Snack & Bakery - 07 JUL 2009

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Trade Magazine of the Snack Foods and Baked Goods Industries

Transcript of Snack & Bakery - 07 JUL 2009

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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 qualifi ed individuals. Annual rate for subscriptions to nonqualifi ed individuals in the U.S.A.: $104.00 USD. Annual rate for subscriptions to nonqualifi ed individuals in Canada: $137.00 USD (includes GST & postage); all other countries: $154.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2009, 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 offi ces. 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 Bleuchip International, 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 Gisele Manelli at (847) 405-4061 or [email protected].

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Contents

Columns 8 | Editor’s NoteMany Americans need to take personal responsibility for their poor eating habits, especially when they are dining out, says editor Dan Malovany. To be healthy, people need to practice what they preach.

52 | Engineering ManagementOur award-winning columnist, Jeff Dearduff, advises that plant personnel go below the surface and take a more proactive role in cleaning their facilities.

66 | The Final WordManaging editor Marina Mayer creates her own chip fl avor, thanks to a Create-a-Chip Kit and a couple of experimental spices.

Cover Story12 | Breaking the RulesFirst, Ozery’s Pita Break redefi ned the pita bread category with innova-tive, nutritious products. Now, the newly named Ozery’s Bakery plans to reinvent the fl atbread and sandwich bun categories.

Plant Story18 | Breaking New GroundWith its current production facility quickly maxing out on capacity, Ozery’s Pita Break prepares for the future by starting up a new 90,000-sq.-ft. plant later this year.

36 | iba 2009 Show PlannerIt’s time to start planning for the World of Baking show, which runs from Oct. 3-9 in Düsseldorf, Germany. If you haven’t made your travel plans yet, we’ll give you some helpful information. In addition, get a sneak preview of what some key exhibitors will be showing at this year’s event.

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Contents

Peter Havens Senior Group [email protected] Bean [email protected] 847-405-4074

Editorial Dan Malovany [email protected] Mayer Managing [email protected] J. Escobedo Senior Art Director

Advertising & Internet Sales Barbara Szatko Senior Sales [email protected] 630-527-9927Lisa Calhoun Advertising Production [email protected] 847-405-4041Sharon Ward Classifi ed [email protected] 847-405-4078Deb Soltesz Reprints Sales [email protected] 248-786-1405

Support Services Michele Weston Rowe Marketing Director

Audience Development Christine A. Baloga Corporate Audience Development DirectorKourtney Bell Audience Development ManagerMegan Neel Multimedia ManagerCarolyn Alexander Audience Audit CoordinatorList Rental Postal contact: Rob Liska at 800-223-2194 [email protected] contact: Shawn Kingston at 800-409-443 [email protected]

BNP Corporate Timothy A. Fausch PublishingJohn R. Schrei PublishingChristine A. Baloga Audience DevelopmentSteve M. Beyer Custom MediaRita M. Foumia Corporate StrategyScott Kesler Information Technology Vincent M. Miconi ProductionLisa L. Paulus FinanceMichael T. Powell CreativeMichele Weston Rowe MarketingNikki Smith DirectoriesMarlene J. Witthoft Human ResourcesScott Wolters Conferences & EventsSarah Corp Clear Seas Research

BNP Media Helps People Succeed in Business with Superior Information

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

Ingredient Technology26 | No Holds BarToday’s bar producers will stop at nothing to deliver innovative, better-for-you products, and they are even turning to social media outlets to get the word out.

34 | New ProductsRead about some of the most recently introduced products, including DynaBites bite-size protein cookies, Barbara’s Bakery snack mixes, Snack Patrol’s Cheese Jerky and Meringues cookies.

48 | Something SpecialToo much starch doesn’t have to be a bad thing, especially when today’s ingredient manufacturers are pushing the enve-lope to bring better-for-you options in a tasteful manner.

Production Technology54 | Going GreenIn these challenging times, “sustainability” takes on multiple meanings. For some bakers, it’s all about different shades of green, as in saving the environment and money, as well.

Snack Food Today60 | Lesser Than EvilIn today’s ghoulishly gloomy world, it’s diffi cult for some compa-nies to believe in superheroes. But LesserEvil Brand Snack Co. continues to fend off darkness with brightly colored products and a virtuous plan.

Production, Technology & Product Development Solutions for a Changing Industry.

JULY 2009 Vol. 98 No. 7

Coming Next MonthStarr Culinary Delights brings elegant, restaurant-quality, signature desserts to in-store bakeries and retailers’ freezer case. Find out how this Mississauga, Ont.-based company custom designs signature products with ease, and join us on a tour of its ever-expanding bakery.

In addition, SF&WB talks to the leaders in the tortilla industry to uncover the latest trends and new products impacting this category for our Tortilla Trends special report. Plus, get a sneak preview to the Tortilla Industry Association’s 20th Annual Convention & Expo, which will be held September 20-21 at Bally’s in Las Vegas.

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Editor’s Note

Dan Malovany, [email protected]

In these desperate times, yours truly is of-fering a Summertime Spectacular. Here’s three columns for the price of one. What

can be better than that?Forget I asked. Just shut up.First, when it comes to eating healthy,

it’s a safe bet that most Americans would be lying through their teeth if they weren’t so busy stuffi ng their faces with food.

That’s been confi rmed once again in a sur-vey by Chicago-based Mintel Menu Insights that shows only 20% of consumers rank food health as an important factor when ordering dinner at a restaurant. Rather, good

old primeval factors like taste (77%) and hunger satisfaction (44%) determine what they’re looking for on a restaurant menu.

When it comes to eating out, Mintel adds, most consumers blame the restaurants. Some 54% of those surveyed noted that healthy menu items are expensive and the nutritious choices are few and far between. In fact, only 5% of new items on menus carry a nutri-tional claim, and nearly one in fi ve new items were fried, according to Mintel.

Ya’ gotta love it when people blame everyone but themselves for their lack of personal responsibility.

In my second column, here’s more data to chomp on.

Personal Responsibility

The most frequent purchasers of white and whole grain breads consume an average of 38 lb. of total bread per year, according to Catalina Marketing USA, the St. Petersburg, Fla., company that tracks actual purchasing behavior.

When it comes to white bread, 54% of buyers account for 80% of the volume of product purchased while an amazingly low 12% of shoppers generate 80% of the whole grain bread volume.

But what other products do shoppers purchase with their white or wheat bread? Looking at the top 30 white bread product

interactions, a majority of those shopping baskets also contain “kid-friendly” items, including Kool Aid, Chef Boyardee canned pasta and Little Debbie snack cakes (which take four of the top 30 slots of other prod-ucts purchased by white bread producers).

Not surprisingly, white bread customers are fi ve to seven times more likely to buy these “kid-friendly” items than the average shopper, according to Catalina’s tracking of millions of retail food transactions.

Heck, moms have to keep their children happy.

On the other hand, more sandwich-making items, as well as products perceived as healthy, are among the 30 products most frequently

purchased with whole grain bread. Little Deb-bie snacks didn’t make this list, but Kellogg’s Nutri-Grain bars and Nature Valley granola bars did, Catalina notes. Maybe there’s a slight correlation between buying whole grain breads and trying to eat more healthful foods.

Moreover, 100-calorie pack shoppers are more than 6.5 times more likely to buy products that are portion controlled, nutri-tional or diet-related. In fact, 75% of the top 30 products purchased with 100-calo-rie packs have portion, diet or nutritional attributes. Apparently, these are people who are trying to take some personal responsibility when it comes to eating more healthful foods.

That said, who buys the most chips? Ac-cording to Catalina, 16.3% of all shoppers generate 80% of snack chip volume. Those who love their snacks must love them a lot.

Thirdly, the Holsum branded bakers are teaming up with the Muscular Dystrophy Association (MDA) to help make a difference for Jerry’s Kids this summer. Special packag-ing will be in stores the month of August, highlighting the Holsum brand’s support of the MDA. The Holsum bakers will donate a minimum of $20,000 to the organization. Each participating bakery will appear on their local Jerry Lewis Labor Day Telethon to present their portion of the donation, notes Janine Knetl, marketing manager for The Long Co. in Chicago.

The Holsum bakers walk the walk when it comes to personal responsibility. Those people who just talk the talk should keep their big yaps shut.

Editor’s Note: Go to www.snackandbakery.com and check out Dan’s exclusive online-only columns.

Ya’ gotta love it when people blame everyone but themselves for their lack of personal responsibility.

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bakery and produce their winning formulas for all to share.

All of these bakers view the California Raisin-sponsored events as an opportunity to step up on the world stage and show that they are among the best craftsmen and women in the baking world. Meanwhile, the California Raisin industry has plans to extend the overseas contests into China and the United Kingdom in 2010.

Are you artisan and commercial bakers, bakery technicians and baking teachers and students ready to prove that Americans can rise to the challenge?

Between now and August 16, the 2nd Annu-al America’s Best Raisin Bread Contest will be wrapping up, and several of last year’s winners have already turned in their next batch of for-mulas, as have a number of new entrants. You too can show your skill and gain recognition as a top baker here in the United States.

With the assistance of the best talent in America, it is hoped that bread quality can be leveraged worldwide. Help make that dream a reality, and not only will your company benefi t, but consumers in North America also will be the ultimate winners when these new products go to market.

Editor’s Note: Larry Blagg is senior vice president of marketing for the California Raisin Marketing Board, Fresno, Calif. Interested participants for the America’s Best Raisin Bread Contest should send their applica-tions to Theresa Cogswell by August 15. Or visit www.loveyourraisins.com to receive additional information.

Advertorial

By Larry Blagg

In the past 10 days, I’ve been fortunate enough to participate in and visit bak-ing schools and research facilities in the United States, Taiwan, Japan and South Korea. Amazingly, every school shares their lecturers, research and formulas. It’s also remarkable that they collaborate on articles published to further the knowledge of baking science and provide practical tips in the daily world of artisan and commer-cial baking.

On June 27, the Japan Institute of Baking in Tokyo hosted its 18th Annual California Raisin New Products Develop-ment Contest for 22 fi nalists from among a record-setting 269 entries.

Simultaneously, the SuWon Women’s School Baking Department in Inchon, Korea and the Korean Baking Association hosted its 3rd Annual California Raisin New Products Development contest, where an additional 54 entries were received with 20 fi nalists in their bake-off.

Furthermore, at the Taipei Baking Asso-ciation’s annual trade show on March 29, another 12 fi nalists from among 52 bakers competed in their 1st Annual California Raisin Bread and Pastry Bake-off.

That’s right! An incredible 375 North Asian bakers created new formulas utiliz-ing California Raisins.

Is it any surprise that the bakers and their amazing breads have helped them to become Gold and Silver Medalists in the Coupe Du Monde de la Boulangerie com-petition in Paris over the past six years?

On August 21, the 19 total winners, along with a delegation of educators and press, will descend on the Culinary Insti-tute of America (CIA) in the Napa Valley for lectures and a chance to compare their prize-winning formulas with top bakers and pastry chefs. The following day, the Asian winners will take over the CIA’s

Can American Bakers Top These Achievements?

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California Raisin

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Continued on page 14

By Dan Malovany

Alon and his brother Guy Ozery don’t believe in taking the road less traveled. To succeed in the highly competitive baking indus-

try, their company needs to blaze its own path and boldly go where no business has gone before.

That’s especially true when it comes to product innovation.

“Our philosophy when it comes to developing products is not to come up with something that’s out there and not go di-rectly against somebody,” says Alon, who with Guy is the co-president of Ozery’s Pita Break in Toronto.

“We love food. We love every city that we go to [and] every show that we go to,” he adds. “We go to restaurants and food markets. That’s how we know cities. We take ingredients from different foods and put them together and try to come up with products that aren’t already on the market.”

For some companies, rules are made to be broken. Ozery’s Pita Break takes it a step further. The intermediate wholesale bakery prefers to reinvent the rules as it goes along.

Thirteen years ago when Alon formed the company with his father, for instance,

the Rules

First, Ozery’s Pita Break redefi ned the pita bread category

with innovative, nutritious products. Now, the newly named

Ozery Bakery Inc. plans to reinvent the fl atbread and

sandwich bun market as a whole.

Breaking

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Photo by Vito PalmisanoProduct images courtesy of Ozery’s Pita Break

Guy and Alon Ozery are reinventing the pita and fl atbread categories and breaking the rules when it comes to new product innovation.

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Continued from page 12

Continued on page 16

New Products, New NameWith an ever-expanding product portfolio of fl atbread, including its all-natural whole grain line of lavash crackers, the company is once again changing its brand name for many of its new products. Although it will keep Ozery’s Pita Break name for pita items, the broader line of fl atbreads, including its OneBun, will now be sold under the more encompassing Ozery Bakery Inc. brand.

The use of the family name refl ects the continued evolution of the the company and perpetual innovation in the overall fl atbread segment. Take the bakery’s breakfast muesli,

the time, and people were buying our pitas at greater rates.”

And consumers were willing to pay $2 a package for value-added pita bread, or double what others charged.

Then the company rolled out its break-fast muesli pita, which was loaded with whole grains and other natural ingredients, and targeted a new morning eating oc-casion for the Mediterranean staple. The toaster-friendly product also had one thing that no other pita bread had.

“It didn’t have a pocket in the middle like every pita has so we broke away from the traditional pita breads and came out with something different, and this created a new category in supermarkets,” Guy says. “Eventually, it was copied by all of the other companies trying to get into this segment of the market.”

Often imitated and never duplicated, the company now has introduced its Whole grain OneBun, which is a fl at sandwich bun that can be used for “French toast, croutons, panini, toasting, dipping and even feeding the little league,” according to the back of the package. Originally, the company had developed a version of the product for a private label account a few years ago, but the latest version’s nutritional profi le features 31 g. of whole grains per serving and contains Omega-3 polyunsaturates.

