - July 2011

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S TAT E O F T H E I N D U S T RY Potato Chips Continued from page 18

In that regard, Natural Snacks, LLC, Addison, Ill., sees big demand for low salt/sodium and all-natural ingredients. “Consumers are more likely to purchase a better-for-you snack than junk food,” says Christine Brown, director of marketing. “Also, the way snacks are being processed is changing, from fried to baked to popped. We’re leveraging these trends with new products such as our line of kettle-cooked potato chips, which are reduced fat, low sodium and with the majority of them having zero g. of sugars.” The cooked chips contain 40% less fat, she says. They are available in Lightly Salted, Unsalted, Honey BBQ, Sea Salt & Balsamic Vinegar and Jalapeño varieties. Launched in March, they come in a singleserve 2-oz. bag, as well as in 5-oz. bags that sell for $1.19 and $2.99, respectively. Natural Snacks’ products are made with all-natural ingredients and no preservatives, artificial colorings, artificial flavorings, hydrogenated or partially hydrogenated oils, monosodium glutamate, wheat or gluten, Brown points out. “Consumers are looking for quality food without cutting corners for the best price. They are also looking for snacks that will minimize health conditions or manage health issues, such as low sodium, low sugars and low fat,” she says. “They want a benefit factor: Snacks that add protein/fiber/antioxidants. Our focus is to meet that demand. The numbers we are receiving indicate that organic snacks are experiencing 8% growth versus natural snacks, which are seeing 7% growth.” Brown adds that Natural Snacks is expanding into local markets and also into the vending arena. “Our 100-calorie products meet the educational nutritional guidelines and our vending partners are growing in the ‘healthy vending’ category,” she adds. Thus, the meager chip isn’t so meager any more. Snacks are moving toward healthier, often all-natural ingredients and away from indulgence. Both the healthier and the all-natural segments are growing, Brown says. “Consumers will also shop price before brand, so you need to give

20

Snack Food & Wholesale Bakery - July 2011

them all of that.” Other projects Natural Snacks is working on include an aggressive search for compostable packaging. The company also started to see retailers minimize their private-label stock. “You respond to that by keeping pricing competitive, without compromising the quality of the product or the brand,” says Brown. “We are seeing nutrition keys on the front of packages. So, starting with our new kettle-cooked ripple potato chips, we are also adding this benefit to our packaging. It’s easier for consumers to see what the nutritional facts are.”

Major milestones Chip companies such as Utz Snack Foods, Hanover, Pa., are celebrating quite a bit of longevity these days. Utz, for example, reached its 90th anniversary and marked the occasion with commemorative 90cent chip bags. The company has been a fixture in Hanover, starting when Bill and Salie Utz began making kettle chips in their kitchen. Now, Utz employs more than 2,200 people, has four manufacturing plants and produces a full line of snacks. “We’re hoping to spur some interest with the 90-cent bags, let people know we’re here and still successful,” says Tom Dempsey, president. Each week, Utz produces more than 1 million lb. of potato chips. “Number one, you can’t do it without luck and No. 2, you need vision,” says Dempsey. “The Utz Rice family has brought vision, and we took advantage of expansion, so we’re probably the biggest regional snack company or at least close to it in the potato chip perspective.” “Consumers are looking for food that is all-natural,” adds Utz’ Alec Sivel, vice president of marketing. “More than 50% of Utz’s snack line is all-natural, and has been from the start. These snacks are made with only

the finest quality products, with no preservatives, monosodium glutamate, artificial flavors or additives. All-natural doesn’t only apply to Utz non-seasoned items—many of our seasoned items such as BBQ Chips, Smokin’ Sweet Kettle Classics Chips, Cheddar Cheese Sunflower Chips, Butter and White Cheddar Popcorn, Sweet Chili and Salsa Fresca Rice Crisps are all-natural. Our best selling item, Regular potato chips, is not only all-natural, but contains the lowest sodium levels in the industry…another emerging consumer trend.” Other trends Sivel sees include the growth in functional foods. “Foods that can provide extra nutritional ingredients such as whole grains, fiber and calcium,” she says. “If competitive items seem comparable on all fronts (price, weight, etc.), but one item offers an added nutritional benefit, then it’s our opinion that the consumer will more often than not choose the one with the added nutritional benefit.” But the hottest trend right now is the huge interest in healthier foods. “Healthy has morphed from low fat, low calories to all-natural and fortified,” she says. “’Betterfor-you’ no longer means snacks that help you watch your weight; it now represents foods that can provide nutritional benefits as well. Meanwhile, Herr Foods, Inc., Nottingham, Pa., toasted its 65th year of producContinued on page 22

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S TAT E O F T H E I N D U S T RY Potato Chips Continued from page 20

ing various snacks such as potato chips, pretzels, tortilla chips, cheese curls and pork rinds. And there are countless other chipmakers celebrating milestones with new

chips in snazzy jalapeño and chili flavors, sophisticated balsamic vinegar and sea salt versions and new cues on barbecue, which is as popular as ever. But barbecue is now even morphing into hickory or honey barbe-

cue and more. For example, Herr’s joined forces with T.W. Garner Food Co., the Winston-Salem, N.C., maker of Texas Pete to bring Texas Pete hot sauce chips to the Herr’s lineup. “This new flavor of Herr’s chips is guaranteed to be one hot item,” says Ed Herr, president. “Hot sauce lovers, your chip has come in.”

