Commercial Baking August | Q3 2022 by AvantFoodMedia

DIGITAL www.commercialbaking.comEDITION MAKING WAVES IN THE US MARKET Cérélia ISSUE Q3 | STELLAR SNACKS’ ELISABETH GALVIN | FLAVOR INNOVATION | GREYSTON AUG 2022

Find out more at www.jkingredients.com or call us at 973-340-8700 These days, egg might as well be made out of gold. Or at least that’s what the price would suggest. Don’t worry, J&K Ingredients has the solution! All Vita-Ex products are certiﬁed Kosher Pareve! √ Soy-Free √ Vita-Ex has options for any of the following needs! Non-GMO √ √ √ Gluten-Free √ and KosherAllergen-Freemore!Pareve Our Vita-Ex line of superior egg replacement products has all the benefits of eggs without the high cost! Plus, you’re sure to find a solution for any baker’s needs with more than ten variations of the product!

SHEETINGSTRESS-FREEWITH

Learn more about AMF Tromp solutions for artisan bread and roll production. Booth #3625

Engineered to the highest sanitary design standards, the SFA Artisan Bread Line by AMF Tromp delivers a wide range of artisan bread and roll products like baguettes, ciabatta, batard, and sourdough breads on a single, high-speed production line. For quick product changeover and simple sanitation, AMF Tromp’s stress-free sheeting lines ensure shorter cleaning times, reduced water usage, and toolless cleaning options while delivering premium, artisan-style products. Grow your artisan bread portfolio with sanitary, stress-free sheeting and decorating technologies. the SFA Artisan Bread Line AMF delivers a wide range of artisan bread and like line. and AMF stress-free lines ensure shorter times, reduced water usage, and

One where advanced analytics and automated production systems combine to elevate technological achievement and change the way your plant operates. A new era where productivity is maximized, downtime is minimized, food safety is prioritized – and possibility is reborn. Rexfab is at the forefront of this revolution. We partner with bakeries and food manufacturers to automate downstream processes, implement advanced analytics and install more efficient conveying solutions. We’re ready to serve your needs now and help you reimagine your company’s potential. Get started at rexfab.com. WE’RE CLOSER THAN YOU THINK TO A NEW AGE IN THE BAKING AND FOOD INDUSTRIES. Visit us at IBIE booth #1355. COMMITTED PARTNER

Active Integrated Motion™ (AIM™) technology transforms frozen pizza handling by enabling automation in washdown environments. Intralox® AIM solutions include sorting, switching, and merging equipment that deliver maximized, reliable throughput and gentle product handling to your pizza packaging lines. AIM TECHNOLOGY FOR PIZZA © 2022 Intralox, L.L.C. 5011057_EN Automation for pizza handling that no one else can deliver. Scan QR code to learn more.

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Commercial Baking considers its sources reliable and verifies as much data as possible, although reporting inaccuracies can occur. Consequently, readers using this information do so at their own risk. Commercial Baking is distributed with the understanding that the publisher is not liable for errors and omissions. Although persons and companies mentioned herein are believed to be reputable, neither Avant Food Media nor any of its employees accept any responsibility whatsoever for their activities. Commercial Baking magazine is printed in the USA and all rights are reserved. No part of this magazine may be reproduced or transmitted in any form or by any means without written permission of the publisher. All contributed content and advertiser supplied information will be treated as unconditionally assigned for publication, copyright purposes and use in any publication or digital product and are subject to Commercial Baking ’s right to edit.

COMMERCIAL BAKING Paul Lattan |Publisher816.585.5030 | paul@avantfoodmedia.com Steve Berne Director of Media | 816.605.5037 | steve@avantfoodmedia.com Joanie Spencer |Editor-in-Chief913.777.8874| joanie@avantfoodmedia.com Jordan Winter Creative jordan@avantfoodmedia.comDirector Olivia Huels Multimedia olivia@avantfoodmedia.comSpecialist Annie Hollon Managing annie@avantfoodmedia.comEditor Evan Bail Associate evan@avantfoodmedia.comEditor Maggie Glisan | Bella Foote info@commercialbaking.comContributors OUR COMMUNITYAVANT FOOD MEDIA Paul Lattan President - Principal | 816.585.5030 | paul@avantfoodmedia.com Steve Berne Vice President - Principal | 816.605.5037 | steve@avantfoodmedia.com Joanie Spencer Director of Content - Partner | 913.777.8874 | joanie@avantfoodmedia.com American Society of Baking FIND US ON AUGUST 2022 Q3 OUR MEDIA QuickTakesTechTalksPodcastNewsletterscommercialbaking.com | digital edition

937.652.4480 | info@shaffermixers.com | shaffermixers.com FOLLOW US 24/7 PARTS & SERVICE +1 888.508.1298 service@shaffermixers.com VISIT US AT IBIE BOOTH #917 YOUR BAKERY. YOUR MIXER. Quality mixers, processing equipment and service. Global innovation and resources. Expertise Confidence in a product starts with trusting the people behind it. And no one has more experience than the engineers and operations team behind Shaffer. Innovation For more than 30 years, Shaffer has revolutionized horizontal mixers - from the first open-frame mixer in 1993, to today’s cutting edge sanitary designs and dough cooling technology.

→ significantly extended natural freshness → significantly extended frozen storage stability of your baked goods → reduction or waiver of premixes/bread improvers → reduction of preservatives → cost reduction (yeast, flour, logistics) VISIT US IN LAS VEGAS BOOTH # 1201

Healthy and sustainably produced products are playing an increasingly important role in the current consumer society. That is why DIOSNA recommends grain cooking processes for an optimal product quality of your baked goods. The process involves heating flour and various grains with a large amount of water until you get a gelatinized hot soaker. By adding it to your ingredients you extend natural freshness and gain a higher dough yield. Get free consultation now!

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COMMERCIAL BAKING9 IN THIS ISSUE Features 70 Product Development: Flavor Innovation 62 Critical Issues: Values-Based Management 44 Greyston: A Case Study in Conscious Capitalism PLUS: Look for QR codes that contain exclusive digital content throughout the issue. 22 Cérélia: Making Waves in North American Sweet Goods 36 Elisabeth Galvin: Stellar Snacks’ Founder Leads with Passion

NEW CHALLENGES. NEW SOLUTIONS. Packaging Automation For Your Baked Goods Production Quality meets innovation with Benchmark, Kleenline, and Southern’s food distribution, loading, and pouch packaging solutions. Our high performance line of equipment offers solutions for automatic feeding, carton infeeding, tray loading, product orienting, laning and conveying, pouch packaging, and more. Our ultra-sanitary, fully integrated solutions are designed in-house for each customer and are built to last. Turn to the company that knows your business, your customers, and has the commitment to be the leading supplier of packaging automation. Benchmark provides automated food distribution and loading solutions. Kleenline provides sanitary conveyors for increased line efficiency and superior performance. Southern provides a complete line of horizontal form-fill-seal pouch packaging solutions. To find a solution for your sweet or baked good, dessert, cookie or bar packaging lines, call 706-208-0814 or visit www.benchmarkautomation.net/industry/baked-goods-packaging/. PERFORMANCE, PACKAGED Visit us at Booth #4244 during IBIE 2022 to learn more about our solutions!

COMMERCIAL BAKING11 116 126 TRENDS IBIE Perspectives 81 Category Outlook: 89 Cookies Category Outlook: 95 Tortillas International Market 116 INNOVATIONS Featured Brand: 58 Breton Category Insight: 101 Cookies Category Insight: 109 Tortillas Supplier Solutions 126 Commercial Baking Channel 134 IBIE Booth Trailers 141 Ad Index 144 QUICK READS Editor’s Note 12 Seen and Heard 15 Business Intel 123 The Last Word 146 Departments101 IN THIS ISSUE

Ahem … I’ve said this before, but I’ll say it again a little louder for the folks in the back: Relationships matter.

| joanie@avantfoodmedia.com

JOANIE Editor-in-Chief

SPENCER

AUGUST 2022 Q3 12

You can see this theme threaded throughout the issue. From a snack producer who got help from a co mpetitor to fill an order before starting up the first line in her new plant, to a cannabis snacks entrepreneur paving the way for underfunded BIPOC businesses, to our featured bakery, which relied on rock-solid vendor relationships to complete a greenfield project in the face of the pandemic, relationships are moving the industry forward. We could even take a cue in relationship-building from the influencers infiltrating IBIE next month.