“It is called OneBun because it’s a bun for everything,” Alon says. “It can be used as a mini pita. It can be used for toppings. It can be used like a tortilla or as a sandwich press. You can cut it and toast it up. You can do so many things with it that you can’t do with conventional buns. We’re very proud of it. We think it’s a great product.”

Introduced at the International Dairy-Deli-Bakery Association show in Atlanta in June, the new OneBun comes in three varieties. Currently, the 190-calorie prod-uct is available in a more conventional round shape for sandwiches and burgers. However, in addition to coming out with a consumer-friendly, 100-calorie variety, the company has developed a diffi cult-to-make, hot dog shaped OneBun that’s truly unique to the market.

the small shop in downtown Toronto served wholesome sandwiches made on all-natural pitas baked fresh daily in the back of the house. The natural evolution was to open up new stores, but when its customers kept clamoring for the shop’s unique, all-natural pita bread, the company ignored conventional wisdom and opened a small wholesale operation instead.

“At the time, all existing pita breads and fl atbreads were around 99 cents. They were cheap and thin and white and

whole wheat,” Alon recalls. “We had a line of whole grain products with multigrain, with fl ax, with spelt at

Named One of Canada’s BestIn these tough economic times, where com-panies are laying off workers, slashing pay, cutting benefi ts and demanding more work from fewer employees, not many ordinary businesses would even be considered for an award based on camaraderie of co-workers and overall employee health, happiness and wellness.

However, Ozery’s Pita Break is anything but ordinary, according to Canada’s Queen’s School of Business and Hewitt Associates, a human resources consulting fi rm.

Earlier this year, the two groups named the Toronto-based bakery as one of the 50 Best Small & Medium Employers in Canada.

“Most companies measure success by looking at the bottom line. To us at Ozery’s Pita Break, a major part of our success lies with employees’ well being,” says Alon Ozery, founder and co-president of company with his brother, Guy.

Guy Ozery notes the company offers a wide variety of benefi ts, including a loan program where one of the bakery’s 300 em-ployees can tap into to pay for an emergency medical procedure, a replacement car or other investments.

As part of the award competition, em-ployees must fi ll out surveys outlining their happiness with their job, their co-workers, company benefi ts and more. The Ozerys’ open-door policy, Guy says, is one reason for its success.

“It’s our goal to create a workplace that’s friendly, caring and just as healthful as the products we bake,” he says.

Many executives talk about how valuable their workforce is. Ozery’s Pita Break prefers to walk the walk instead.

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JULY 2009 - Snack Food & Wholesale Bakery 15www.snackandbakery.com

Company: Ozery’s Pita BreakLocation: Toronto, CanadaProducts: All-natural and organic pita breads, lavash crackers and assorted fl atbreadsSales: Around $30 million (CAD)No. of Employees: Around 300Size of Plant: 40,000 sq. ft. that houses three pita lines and one cracker line.Expansion: The company is investing $5 to $10 million to build a new 90,000-sq.-ft. plant.Distribution: Retail shops throughout Canada and the United States

Key PersonnelCo-Presidents: Alon and Guy OzeryMarketing Director: Lisa D’Ambrosio

At a Glance

The company’s fl atbreads and new OneBun line are versatile enough to be made into sandwiches or eaten by them-selves in a wide variety of occasions.

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are now considered more of a staple than an ethnic product in Toronto and through-out Canada.

“Pita is just a small part of the larger fl atbread category,” Guy says.

Despite venturing into new categories, the company remains committed to its core philosophy of developing nutritious, all-natural, Kosher-certifi ed products. Innova-tion doesn’t mean producing products that go against the Ozerys’ core values.

“As far as the ingredient trends, we have always been ahead of the market because we always use whole grains, or as much as we possibly can, and you can see today, a lot of the market has gone that way,” Guy says. “Even a larger number of companies are now going whole grains. They are following the trends of the innovators.”

Although the baking industry has embraced whole grains during the past fi ve years, many companies still use ingredients that the Ozerys won’t, including dough conditioners, shelf stabilizers or other chemical preservatives.

“It’s easy to make baked goods with chemicals because you want softness,” Alon says. “It’s a great challenge to make quality baked goods without chemicals. You pay for it with shorter shelf life, but at least, you know when you give it to your kids, you’re safe.”

It’s an oxymoron, he adds, for bakers throughout North America to develop whole grain baked goods, which he calls a “great shift toward healthy eating,” and then add ingredients such as calcium propionate.

“It doesn’t make sense,” he says. “You’re giving consumers, on one hand, healthful benefi ts, but on the other, you are adding a chemical to their product.”

Overall, fi ve of the company’s 13 all-natural pitas contain whole grains. Several products, including its whole grain pitas and its Organic Whole Wheat grain crackers, carry the Canadian Whole Grain Council’s stamp on their packages. The crackers, sold under the Skinny Dippers name, currently come in 6-in. strips that are about 1-in. wide and are sturdy enough for topping with spreads or dip. To provide

for instance. In many ways, the product isn’t really a pita. It’s shaped more like a scone or English muffi n, and it contains a variety of fl ax, crack rye, millet meal, sunfl ower seeds, rolled oat and other grains that give it a com-plex texture. A tad of honey that provides a sweet note is countered by the use of a natu-ral sour to give it its wholesome fl avor.

“People were calling it a pita bread, but it was something completely different,” Alon says. “We changed the focus of our company from pita breads to fl atbreads, and this whole family of products is doing amazing in stores.”

The strategy is to extend its unique ap-proach to new products into new avenues of growth and, certainly, beyond its line of Kosher and preservative-free pitas, which

Big Risk Pays OffAlon Ozery grew up in a household where the family celebrated special occasions by baking fresh pita. Not surprising, while attending Ryerson University’s Hospitality and Business Program, he wrote up a business plan to make pita breads in the back of the house and fresh sandwiches in the front.

His father, Al, had no food experience. He had held a number of jobs, including being an insurance agent, which he didn’t like. Overall, he was an entrepreneur at heart. So when he heard of his son’s plans, he invested his life savings, which allowed Alon to obtain a small business loan and open up a sandwich shop in downtown Toronto.

Besides, his father told his sons, he al-ways wanted to work in the food business.

“At the age of 60, when most people retire, he decided to take up the savings he had and put it into business with himself and Alon,” recalls Guy Ozery, Alon’s brother and co-president of the bakery. “Our father came in during the evening, baked all night and then took the pita bread wholesale to stores, went home, slept and went back to work.

“This is what he did at 60, 61 and 62, which is insane,” he adds. “It’s crazy. Whenever people who are in their 50s are looking for a new career, I tell them that story because it’s a wonderful story, and in this case, a success story.”

By the way, their dad, at age 73, is happily retired and traveling the world.

portion control, the company is rolling out 1-in. square ones that provide greater us-age in multiple eating occasions.

Award-winning ProductsEarlier this year, the Ozerys’ commitment to all-natural, wholesome products paid off. The company received recognition from the Ca-nadian Liver Foundation, which issued its 2009 LIVERight Awards to raise awareness of fatty liver disease resulting from poor nutrition and

Skinny Dippers are wholesome, whole grain crackers that stand up to any type of dip.

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www.Dorner.com

From food processing to final packaging, Dorner’s stainless steel conveyors will keep you moving.

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we look at North America as our market. We want to be leaders in our category and in the clean label market. How big or small? We don’t know. You don’t know, when you swing, if you’re going to hit a home run or not, but we’ll be the best that we can.”

sedentary lifestyles and is now the most common type of liver disease in North America.

In the second year of competition, the foundation received 90 submissions for awards in 12 categories. An independent panel of health experts, chefs and food edi-tors, as well as a grade school class, judged the entries for taste, visual appeal and nu-tritional value. Ozery’s Pita Break captured three awards, including best breakfast item for its Apple Cinnamon Breakfast Pita, best lunchbox item for its Flax Pita and best family-friendly item for its Morning Grains Breakfast Pita.

Because of its products’ acceptance and success, the $30 million company continues to expand distribution. In addition to 12 trucks, which distribute fresh product throughout metropolitan Toronto and the rest of Ontario, common carriers deliver product to distribu-tion centers as far as Montreal and throughout Quebec via brokers.

In addition, its products are shipped to a wide variety of retailers in dozens of states from the Northeast to the Midwest to California.

In the coming months, the company plans to broaden the distribution of its Ozery Bakery Inc. brand, headlined by the rollout of its OneBun line throughout chains in the United States and Canada.

“We changed a lot of the last fi ve years,” Guy says. “When we look at the market, we used to look at Toronto and Ontario. Today,

No doubt, the company will be looking to rewrite the rulebook as it continues to intro-duce new products in the market as well. SF&WB

Editor’s Note: Go to www.snackandbakery.com for more about trends in the pita, fl atbread and cracker categories.

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Continued on page 20

By Dan Malovany

When Alon Ozery and his father decided to begin wholesale production of pita bread a dozen years

ago, they knew they had something special.They just didn’t understand what they

were doing at that time.“We leased a 4,000-sq.-ft. bakery,

bought used equipment and did not know anything about commercial baking,” recalls Alon, co-president with his brother Guy at Ozery’s Pita Break in Toronto. “All we knew was how to make pitas at home and at the sandwich shop. Back home, we always had fresh pita breads for every fam-

ily event and that’s where the special recipe came from. It was handed down from our grandmother to our aunt to us.”

Certainly, the product quality was fi ne, but there was that little nagging issue called “making money” that eluded them.

Fortunately, someone showed them the way.

“At a certain point, we had a supplier of equipment who believed in our product who said, ‘You know, guys, I’m willing to fi nance the automation of your line. I believe in your product. I’m a little slow right now so let me build the line, and you can pay in installments,’” Alon says.

New Ground

EBR AKING

With its current production facility quickly maxing out on capacity, Ozery’s Pita Break

prepares for the future by starting up a

new 90,000-sq.-ft. plant later this year.

Photos by Vito Palmisano

Production lines at the Toronto bakery produce thousands of products an hour.

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Continued from page 18

bining it with innovation, it proved to be a winning combination.”

Alon adds that the company focuses not only about automation, but also on producing high-quality products.

“It’s [a] little labor-intensive, especially in the packaging area, but it’s worth the extra effort to have someone check each product to make sure it’s up to our stan-dards,” he says.

Today, with the existing bakery operat-ing 24 hours a day and six to seven days a week, the company is spending $5 to $10 million to start up a second 90,000-sq.-ft. operation. Unlike in the past when the Oz-erys ramped up production on their own, the company hired an engineer to oversee the proper renovation of the building and to fulfi ll their “wish list” that anticipates the business’ needs over the next few years.

“We’re making sure that everything from the drains to the walls to the fl oor to everything there is up to par,” Guy says.

This fall, Alon notes, they expect to install the fi rst line, which will produce the company’s new OneBun line, which is comprised of three varieties of extra-thin, whole grain buns that can be used to make everything from hot dogs and hamburgers to sandwiches, paninis and even French toast.

By the end of the year, it also plans to add a cracker line to bolster production of crispy, multigrain lavash fl atbreads. Pro-duction at its existing facility will remain intact as the expansion goes on. That way, the $30 million company also will have enough storage space at the two facilities to accompany future new growth and go to market with new products.

“We now know how to design a facility to accommodate everything that we need for the next few years,” Alon says. “With the larger plant, we have the opportunity to triple our sales.”

Built for VersatilityAt the current plant, the packaging crew operates on three, eight-hour shifts a day while production personnel work on 12-hour shifts, which allows them to have three days off each week, Guy notes.

with the general contractor to transform the former warehouse into a food facil-ity that’s certifi ed for Hazardous Analysis Critical Control Points and houses three pita lines as well as a lavash cracker opera-tion.

“I think the biggest thing that we offer is product innovation with automation,” Guy says. “By taking automation and com-

The rest was history. Well, almost.Riding the popularity of its all-natural,

whole grain products, Ozery’s Pita Break expanded again and again until Alon and Guy moved into their current 40,000-sq.-ft. facility fi ve years ago.

Guy, who oversaw the startup of the plant mostly by himself, logged endless hours of on-the-job training and worked

Two spiral mixers are dedicated to each production line at Ozery’s Pita Break. Typically, batches weigh no more than 440 lb. to ensure quality and product consistency.

After dividing, rounding and intermediate proofi ng, dough balls travel down chutes to a conveyor for sheeting.

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natural products. Ozery Pita Break never uses additives, preservatives, artifi cial fl a-vors or dough conditioners in its products.

As the bakery has expanded production over the years, it has improved its opera-tional effi ciencies as well. The fi rst two lines were custom designed using a combi-nation of modifi ed and existing equipment. The fastest or third line, Guy points out, currently produces about 10,000 pitas per hour and is designed with an enclosed natural gas tunnel oven that is about 90% more energy effi cient than the previous two lines.

In the new plant, Alon adds, the com-pany will use a combination of custom-modifi ed and existing equipment.

Nobody touches the dough from the moment it is mixed until the pitas, OneBun items or fl atbreads reach the packaging area, he adds.

After passing through a piston divider, the dough pieces pass through a rounder before receiving an ambient, intermedi-ate proof. The dough pieces pass down chutes, much like in a tortilla line, and simultaneously drop down onto the conveyor before traveling on multi-length

When the bakery opened a few years ago, only 40% of sales went to whole wheat varieties. Now, Guy says, whole wheat products account for 80% of the plant’s volume.

“Over the years, the ingredients used to make whole wheat products make them taste much better,” he says. “We’re now producing higher quality and better-fl avored products that are all natural, and many of them are made with whole grains as well.”

Whole wheat fl our is stored in a 53,000-lb. silo while a separate 37,400-lb. silo holds white fl our. Because of the num-ber of different products it produces, most whole grains, including spelt, fl axseed and others, come in 50-lb. bags. Some minor ingredients, like all-natural honey, feed the lines from 3,000-lb. totes.