Seasonings to savor Shearer’s Foods, Inc., Brewster, Ohio, launched chips with 0 g. trans-fat under its Shearer’s line. Available in Classic, Rippled, Barbeque and Sour Cream & Onion options, the chips are made with 100% premium high-oleic canola oil. “’Better-for-you’ products that also taste great is an emerging trend,” reports Jeff Binczyk, vice president of marketing for Shearer’s Foods. “Consumers want their healthy foods, but they aren’t willing to give up taste.” Binczyk says a hot trend is the ability and willingness for consumers to try new seasonings and flavors. “Food is very dynamic right now, with consumers viewing shows on the Food Network, for instance, that are romancing food and driving experimentation.” Shearer’s Rippled Home Run Hot Dog potato chips, which in May starred on Food Network’s Unwrapped series, maintain a classic take on American food. The chips, packed in 11-oz. bags, are loaded with the classic hot dog flavor of plump, juicy wieners smothered with mustard and relish. The seasoning was developed by a Shearer’s product development team along with its seasoning suppliers to ensure the flavors are perfectly balanced. The seasoning is placed on a special v-cut potato chip, which results in a more intense flavor experience. Creating a cult-like following, SFWB0209JR_OL.indd 1

22

Snack Food & Wholesale Bakery - July 2011

1/20/09 11:46:19 AM

www.snackandbakery.com

S TAT E O F T H E I N D U S T RY Potato Chips

the Rippled Home Run Hot Dog chips are available at grocery and convenience stores in Ohio and surrounding states, as well as through Shearer’s online store at www. shearersstore.com. In addition, on April 1, Shearer’s launched wild riceworks, a crisp extension of its successful riceworks brand. Wild riceworks is a hybrid between a chip and a cracker. Available in Sea Salt and Black Sesame Seeds, they are all-natural, gluten-free and provide a good source of fiber. Black sesame seeds are also a hot new trend. That’s why on May 1, Shearer’s launched four new varieties (Original; Rippled; Barbeque; and Sour Cream and Onion) that have 0 g. of trans-fat and are cooked in canola oil. Binczyk says that in this economy, consumers want and love to snack. “We operate in a competitive category, with lots of price promotion and new item activity. As far as organic versions are concerned, our portfolio of these products is quite limited,” he says. “The snack category is very impulse-driven, so features and displays drive high lifts for our products. Space is limited for these types of vehicles, however, so we need to be fact-based in gaining this type of real estate in a retail store.” Shearer’s makes both branded and private-label products, so he knows there’s a place for both types of product at the supermarket. “Both products need to provide differentiation and be of high quality for this to work,” Binczyk adds. [Editor’s update: Shearer’s recently opened a plant in Massillon, Ohio, which is the world’s first LEED Platinum snack manufacturing facility. The company is in the process of rolling out a second phase of the plant, as well as communicating the benefits of a sustainable manufacturing facility to consumers.]

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“We now have national distribution, with multiple plants across the United States,” Binczyk points out. “Filling in those geographic distribution gaps is a focus for us right now.”

Kettle chips go Hawaiian and then some As many chipmakers attest, exotic flavors are a popular trend this summer, and one indication is Hawaiian-brand kettle-style Continued on page 24

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July 2011 - Snack Food & Wholesale Bakery

23

Puzzled about color selection?

Potato Chips Continued from page 23

The solution is ROHA.

potato chips and snack rings, which became available nationally this spring from Pinnacle Foods, Mountain Lakes, N.J. The line offers four exotic and unique options, including Original, Luau BBQ, Sweet Maui Onion and Wasabi. Having a loyal following on the West Coast, the Hawaiian brand brings something unique to the supermarket, says Terri Barberi, brand development manager in the specialty foods division of Pinnacle. With the tagline, “Lolo ‘Ono,” which translates to “crazy delicious,” Hawaiian kettle-style potato chips use a traditional Polynesian recipe that originated the chips. Hawaiian kettle-style potato chips and snack rings are recognized not only for superior taste and quality, but also for the artistic, colorful, tropical artwork that appears on the packaging. “We are delighted to bring a taste of the islands to the rest of the country to expand people’s taste horizons,” says Barberi. “The distinctive flavor profiles, crunchy texture and unique packaging all combine to offer consumers a product that is above comparison, and we know they’ll love it.” Hawaiian kettle-style potato chips come in 2-, 8-, 16- and 32-oz. bags and sell for $2.99-$3.49. They are distributed by Tim’s Cascade Snacks, Algona, Wash., and Snyder of Berlin, Berlin, Pa.

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