But these aren’t the only relationships I’m talking about. Businesses are built from the inside, so we have to nurture that network first. That means taking a moment to pay attention to — and learn from — everyone around us. Could hierarchical thinking be a thing of the past?

Don’t panic ... hierarchy doesn’t have to be replaced with anarchy. But diversity of thought is the birthplace of innovation. Imagine inviting junior staff into a strategy meeting, asking an intern to look for a design flaw or talking about product pack aging with someone from accounting. What if you spent a day being trained by a line operator on their job? Or chatted at IBIE with a competitor about how to solve a problem? In the age of disruption, we’re all running on empty. But if we take a minute to listen to new voices, we just might be able to build a new culture … and not another echo chamber.

Not EchoAnotherChamber

A NOTE FROM THE EDITOR

LEAD YOUR BAKERY FORWARD American Pan | DuraShield | Synova | Pan GloPan |DuraShield|Synova|PanGlo Achieve maximum product quality and consistency while minimizing your cost per bake by partnering with us to select the right design, coating, release agent, and cleaning schedule for your baking pans. BakingIndustrialPans Create pans designed for your bakery’s exact needs and specifications to throughputmaximizeand increase efficiency. ProprietaryCoatings Work with our experienced team to select the optimal silicone or fluoropolymer coating to ensure great releases. Release Agents & Applicators Reduce your oil budget, increase uptime, and achieve clean releases with our high-quality oils and precision applicator. Pan Cleaning & Recoating Maximize pan life with a cleaning and recoatingcustomizedscheduleforyourbakery’spancyclesand release agent usage. For more information about our products and services contact us at +1.800.652.2151 or email info@bundybakingsolutions.com. BACKED BY BUNDY Partnering with the Bundy team means that, together, we are developing a plan to make your bakery as successful as possible. We stand behind our products and are committed to the success of every project and every bakery, every day. VISIT BOOTH #2625!

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Bernhard van Lengerich, PhD | founder | Seeding the Future Foundation

“At the moment, I cannot imagine Bakehouse relocated. I want my business to thrive and be successful in Ukraine.”

Anna Makievska | founder | Bakehouse

“Different diets go in and out of fashion, and different ingredients can become the new ‘bad’ ingredient. And this can shape consumers’ perception of food and nutrition for the rest of their lives.”

Nancy Baum | senior research director | C+R Research

Seen Heard AND

Presenting some grant award winners developing food systems and products at IFT FIRST

On her dreams for the bakery in a post-war future

During the American Bakers Association Clean Label Insights member research webinar

“The most impactful innovations start as an idea. They are human-centered, and they consider the end user or consumer as a key enabler for a flourishing food system.”

SEEN AND HEARD

“We became profitable within 7 months of my buying the company. And we did it by selling the product and telling the story. My grandfather’s way of growing the business works.”

Stephanie Stuckey | CEO | Stuckey’s Corp. On overcoming the challenges of buying back a family company

A Fresh Approach To Custom Automation®… capwayautomation.com

On why a brand’s story should be the foundation of the marketing plan

Kindra Hall | marketer and author | IDDBA 2022 keynote speaker

The Capway DEFP Jet Pulse Filter System is designed to prevent the flour mess from your Depanner operation. Our new flour filtration system is designed to operate in a vacuum environment. As extra-fine flour dust collects on the filters in the system, a reverse jet pulse blast removes the particles from the filters where they drop to the hopper below. The DEFP Filtration System contains a hydrophobic, oleophobic, anti-static polyester felt filter media that resists oil absorption from sesame seeds or other product toppings containing oils. This also aids in dust release from the filter. The system is built with stainless steel for sanitation and durability. It features a dust collector, a hopper with a removable collection bin and a gate valve to facilitate tote removal. The vacuum ducting has buna rubber gaskets with quick-clamp connections to reduce static electricity. It’s the easiset cleaner-upper on the market! Call today to be the first in line to have our new DEFP Jet Pulse Filter installed in your bakery. 877.222.7929

“I hear so many marketers say, ‘The numbers speak for themselves.’ Unless they’re on Sesame Street, they do not. Data is important for making decisions and predicting the future, but not for communicating in a compelling way. The numbers might indicate what story you should tell, but the numbers are not the story.”

Is excess flour creating a mess?

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Pauline Kariuki | director of operations | The Women’s Bakery

“It used to be that slotting fees were the way that grocery stores would get their benefit. But now you’re seeing a bit more of a hybrid, which is not just getting some kind of advertising or rebates but also getting a piece of that equity.”

“When I started at The Women’s Bakery, I had a singular goal to bring the bakeries to sustainability. We are all facing challenges, from labor shortages to rising costs of raw materials to logistics. These are making achieving sustainability very difficult. But I am committed to getting as close as possible.”

“What I see a lot is, ‘This health and wellness trend is going to be very bad for candy, snacks or bakery.’ But in reality, consumers very much believe that physical health and emotional wellbeing are the total definition of what’s healthy.”

Anne-Marie Roerink | president | 210 Analytics

During her operational update at BEMA Convention 2022

During an industry trends report at IDDBA 2022

On entrepreneurial in-house venture strategies during IFT FIRST

Lloyd Greif | president and CEO | Greif & Co.

SEEN AND HEARD

Pfening’s in-house production capabilities allow full control over our equipment design and quality. www.pfening.com | sales@pfening.com WITH PFENING IT’S ALWAYS Customer First Delivering Superior Value Since 1919 • Water and liquid dosing systems • Dough conditioning systems • Comprehensive engineered systems • Automated ingredient handling systems • Turnkey projects from design to startup • Integrated control systems BOOTH 2516

SEEN AND HEARD “I often say diversity, equity and inclusion is a journey, not a destination. You will never arrive; if you think you’ve arrived, start again because something else will come.” Sherri Dublin | VP of DEI, communications and talent acquisition community of expertise | Ingredion On DEI strategies during a panel at IFT FIRST

Cordia Harrington | founder and CEO of Crown Bakeries | ABA board chair During a state of the industry discussion at BEMA Convention 2022 courtesy of BEMA

Photo

Patent Pending

“There have been some price increases for certain baked goods due to inflation, but if you look at the price increases for proteins and dairy, baked goods are still a lower-cost item that’s fulfilling and that people enjoy.”

AUGUST 2022 Q3 22 In a brand-new US facility, Cérélia is making waves in the North American sweet goods market.

CONNECTIONFRENCH JOANIE SPENCER

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Dominique Lacroix | director of operations and supply chain | Cérélia

“We designed this facility to be a plantnext-level...Thisisbestofbreed.”

Bold. Then lucky. That’s the formula for a successful startup during perhaps the most challenging time in the history of the baking industry.

It’s also the key takeaway from Cérélia, a Paris-based producer of branded and private-label frozen and refrig erated dough for cookie, pastry and sweet goods, after starting up a new 160,000-sq.-ft. facility in the height of the Inpandemic.commercial bakery production, timing is everything, whether making a product, breaking into a new market or simply laying out the plans to get there. Cérélia’s timing was bold, to say the least, and included developing a green field building in Whitehall, OH, during the early stages of COVID amid shut downs, supply chain disruption and massive uncertainty. But the move was also lucky, as the with ering construction business afforded Cérélia its pick of contractors to execute the “Weproject.hadeverything we needed, and everyone was happy to have activity going again,” said Claude Le Bourg, Cérélia group COO. Building a new facility during COVID was quite unusual and, of course, not without its challenges. Most of the company’s leadership was based overseas at a time when international travel regulations were changing every month — and at every border. To get from groundbreaking to startup, relationships with vendors, contractors, government officials and attorneys had to be as rock solid as the foundation walls themselves. FEATURED CÉRÉLIABAKERY: Operating nine facilities in five European countries, Cérélia has a reputation for not only its product quality and production efficiency but also its agility to take on new product development. The team found that working with European partners with a strong foot hold in the US provided reliability with the added bonus of easy access to the plant. And the familiarity of US standards — especially for food safety — placed a high value on state-side experience. With supplier partnerships playing such a critical role in the startup, many were chosen based on Cérélia’s estab lished European relationships. But the team went a step further and focused on the ones who also had a strong pres ence in the US, which provided ease of onsite interaction amid challenging travel scenarios, especially during commis sioning, installation and training. Those relationships were about more than interaction with the Cérélia team. They also had to work well with one another to bring the project together, especially when some lines had compo nents from as many as six different suppliers, requiring them all onsite at the same time to ensure that adjustments on one aspect didn’t impact other areas of the Cérélialine. is known for its high standards, not only in its product development but also for high expectations of its supplier network. If this project was to be successful, it had to be, in every aspect, the best of the best. Breaking into the US market — or any new market, really — during a time of disruption requires strategic finesse.