The bakery uses two dedicated spiral mixers to feed each of the three pita lines. Typically, batches weigh no more than 440 lb. to ensure quality and product consis-tency. Additionally, most products rely on ferment from a liquid leaven system, which creates the sponge in about four to six hours to add fl avor and shelf life to the all-

An employee checks the quality of the innovative OneBun at Ozery’s Pita Break’s facility in Toronto.

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continually break the rules when it comes to innovation and perpetually break new ground in area of automation. SF&WB

Editor’s Note: Go to www.snackandbakery.com to read about the latest in equipment technology.

“We have spent a lot of time figuring out how to produce pitas in the most efficient way to accommodate differ-ent sizes and to get the quality that we want,” he notes.

To do that, Ozery’s Pita Break needs to

fi nger conveyors that align the symmetri-cal doughballs onto a third conveyor and into two sheeters.

During the process, the pieces are docked to release gas during the proofi ng and baking process. The pitas are then baked on a steel-belted oven.

“We have very high heat because we want to bake the outside, but maintain the softness on the inside,” Alon says.

After about 30 minutes in spiral coolers, the products head to the packaging depart-ment. Because the products are all natural, packaging operators wear plastic gloves.

“It’s all sterile here out of the oven because the all-natural products have no preservatives or mold inhibitors,” Guy notes.

Here, packaging operators inspect all products. Quality assurance personnel also score products prior to shipping.

“We will never automate this part of the process completely because we need people to visibly inspect every product prior to packaging,” Alon says.

The products then are bagged and receive metal detection until they’re placed in baskets for local delivery or cartoned, palletized and shipped.

The fourth line produces crackers, which are sheeted out like lavash and cut into triangles prior to baking for 30 min-utes in one of the eight rack ovens.

“This product is very dense,” Guy says. “It’s not a water-based product. It’s a grain-based cracker so it doesn’t bake quickly for one minute like with a water-based cracker.”

The new facility, he adds, will allow Ozery’s Pita Break to produce a greater amount of pitas, fl atbread and crack-ers more effi ciently. During the past year, however, the bakery also installed additional PLCs and software to stream-line production in its current operation. Specifi cally, the company has started a “war on waste” to monitor and minimize product rejects, reduce waste and improve production volume.

Going forward, Alon says, the bakery plans to focus on obtaining greater effi cien-cies as it pushes the envelop on innovation.

Fresh-baked products are packaged and receive metal detection prior to shipping.

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Business Briefs

Barry Callebaut Selects Marketing DirectorChicago-based Barry Callebaut named

Parveen Werner as director of marketing

for the Americas region. In her new role,

Werner will be responsible for market-

ing Barry Callebaut’s extensive line of

chocolate products to gourmet customers

and food manufacturers in the Ameri-

cas region, including the United States,

Canada and Mexico.

She most recently served as a market-

ing consultant for Synergy Flavors, Inc.,

and has held marketing and business

development positions with HJ Heinz’s

business unit in Chicago and with Best-

foods FoodService, where she managed

the Knorr and Legout brands.

Sarlls Becomes Fisher’s New V.P.John B. Sanfi lippo & Son selected Robert

J. Sarlls as vice president, strategy and

business development of the Elgin, Ill.-

based owner of Fisher nuts. Sarlls will be

responsible for working with the senior

management team in further developing

and refi ning the business strategy and

supporting its execution. In addition, he

will pursue new domestic and interna-

tional business opportunities, including

future acquisitions, joint ventures or

strategic alliances. A 10-year veteran of the food indus-

try, Sarlls has worked with large global

and growing, mid-sized food compa-

nies, primarily with privately held and/

or family-operated businesses across

all major industry sectors, ranging from

production agriculture to branded and

non-branded food manufacturers, food

distributors and food retailers.

people

BNP Media, the publishing company that owns Snack Food & Wholesale Bakery magazine, will join forces again with the International Baking Industry Exposition (IBIE) as an offi cial media sponsor.

BNP Media, based in Troy, Mich., is one of three major publishers that entered into agreements with IBIE as part of a co-operative effort to market the 2010 event. The other publishers are Penton Media and Sosland Publishing Co.

Offi cial media sponsorship agreements will consist of in-book and online promo-tional opportunities, support for tar-geted marketing activities and educational programming. Media sponsors also will work closely with IBIE to convey news and reports of show developments in print and electronic communications.

According to Rich Hoskins, president of, Colborne Corp. and IBIE committee chair, “The media partnerships proved to be highly valuable in 2007 — allowing IBIE to reach a broader audience and cost effectively expand the scope and frequency of its direct marketing campaign. Mov-ing forward, the IBIE Committee hopes to

build on the solid foundation that’s been established to promote the exciting new features slated for 2010.”

IBIE selected BNP Media based on its commitment to and reputation for delivering timely, relevant news to leaders in volume baking and snack food manufacturing.

Additionally, its diverse portfolio of media, including Snack Food & Wholesale Bakery, Refrigerated & Frozen Foods and Industria Alimenticia magazines among others, gives IBIE access to new markets in related food industries both domestically and internationally.

“We know that the same professionals who rely on BNP Media for breaking news about new products, healthier formula-tions, governmental regulations, etc., also attend IBIE for the knowledge and resources that will enhance their operations and improve the way they do business,” said Mike Beaty, executive vice president of Thomasville, Ga.-based Flowers Foods and IBIE committee vice chairman. “We know that many natural synergies exist between the two entities and that’s why we are ex-cited to bring them on board as a partner.”

BNP Media Becomes IBIE Media Sponsor

PepsiCo’s Frito-Lay North America division will sell and distribute a new line of meat snacks under the MATA-DOR by Jack Link’s brand. The move comes just weeks after Frito-Lay and Oberto Sausage Co. agreed to end their 10-year sales and distribution partnership with Oh Boy! Oberto branded meat snacks.

Under terms of the agreement, Plano, Texas-based Frito-Lay will distribute and sell MATADOR by Jack Link’s meat snacks beginning August 17. Existing MATADOR retail customers will receive full sales and distribution coverage through Jack Link’s direct sales and distribution partners until that time, according to the Minong, Wis.-based company. All other Jack Link’s products will continue to be sold and distributed under the current system via existing distributors, wholesalers and direct retail customers.

Other terms of the agreement were not disclosed.In April, Kent, Wash.-based Oberto Sausage fi led a lawsuit against Frito-Lay in an effort to terminate their distribution deal, claiming that sales fell

below a threshold in the original agreement. Oberto Sausage noted it was losing share to other brands in this competitive market.Frito-Lay will continue to sell and distribute Oh Boy! Oberto meat snacks to the United States and Canada until August 15. From then on, Oberto Sau-

sage will transition to its own direct sales and distribution model.

Frito-Lay Hooks Up with Jack Link’s

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Page 25: Snack & Bakery - 07 JUL 2009

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www.snackandbakery.com26 Snack Food & Wholesale Bakery - JULY 2009

Market Trends

In January, Clif Bar introduced a White Chocolate Macadamia Nut variety, which delivers the goodness of a home-baked treat with healthy ingredients. Each bar is made with chunks of white chocolate, freshly roasted macadamia nuts and rolled oats, and provides 23 vitamins and miner-als and is rich in antioxidants.

Another newly introduced option is Clif’s Builder’s Lemon bar, offering a re-freshingly smooth-and-zesty lemon fl avor. The bar contains 20 g. of protein and is made from wholesome soy and nuts, which also provides some of the key ingredients that women need.

“In our careful review of what women eat daily in comparison to the recommend-ed daily allowances,” Ferguson says, “we have refi ned the levels of vitamins and min-erals such as thiamin, copper, magnesium and bioton that women are commonly getting plenty of elsewhere in their diets.”

To provide clinically proven health benefi ts, San Francisco-based Attune

adorn the packaging while vivid pictures of strawberries, raspberries and almonds show-case all-natural ingredients.

While health and wellness continue to be at the forefront, several consumers want bar producers to take it a step further, says Michelle Ferguson, vice president of brand strategy for Clif Bar & Co.

“As more people care about their personal health and wellness, they choose more organic products,” says Ferguson of the Berkeley, Calif.-based company.

Consumers also are opting for products that provide better-for-you attributes.

Today’s bar producers will stop at nothing to deliver innovative, better-for-you products, and now in tech savvy ways.

By Marina Mayer

To be successful in today’s day and age, it’s all about making a breakthrough, standing out from the crowd and

creating new products that differentiate a brand from its competition. It’s about giv-ing consumers what they’ve been looking for or didn’t know that they were missing. And it’s about doing all of the above in the fastest, most convenient way possible.

That’s why many bar makers are separat-ing themselves from their conventional trap-pings and producing wholesome, powerful bars with a new array of benefi cial nutrients. Words like antioxidants and clean labels

No

Bar Category Totals(For the latest 52 weeks ending May 17, 2009)

Dollar Sales % Change vs. Unit Sales Unit Sales %Rank Segment (in millions) Previous Year (in millions) Previous Year

1. Granola $882.1 -1.4 338.3 -4.72. Breakfast/Cereal/Snack $720.5 +3.5 261.2 -0.1 3. Nutritional/Intrinsic Health Value $578.8 +5.0 315.8 -2.44. Rice Snack Squares $112.4 -1.4 43.5 -7.35. All Other Snack/Granola $23.5 -16.4 10.9 +5.8 Total*: $2,317.2 +1.5 969.7 -2.8

*Includes brands not shownSource: Information Resources, Inc., a Chicago-based market research fi rm, www.infores.comTotal U.S. – Supermarkets, drug stores and mass merchandisers (excluding Wal-Mart)

Holds Bar

Continued on page 28

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SERVICE AND TECHNOLOGY WORKING FOR YOU

Caravan Ingredients’ technical services team is working 24 hours a day, 7 days a week to help keep our customers at the forefront of the baking industry. From optimizing the introduction of new products, to ensuring our ingredients produce consistent, superior quality products; this team is where you need them, helping to increase your profitability.

Find out more about this value added service that Caravan Ingredients provides by calling 800.669.4092.

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Page 28: Snack & Bakery - 07 JUL 2009

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Market Trends

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dairy free. Each bar contains 5.55 billion colony-forming units of probiotics, more than what’s available in 12 cups of yogurt. And they are available in Blueberry/Acai, Cherry/Vanilla, Peanut/Chocolate Chip and Pomegrante/Goji varieties.

Odwalla’s Mocha-walla Food Bar also cures cravings for chocolate with some nutritional benefi ts on the side. Produced by Odwalla, Inc., based in Dinuba, Ca-lif., the Mocha-walla Food bars combine chocolate and coffee to deliver an energy-packed bar, fi lled with whole grains, real fruit, natural fi ber and six essential vitamins and minerals.

Fueled by a demand for tasty, yet nutri-tious snack bars, Columbus, Ohio-based Abbott Nutrition launched Dark Chocolate ZonePerfect Nutrition bars. Made with real cacao, the ZonePerfect Nutrition Bars provide an excellent source of protein, antioxidants and essential vitamins and minerals. They are available in Dark Chocolate Caramel Pecan, Dark Chocolate Mocha and Dark Chocolate Cookies N’ Crème varieties.

Likewise, GoMacro, headquartered in Viola, Wis., introduced Omega-3 Ma-croNutrient bars, which come in Banana

Foods released an assortment of probi-otic chocolate bars in Coffee Bean Dark Chocolate and Raspberry Dark Chocolate varieties, which combine the antioxidant benefi ts of dark chocolate with whole, crunchy coffee beans or sweet raspberries. Additionally, its Almond Milk Chocolate option delivers chunks of almonds in sweet milk chocolate. Each all-natural bar has less than 100 calories and is packed with more than 6.1 billion colony-forming units of probiotic cultures.

“Attune’s probiotics are clinically proven to boost immunity and support a healthy digestive system,” says Rob Hurl-but, the company’s chief executive offi cer. “Unlike yogurts and probiotic shots, the low-water content of Attune’s chocolate protects the cultures so they live longer.”

The bars also are an excellent source of calcium, deliver 3 g. of fi ber and contain less sugar that most yogurts, Hurlbut says.

“Combined with a cleaner ingredient panel, consumers can connect the dots to the health benefi ts of those ingredients,” he notes.

Furthermore, Cascade Fresh, Seattle, Wash., presented Activ8 Probiotic Crunch bars, which are organic, naturally sweet-ened with Agave and 100% gluten and

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Page 29: Snack & Bakery - 07 JUL 2009

For customers around the world, ADM draws on its resources—its people, products, and market

perspective—to help them meet today’s consumer demands and envision tomorrow’s needs.

[email protected] 800-637-5850© Archer Daniels Midland Company

TheDifferenceis Dry.ADM dry sweeteners deliver all the tastewith less waste. Conveniently packaged incartons and boxes, our powders and flakesgive you control over the flavor andconsistency of your products while reducingcleanup and the need for fluid handlingequipment. Made from honey and molasses,ADM offers a full range of dry sweetenerproducts, making us the premier resource formaking the switch to dry.

Call today for a FREEtechnical consultation.

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SNACK FOODSFOODINGREDIENTS

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Your One-Sto Baker S stems ShopYour One-Stop Bakery Systems Shop

Phone: 630.257.2900 • Fax: 630.257.3434www.dunbarsystems.com

project management

installation

start-up

conceptconcept

designdesign

engineeringengineering

SFWB07094DUN.indd 1 6/30/09 11:17:09 AMwww.snackandbakery.com30 Snack Food & Wholesale Bakery - JULY 2009

Market Trends

Continued from page 28

Continued on page 32

The company has its own podcasts, email newsletters and YouTube channel that are used to get the word out, Harr notes.

“We’re really leveraging cost-effective ways but that are actually very, very effec-tive,” he says.

For its part, Chicago-based Quaker Snack Bars connects with its customers through Twitter, Facebook and its partnership with

for Organic Food Bar, Inc., so companies have to keep abreast of their ever-changing habits and needs.

The Fullerton, Calif.-based producer of the all-organic ONE bar takes advantage of the many viral media outlets available at its fi ngertips.