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“We have to manage these volume shifts and the comparables from the previ ous year,” Le Bourg said, though it’s also important to remove those volume metrics from lockdown periods and weigh against non-lockdown years for a realistic comparison. COVID is far from over, and if baked goods producers have learned anything from it, it’s that diversification of markets is critical to not only success but also, quite possibly, survival.

It’s a tactical strategy to have one foot each in retail and in foodservice, according to Le Bourg. While that helps the business in terms of volume shifts, it also means the operation has to be ready to execute based on any market demand. That made the facility design all the more “Weimportant.designed this facility to be a nextlevel plant,” said Dominique Lacroix, director of operations and supply chain for Cérélia. “Our product portfolio is best of breed. That’s not only in terms of tech nology, but we also have to be the best co-manufacturer for our customers and also for our own Jus-Rol brand.” Specializing in chilled and frozen dough for “place and bake” or “break and bake” formats, Cérélia makes prod ucts for foodservice as well as retail under what it calls a “dual-track” philos ophy that creates a balance between co- manufactured private label and branded products. That meant going far beyond installing five lines in the facility. Production is designed monodirectionally to ensure that everything — people, products, machines, ingredients — moves in the right direction. Further, the operation is separated into four distinct production rooms, constructed with floor-to-ceiling walls and individual entrances, each designed for a specific product type with its own needs: gluten-free cookie dough, tradi tional cookie dough, rolled pastry dough and pizza crust. “It’s a simple concept, but inside each room is very complex,” Lacroix said, noting that the separation is not just by walls but also plumbing and HVAC. This infrastructure essentially segre gates allergens and ensures the facility’s SQF Claudecompliance.LeBourg(left),

Cérélia group COO, and Dominique Lacroix, director of operations and supply chain, believe in making bold moves to execute best-in-class production.

Claude Le Bourg | group COO | Cérélia Tracking market trends and sales data to forecast future growth is a different animal these days. COVID lockdowns caused massive swings in consumption habits, first spiking at retail and then fall ing when restaurants finally reopened.

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AUGUST 2022 Q3 24 CÉRÉLIA

“You need to have people who know the dough, so if it’s not correct, they can mustThat’sadjustments.makeaskillthatbedevelopedovertime.”

automate your process thetoingredientfromintakedoughonline. FermentationIngredient handlingMixing Over 50 years experience Find us at spiromatic.com or call us at 203 497 3285 Find us at booth 4465

AUGUST 2022 Q3 26

A separate drainage network also prevents potential water backflow from cross-contamination as well. Each production room has its own entrance, and associates are typically assigned to one room, each designated by color-coded smocks and hair nets. If anyone leaves a production room, before they can enter another, they must start the process over. That means discarding the color-coded gear to re-dress for the appropriate room, as well as going through the hand-washing and foot-bath stations in the foyer of each entrance.

“The dosing system is the ‘brains,’” Lacroix said, noting that the Spiromatic system is also interfaced with the bakery’s ERP. Ingredients are scanned into the bakery before they’re run through any of the three outdoor or other indoor silos and conveyed above the ceiling and directly into hoppers

To support this production, expansion is already on the horizon as the company takes off. Two more lines are currently being added to existing production, and the facility was also designed with even more growth in mind. With knockout walls, the packaging area has room to expand, and there is space on the 24-acre lot to further expand the existing building or erect another one.

Today, the company, has facilities in Liberty, SC, and Toronto, Canada, and has moved from the original location in Columbus to the current facility in Whitehall, OH, where it manufactures its branded product, Jus-Rol, a chilled rolled pastry dough packaged with parchment paper for easy consumer use, and comanufactures an array of frozen and chilled dough for private label and other large brands. This is Cérélia’s “dual track” platform, which balances its co-manufacturing expertise with production of the Jus-Rol brand, which only recently entered the US market.

“But I would like to see the first building expansion be well underway within the next five years.”

NORTH AMERICAN FOOTHOLD Gentle sheeting and laminating create more than 60 layers in Cérélia’s Jus-Rol pastry dough.

For efficiency and enhanced food safety, Cérélia designed the rooms with one overarching drop-ceiling, ensuring the Spiromatic ingredient handling system transfers the appropriate material from the dosing stations to each specific line while maintaining strict separation.

Based in Paris and known throughout Europe for its pastry dough, crepes and pancakes, Cérélia first broke into the North American market with the 2017 acquisition of the English Bay Batter facility in Columbus, OH.

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CÉRÉLIA

For example, the separation prevents wheat blowback from the traditional cookie line in Room Two from entering the gluten-free Room One, for which the HVAC is always set with over-pressure. On the other hand, Room One is always kept under pressure.

“Our people know when they’re trained that these are part of our GMPs,” Lacroix said. “And it’s a state-of-the-art way of doing business and staying truthful to our allergen control.”

“It’s difficult to make predictions on market evolution in these current conditions,” said Claude Le Bourg, Cérélia group COO.

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“We may have to change a recipe because of a shortage, especially while there is war in Ukraine,” Lacroix said. “But that change must be approved by the client and confirmed with our systems and R&D team, and we need to make sure it can run properly. All of this has to happen because, again, this is a founda tion of who we are.”

AUGUST 2022 Q3 28

“It’s a double verification, not just for the system we use to manage inventory but also the system we use for the recipes,” Lacroix added. But some ingredients, such as hard shortening or certain inclusions, can’t be piped through the system. In such an intricate network of tubes, if adhesion were to occur, it could shut down a length of piping and create major downtime on the lines. The conveyance system is self-cleaning, and inspections are performed to ensure quality and safety of those ingredients.

Specifically speaking of Jus-Rol, Cérélia’s branded rolled pastry dough sold refrigerated at retail, Le Bourg noted that the consumer should always experience a dough that unrolls easily without being sticky or, at the other extreme, breaking. It’s a daily challenge, he said, to focus on factors like quality of ingredients that can impact the dough. Creating that perfect consumer experience is also about more than just the precise ingredients. It’s how the dough machines on the line, and that’s up to the equipment to treat it right.

“The

A chilled dough is still active, unlike a frozen baked item that has completed the process before it goes out the door or a frozen dough that has essentially stopped in time. For refrigerated raw dough, by the time its life cycle is over, it can become something very different, especially from a quality standpoint. As a result, the process has to be as stringent as possible to ensure the best possible quality of dough.

EuropeanisAmericanintopenetrationtheNorthmarketbasedonasolidfoundationinournetwork,andthatincludesEuropeansourcingwe’vebeenabletotransitionintoourUSoperation.”

Dominique Lacroix | director of operations and supply chain | Cérélia

Food safety protocols at this SQFcertified facility go beyond in dustry stan dards, whether for North Am erica or abroad. For Cérélia, producing safe food is the primary mission. The third shift is dedicated to sanitation that runs a fivestep process from 10 p.m. to 6 a.m., with staggered starts for the first shift. “We eat this food,” Lacroix said. “Our families eat this food. So, we leave no room for error in manual processes; that’s not who we are. We make things systematic and pride ourselves with our associates’ engagement.”

Jus-Rol rolled dough in Room Three is produced on a Rademaker line that extrudes the dough, taking it through a gentle sheeting and laminat ing process that creates more than 60 layers of dough and fat. This ensures a perfectly puffed pastry when it’s baked. A similar process happens inside Room Four, where Jus-Rol pizza dough also runs on a Rademaker line.

“Our products are evolving over time,” Le Bourg said. “So, our biggest concern is that we want to provide consumers the same experience, whether at the beginning or end of shelf life.”

ofCÉRÉLIAtheVMI mixers located in each production room.

And when it comes to quality, Cérélia will not compromise. A formula wouldn’t change for non-critical reasons; though in today’s environment, critical situations are now the status quo.

www.rademaker.comT: +1 330 650 2345 E: info@rademakerusa.com Innovative bakery production solutions Radini dough processing solutions NEW Bread line sheeting section & DSS NEW Product showcase, Robotics and much more! VISIT US AT BOOTH 2645 Live DutchDutchdemonstrationBoulangerieTeamBoulangerieTeam T: +1 E: info@rademakerusa com

“It requires top-end equipment to discriminate natural particles of metal from those that are unwanted or danger ous,” Le Bourg said. “When you’re getting into a large variety of ingredients, some metal detectors can be triggered by the ingredients themselves.”

Conversely, cookie dough production lines in Rooms One and Two have a more complex process with a significantly faster throughput of a much denser prod uct. For instance, in Room One, glutenfree dough requires rest time in a cooler between mixing and makeup to more easily process such a sticky dough.

To maintain certainty that there are no additional risks for consumers, the Cérélia team carefully calibrates the Thermo Fisher equipment on a regular basis to ensure it properly identifies inorganic impurities. Magnetic screening, sifting and other rigorous scaling processes also take place when all ingredients are received into the Spiromatic Complexitysystem.isonly one factor in the company’s cookie production. Speed is also critical to get product out the door for its co-manufacturing clients.

Because gluten-free dough requires alternative ingredients like almond flour, which may contain trace amounts of organic metal from the nuts, high-quality metal detection equipment is essential.

Great bakers are not always born, and they certainly don’t magically appear like a prize in a Cracker Jack box. Cérélia facilitates a three-month onboarding process, and it takes approximately a year for an associate to know the dough so well that they recognize quality by sight, touch or even smell.

AUGUST 2022 Q3 30

Cérélia’s process ensures the consumer experience with a Jus-Rol pastry dough is exceptional at any point in its shelf life.

There can be times when workers need to lend a hand in other areas. But at Cérélia, it’s all about dedicating the time to developing dough experts, rather than spreading people thinly across every aspect of the opertion. Human interac tion with the operation is key to creating an upscale product.

In Room Two, two mixers feed one Minipan extrusion line in a high-speed operation to create “break and bake” cookies that then feed back into two Ilapak flowwrapping machines and then onto spiral cooling and freezing.

SpecificCÉRÉLIAquality checks, including metal detection and check weighers, occur once the product is packaged in all rooms. This ensures zero breakage in the packaging seams before they are conveyed through the Heinen refriger ation and on to secondary packaging in a common area outside the segregated production rooms.

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“We like to say the mixers have to feed the monster,” Lacroix joked. “But the truth is, rather than allowing things to go wrong, we have the expertise to create a high-quality dough through this stable production because the customer needs repeatable quality.”

“The equipment can’t run without people,” Lacroix said. “Systems are important, but people — they know this from the time of their onboarding — they are our most important asset.”

Even in this highly automated plant, Cérélia places a distinct focus on its associates. Machines enhance the process, streamline efficiency and ensure food safety, but it’s people who run that process and people who put the food into customers’ hands and consumers’ mouths.

Thermo Fisher metal detection and checkweighers

AUGUST 2022 Q3 32 CÉRÉLIA

Rademaker sheeting and makeup lines

Although working on a manufacturing line can be mundane, the truth is that in a bakery, people can impact even the most automated process. It’s not like moving boxes or keeping widgets going on an assembly line. Here, a change at the beginning will have major implications down the line, and it requires experts who can stay engaged with the product and equipment. “We want to have people building up experience, so they will know which settings work best for a specific product,” Le Bourg said. “If something isn’t going in the right direction, we need people who can understand what needs to be modified to bring the dough back where it needs to be. Our production is a multi-step process, and every person can have an impact at every step, so training for mastery on each piece of equipment is vital.”

From Le Bourg’s perspective, the purpose of equipment is to support the work with some level of autonomy. Roles like “line leader” and a focus on talent development for critical points like mixing bring the equipment and expertise together. Mixer operators are trained to understand concepts like timing and dough quality, and line leaders manage the overall line settings and speeds. “We can change the speed and replicate certain things at different stations,” Le Bourg said, “but you need to have people there to understand what’s happening. That way, when they make changes to the line settings or recipe, they know how to make the right decisions.”

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“When you see someone who’s great at running their line, it looks like they aren’t doing anything,” Le Bourg observed. “That’s the sign of a good operation.”

It’s been a year since the first line started up at Cérélia’s new greenfield plant in Whitehall, OH, which broke ground in 2020 and continued construction and line commissioning throughout the pandemic, war in Ukraine and massive supply chain disruption. It was an arduous process, but this state-of-the-art plant came together out of the strength of Cérélia’s supplier relationships. Below is a list of the top supplier innovations that can be found throughout the bakery.

“Our ultimate goal is to supply foods made with what people would find in their own kitchens, and foods that are safe to eat,” Le Bourg said. It’s the mission that will support plans to eventually double this facility, providing stability for the workforce as they continue to engage in the craft. That might not be the result of luck, but it’s certainly a bold move forward. CB CéréliaofcourtesyPhoto

There’s an element of beauty in the marriage between properly designed equipment and well-trained operators. When both are done properly, and they come together perfectly, it looks like … nothing.

The industry may be living in an era of disruption, but in consumers’ minds, disruption is no deterrent. People want to consume quality food, whether it’s artisanal, from a beloved brand or both. That is perhaps what Cérélia brings to the North American market — and workforce — the most.

BluePrint Automation robotic secondary packaging

INNOVATIONS FROM THE BAKERY FLOOR

Minipan cookie processing

Spiromatic ingredient handling

VMI mixers

“At the end of the day, we are bakers,” Le Bourg concurred. “You need to have people who know the dough, so if it’s not correct, they can make adjustments. That’s a skill that must be developed over time, and that’s how you create experts in pizza dough or pastry or cookie dough.”

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Elisabeth Galvin (right), passionate founder of Stellar Snacks, has built a pretzel empire with her daughter, Gina (left), marketing and advocacy director.

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withLeadingPassion

Stellar Snacks’ Elisabeth Galvin built one of the largest pretzel manufacturers with a combination of grit and grace. BY JOANIE SPENCER

SnacksStellarofcourtesyphotosAll

“Food should never be a luxury,” Galvin said. “It should be for everyone.”

“Itcalling.requires

Galvin, a French immigrant, launched Stellar Snacks in addition to her flagship company, Delyse, a copacker special izing in snack mixes and nuts includ ing Delyse’s original signature product, French pralines. Long before she introduced American consumers to her beloved pralines, Galvin grew up a foodie in the south of France.

COMMERCIAL BAKING37 EXECUTIVEELISABETHPROFILE:GALVIN

“I became accepted as a manufacturer who was capable of delivering quality snacks by the truckload to the airlines,” Galvin said. “It put me on the map. No longer were there questions of, ‘How is she going to do that?’”

In addition to helping her grandparents sell produce and traditional windmillproduced olive oil, she worked in a bakery before earning degrees in economy and pre-law. But despite her prestigious education, Galvin’s heart belonged to food. “I absolutely love food,” she said in her decadent French accent. “On one hand, food is not hard to love. But I also think that, growing up with a family of farmers, manufacturers and bakers, I learned that you have to be passionate about what you do because it’s probably the hardest work out there.” Food manufacturing, like entrepreneur ialism, is not just a passion; it’s also a consistency and dedica tion, and it’s your life,” she said. “It’s in your DNA.”

When she was ready to grow the business, Galvin developed a bold — but highly risky — strategy to get her snacks into the hands of more passengers: She gave them away for free. Offering free snacks made them quite attractive, and she hatched a plan to cover costs by attaching advertising to the prod uct. The concept worked … in spades.

Delyse grew into a 30,000-sq.-ft. facility in Reno, where on three lines, the company became the marquee co-packer for some of the largest snack brands, and known in the transportation industry as the manufacturer who could get a finished product — from setup through production and packaging — delivered within a week.

“That can’t be done by many people,” Galvin attested. “It’s because of my team and my suppliers.” In fact, Delyse relies on many of the same suppliers it used when those first kettles fired up 30 years ago. When she broke into the manufacturing game, Galvin had no brand or contracts, but she had something that lives inside every entrepreneur.