“We don’t have a million dollar budget, so fortunately the playing fi eld is different now,” Harr says.

Almond Crunch, Cashew Mesquite and Chocolate Crunch varieties. These nutrient-fi lled bars are high in Omegas 3 and 6, fatty acids, fi ber and folate, and are sweetened with raw organic agave nectar.

Bookmark the BarAside from whipping up healthy-but-tasty snack bars, today’s producers also are jumping face-forward into the social media world to get their brands recognized.

For example, Attune Foods promotes its new products through the company’s Twitter and Facebook pages, in addition to its blog outreach, sampling programs and grassroots contests, Hurlbut says.

“We think innovation is the key,” he adds. “Retail customers need real innova-tion to bring consumers to their stores, and products need to deliver real health benefi ts to address the value challenge.”

Plus, consumers are becoming increas-ingly savvy, says Eric Harr, media director

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Page 31: Snack & Bakery - 07 JUL 2009

www.treetop.com

F r o m t h e T r e e t o t h e T a b l e .

You’ve got a great idea for a new hand-held snack with fruit and nuts but no time for

development. No problem…you’ve got Tree Top, the fruit experts with over 300 years

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our R&D staff can make your ideas come to life. Who knows, you might even find a few

new ideas to snack on!

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At TreeTop we’re taking an old tradition and GROWING NEW IDEAS.

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The newly redesigned snackandbakery.com brings EVEN MORE VALUE to the industry than ever before!

• View SF&WBTV – Our own 30-second video showcase where you can view production lines and other new systems at work.

• Subscribe to SF&WB’s Operations Weekly e-newsletter – The only weekly e-newsletter that covers key operational issues pertaining to volume bakery and baked snack markets.

• Link to SF&WB’s state-of-the-art Digital Edition. View current and past issues in digital format. Print, copy or forward pages to co-workers. Live links to online content and advertiser Web sites.

• Columns by editor Dan Malovany, Marina Mayer, our managing editor and award-winning Engineering Management columnist Jeff Dearduff.

• SF&WB’s Buyers Guide – The industry’s leading online searchable directory of industry suppliers, products and services.

Visit snackandbakery.com for immediate access to industry news and exclusive snack and baked goods marketplace resources.

SFWB0709ADMCO2.indd 1 6/17/09 3:26:20 PM

www.snackandbakery.com32 Snack Food & Wholesale Bakery - JULY 2009

Market Trends

Continued from page 30

social media sites like FoodBuzz.com, says Jeff Caswell, the company’s director of marketing.

“We feel this is an area where we can set ourselves apart from our competitors by interacting with our customers on an authentic and real-time platform,” Caswell says. “Through these interactions, we’ve been able to demonstrate our commitment to our consumers’ communities, talk about the issues that matter most to them and hear their immediate feedback.”

So whether it’s focusing on healthy at-tributes or the next generation of advertis-ing, snack bar producers are stopping at nothing to deliver grab-and-go products in fast and convenient ways. SF&WB

Editor’s Note: To read more about new products within the snack bar category, look for an in-depth article in SF&WB’s June State of the Industry report. And go to www.snackandbakery.com to read exclusive, un-cut versions of interviews conducted with several top play-ers in the bar aisle.

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Page 33: Snack & Bakery - 07 JUL 2009

From sourcing cocoa beans in various origins, to processing and manufacturing

chocolate, to delivering top-quality Ambrosia® chocolate to you, ADM Cocoa

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call ADM Cocoa at 800-558-9958.

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COCOA CANDY &CONFECTIONERY

BAKING & CEREALS

BEVERAGESSNACK FOODS

DAIRY

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New Products

1

2Cheese Jerky

Company: Snack Patrol, LLC, Glendale, Wis.Web site: www.cheesejerky.comIntroduced: JuneDistribution: NationalSuggested Retail: 99 cents to $1.39 for a 1.5-oz. stickProduct Snapshot: Cheese Jerky consists of shredded beef jerky that is added right into Wisconsin Farmstead string cheese. The Original variety is a combination of premium beef jerky and mozzarella cheese, and the Peppered Cheese option consists of all-natural mozzarella cheese infused with black pepper beef jerky.Ingredients (Original): Part skim moz-zarella cheese (cultured pasteurized, part skim milk, salt, enzymes), beef jerky (beef, water, sugar, brown sugar, salt, white sugar, fl avorings, monosodium glutamate, sodium erythorbate, sodium nitrate).

3Meringues Cookies

Company: Touché Bakery, Inc., Ontario, CanadaWeb site: www.touchebakery.comIntroduced: JuneDistribution: NationalSuggested Retail: $4.49 for a 2.64-oz. boxProduct Snapshot: Savor the moment with an assortment of Meringues cook-ies, which can be eaten as a snack, used to garnish a dessert or crushed and sprinkled on top of ice cream, sorbet or yogurt. Additionally, each item is pro-duced in a nut-, peanut-, sesame seed- and coconut-free facility. They come in French Vanilla, Chocolate Chip, Mint Chocolate Chip and Rainbow varieties. Ingredients (Rainbow): Sugar, egg whites, cream of tartar, natural and artifi cial fl avors and colors (contains tar-trazine), wheat fl our, skim milk powder, soya fl our.

4Barbara’s Bakery Snack Mixes

Company: Barbara’s Bakery, Inc., Petaluma, Calif.Web site: www.barbarasbakery.comIntroduced: AugustDistribution: NationalSuggested Retail: $3.99 to $4.49 for a 7-oz. bagProduct Snapshot: Delivering 120 calories per serving and 2 g. of fi ber and protein, these snack mixes offer 61% less fat than natural potato chips. Three of the varieties, Salsa, Bruschetta and Honey Mustard — featuring mustard, horserad-ish and honey — contain Puffi ns Original cereal bits. The fourth offering, Honey Cinnamon, includes Honey Rice Puffi ns. All four SKUs [stock-keeping units] also include pretzel pieces, Cheddar sesame sticks, rice puffs and garlic sourdough chips.Ingredients (Honey Cinnamon): Pretzels (unbleached wheat fl our [wheat fl our, malted barley fl our], salt, corn barley malt, canola oil, baking soda, yeast), Puffi ns Original cereal (yellow corn fl our, corn bran fl our, un-sulphured molasses, oat fl our, expeller pressed canola or sunfl ower oil, salt, baking soda, natural Vitamin E [mixed tocopherols], Vitamin C), Cheddar sesame sticks (unbleached wheat fl our [wheat fl our, malted barley fl our], soybean oil, bulgur wheat, sesame seeds, cheese powder [Cheddar cheese {cultured milk, salt, natural enzymes}, whey protein, milk sugar, buttermilk solids, salt, annatto], salt, annatto, citric acid), rice puffs (rice meal), sourdough chips (unbleached wheat fl our [wheat fl our, malted barley fl our], canola oil, corn barley malt, salt, wheat gluten, yeast and/or baking soda), honey cinna-mon seasoning (dehydrated cane juice, brown sugar, honey, cinnamon, butter [cream, salt], salt, non-fat milk solids, cit-ric acid, natural fl avor), expeller-pressed sunfl ower, saffl ower or canola oil.

1DynaBites Bite-size Dark Chocolate Chip Protein

CookiesCompany: EB Performance, LLC, Boca Raton, Fla.Web site: www.ebperformance.comIntroduced: JuneDistribution: NationalSuggested Retail: $2.79 for a 2-oz. bagProduct Snapshot: DynaBites are preservative-free, Kosher-certifi ed, dark chocolate chip protein cookies sweet-ened with organic agave syrup and made with whey protein.Ingredients (Dark Chocolate): Whey pro-tein (whey protein isolate, whey protein concentrate, hydrolyzed whey protein), enriched self-rising fl our bleached (wheat fl our, leavening [sodium alumi-num phosphate, baking soda, calcium sulfate, monocalcium phosphate], salt, niacin, reduced iron, thiamin mononi-trate, ribofl avin, folic acid), semi-sweet chocolate chips (sugar, chocolate liquor, dextrose, cocoa butter, soy lecithin, vanilla extract), organic agave syrup, canola oil, water, soy lecithin. Contains less than 2% of the following: fructose, tapioca dextrin, natural fl avor, sucralose.

3

4

2

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The World Market for Baking

iba 2009, the largest global trade fair of its kind, provides you with:

n all innovations and standards for the manufacturing of bakery products

n the latest trends in the café and snack sector, as well as in the take-away sector

n new impetus for sales and marketing

n a comprehensive, specialist fringe programme with guided bakery tours, seminars and discussion forums.

For detailed information on the exhibitors as well as travel and accommodation services go to www.iba.de

. . . everything for Bakers and Confectioners

Oct. 3-9

Kallman Associates, Inc.

20 Harrison Avenue Waldwick, NJ 07463

Tel: (201) 652-7070 Fax: (201) 652-3898

Mail: [email protected]

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Photos courtesy of iba 200936 Snack Food & Wholesale Bakery - JULY 2009 www.snackandbakery.com

iba Show Planner

Continued on page 38

A s the deadline approaches, many companies are be-ginning to make a dash to get exhibition space and to register at iba 2009, which runs from October 3-9

in Düsseldorf, Germany.For trade visitors, iba offers a wide range of products

and services in the segments of raw materials, production technology and sales. In the area of raw materials, bakers can fi nd everything from ground cereals, bakery improv-ers and ingredients to fl avorings and semi-fi nished and fi nished products.

Furthermore, exhibitors will display the latest devel-opments in production technology with energy-effi cient bakery and confectionery systems along with innovative techniques for refrigerating and freezing products. With a heightened interest in food safety, there also will be a clear emphasis on sanitation.

Moreover, bakers will discover all the latest new prod-uct trends from countries around the world. According to show organizers, one main area of focus this year will be on snacks, light meals and convenient, portable and handheld products. The baking trade in particular is cur-rently undergoing a period of rapid change due especially to the changing consumption behavior of many consum-ers across the globe. This is increasingly shifting toward eating out and is presenting the food industry with new challenges.

On iba’s Web site, bakers will fi nd an online fair plan-ner with a cost calculator and a regularly updated list of

This year’s big baking industry exhibition attracts hundreds of exhibitors from dozens of countries despite a challenging economy.

Show Attracts World of Baking

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When only the best is good enough

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How to Plan YourTrip to iba 2009If you’re looking at how to get to iba 2009 and where to stay in Düsseldorf during the show, perhaps the fi rst place to visit is www.ibe.de.

The offi cial Web site of this year’s big event, which runs from October 3-9, has almost everything bakers need to book air fare, hotel, rental cars and even dinner reservations well in advance of the show. The site also fea-tures many links to Düsseldorf’s travel bureau, the convention center and the show’s organizers.

What generates the most power?Combined forces.

Rondo Doge is now RONDO. ROndo aNd DOge are merging to create a new, strong brand. RONDO stands for the best in sheeting and shaping dough. For artisanal bakeries, industrial and more. For knowledge and experience in dough processing. For Dough-how & more. www.rondo-online.com

AD_en_9-1/8x11"_bleed_090417.indd 1 20.4.2009 11:16:59 Uhr

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www.snackandbakery.com38 Snack Food & Wholesale Bakery - JULY 2009

iba Show Planner

85% of all exhibitors and 94% of visi-tors rated iba 2006 as “excellent,” “very good” or “good.”

During these challenging times, iba 2009 provides an opportunity for bakers and others in the food industry to plan for the future and take advantage of the upcoming economic turnaround.

Go to www.iba.de for the latest in-formation on exhibiting, registering and getting to the show. SF&WB

in 2006 attended by 76,206 trade visitors from 144 countries. Additionally, there were 979 exhibitors from 49 countries who provided information about the latest developments in their branch of industry. According to show organizers,

exhibitors. The show also will provide a free airport shuttle service. In addition, the fair ticket includes the free use of the public transport system in Düsseldorf.

The iba exhibition takes place every three years. The last event was in Munich

Continued from page 36

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Kemper Bakery Systems Ltd. 3 Enterprise Drive . Suite 108 . Shelton . CT 06484 . USA . Phone 800-244-9819 . www.kemperusa.com

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MATADOR® – Stone Hearth Deck Ovens For over 60 years Werner Pfleiderer has been manu-facturing more than 60,000 MATADOR® Deck Ovens for bakers all over the world. The MATADOR® Oven is the most trusted name in deck ovens for the professional baker.

– Strong, robust, even-heating system with quick recovery for 24 hour per day production.

– NAVIGO® controls for the most precise baking & steaming, allowing each baker to achieve the same quality.

– Multiple loading options to meet every need and to grow with the bakery.

– Energy saving technology– up to a 30% savings over

similar oven types.

Call us today Phone 800-244-9819

KEMPER BAKERY SYSTEMSNorth American Subsidiary

MATADOR®

SFWB03094WPB1.indd 1 2/17/09 1:47:26 PM

www.snackandbakery.com

iba Show Planner

iba 2009 Bakery Tours, Seminars and MoreAt iba 2009, which runs from October 3-9 in Düsseldorf, Germany, North American exhibitors and visitors will be able to discover the latest in the world of baking.

Like in Munich three years ago, there will be a comprehensive program in Düsseldorf to complement the offerings of the exhibitors. Particularly worth mentioning is the iba Cup, a unique international competition for bakers and confectioners that’s designed to promote the exchange of ideas between the various baking cultures. According to the organizers of the show, more information on the iba Cup will be avail-able in the near future.

In addition, the widely popular tours of regional wholesale and retail bakeries will be offered to North American trade fair visitors to provide an insight into the expertise of German bakeries. Bakery tours are avail-able free of charge, but organized groups will be responsible for their own transportation as well as interpreters for their respective languages. If possible, touring also will be accompanied by a business consultant from the state guild association. Often times in the past, these guides provide information on the bakery in both German and English.

Most tours will be held every day during the show. More often than not, they are held in the early morning so plan on getting up before or right at the crack of dawn because you will need to take a taxi to the bakery’s operation. For more information, contact Walter Dohr at Verband des Rheinischen Bäckerhandwerks at [email protected] or call +49 (0) 203 710120.

For those interested in additional education, the Erste Deutsche Bäckerfachschule offers basic and further training by bakers for bakers. Founded in 1926, the college lies in the picturesque surroundings of the southern Sauerland region, or about a one-hour drive from Düsseldorf.

Throughout iba 2009, the institute also will be offering seminars cov-ering all aspects of baking to any guests who are interested. If requested, the college will incorporate a personalized program of events as well. For more information, contact Friedrich Wirsam from Bäckerinnungs-Verband Westfalen-Lippe at [email protected].

Check out iba 2009’s offi cial Web site at www.iba.de for more infor-mation.

Visit Us at IBA Hall 10

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Kemper Bakery Systems Ltd. 3 Enterprise Drive . Suite 108 . Shelton . CT 06484 . USA . Phone 800-244-9819 . www.kemperusa.com

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CRUSTICA+

The CRUSTICA+ for the Artisan Baker

Our most versatile breadline designed for products with high hydrations and long bulk fermen tation times. This line loves slack, extensible dough which can divide very gently and move and shape the dough through the system to retain cell structure and provide a myriad of shapes. The result? A true solution for the artisan bakeries much needed labor savings solution without compromise to quality. In fact, it produces consistent quality, day in day out!

Are you producing 3000 loaves or more daily and need to save labor and will not sacrifice quality? You must look at the CRUSTICA+.

Call us today Phone 800-244-9819

KEMPER BAKERY SYSTEMSNorth American Subsidiary

SFWB03094WPB2.indd 1 2/17/09 1:50:45 PM

www.snackandbakery.com

iba Show Planner

Düsseldorf After HoursWalking a show fl oor for hours upon hours can be tiresome. As the saying goes, all work and no play makes for a dull day. That’s why it’s important to take advan-tage of Düsseldorf’s simple pleasures after the show. Fortunately for attendees of the iba 2009 show, which runs from October 3-9 in Düsseldorf, Germany, entertain-ment awaits right outside the convention center that houses the world of baking.

For those looking for some mindless diversions, catch a fl ick at the IMAX Filmthe-ater on Worringer Strasses 142 or head up Klosterstrasse 78 for Bambi, the local theater. Movie lovers also can roam the halls of the Düsseldorf Film Museum, located at Schulstrasse 4, where they can explore a full range of fi lm history.

For a bit of fresh air, visitors can soak in the rich fragrance of Germany’s fi ne fl owers by sauntering through the Botanischer Garten, or Botanical Garden, housed on Heinrich-Heine-Universitat.

Early risers can catch the early bird special at meerbar, a quaint restaurant that caters to businessmen and women in search of a hot breakfast or brunch.

For those with a craving for burritos or tacos hit up a couple of the town’s notable Mexican restaurants such as El Ommes, Wielandstr 37, El Gitano, Sch-neider-Wibbel-Gasse 5 or venture onto Adersstr to hit El Toro or Pssst Bandido.

American visitors can get back to their roots with El Lazo, a notable steak-house located on Bolkerstrasse 40; Banana N.Y.C. on Linienstr 77; Citrus on Grunster 5 or Blockhouse with outdoor seating, situated on Blumenstrasse 2-4.

For those looking to go a little on the wild side, check out the city’s ethnically diverse restaurants. For example, Gunnewig Rheinas invites guests to sit atop a 172-metre fl oor and soak in the view of the city as the eatery softly rotates on its own axis. Located at Stromstrasse 20, diners are served fi rst-class international dishes and can choose from a list of international wines.

For food from the German homeland, go to Curry on Hammer Strasse 2. Im Schiffchen on Kaiserswerther Markt 9 offers up fi ne French cuisine. Hyuga on Klosterstrasse 78 is a recommended Japanese restaurant. Ganesha on Luisen-strasse 3 is perfect for those who have a craving for Indian food or head to Agave on Neusser Strasse 47 for Mediterranean entrees.

After a long day at the show, those bakers or suppliers to the industry can relax and throw back a beer or two at some of the town’s lineup of bars. There’s the Sinatra Club on Koenigsallee 6-8; Porky’s on Neubruckstr 2; Frontpage on Mannesmannufer 9 and Cape Coast on Roemerstr 16. Or interested guests can take a table at Miss Moneypenny on Brunnenstrasse 2/a or La Strada on Immer-mannstrasse 32; both offer breakfast menu offerings.

Most restaurants recommend that you make reservations in advance. At-tendees can do so by logging on to www.bookatable.com. This site also provides additional information about the restaurant, including average cost of a meal, hours, payment options and a map.

Walking a show doesn’t have to be a tiresome task, especially when the night-life is happening right outside the show doors.

Visit Us at IBA Hall 10

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Kemper Bakery Systems Ltd. 3 Enterprise Drive . Suite 108 . Shelton . CT 06484 . USA . Phone 800-244-9819 . www.kemperusa.com

KEMPER BAKERY SYSTEMSNorth American Subsidiary

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President 75/100/125/150/200/250 (kilo flour capacity)

The family is complete – six sizes, one concept: 1. The renowned KEMPER 3 Zone Mixing Principle

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2. The hydraulic fork locking device. 3. The double frictional wheel (DUO) bowl drive for

a smooth and stable process. 4. The ‚easy to move and dock‘-System for simple

operation with the bowl carriage. 5. The large floor clearance (approx. 150 mm). 6. Industrial Strength with automated systems!

Kemper – The mixer brand for the quality bakery!

PRESIDENT

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www.snackandbakery.com

iba Show Planner

Continued on page 42

New Product InnovationContinues in EuropeWhile new products in the U.S. baking industry are down precipi-tously in 2009, the total number of bread and bread-related prod-ucts launched in Europe this year is trending on line with previous years’ averages, according to Mintel Global New Products Database (GNPD).

Through June 11, 460 bread-related products have been launched in Europe. During the last fi ve years, total new bread products ranged from a low of 646 in 2005 to a high of 1,118 in 2008. If this year’s total new bread-related products maintained its pace, the annual number would be down from last year’s amount, but toward the high end of a fi ve-year trend for Europe.

In Germany, for instance, 62 new bread and bread-related prod-ucts have hit the shelf, according to Mintel’s GNPD. That compares to 115 for all of 2008, 74 for 2007, 126 for 2006, 51 for 2005 and 105 for 2004, Mintel reports.

In the United States, total new products in some categories have been down 50% from last year. Mintel’s analysts attribute the decline to the current recession and the unwillingness of bakers to take unnecessary risks in these uncertain times.

Rather, U.S. bakers are focusing on new packaging, deep dis-counting and other measures to spark sales of branded products as consumers tend to shift their purchases toward private label.

Breakfast, International Products Driving BakedGoods SalesMultigrain croissants and high-bran bagels are among the innovative products fueling sales of baked goods in the United Kingdom and throughout Europe, according to Mintel International Group Ltd.

Daily consumption of bread, however, has been declining steadily since 2004, with white bread consumption falling off the most as more consumers turn to whole wheat and other “brown” breads that are perceived as most healthful, notes Mintel in a report on “Bread and Morning Goods” published earlier this year.

Unlike in the United States, rolls remain most popular in the United Kingdom. Specifi cally, 80% of consumers surveyed noted that they eat rolls for breakfast. The most popular were soft bread rolls or baps, fol-lowed by crusty bread rolls and burger buns.

“Foreign” pastries such as croissants, bagels, Danish, pains au collate, sweet American-style muffi ns and waffl es were consumed by 62% of U.K. adults. Some 40% preferred donuts while 30% ate ever-popular scones.

Parbaked and baked-at-home products have not gained in popularity.“It is clear that more hectic lifestyles encourage immediate rather

Visit Us at IBA Hall 10

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Less cost

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iba Show Planner

Continued from page 41

at barbecues, Mintel analysts note. In ad-dition to dipping with hummus, consum-ers are eating more pita bread because it is perceived as more healthful than other bread products. SF&WB

Indian breads are a natural accompani-ment to Britain’s favorite dishes, which are curry-fl avored entrees. Pita bread has become an alternative to sandwich breads and as a substitute to burger buns

than plan-ahead consumption,” the report said.

Perhaps the fastest-growing breads and baked goods are those specialty and ethnic products that also have become increasingly more mainstream in the United States. They include garlic breads, Indian fl atbreads, pita bread, tortillas and wraps, and French bread just like in the States.

“The Italian segment is the most dynamic and benefi ts from widening ability and variety,” Mintel analysts noted. “Topped ciabatta, focaccia and other fl atbreads have been the focus for much product development.”

The analysts added that tortillas and wraps experienced strong growth, al-though from a small base. Mexican-style foods and multi-fl avored wraps are more widely accepted and have found a com-mon base, even in well-established bars and pubs.

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www.auto-bake.comwww.dunbarsystems.com

To see how you can free space with Auto-Bake Serpentine Systems call us for a free dvd.

Visit us at Hall 16,

Booth 16E38

SFWB07094AUTO.indd 2 7/1/09 9:29:06 AMJULY 2009 - Snack Food & Wholesale Bakery 43www.snackandbakery.com

iba Booth Profi les

alit USAiba Hall 16, Booth D21

At this year’s iba 2009 show, alit USA will present its new spiral and conveyor system, which represents an important changeover compared to the old technologies of product handling.

The engineering department has developed a unique concept, taking into consideration maximum fl exibility, space optimization and cost savings.

Visitors are encouraged to stop by the alit booth to better understand the advantages their machinery has to offer.

alit USALuverne, Minn.

1-507-449-0270www.alit.com

Auto-Bake Americasiba Hall 16, Booth E38

The Auto-Bake Serpentine modular baking system delivers greater productivity in smaller spaces. The Multizone oven’s small footprint of only 17 ft. is achieved by transporting oven trays across multiple horizontal levels.

Auto-Bake’s Serpentine proofi ng and cooling modules also provide space-saving technology, and are one of the most compact baking solutions available today.

Dunbar Systems, Inc., an exclusive U.S. representative for Auto-Bake, will be providing support at the booth, along with daily demonstrations.

Auto-Bake AmericasLemont, Ill.

1-630-257-2900www.auto-bake.com

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DFE Meincke A/STonsbakken 10

DK-2740 SkovlundeDenmark

Tel: +45 77 42 92 00 Fax: +45 77 42 92 [email protected]

INNOVATING BAKING INDUSTRY

Quality is essential

G E T Y O U R H A N D S O N T H E P E R F E C T B A K E R Y S O L U T I O N

Tailor-made baking solutions meeting

effective production systems geared to accuracy, capacity,

quality and flexibility

The DFE Meincke type Three ovens are the third generation of indirectly and directly

heated convection and radiation tunnel ovens. All ovens are pre-assembled, tested and

delivered in modules securing a fast installation time.

Hybrid ovensStone band ovensDirectly fired ovensHigh temperature ovensRadiant ovens (cyclothermic) Indirectly fired convection ovens

Please contact:Our US representative: Naegele Inc. Bakery SystemsTel: 708 671 9322

Our US office: Tel: 404 580 0416

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iba Booth Profi les

Dunbar Systems, Inc.iba Hall 16, Booth E38

Dunbar Systems’ mission is to assist its customers in achieving their “vision” by providing premier system solutions for their production needs.

Since 1982, Dunbar has continued to be a provider of knowledge-based design and engineering services to the baking industry.

Dunbar formulates these solutions with strategic analysis of the current environment, planning and design automation for optimum performance, state-of-the-art equipment and engineering services and experienced project management for precise execution.

Dunbar Systems, Inc.Lemont, Ill.

1-630-257-2900www.dunbarsystems.com

DFE Meinckeiba Hall 14, Booth A29/B30

DFE Meincke will launch an oven for bread production that combines radiation and convection heat, and is mounted with the heat recovery unit, which reduces the energy consumption by 15%.

Moreover, DFE Meincke will present a high-speed rotary moulder for cracker production, a twin-head cake depositor and a triple depositor/extruder type V50 with the newest equipment.

DFE MeinckeAlsip, Ill.

1-708-388-7766www.dfemeincke.com

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iba Booth Profi les

Fritsch USAiba Hall 15, Booth C11/D12

Eight master bakers will take turns at the Fritsch USA booth demonstrating the Laminator 300+. With the Multicut, the Laminator 300+ fi ts right in with SoftProcessing, which is designed to ensure the gentlest handling of the dough throughout the entire production process.

Fritsch also will showcase a Mediterranean croissant especially designed to show off the amazing capabilities of the SCS croissant coiler in combination with the new key-control unit for croissants.

Fritsch USACedar Grove, N.J.1-973-857-7272

[email protected]

Koenig Technology USAiba Hall 17,

Booth A30/A31/B32

Koenig will feature a wide variety of equipment at its exhibit for bakers of all sizes.

For example, Koenig, will demonstrate its stress-free roll lines that include the Artisan SFC divider, the Artisan SFR roll line, the Artisan SFI industrial line, the Ceres bread line and its Menes lamination line.

For roll producers, the company will feature its KGV industrial roll plant and its Combi line roll plant. Bakers also can check out Koenig’s Roto Passat oven and its array of spiral and twin mixers.

Contact Rich Breeswine, national sales manager, for more information.

Koenig Technology USARichmond, Va.

1-804-377-9620www.koenig-rex.com

Kwik Lok Corp.iba Hall 9, Booth F17/G18

Kwik Lok Corp. is a manufacturer of world-class semi-automatic and automatic machinery and the inventor of the Kwik Lok bag closure, which is a degradable plastic “tab” or “bread clip.”

Kwik Lok celebrates 60 years of providing bag-closing solutions with printing options for today’s recall and traceability concerns.

Stop by the Kwik Lok booth and see one of the earth’s most environmentally friendly closures in action.