In the world of food production, loyalty is everything. And not just the run-ofthe-mill kind of loyalty, but that steadfast, unwavering, passionate loyalty that builds brands and keeps customers coming back for more. No one knows this better than Elisabeth Galvin. In fact, it’s in her title as pa ssionate founder of Carson City, NV-based Stellar Snacks, the only pretzel manufacturer west of the Mississippi.

In the early ’90s, when she was just a 20-something following her dream of coming to America, Galvin discovered, rather unconventionally, that she had what it takes to be an entrepreneur in the US food industry. She arrived to a party bearing small bags of French pralines she’d prepared in a kettle in her apartment kitchen, and she left the party with a business offer from the owner of Reno Air. Soon after, Galvin found herself in a 15,000-sq.-ft. kitchen with two small copper kettles. That’s where she launched Delyse, a name inspired by délicieuse the French word for “delicious.” Galvin began selling her French pralines, branded as Thoz Nuts, to Reno Air and at football games in Reno, NV, where she’d sell them by the thousands. Within two years, she was in full production mode with pack aging equipment and a full staff, some of whom still work for Galvin today. As the Reno Air business picked up, Galvin maintained that her snacks were for all passengers, though some custom ers contended that such decadent treats should be reserved for first-class passen gers only. It was a pivotal moment for her, one that would become her motto and a pillar of what Stellar Snacks was destined to become.

Delyse landed coverage in publications including Forbes , the Los Angeles Time s and Adweek , all telling the unique story about the woman who was putting ads on airplane snacks. It also led to contracts with the country’s top commercial airlines, including American, United, Northwest, SkyWay and more. The in-flight packs included pralines packaged with CD-rom promotions for AOL, CompuServe and Prodigy, along with ads for Motorola, American Express, General Motors, AT&T and more. For two years in the mid-’90s, it was a multi-million-dollar concept that changed Galvin’s course.

Today, Stellar Snacks has its branded pretzels in retailers nationwide and is Stellar Pretzel Braids, like Galvin’s pralines she first supplied to airlines, come with unique packaging. Only now, it’s artwork on the pack instead of advertising.

EXECUTIVE PROFILE

“I believed,” she said. “The universe brings you opportunities, and you have to take them when they come. I had faith I could do it. When you have some type of epiphany, when you believe in some thing, the only ingredient for success is bracing yourself and knowing it will follow. If it’s what you’re meant to do, never be afraid of the unknown.”

AUGUST 2022 Q3 38

“I became accepted as a manufacturer who was capable of delivering quality snacks by the truckload to the airlines ... No longer were there questions of, ‘How is she going to do that?’”

That fire and faith is not only what has kept Delyse going for 30 years, but it’s also what prompted Galvin to parlay into the pretzel business … and sustain her through the biggest challenge yet. Wanting to take more control over the process and manufacture according to her own mission, Galvin chose to change course once again and put all her chips in on a pretzel plant. TreeHouse Foods was shuttering a pretzel facility in Visalia, CA, and Galvin knew in a matter of months,

“Everytime.night, I walk outside and look up,” she said. “I send my desires, my fears, whatever it is, up to the stars. Somehow, I feel like somewhere up there, someone is listening. That night, I knew it was my time. And I knew I was going to call my new company Stellar.”

It was

there would be a major gap in pretzel supply for the entire West Coast region.

Elisabeth Galvin | passionate founder | Stellar Snacks

In 2019, in a 100,000 sq.-ft. former Sunopta warehouse in Carson City, NV, Galvin designed her pretzel operation. Before she had even commissioned an oven, the calls started rolling in. Her strong relationships — and stellar reputation in the in dustry, even among competitors — provided the resources she needed to get production going until her own lines started up.

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AUGUST 2022 Q3 40 back to supplying major US airlines including United, American, Alaska and JetBlue. But this time around, the snacks don’t come with advertising, they come w ith “Becauseart. of loyalty, I have a good network in terms of suppliers and customer base,” she said. “And during the pandemic, it was so wonderful to have that network of people I could trust and who trusted me.”

Eventually, it turned into $2 million in orders, and it saved the company, all the while helping families — like all those airline employees — who were out of work and in need of food. “I’m still alive,” Galvin said, “and I know it’s because of loyalty.” These are the virtues with which Galvin ran Delyse and now leads Stellar as the passionate founder. And it’s the reason why her daughter, Gina, left a corporate advertising career working with clients like Apple Inc. to take the helm as Stellar’s marketing and advocacy director, aptly coining the company as “Pretzels with a Purpose.”

EXECUTIVE PROFILE

That network may have saved Stellar and Delyse (which now operates in Carson City inside the Stellar facility) when the pandemic dealt a crushing blow to more than 90% of the business. When that happened, Galvin took one of her evening walks by the lake near the plant, and she again gave her worries to the stars. The airlines were grounded, inventory filled the warehouse and the pretzel lines were ready to shut down. And then, she remembered her motto: Food should never be a luxury. Once again, adversity ignited her passion, and Galvin reached out to Feeding America.“I connected with the CEO and said, ‘My name is Elisabeth Galvin, and I am the passion ate founder of Stellar Snacks. We have several production lines and 100 employees, and we have no work to do. We have the best pretzels ever, and you’re trying to feed people. How can I help?’”

Everything Galvin has done has led to this. And it’s all been stellar.

“Every time I have found myself feeling fear or asking myself, ‘Can I really do this?’” Galvin explained, “I just tell myself, ‘Yes. You just have to get rid of the self-doubt.”

Claire Babineaux-Fontenot, Feeding America CEO, suggested that Galvin donate product to food banks, so she gave unused inventory sitting in the plant and picked up unused product from some of the airline custom ers to donate as well. After that, the organization’s buyer connected her with McLane Distribution, which ordered more. Then, Good Source Distribution in Los Angeles ordered product by the truckload for various schools.

“The people who questioned my ability to perform, they helped me. They empow ered me and infused a challenge in me. Because if someone tells me I can’t do something, I will make sure I do it — better, bigger and faster.”

CB Galvin (left) has built her manufacturing business on faith, loyalty and perserverance against the odds.

Not knowing how something will get done can never be the stopping point. Even in the most chaotic of times, Galvin believes in the power of grounding herself.

For her, it’s all about faith, courage, clarity and perseverance, despite challenges, roadblocks or even naysayers.

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AUGUST 2022 Q3

As a certified B Corp focused on a triple bottom line, Greyston is changing the face of food manufacturing. BY JOANIE SPENCER

A CASE STUDY IN CONSCIOUS CAPITALISM

FEATUREDGREYSTONBAKERY: After just a few years of this practice, Glassman found a kindred soul: Jerry Greenfield, co-founder of Ben & Jerry’s. The original idea was to produce choco late cookies to make an ice cream cookie sandwich similar to a whoopie pie. With no experience producing cookies, the idea flopped from a manufacturing perspective, but the product — which literally fell flat — inspired the now iconic chocolate fudge brownies still found in some of the best-selling Ben & Jerry’s varieties. And those brownie inclusions put Greyston on the map in the baking industry as a legitimate manufacturer.

That was the genesis of Greyston’s open hiring policy, the cultural founda tion that built the bakery. The company has a slogan: “We don’t hire people to bake brownies; we bake brownies to hire people.” To Glassman, cakes were a means to providing life skills.

That question set in motion 40 years of humanitarianism combined with product innovation that would become one of the most popular inclusions in Ben & Jerry’s ice cream — and change the way companies should think about their hiring practices. It can be said that as a bakery, Greyston was founded more on social justice than a baked good.

Joe Kenner | president and CEO Greyston| —Left Greyston is known as much for its open hiring practice as it is for its brownies. All photos courtesy of Greyston

“He literally pulled people off the streets when he saw them looking for work,” Kenner said. “He’d just say, ‘Hey, do you want to help us out by learning how to bake? You just have to show up for the job, and you can learn a trade that might help for long-term employment.’”