Kwik Lok Corp.Yakima, Wash.

1-800-688-5945www.kwiklok.com

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Lawrence Equipmentiba Hall 9, Booth E11/F12

Pressed fl atbreads are one of the fastest growing product lines in the bakery market. Tortilla, wrap, Turkish durum, chapatti and roti are all variations of their original fl atbread. However, now they are pressed to form rather than sheeted.

Part of the appeal of these products outside of their original ethnic origins is their versatility, convenience and low cost to produce. They can be packed with various types of fi lling, from fruit to meat, and can be hand held or eaten on the go. However, press forming yields a moisture barrier that is created by the gelatinization of the starch on the skin of the product. This provides excellent elasticity and a guard against fi llings that would otherwise saturate the bread and leak onto the consumer.

Lawrence Equipment is a provider of hot-pressed production lines. Rates vary from 1,000 to 40,000 pieces per hour.

Lawrence EquipmentSouth El Monte, Calif.

1-800-423-4500www.lawrenceequipment.com

WP Bakery Group USAiba Hall 10, Booth D41

The WP Bakery Group is the baker’s company. The competence centers of WP and Kemper work hand-in-hand according to the company’s “think process!” philosophy to offer innovative solutions for the entire bakery process. Consistent high quality and economic effi ciency is only possible when all bakery sub procedures are coordinated precisely.

All processes for artisanal and industrial bakeries — from mixing, kneading, dividing and forming loaves to prebaking, cooling and in-store baking — will be featured at the show.

In addition, iba 2009 show visitors can experience live baking and meet with experts to discuss total cost of ownership, energy savings, economic effi ciency and added value.

WP Bakery Group USA(dba: Kemper Bakery Systems)

Shelton, Conn.1-203-929-6530

www.wpbakerygroupusa.com

iba Booth Profi les

Rondo Inc.iba Hall 16, Booth C11/E12

RONDO, the former Rondo Doge group, will showcase its new brand, along with numerous innovations at iba 2009.

For example, RONDO presents an industrial bread line, which is designed for the most modern bakery in Europe. In addition, producers of croissants and pastry products can expect to see interesting innovations.

In the spirit of Dough-how & more, RONDO presents its company’s core competencies in a unique manner.

Rondo Inc.Moonachie, N.J.1-201-229-9700

www.rondo-online.com

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Ingredient Technology

By Marina Mayer

Too much of anything is a bad thing, especially when it comes to pushing a product’s performance beyond a

particular point. That’s why several wholesale bakers

and snack manufacturers rely on stable, clean label ingredients to maintain taste, texture and mouthfeel.

For instance, as processors continue to extend shelf-life, push the limits on operating capacity and replace ingredients, starches add the structure and rheological

properties necessary to produce qual-ity products, says Susan Gurkin, bakery, snacks and cereals category marketing manager for Atlanta-based Cargill Textur-izing Solutions, North America.

“As the recession drags on, consumers will continue to look for ways to save on food among many other essential consumer goods and staples,” she says. “Therefore, manufacturers will continue to have a vested interest in cost-saving ingredient solutions.”

One such solution is Cargill’s HiForm 12754, which is a cold-water swelling starch that exhibits superior dispersion and less dusting.

“Cold-water starches are heat-, shear-, acid- and freeze-thaw stable,” Gurkin says, “which translates to a stable viscosity for products in abusive or acidic storage conditions, and a smooth texture even after freezer or refrigerator storage.”

According to Cargill, HiForm 12754 starch is comparable to agglomerated cold-water swelling starches and delivers value and ingredient functionality to customers.

“[The HiForm 12754] reduces mix times and gives manufacturers fl exibility and cost advantages,” Gurkin notes.

Another cold-swelling solution is Tate & Lyle’s X-PAND’R SC, a natural instant starch. It’s an unmodifi ed, premium cold-swelling starch that delivers a clean label and aids in the development of cohesive,

Bakers and snack producers are faring well, thanks to a fl urry of unconventional varieties of starch that deliver better-for-you opportunities and a little something out of the ordinary.

SpecialPhoto courtesy of Tate & Lyle

Photo courtesy of National Starch Food Innovation

Something

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Ingredient Technology

sion, but starch technology allows for new solutions to these age-old issues.

“Cold-water starches also complement other texturizers, allowing for unique tex-ture solutions to be created and customized to meet specifi c customer needs,” she adds.

Likewise, it’s all about creating a unique texture and satisfying consumers’ desire for healthy indulgence, Turner says.

“The use of specialty instant starches can be used to provide textures from crisp pretzel-type to laminated or fl aky,” she notes. “[Meanwhile], consumers have an increased interest in healthy eating. To meet consumer demands, manufacturers are offering items reduced in fat or sugar or enriched with a good source of fi ber for more sensible snacking.”

Too much of anything doesn’t have to be a bad thing, especially when today’s ingredient manufacturers are pushing the envelope to bring out the special in their customers. SF&WB

Editor’s Note: Go to www.snackandbakery.com to read other articles pertaining to ingredient solutions, and check out our Buyer’s Guide for a complete list of ingredient manufacturers.

risen cracker with the texture and sensory characteristics of a ‘fermented’ cracker and potentially reduce the leavening time from 16 hours to six hours.”

Almost Too GoodAlthough today’s ingredient manufactur-ers have developed ways to make their customer’s lives easier, sometimes it’s just not good enough.

For example, one of the challenges ingre-dient manufacturers face, Green says, is to create a consistent product with an unwaver-ing texture and eating experience.

“[Our] texture capabilities, which are based on the unique integration of our core capabilities in consumer in-sights, sensory expertise, material science knowledge, formulation experience and processing understanding, enables us to recommend the best starch product, the appropriate use level and product formu-lation for a particular process to achieve the desired texture in [our customers’] end-product,” he adds.

Other challenges that exist, Gurkin says, are factors such as shelf-life exten-

pliable and non-sticking dough.“The hydration characteristics of the

starch and its interaction with the fl our and fi ber ingredients create the bite and chew characteristics,” says Judy Turner, applica-tions manager for Tate & Lyle, headquar-tered in Decatur, Ill. “Extruded snacks rely on the viscosity and rheology of the dough to optimize the expansion of the snack as well as the eating qualities.”

The X-PAND’R SC provides snack and bakery products with a layered texture that balances crispiness and crunchiness, Turner says. It also offers a light and crispy coat-ing that adheres to nuts and dried fruits, and is designed for cold-forming or low-temperature extrusion applications.

“A snack cracker, for instance, can be light and crispy or have a laminated-type texture depending on the starch that is used,” Turner notes.

Furthermore, specialty starches can be used to impart functionality in a number of baked and snack product applications, says Marc Green, senior manager of marketing communications for National Starch Food Innovation.

That’s why the Bridgewater, N.J.-based ingredient manufacturer introduced NO-VATION 4300/5300, which also are cold-water swelling starches that are clean label and process tolerant and can withstand downstream processing, such as heat, shear and recycling.

“While developed primarily for sauces and dressings, [NOVATION 4300/5300 starches] are also excellent for nutrition bar fruit preps where they reduce spread and boilout in high solids fi llings,” Green says.

Meanwhile, National Starch’s Hi-maize resistant starch can be incorporated into a variety of snack foods such as nutrition bars, sheeted crackers, biscuits, cookies, extruded snacks and more.

“With National’s texture capabilities, we can help [our customers] match an industry benchmark, enhance positive tex-tural attributes or minimize negative ones,” Green notes. “We can enhance productiv-ity by reducing the time and variation in manufacturing, for instance, by helping [our customers] formulate a chemically

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Ingredient Briefs

Caravan Ingredients has added an innovative, unique base to its line of Invisible Goodness products, called the Invisible Goodness Bar Base. This product is a versatile, whole wheat base that enables producers to add sweet or sa-vory fl avors to make a 0 g. of trans-fat snack bar. The bar base is the fi rst single-serve, convenient, yeast-raised food bar product of its kind, which fulfi lls the consumers’ desire for better-for-you foods. Designed with versatility in mind, it is a great carrier for inclusions, fl avor combinations and vitamin and mineral pre-mixes, provides an excellent or good source of fi ber and qualifi es for the basic Whole Grain Stamp label.Caravan IngredientsLenexa, Kans.1-800-669-4092bjagels@caravaningredients.comwww.caravaningredients.com

Plenish brand high-oleic soybean oil, produced by Pioneer Hi-Bred, is the next generation of healthy soybean products that provide nutrition-ally enhanced oil with the highest oleic content in soybeans under commercial development. Designed to meet food industry needs for a soy-based trans-fat solution with superior perfor-mance characteristics, Plenish contains about 80% oleic acid, which is more than three times higher in heart-healthy monounsaturated fats than commodity soybean oil. The soybean oil also can be used alone or in combination with other oils to optimize cost, functionality and taste. Pioneer Hi-Bred International, Inc.Johnston, Iowa1-515-270-3200www.pioneer.com

Virginia Dare’s “IFTea Room” at the 2009 IFT Food Expo provided several creative fl avored iced tea concepts for tasting, thus demonstrating the company’s range of high quality tea fl avors, extracts and concentrates for delicious sweets. Among the refreshing selections were Raspberry Hibiscus Black Tea, Nectarine Rose Green Tea, Lime Green Tea and Mangosteen Black Tea, as well as Orange Blossom Rooibus Tea Latte and Vanilla Rooibus Tea Latte.Virginia DareBrooklyn, N.Y.1-718-788-1776www.virginiadare.com

Tree Top’s evaporated apples, or dried apples, are an amazingly versatile food ingredient. With a great taste and excellent texture, evaporated apples can be used in baked goods, fruit fi llings, bars and more. Natural dried apples are shelf stable and offer a perfect palette for fl avor and color additions.Tree Top, Inc.Selah, Wash.1-800-542-4055www.treetop.com

VegeFull, Archer Daniels Midland’s product line of bean ingredients, provides a convenient way for food manufacturers to take advantage of the many nutritional benefi ts of beans when creating better-for-you foods. Beans are the only food to appear in both the vitamin-packed vegetable group and the protein-dense meat and beans group of the USDA Food Guide Pyra-mid. This all-natural food staple is full of protein, fi ber and benefi cial nutrients, offers convenient storage and handling and provides a lean, cholesterol-free alternative to meat. Additional-ly, they can be used in several applications such as snacks, baked goods, breads and more.Archer Daniels Midland Co.Decatur, Ill.1-800-637-5843www.adm.com

SF&WBtv View videos demonstrating the newest bakery & snack food ingredients by visiting www.snackandbakery.com

Frozen blueberries are hot. That’s why the U.S. Highbush Blueberry Council has increased production to deliver stable supplies of formula-ready, frozen blueberries. This makes blueberries an exceptional value for savvy product develop-ers to meet consumer demands for real blueber-ry-containing products. Last year, more than 1,300 blueberry products came to market boosting per capita consumption of real blueberries in baked goods, fi llings and healthy snacks. Consumers prefer real blueberries for their fruit identity, rich fl avor, lush color and real fruit benefi tsU.S. Highbush Blueberry CouncilSan Mateo, CA 1-800-824-6395www.blueberry.org

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the American Bakers Association (ABA) and the Grocery Manufacturers Associa-tion (GMA). News stations such as CNN, FOX and MSNBC have nothing on these groups when it comes to communicating the right information to bakers at the right time. While the ABA and GMA are only two of the many food-related organizations that keep the interest of such categories at heart, these are the two most historically proactive organizations and are known for sharing their fi ndings in a timely manner.

If you don’t have a connection in D.C., get one.

Industry personnel also should take a

subject and is now spending time on trying to fi x other companies’ problems versus resolving our own nation’s issues. The interest shown by our elected offi cials will likely result in stiffer regulations that will eventually produce new marching orders and force regulators to re-stuff their ac-counts with freshly printed $20 bills.

This industry will see audits and inspec-tions like it’s never seen before.

As a result, bakers, equipment manufac-turers and ingredient providers should stay abreast of the news and keep up-to-date on the debates taking place in D.C. For example, get connected to groups such as

There sure is a lot of talk these days about the cleanliness of food plants — or the lack thereof.

In fact, the minimal amount of food safety initiatives is what’s forcing some industry execs into the “Big House.” These folks, who pull their britches up one leg at a time like the rest of us, are now, or soon will be, sliding uncomfortably into their orange jumpsuits instead of their white smocks.

Who ever thought an American could serve time for sanitation issues in a food plant?

Don’t get me wrong, these bakers and snack producers are headed to the lockup not just because they ran unsanitary food plants — they also “resolved” their food safety issues in unethical ways.

Think back to the Peanut Corp. of America recall, for example.

An insider for the Blakely, Ga.-based facility, which has since shut down, admit-ted that the company knowingly produced contaminated products as far back as Janu-ary 2007.

On the other hand, if these higher-ups were running sanitary food plants where employees followed the rules, they wouldn’t have to compromise their ethics, right?

This is a true case where other people’s problems become someone else’s fortune. These ill-timed circumstances are a wakeup call to the industry, as they set the stage for bakers and snack producers alike to take a deeper look into the cleanliness of their plants, and review the processes and procedures in place.

What’s more concerning is that Con-gress has taken an intense role in this

Engineering Management

Sani-CauseSani-Cause Jeff [email protected]

Companies may not be losing sleep now over their plant’s cleanliness. However, when the impending regulations launch alongside the continued media hype with a side order of the occasional news story reporting further salmonella cases, employees are going to begin lunging for the Lunesta and aching for the Ambien.

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JULY 2009 - Snack Food & Wholesale Bakery 53

planning on staying put, as many manu-facturers are these days, you may want to invest in taking off the blinders and really “look” for what can be hiding.

Companies may not be losing sleep now over their plant’s cleanliness. However, when the impending regulations launch alongside the continued media hype with a side order of the occasional news story re-porting further salmonella cases, employees are going to begin lunging for the Lunesta and aching for the Ambien.