COMMERCIAL BAKING45

In manufacturing — and in business — a company’s core values can be woven throughout its culture or relegated to a sign on the wall or the employee hand book. But in Greyston’s case, Glassman’s goal never changed. Whether supplying inclusions to Ben & Jerry’s, outfitting a national airline or selling branded individ ual brownies in retailers such as Whole Foods nationwide, Greyston’s purpose, to this day, is steadfast: Employ those who mainstream society deems unemployable. “We create thriving communities, and we’re showing how conscious capitalism can look,” Kenner said. “We sell a quality, premium product, with a marquee customer, and it’s made by folks who society would have otherwise cast Today,aside.”anyone can walk up to the front door of Greyston’s facility in Yonkers, NY, and get a job. The only requirement is an application … and patience (the current wait list has about 200 names, or a one-to-four-month wait). That’s greatly attributed to the loyalty of the workforce. While much of the baking industry is strategizing on workforce

“I notopportunity,‘Thiseveryone,tellisanapromise.It’suptoyoutomakeitwork.’”

“Bernie Glassman saw injustice, where there were people who wanted to work but couldn’t,” said Joe Kenner, Greyston president and CEO. Changing lives through baked goods wasn’t necessarily the original plan.

In that Zen Buddhist community, the group was supporting themselves by making and selling cakes, and Glassman simply seized the moment.

The year was 1982, and the late Bernie Glassman, an aeronautical engineer turned Zen Buddhist, did something good for the people on the streets outside the Buddhist Greyston mansion in Riverdale, NY, near The Bronx. He asked them if they wanted to come inside and bake cakes.

John Wagonstein | QA team member | Greyston Greyston invests in its workforce, from hiring to training to personal and professional development resources.

46 retention strategies, Greyston’s retention is inherent in its existence.

The loyalty comes from more than just the open hiring. It’s about the care Greyston takes in treating each open hire as a full human being. From hiring to training to a full array of personal and professional development resources, Greyston invests in moving its work force “up” or “out.” With a staff resource specialist trained in social services, the goal for each worker is to gain the core competencies to move into higher-skilled positions or become employable else where in the community. Management positions aside, the bakery is a place where anyone can come in to take an entry-level position and learn the bakery trade. Of about 120 total employees at the bakery, roughly 80 of them are open hires.

“Our workforce is loyal,” Kenner empha sized. “There have been so many stories over the years. When you talk to our people, you can see that this company has literally changed their life. It’s changed their whole trajectory in terms of where they would be if it weren’t for Greyston. And for me, that’s the real value of a company. You can call it economic development or social justice, but at the end of the day, you’re improving society.”

In fact, every department, from supply chain to engineering and R&D, has at least one open hire.

Some might wonder, “But what’s it like to work there?” Easy: It’s just like any other manufacturing facility; there’s just no barrier to entry.

GREYSTON

“You work your tail off and noticed.”andyourself,proveyouget

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Greyston’s open hires average 16-17% above the Mas sachusetts Institute of Technology’s LivingWage Calculator for New York state, and many workers in leadership roles started as open hires.

Anthony Norwood, an open hire now on the QA team, has worked for Greyston for nearly four years. John Wagonstein, also an open hire on the QA team, moved up after working the bakery floor for a year and has worked in quality for two years and counting. After spending a year on the bakery floor, Abigail Amegbedzi was promoted to the fulfillment department and is now a team lead.

When it comes to training and devel oping manufacturing skills, Greyston

“All you have to do is be willing to show up, take instruction and do a good job,” Kenner said. “We’ll take care of the rest. We can teach you how to be a mainte nance person or baking apprentice. It doesn’t matter if you went to college or have 10 years experience, or even if you served time or just have an arrest record.”

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Although the e-commerce side of the branded business quintupled in 2020 and remains consistent as the brand dabbles in corporate gifting, Ben & Jerry’s remains the lion’s share of the business. In fact, three of the top 10 best-selling Ben & Jerry’s ice cream vari eties are made with Greyston brownie Makinginclusions.close to 50,000 lbs. of brownies a day — nearly 12 million lbs. a year — the operation in this modest 20,000 sq.-ft. facility has nearly doubled its output in the past two years. While demand for the product is booming, Kenner also credits process improvements and equipment upgrades throughout the bakery. Capital investments in recent years have included a new pack room with new equipment and a 30,000-sq.-ft. offsite warehouse where the space has poten tial to add another production line in the next few years, as well as several tweaks and upgrades throughout the line.

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Greyston has a motto that the bakery doesn’t hire people to make the brownies; it makes brownies to hire people. That’s the core value for this B Corp-certified bakery.

standards as any other baking company firmly in place, including the bakery’s SQF certification. There may be no barrier to entry for open hires, but make no mistake: Expectations are high.

“You work your tail off and prove yourself, and you get noticed,” Wagonstein said. For Greyston to serve customers like Unilever, which is Ben & Jerry’s parent company, the bakery can leave no room for slacking on the floor. “Workers have to adhere to the standards,” Kenner said. “If they can’t, then yes, we’ll have to part ways. I tell everyone, ‘This is an opportunity, not a promise. It’s up to you to make it work.’”

With a product mix that includes variet ies like Brown Sugar Blondie, Pumpkin Spice, Cinnamon and a new vegan line, the operation and R&D are evolving as well. Greyston brownies can be found in iconic Ben & Jerry’s varieties includ ing Chocolate Fudge Brownie, Brownie Batter Core, Netflix & Chilll’d, Justice Remix, Mint Chocolate Chance, and Change is Brewing.

hasGREYSTONthesameGMP

“Working here gave me what I need,” she said. “It gave me financial independence and helped me build my mind. And that helped me improve.”

Greyston’s philosophy may be that it makes brownies to hire people, but at the end of the day, those brownies are a high-quality, widely known product that must get to customers without a hitch. Everyone is as connected to that mission as they are to unlocking the human potential required to get there. Since those days of making cakes, this bakery, currently in its second location since delving into manufac turing, has evolved significantly. Now that brownies are Greyston’s signature item, whether as inclusions or branded for retail, the bakery has a full B-to-B mindset, constantly considering how its products can support other dessert producers or retailers.

“I came here as a nobody, as I would say,” Amegbedzi said. “But now, I can say I am somebody.”

Many open hires learn skills that can help them move up in the company or be used at home or even another job.

But in a world where the supply chain has all but stalled out, labor shortages are at crisis levels and inflation is at a record high, some might question if Greyston’s open hiring is a viable business plan or a pie-in-the sky aspiration. The proof is in the workforce. Abigail Amegbedzi was an open hire who came to Greyston as a young African immigrant and new mother. With few skills and fewer options, she took a job at Greyston after being on the wait list for a month.

THE PROOF IS IN THE WORKFORCE

Though Amegbedzi felt a little lost when she first started working in the bakery, she quickly learned the trade and landed a promotion to the fulfillment department within a year. Today, she’s a fulfillment team lead.

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Bakery is a careful balance of art and science, and in this operation, Greyston has mastered the equilibrium between people and process.

“Our product is very liquid, similar to a cake batter, and the Vemag handles it very well,” said Jose Godoy, director of operations for Greyston. Another important capital improve ment was with its 90-ft. Babbco tunnel oven: gas burner upgrades in the first phase and a complete overhaul of the electrical panels in the second.

Greyston’s operation includes an “artisan” bakery, where branded brownies sold at retail are produced, in addition to the commercial line for the inclusions.

OnGREYSTONthebakeryfloor, efficiency is the name of the game, with two silos housing sugar (the brownies’ primary ingredient) and liquids to mix batter in two 800-lb. mixers that is pumped into trays by a Vemag depositor.

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“We can now bake much more evenly and more efficiently because we have the air more properly circulating,” Godoy said. Meanwhile, branded brownies are baked separately in two Revent rack ovens before they move onto their own “artisan” bakery just off the pack “Everythingroom. we do depends on how fast we bake and cut,” Godoy said, noting that because the oven is like the heart of the bakery, improving its efficiency was critical to the process. Greyston also invested in a “refrigeration project,” which includes two spirals after the oven — the first ambient, followed by refrigerated — from I.J. White. Once the brownie sheets are cooled, they’re depanned and cut for Ben & Jerry’s with either a BCA ultrasonic cutter or a mechanical one, and then run through a tumbler to remove any crumbs before being frozen in a new Praxair nitrogen tunnel at -110°F.

Investing in two cutting lines has also increased production speed by up to 20%, according to Godoy.