This will be a wide eye-opening experi-ence for everyone who is forced to face the fear of what might be lying beneath the surface.

Remember to “clean as you go” and don’t let sani-cause you any grief. It’s the lack thereof part that should be of con-cern. SF&WB

Editor’s Note: Go to www.snackandbakery.com to read more of Jeff’s problem-solving columns.

down, but rather visualize you’re a tiny be-ing that could crawl into minuscule cracks and crevices.

Plant employees are continuously run-ning around with a caulking gun trying to seal up those gaps, and it seems like every time, new ones appear. We need to start thinking about what we are sealing “in.” Simply covering something up with caulk, even in the newest of plants, will most likely seal something into the void that shouldn’t be there. Therefore, our practices may need some work.

Take a stroll through a food plant or a production line that’s being torn down to learn how bad stuff hides really well.

Over the years, I have walked through a laundry list of plants as they were taken apart and have even helped remove ma-chines from their long time moorings. It’s this type of environment where minia-turizing yourself isn’t necessary because everything is out in the open. But if you’re

more proactive dive in, around and under their processes, procedures, equipment and buildings to ensure that there aren’t any unwanted critters hanging out. Everyone needs to get involved.

Walking around a plant everyday with the same set of eyes can lead to varied lev-els of complacency. For instance, internal auditing teams may see some shiny stain-less steel, a well-swept fl oor and some dap-perly dressed employees, thus producing a positive report on the company’s sanitation efforts. Couple that scene with a wall full of above-average ratings plaques and fl ags from third party auditors, and it’s easy to get a good night’s sleep.

The root of the problem though is really what lies beneath.

So how do companies get below the sur-face in such complex production systems and buildings? This may sound bizarre, but try to mentally miniaturize yourself. Hold on there, I don’t mean dumb yourself

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Production Technology

In these recessionary times, “sustain-ability” takes on multiple meanings. For some businesses, it can be synony-

mous with survivability. For others, it can be translated into reducing waste and operating more effi ciently, especially in the packaging department.

“The economy is factoring into every aspect of every business,” notes Hal Miller, vice president of sales for Kwik Lok Corp.,

Yakima, Wash. “It’s important to watch all costs, as well as eliminate as much waste as possible.”

In addition to reducing waste and low-ering overhead, bakers are exploring new avenues to control labor costs as retailers press bakers to slash prices to attract more value-conscious consumers.

“Reduced workforce and higher wages are areas impacting bakers in their

production departments,” explains Den-nis Gunnell, vice president of sales and marketing for Formost-Fuji, Woodinville, Wash. “Most automation solutions can increase production volume and lower labor [costs].”

Going green has blossomed in popularity because many of its practical solutions have bakers seeing “green” in more ways than one. In addition to sav-ing money, sustainability efforts address the increasing awareness of consumers about how companies, their packaging and their carbon footprint impact the environment. Additionally, packaging companies are addressing the pressure that the snack and baking industries are getting from retailers who want to be seen as good corporate citizens that just happen to be selling quality products at lower prices.

AMF Bakery Systems, for instance, is addressing the issue in a number of ways, says Larry Gore, director of product marketing for the Richmond, Va.-based company.

“First, we are incorporating energy-saving features in our equipment that include high-effi ciency motors and effi cient mechanical designs that reduce required horsepower for operation,” Gore says. “We also are designing additional fl ex-ibility in our equipment to allow use over a wide variety of applications. This will reduce the number of lines required to

Bakers search for new ways to make their packaging departments operate more effi ciently to meet their customers’ environmental concerns and fashion a favorable public image while saving money at the same time.

GoingGreen

Photo courtesy of AMF Bakery Systems

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Production Technology

Continued on page 56

for bakers. Formost-Fuji offers its Reseal-It System with a recently improved “Kiss Cut” that provides a cleaner opening cut that helps maintain the re-sealable pack-age’s integrity, Gunnell says.

Kwik Lok’s managers, Miller notes, are seeing a gamut of trends toward smaller portion packages as well as efforts to pro-vide traceability and show value.

“Bakers are faced with consumer trends to eat local, support local charities, show community awareness and show when the product was produced,” he explains. “Con-sumers are more price and quality conscious as they are looking for coupons, cents off and cross promotions with other products.”

Kwik Lok’s 893 Ultra with its 894 Squid Ink Turbo Printer provides a closure along with a coupon, cross-promotion ma-terial or a host of other information about the product, he adds.

Laboring Becomes AutomaticIn the packaging department, labor has historically been an issue from a number of perspectives. To solve this challenge in bread and bun operations, AMF’s Gore is seeing increased interest in automated

closure where it is easy to find and easy to read,” Miller says.

Up to the ChallengeWhile many bread producers and snack manufacturers are pushing the envelope to use more environmentally friendly packaging material, some of the latest paperboard that contains recycled material or green fi lms re-quire advanced technology to work as seam-lessly as their not-so-green predecessors did.

“Special sealing jaws for new ‘green’ fi lm have been created and the develop-ment of new seal technology to reduce seal width, fi lm usage and improved appear-ance are in the works,” Gunnell says. “We are always looking for ways to help our customers improve their bottom line and maintain their marketing goals.”

Other packaging fi lms such as Bemis’ bMET brown, metalized sealing fi lms use 20% less material. By creating two-ply laminations with the performance of three-ply ones, the Oshkosh, Wis.-based company notes that bakers can save 10% in costs as well.

Resealable packaging, Gunnell adds, is another area that provides a challenge

produce the same output, in many cases. The result is reduced equipment count and the associated reduced power usage and reduced plant space that must be lighted, heated and cooled.”

For bag closure producers, going green means developing biodegradable closures, among other options, to minimize the vol-ume of material that is going into landfi lls.

In some cases, companies are going multimedia to get the message out.

“Kwik Lok has produced a video pre-sentation for our industry explaining and showing Kwik Lok’s effort to lower carbon emissions and to provide and maintain our closure as a truly environmentally friendly, degradable and recyclable product,” Miller says.

The latest generation of twist ties also degrades in landfi lls, adds Mark Hotze, operations manager for Burford Corp., Maysville, Okla. In separate efforts to address sustainability, Burford can close bags with a slightly shorter tier than in the past. Instead of a 4.25-in. tie, the Model 2200 can do the job with only 3.75-in. ties, resulting in savings of more than 10% in tying material.

Moreover, Hotze says, Burford’s latest energy-effi cient, twist tyer systems use 15% to 20% less electricity than previous models. Internationally, he adds, Burford is seeing a big increase in bag selling to provide a tamper-evident closure system throughout Europe. The feature is not only being driven by bakers, but also by retailers looking for enhanced food safety applications.

In addition to biodegradability, Kwik Lok’s machines such as its 893 Ultra with the 894 Squid Ink Turbo Printer offer simplifi ed maintenance and incorporate the latest in stepper motor advancement and electronic controls to complement other automatic systems built into the packaging line.

“Kwik Lok is an ‘all-in-one’ con-cept providing bag closing technology advancement while also providing the consumer with a convenient, environ-mentally ‘green’ closure with all of the traceability information printed on the

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www.snackandbakery.com56 Snack Food & Wholesale Bakery - JULY 2009

Production Technology

Continued from page 55

To accomplish this, AMF is working with bread, bun and roll producers to eliminate many manual functions with sec-ondary packaging systems, which include automated dolly unloading, basket stack-ing, basket washing, robotic basket loading and more. Specifi cally, AMF has developed a patented vacuum head end-of-arm tool for its articulating arm robotic product loader used for handling poly-bagged prod-ucts in a way that has no negative impact on the bag.

Over time, robotics have gained increas-ing acceptance among bread producers as the systems evolved and became more ad-ept at handling delicate products without damaging them.

“Robotics offer a labor reduction, fl ex-ibility, as well as adaptability to multiple products further reducing changeover downtime,” Millers says.

Kwik Lok’s 893 “Ultra lok” manage-ment system combined with an “out-of-lok” sensor and alarm box can comple-ment existing vision and robotic systems to help eliminate cost and increase product line effi ciency, he adds.

The increased emphasis on automation, Hotze notes, has created different labor issues, specifi cally, one being lack of skilled labor to maintain increasingly sophisticated equipment with a wide variety of advanced electronics and software controls. Training has emerged as a greater issue, especially with the high turnover of maintenance personnel in some operations.

“It’s becoming increasingly diffi cult for [the baking industry] to keep up to date with equipment,” he says.

In some cases with new systems, bakers have to completely retrain their staffs from the chief engineer on down.

Despite the constant new challenges that have emerged, the bottom line in the end isn’t red or black when it comes to packaging technology.

It’s all about different shades of green. SF&WB

Editor’s Note: Go to www.snackandbakery.com for online-only information from companies mentioned in this article. You also can sign up for a free subscrip-tion of SF&WB’s Operations Weekly e-newsletter.

“Our customers are looking at ev-ery area of their operations to leverage technology for incremental performance improvements that will enhance their com-petitive position, customer satisfaction and profi tability,” Gore says.

basket and case loading. Bakers also are looking for automated order make-up systems to reduce operating costs and improve product distribution accuracy and effi ciency as well as reduce product damage associated with manual product handling.

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www.snackandbakery.com

View videos demonstrating the newest bakery & snack food equipment by visiting www.snackandbakery.comSF&WBtvJULY 2009 - Snack Food & Wholesale Bakery 57

Equipment Briefs

Continued on page 58

To better refl ect the company’s commit-ment to offering its customers’ unmatched speed, intelligence and fl exibility, Dorner

Manufacturing unveiled an updated

logo and corporate tagline. The new logo incorporates orange as a differen-tiating accent color, and the new tagline reads, “Move Fast. Move Smart.” The fast relates to the company’s ability to pro-vide quicker quotes, order fulfi llment and delivery times. In fact, select conveyors can be shipped within a 48-hour timeframe. Likewise, speed means nothing without intelligence. Dorner offers expertise when it comes to conveyors and related acces-sories. Plus, the company manufactures a broad range of pre-engineered conveyor solutions that can quickly solve even the most complex product handling challenges. The updated logo and tagline are currently rolling out into a variety of company mate-rials, including its Web site, business cards, letterheads, brochures, signage, advertise-ments and sales- and marketing-related materials. Dorner Manufacturing Corp.

Hartland, Wis.

1-800-397-8664

www.dorner.com

Arr-Tech’s dual line automation system uses two counter/stackers and two auto stack indexers, and is designed for both bagging

and wrapping of tortillas, pizza crusts and other fl atbreads. The versatile function al-lows for running one line to the bagger and another to the wrapper, or both lines can run to either the wrapper or bagger.Arr-Tech, Inc.

Yakima, Wash.

1-866-852-2442

www.arr-tech.com

Designed to mix viscous materials requiring a combination of high and low shear mixing and dispersion, the patented Ross PowerMix by Charles Ross and Son includes two sepa-rate agitation systems within one system. A planetary blade revolves in combination with a separate high-speed dispersion blade. Both revolve on their own axis as well as on a com-mon axis, and the speed of each can be varied independent of the other. This combination allows a user to fi ne tune the mixer to meet the facility’s specifi c process needs and the shear rates that are required to optimize this process.Charles Ross and Son Co.

Hauppauge, N.Y.

1-800-243-7677

[email protected]

www.mixers.com

Ashworth Bros. introduced Omni-Pro

075 to withstand 150 lb. of tension for 100,000 cycles, a rating that only heavy-duty belts could deliver — until now. The belt’s design minimizes cage bar wear, maintenance costs and downtime in the most demanding high-tension spiral appli-cations. The shorter pitch of the Omni-Pro 075 is designed for small products and closer transfers. Unlike a traditional bridge weld, the 360-degree buttonless weld is free from surface imperfections and crev-ices, which eliminates bacteria entrapments and improves hygienic characteristics.Ashworth Bros., Inc.

Winchester, Va.

1-800-682-4594

[email protected]

www.ashworth.com

Wire Belt offers Slim-Profi le Sprockets, designed exclusively for CompactGrid conveyor belts as an alternative solution and offering less mass than other standard

drive components. Available in stainless steel or polyacetal plastic, the sprockets also can be easily installed and contain less material, which results in reduced machine labor.Wire Belt Co. of America

Londonderry, N.H.

1-603-644-2500

www.wirebelt.com

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www.snackandbakery.com

View videos demonstrating the newest bakery & snack food equipment by visiting www.snackandbakery.comSF&WBtv58 Snack Food & Wholesale Bakery - JULY 2009

Equipment Briefs

Often used together, Schenck Process’

MoveMaster Chain Conveyor and Bucket Elevator enable bulk materials to move like a liquid through a dust tight steel casing to avoid internal disturbance or pressure on the material. The system can discharge materials at any opening where the load is permitted to fall away from the fl ights. It can handle a range of capaci-ties from 10 to 2,000 tons per hour and be used as a conventional drag chain. The chain conveyor also features inspection doors that provide easy access and improve installation speed, as well as tail access that allows for easy, timesaving maintenance. Schenck Process

Leetsdale, Pa.

1-888-900-7662

www.schenckprocess.us

Ford’s Transit Connect battery-electric

vehicle is an urban-oriented, light-duty commercial van that serves the environ-ment and its owner. The propulsion system is up-fi tted by SEV-US and can ascend up to a 20% grade. The van also contains a collapsible steering column, a tire pressure monitoring system, an exterior rear panel designed for advertising and a set of second row sliding doors on both sides.Ford Motor Co.

Dearborn, Mich.

1-800-392-3673

www.ford.com

Continued from page 57

pending packaging fi lms that replace both the barrier and sealant layers in typical three-ply structures, thus creat-ing two-ply laminations with the per-formance of three plies. Structures that use bMET fi lms use 20% less material and cost 10% less than the three-ply laminations. They deliver the high-end performance required to protect products such as crackers, cookies and granu-lar products. bMET fi lm thickness can range from 0.75 mil to 1.5 mil. They are available in metallized white and metal-lized clear versions. Plus, they can offer customized convenience features like tear initiation and EZ Peel opening. Bemis Co., Inc.