“If we fail in our production, we could lose a customer,” Kenner said. “And if we lose a customer, we can’t hire people. Every thing comes back to the mission.” In the end, Greyston is successful in both its business and mission. The company is profitable, and the employee turn over rate is decreasing. It’s not only that people want to work for a company with core values that revolve around social justice, but it’s also the type of business that consumers choose to support.

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Vemag depositing

As a certified B Corp, Greyston constantly considers those questions and remains cognizant of the triple bottom line: people, planet and profit. Every facet is equally important and key to maintaining a successful business that can still accomplish its mission of social justice.

Perhaps Glassman foresaw the social impact his Buddhist cake business would make. Or perhaps it was simply the first ripple in a sea of change. Regardless, this case for conscious capitalism could be the key to a whole new world of good manufacturing.

“This isn’t just something we put on paper or post on our website,” Kenner said. “This is unlocking the power of human potential, and it’s what we have to do.”

“This is all a part of the business equation,” Kenner said. “It’s an investment in our resources. I have to constantly evaluate, ‘How am I investing in the resources that help my business, that help people and also help the communities that we’re in?’”

INNOVATIONS FROM THE BAKERY FLOOR

Open hiring is the foundation Greyston’s mission, and an efficient manufacturing operation ensures there will be jobs to fill.

Below is a list of key supplier innovations that support the bakery’s commercial and artisan operations and, in turn, the Greyston mission.

Babbco tunnel oven BCA cutting technology Hobart mixers

And finally, Greyston aspires to create 40,000 new jobs by the end of 2030 through open and inclusive hiring, which equates to an approximate $3 billion economic impact.

CB AUGUST 2022 Q3 52 GREYSTON

Greyston is working toward its 2030 vision as a champion of stakeholder capitalism that demonstrates how a profitable business can be a force for good. Also included in that vision is achieving status as a leader in equality and inclusion by setting an industry standard with its open hiring practice.

I.J. White spiral cooling Praxair nitrogen freezing San Cassiano mixers

Even without a barrier to entry, Greyston holds all open hires to high quality and GMP standards.

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AUGUST 2022 Q3 58

BY JOANIE SPENCER

With a formula upgrade to non-GMO, plant-based and kosher, Breton crackers are upping the snack board game.

Entertaining at home looks very different today than it did back in 2020 ... when people were essentially entertaining themselves.

Parties dwindled, but as people cooked and snacked at home, the cooking and the snacking often intersected. At times, they were even elevated, as pre- di nner snacks arrived on kitchen counters while self-appointed home chefs served up appetizer boards to make the at-home dining experience a little more special. Snacking had already taken off before the pandemic, but in that new, isolated reality, it skyrocketed. Meanwhile, tradi tional entertaining waned … and snuck into the snack realm.

“In 2020 and 2021, most people were not entertaining in large groups,” said Kat Palange, US brand manager for Dare Foods, parent company to cracker brand Breton. “A lot of those big charcuterie platters that were so relevant up to that point weren’t being created because people just weren’t having that many guests in their home.”

“People made casual snack plates, rather than large charcuterie boards, and dressed them up with crackers and toppings that made them feel more elevated,” Palange said. “It didn’t feel like the typical cheese and crackers, and we started to play in that space.”

The shift was a genesis of innova tion for Breton as consumers started spicing up the everyday by trying new food combinations. True to the Breton tagline, “Make every day, less everyday,” and in the wake of restaurant closures and cooking fatigue, Breton’s brand and product innovation has gained serious “Snackingmomentum.hasbecome more elevated, and our marketing message has shifted toward that,” Palange said, noting that Breton’s product size and shape are well suited for sophisticated Today,snacking.there’s a renewed sense of normalcy as parties and other gatherings are happening once again. And while snacking innovation went wild during lockdowns, it’s now infused into the world of home entertaining. For Breton, that’s a winning combination for growth.

“We’re shifting that message back to a combination of snacking and enter taining,” Palange noted. “We’re seeing holiday boards with our crackers pop up on Instagram feeds, with influencers doing things like Fourth of July boards and more gathering-focused messag ing. Our social media users also tend to feature our crackers on charcuterie boards whenever they gather, so that creates beautiful content and relevant messaging year-round.” Breton has tapped into influencer power in three primary sectors repre senting the brand’s core consumer segments: foodies, parenting, and health and Whilewellness.foodies are more adventurous in terms of toppings or occasions, consumers in the parenting space are looking for more whimsical uses such as creating strawberry s’mores with the crackers. But on the health and well ness side of things, Breton positions its crackers as part of the trend toward meal-replacement snacking. “We can reach so many different audiences through our influencers,” Palange said. “And we can get many

COMMERCIAL BAKING59 FEATURED BRETONBRAND:

different ‘micro’ messages out to differ ent consumers who are following partic ular influencers. It can be difficult to get such a customized message across without using those social channels.”

FoodsDareofcourtesyphotosAll

Discovering the new ways that consum ers were approaching snacking and understanding those needs to be filled, Breton evaluated its product attributes and how they could appeal to each demographic group without placing a focus on niche diets that eventually fade Bretonout.recognized consumers’ propen sity toward functional foods and those with specific attributes like plant-based, kosher and non-GMO, and it rose to the forefront of the brand’s product redevelopment.

“That led us down the path of looking at this from a product perspective in what we needed to deliver on the cracker,” Palange said. Meeting — or exceeding — consumer expectations was dependent on two

To better meet those consumer needs in the US market, Dare Foods spent more than a year focusing on the Breton formula as well as the brand to identify the right product claims and how to best deliver them.

“There has been a big consumer focus on transparency, especially with healthy ingredients, and that’s played a big part in our transformation,” Palange said. “It’s something that consumers are continu ally looking closer at with their foods, and they’re looking for companies that care about what they put in their products. That’s why we felt it was important to continue offering a high-quality product with new claims.”

AUGUST 2022 Q3 60

In addition to other capital investments, Dare also made a significant financial investment into the reformulation, includ ing upgrading to non-GMO ingredients.

“The overhaul remained top of mind for [Dare Foods] leadership, and we kept moving forward with it,” Palange said. “Internally, the teams had to say, ‘We are not going to walk away from this, no matter how challenging it is. We’ve discovered this opportunity, and we’re moving forward.’ And we were supported in that effort to bring this to market.”

When working with a completely new formula, there are challenges to over come. Working with different inclusions and avoiding production issues such as dough breakage are just a few.

“All those things had to be considered with the reformulation,” Palange said. “There was time and investment needed, but the challenges were surmountable.”

Although new production lines weren’t required for the reformulation, the company did invest in necessary equip ment upgrades to ensure the crackers could be manufactured efficiently while

The wheels went in motion just in time for the global supply chain to unravel and costs to skyrocket … but the Breton team forged ahead, undeterred.

The result was a revitalized Breton cracker line — Non-GMO Project veri fied, plant-based and certified kosherpareve — on-par with the previous formula, packaged with a whole new look that’s eye-catching on the shelf.

Pulling this off amid industry uncer tainty required a full team effort, includ ing departments ranging from R&D and procurement to supply chain and manufacturing — and everyone in between. That included investigating the manufacturing implications for a non-GMO formula, as well as readying the facility for plant-based and kosher certifications, including a full bakery inspection and blessing by a rabbi for kosher-pareve certification.

Today, Breton’s design showcases the flavors on the front of pack, and the cracker is more visible, along with different types of toppings that go well with it. Dare also updated pack colors for Breton’s Cabaret and Grains First crackers, originally blue and white, to “Breton brown,” leveraging the entire brand block together. The company also upgraded Breton’s gluten-free crackers to a plant-based formula and is currently working on non-GMO certification, projected for Between2023. trend-morphing, supply chain challenges and massive price increases for raw materials across the board, Breton could have been running just to keep up. But by reformulating its product and revitalizing the brand, Dare Foods has set Breton up for the future. CB

factors:BRETONBreton’s ability to manufac ture the new formula and consumers’ ability to find the product on the shelf. That meant a holistic product renovation from the inside out.“This is the sort of thing you only want to do one time,” Palange said. “We wanted to say to our retailers, ‘We’ve thought about all these things in the full picture, and this is how we see the path to success going forward.’”

adhering to strict kosher standards.