Oshkosh, Wis.

1-920-527-2300

www.bemis.com

Let AM Manufacturing’s combination

dough divider/rounder ease the pain of dividing, scaling and rounding dough.

The model S300 provides unprecedented scaling accuracy from one to 32 oz. at 2,000 pieces per hour. With a hopper size capable of holding 75 lbs. of dough, this machine greatly reduces costly manual labor with consistent product results.AM Manufacturing Co.

Dolton, Ill.

1-708-841-0959

[email protected]

www.ammfg.com

Hinds-Bock manufactures a large family of industrial muffi n and cake batter

depositors, which can be fed by bulk intermediate hoppers. Standard and cus-tom systems from stand-alone depositors to complete 12,000-lb. per hour produc-tion depositing lines include tray and cup denesting, multiple batter depositors, pan oilers and dry ingredient depositors. The bulk hoppers are available in double or triple wall confi gurations to accept cool-ing water and insulation to help maintain product temperature. The depositors fea-ture diving positive shut-off spouts with large ports to handle the most viscous batters with large frozen particulates without tailing.Hinds-Bock Corp.

Bothell, Wash.

1-877-292-5715

[email protected]

www.hinds-bock.com

Bemis introduced bMET blown, metal-

lized sealant fi lms, which are patent-

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Page 59: Snack & Bakery - 07 JUL 2009

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Page 60: Snack & Bakery - 07 JUL 2009

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By Marina Mayer

When Michael Sands learned that the theme for SF&WB’s June State of the Industry report was superheroes,

he couldn’t quite come to grips with it.“I can’t even relate to this whole super-

hero thing right now, can’t even get close to it,” says Sands, the founder of LesserEvil Brand Snack Co. “You have distributors

and the retailers taking phony deduc-tions, and you have the administration who is not doing anything to provide capi-tal for investment in small companies.”

For a small business owner like Sands, today’s economical turmoil is doing more than just posing additional threats. It’s pos-ing superhuman challenges.

Despite the darkness that hovers over many of the snack busi-nesses today, the Village of Tuckahoe, N.Y.-based snack producer continues to fi ght back by adding its sig-nature “lesser evil” versions of snacks to

its portfolio of better-for-you products and revamping its operation to remain ahead of the game.

“The emerging trends are that people are going healthier,” Sands says. “We are defi nitely starting to see the consumer get more and more educated and demanding

Lesser Than EvilSnack Food Today

In today’s ghoulishly gloomy world, it’s diffi cult for some companies to believe in superheroes. But for one snack producer in particular, all it took were a few adjustments and a heroic plan of attack to become a superhero in its own world.

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Page 61: Snack & Bakery - 07 JUL 2009

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• SF&WB’s 2009 State of the Industry Report – Expanded category content, IRI supermarket data and exclusive interviews with dozens of industry experts.

• View SF&WBTV – Our own 30-second video showcase where you can view production lines and other new systems at work.

• Subscribe to SF&WB’s Operations Weekly e-newsletter – The only weekly e-newsletter that covers those key operational issues pertaining to volume bakery and baked snack markets.

• Link to SF&WB’s state-of-the-art Digital Edition. View current and past issues in digital format for convenient viewing and easy navigating. Print, copy or forward pages to co-workers. Live links to online content and advertiser Web sites.

• Columns by editor Dan Malovany, who offers his unique perspective on the latest trends; Marina Mayer, our managing editor, provides “The Final Word” from a consumer standpoint; and award-winning Engineering Management columnist Jeff Dearduff tackles the key issues that are impacting people on the production oor.

• SF&WB’s Buyers Guide – The industry’s leading online searchable directory of industry suppliers, products and services to help you make better connections to grow your business.

• White Papers and other Web-only exclusives.

• Webinars and podcasts from industry experts offering commentary and insight into best business practices and

Visit snackandbakery.com for immediate access to industry news and exclusive snack and baked goods marketplace resources.

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www.snackandbakery.com JULY 2009 - Snack Food & Wholesale Bakery 61

bit more pressure on deals,” Sands adds. “And you’re seeing a little bit more pricing pressure from the consumer, retailer and distributor.”

As a result, LesserEvil has streamlined its operation. For example, it reduced its case size to account for an additional level of pallets. It transformed the plant to encompass electronic order processing and tracking, thus reducing labor costs.

It’s all about survival, Sands says.“Cash is king right now,” he notes.

“The small business man needs a super-hero, and I don’t know where it is.”

Whether or not Sands believes super-heroes exist in a world like today, Lesser-Evil continues to fend off darkness with brightly colored products and a virtuous plan. SF&WB

Editor’s Note: Go to www.snackandbakery.com for more interviews on snack and baking industry trends. And to obtain our 2009 State of the Industry issue, e-mail Gisele Manelli at [email protected].

popcorn,” he adds, “but our popcorn has shot out of nowhere to start competing at the threshold of regular salty snacks.”

Meanwhile, the snack maker upgraded its packaging from a small bag in a box to a 5-oz. bag with messages about the product spelled out across the front. This change in format allows the company to obtain mid-range shelf space versus being thrown at the top or stuck at the bottom, Sands says.

Still, one of the biggest challenges small companies like LesserEvil face is the uphill battle against slower store traffi c.

“The only hero out there is the consum-er, but the consumer is defi nitely cutting back,” he explains. “[Consumers] are not shopping as much, and when they shop, they want to make sure that they get the real deal.”

However, the real deal comes at a price.“I think businesses are going to do fi ne,

but you defi nitely are starting to see a little

more and more information.”That’s why LesserEvil introduced Baked

Veggie Krinkle Sticks.“We looked at all the veggie sticks on

the market, and we just found them to be deep-fried vegetable powders with 7 g. of fat,” Sands notes.

Made with all-natural ingredients, the Veggie Sticks contain 60% less fat than conventional veggie sticks, and carry the Whole Grain Council seal of approval. Ad-ditionally, each Veggie Stick is made with real vegetables, including broccoli, spinach, cilantro, corn and potato and an assort-ment of whole grains such as white corn, brown rice, whole oats, barley, buckwheat, millet and quinoa.

While adding new products, LesserEvil also reduced its SKUs [stock-keeping units] from eight to fi ve and, as a result, saw its velocities double, Sands says.

“It’s no doubt that our potato snacks, which are our salty snacks, outsell our

Snack Food Today

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Page 62: Snack & Bakery - 07 JUL 2009

To place your classifi ed ad in Snack Food & Wholesale Bakery

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62 Snack Food & Wholesale Bakery - JULY 2009 www.snackandbakery.com

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Page 63: Snack & Bakery - 07 JUL 2009

To place your classifi ed ad in Snack Food & Wholesale Bakery call Sharon Ward at847-405-4078Fax: 248-502-9089E-mail: [email protected]

www.snackandbakery.com JULY 2009 - Snack Food & Wholesale Bakery 63

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Page 64: Snack & Bakery - 07 JUL 2009

To place your classifi ed ad in Snack Food & Wholesale Bakery

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Page 65: Snack & Bakery - 07 JUL 2009

www.snackandbakery.com JULY 2009 - Snack Food & Wholesale Bakery 65

Reaching a total qualifi ed circulation of 14,854 copies. Source: June 2008 BPA publishers statement.

Ad Index

LETTERS

Dan Malovany

Snack Food & Wholesale Bakery155 Pfi ngsten RoadSuite 205Deerfi eld, IL 60015E-mail: [email protected]

SINGLE COPY SALES/BACK

ISSUES

Gisele Manelli

T: (847) 405-4061E-mail: [email protected]

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Deb Soltesz

E-mail: [email protected]: (248) 244-1726

CUSTOM MEDIA

Steve Beyer

E-mail:[email protected]: (630) 699-7625

LIST RENTAL

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

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Commercial Creamery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51www.cheesepowder.com

CSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21www.csb-system.com

Delkor Systems, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

www.delkorsystems.com

DFE Meincke A/S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44www.dfemeincke.com

Dorner Manufacturing Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17www.Dorner.com

Dunbar Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30www.dunbarsystems.com

Dunbar Systems Inc. / AutoBake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-43www.auto-bake.com

Enreco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28www.enreco.com

Fritsch USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37www.fritsch-usa.us

Hixson Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59www.hixson-inc.com

Kallman Associates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35www.iba.de

Kwik-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3, Back Coverwww.kwiklok.com

Lawrence Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19www.lawrenceequipment.com

Lubriplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7www.lubriplate.com

Pack Expo 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Back Coverwww.packexpo.com

Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5www.reiser.com

Rondo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38www.rondo-online.com

Roquette America Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23www.roquette.com

Tree Top, Ingredient Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

www.treetop.com

WP Bakery Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 40, 41www.kemperusa.com

Company Website Page

Company Website Page

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www.snackandbakery.com66 Snack Food & Wholesale Bakery - JULY 2009

The Final Word

Marina Mayer, managing [email protected]

we’re letting our fans in on the fun, giving chip artists everything they need to dig in and create their own customized fl avor.”

Customizing fl avors sounds like a task for Ms. Won’t Try.

Now, because I’m Plain Jane, I stuck to the rudimentary seasonings — I mixed

one tablespoon each of Cheddar and Caramelized Onion with a tablespoon of Roasted Tomatoes, followed by a teaspoon of Cheddar.

I always have to add extra cheese.Nothing too crazy, I know, but

enough to produce quite the zing.My husband on the other hand is a bit

more daring in the food department and enjoys trying new things.

(I’m sure you can imagine what dinner is like at our household).

So we tossed my hopeless bag of chips aside, and blended a tablespoon

each of the Sweet Chili and Caramel-ized Onion seasonings to create a siz-

zling and spicy snack.After laughing about my “plain”

creation, he says, “well, you’re defi nitely in the right line of business — not being a chef.”

I guess I won’t be submitting my recipe online.

So people, get your shake on. The Create-a-Chip Challenge is only on for a limited time, and the next People’s Choice variety will be unveiled in October.

Now back to creating a chip fl avor that my husband and I can both agree on.

Editor’s Note: Go to www.snackandbakery.com to read Marina’s exclusive online-only columns.

S ince the beginning of time, potato chips have been just that — plain ole potato chips.

Then a couple of years ago, chip producers spiced up their lines and began developing unconventional varieties made with better-for-you ingredients.

Now, one chip maker, in particular, is asking its consumers to be the fl avor artist and create the next up-and-coming chip variety.

The Create-a-Chip Challenge, presented by Salem, Ore.-based Kettle Brand Potato Chips, stems from a Create-a-Chip Kit, complete with four 1-oz. bags of unsea-soned chips and seven packets of all-natural season blends, such as Lemon Butter, Caramelized Onion, Roasted Tomato, Cheddar, Vinegar, Sweet Chili and Sour Cream & Chive. Con-testants also are encouraged to pull spices and seasonings from their own pantry to incorporate into the recipe.

After dreaming up the “perfect” fl a-vor, sprinkle the seasonings on the chips, reseal the bag, shake and taste test.

For inspiration, each kit contains 5-oz. bags of previous People’s Choice winners for varieties such as Spicy Thai, Buffalo Bleu and Tuscan Three Cheese.

Think you can develop the winning fl avor?

Participants can visit www.kettlechipchallenge.com to submit their recipes and enter to win free Kettle Brand potato chips for a year. Or fl ip through the Flavor of the Week, which is voted on by consumers and consists of varieties such as Sweet Cheddar and

Create, Taste, Share

Mike’s Vinegar. Visitors can span through the Recipe Gallery and rate and review formulas submitted from other chip artists on a fi ve-star scale from dull to delicious. Additionally, users can click into Carolyn’s Corner and fi nd tips, recipes, company

history and the Kettle-ictionary, which is an outline of all Kettle-related terms, pre-sented by Carolyn Richards, Kettle Brands chief fl avor architect.

“There’s no denying that making, and munching, Kettle Brand Potato Chip fl avors all day is a dream job,” she says. “Now,

Shake,Shake,

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Page 67: Snack & Bakery - 07 JUL 2009

BECAUSEFOOD SAFETY IS ALL IMPORTANT.

BECAUSESUPPLIERS NEED TO BE RELIABLE PARTNERS.

BECAUSEREDUCING DOWNTIME IS GOOD FOR THE BOTTOM LINE.

BECAUSEYOU WILL FIND IT ALL AT

PACK EXPO AND PROCESS EXPO.

C O - L O C A T E D W I T H :

Register today! www.packexpo.com

Attend PACK EXPO and PROCESS EXPO for creative business solutions and

the latest packaging and processing innovations. No other industry event

this year will deliver as much access and value. Come find everything you

need to cut costs and increase efficiency right down the line.

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Page 68: Snack & Bakery - 07 JUL 2009

KWIK Lok’s New893 Ultra

Fast!Tight Packages!

Prints on the Closure!Labels Packages!

Our customers have asked us for a bag closing machine that will be faster (up to 120 bags per minute), yield tighter packages, print crisp clear information on the closure and have the capability to put labels on the bagged package. The all-new 893 Ultra Automatic Bag Closing Machine gives the modern bakery all these features, plus additional options.

PRINTER OPTIONS: Ink Jet Turbo Printer; Cold Foil Transfer Printer; Programmable Thermal Printer.

ADDITIONAL OPTIONS:Speed Control: Synchronizes the closing speed to the bagging speed.Closure Management System: Monitors the product, closure movement and printing cycle to determine if the bag is closed. If not, a warning signal is given.Closure Sensor: Senses if closures are present. If not, sends a warning signal to the bagger or an alarm box.Ethernet Connection: Monitor operation from a remote location.Touch Screen Monitor: English, French and Spanish.

Kwik Lok® Bag Closures: Consumer PreferredEasy to Open; Easy to Reclose - Reusable and Recyclable!

CALL US TOLL FREE1-800-688-5945

e!

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