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For the next generation of workers, company values and how they are implemented are critical.

AUGUST 2022 Q3 62 A

Workers are more discerning than ever about where they invest their time and energy, and this proves to be notably true for the younger workforce. Accord ing to a 2021 report by global marketing agency LEWIS, only 19% of Gen Z would work for a company that does not share their values. “The next generation are quickly moving into the workforce, and they want to be heard,” said Chris Lewis, CEO of LEWIS. “It’s clear that Gen Z prioritize values above all else, and companies that

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ApproachValues-First

Solving the workforce crisis starts with listening … and ends with action.

BY MAGGIE GLISAN It’s no secret that these are challeng ing times for attracting and retaining a talented and engaged workforce. The COVID-19 pandemic disrupted the commercial baking industry from top to bottom, and the lingering effects make one thing clear … there’s no returning to business as usual. This sentiment rings especially true given current labor challenges. The pandemic cracked open what wasn’t working for many employees, and if the Great Resig nation is any indication, industry lead ers must listen — and act — based on employees’ work-life needs or risk losing their most valuable asset: their people.

“We recognize that the workforce we’re dealing with is totally different,” said Trina Bediako, CEO of New Horizons Baking Co., during a workforce panel at BEMA Convention 2022. “We could decide to do things as we always have, and then we won’t have anybody working on the lines.” All that change has prompted New Horizons to reassess its mission, vision and values to be crystal clear on where the company needs to be and what it needs to do to get there. Many organizations are doing the same, and reevaluation comes at a critical time when employee engagement in the US remains in a slump. In 2021, engaged full- and part-time employees dropped to 34% — down from 36% the previ ous year — the first annual decline in a decade, according to Gallup. The downward trend continued into early 2022, as 32% of full- and part-time employees reported being engaged. What’s more, 17% — up one point from last year — say they are actively disengaged. Building a highly connected work force isn’t just good for morale; it’s also good for business. According to Gallup, companies with engaged work ers have 23% higher profit compared to those with despondent workers. They also see significantly lower absenteeism, turnover and accidents, in addition to greater customer loyalty. If organizations aren’t proactive about making changes to engage employees, their workforce will look elsewhere. It’s a competitive market for job seekers, and according to Mintel, three in 10 workers are likely to look for a new job in the next year. So, what can be done? Using company values as the guidepost of all decision making is key. But it’s not enough to put up a poster with inspirational words like “integrity,” “collaboration” and “respect” in the break room, and then expect workers to feel like they have value and ownership in the organization. In fact, a recent Gallup poll revealed that only four in 10 employees strongly agree that the mission or purpose of their organization makes them feel their job is important. To build trust, employees need to see that mission lived out daily through its leaders. Managers can’t just talk the talk. They must walk the walk.

Trina Bediako | CEO | New Horizons Baking Co. don’t understand or reflect that will find themselves struggling to attract and retain the best talent.” Today, purpose is paramount. Company leaders are increasingly aware of the need to play an active role in tack ling greater societal challenges, and sitting on the sidelines is no longer a viable option if they want to remain competitive. In a manifesto published by Harvard Business Review, Paul Polman, former Unilever CEO, and Andrew Winston, a consultant and author, call this a “net-positive” approach to busi ness in which the company “improves wellbeing for everyone it impacts and at all scales — every product, every operation, every region and country, and for every stakeholder, including employ ees, suppliers, communities, customers, and even future generations and the planet itself.” The pre-pandemic status quo simply doesn’t cut it anymore, and leaders need to reconsider how they use their organi zation’s culture and values to drive busi ness decisions.

COMMERCIAL BAKING63 CRITICAL ISSUES: VALUES-BASED MANAGEMENT

“If our leaders don’t know the message, then ourdon’temployeesgetthemessage.”

During the pandemic, the company also stepped up its frequency of global all-hands meetings for its widespread workforce and leadership focus meet ings for the top 50 to 60 leaders in the organization. In an October 2021 episode of the American Bakers Associ ation’s Bake to the Future podcast, Dawn CEO Carrie Jones-Barber emphasized the need for strong, clear messaging during these connection points.

“If you’re not living up to [your values], you’re losing trust of your team, you’re losing trust of your suppliers, you’re losing trust of your customers,” she added. “It’s not great for business, and you’re going to very quickly see the impact of operat ing without that standard in place.”

AUGUST 2022 Q3 64

“Notsuggestions.everyone communicates in the same way,” Gilbert said. “We want to make sure — regardless of your comfort or ability, or whether you’re an introvert or an extrovert, or someone who speaks up in every meeting or someone who sits back and listens — that your opinion and your ideas matter.”

“We’ve got a real responsibility for those leaders to share with their teams Proper onboarding, training and mentorship, along with allowing people to bring their authentic selves to the workplace, are key factors in employee retention.

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VALUES-BASED MANAGEMENT

“When you don’t have a strong foun dation of values, or a culture that truly permeates outside of the headquarters, you’re just going to run into challenges,” said Alexis Gilbert, Dawn Foods’ senior director, global brand and communi cations. “Your customers, your team members, they’re going to feel it. They’re going to see it, and you will lose Gilbertcredibility.”said that for Dawn Foods, team members adhering to and living the company values of relationships, opti mism, integrity, passion and process is non-negotiable. But she also acknowl edged that those values have to be backed up with action; otherwise, they’re just empty words. Trust in values-based leadership requires consistency.

Dawn Foods is living out its values by placing a premium on feedback. The company offers a 24-hour Speak-Up hotline, operated by an independent third party, where customers, supp liers, vendors and team members can share concerns, voice opinions or offer

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AUGUST 2022 Q3 66 what the lay of land is and where we’re going to ensure everyone understands,” Jones-Barber said. “We talk a lot about our vision and our mission and our Bediakoculture.”underscored that point by artic ulating the importance of understanding and embodying the company’s values at a leadership level. “If our leaders don’t know the message, then our employees don’t get the message,” Bediako said. “Leaders direct the culture, the culture directs the behavior, and the behavior directs the results.”

Tapping into the social and environ mental issues workers feel passionate about brings about alignment and makes employees feel invested in the work that they’re doing. Gilbert said many new initiatives and resources have been brought about by asking team members what they value and what’s important to

are looking for organizations that represent the things that represent them selves,” she said.

At St. Louis-based Companion Baking, using unconventional metrics to drive values-based performance has been a helpful way to motivate employees. For example, one of the company’s key initiatives is waste reduction. Founder Josh Allen and his team established a trash efficiency metric, which is sales divided by pounds of trash to measure success. As a result, the company has reduced its trash by 1 million lbs.

“Peoplethem.

Source: Gallup (down from 36% the previous year) (the first annual decline in a decade)34%

MANAGEMENT

Diversity, equity and inclusion (DEI) initiatives are ways to support employees more holistically. In a recent company-wide Pride Month campaign, Dawn Foods invited employees to finish the sentence “Inclusion is…” and share

In 2020, engaged full- and part-time employees dropped to and that downward trend continued at 32% in early 2022.

“Weemployees.wantto give them a sense of owner ship in their own path and their own development,” he said. “That’s the best way to get folks to stick around and want to stay.” But it’s also critical to take a 360-degree view of employees and take more into consideration than just their careers. The pandemic exacer bated the already blurring lines between work and personal life, and according to Gallup, fewer than one in four US employees feel strongly that their organi zation cares about their wellbeing. That’s the lowest in nearly a decade.

In thinking about values-based manage ment strategies, leaders need to invest in the growth and development of their employees’ careers. Strong onboard ing, coaching and mentorship are all key components to the retention puzzle.

Some leaders are thinking outside the box to cultivate a mission-driven culture.

“We needed to create some metrics that people can get excited about,” Allen said. “And people have gotten excited about trash and its reduction. Obviously, it feels good to throw less stuff away. Folks that take pride in what they do don’t enjoy generating waste. So, to be able to drive that number in the right direction has had a very positive impact on morale, and really ignited passion in the craft.”

VALUES-BASED

Allen said his company is focused on setting employees up for success through onboarding and mentorship programs that build upon the company’s mission and values, including a buddy system for new employees and a career development matrix for more tenured

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VALUES-BASED MANAGEMENT AUGUST 2022 Q3 68

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she was “blown away” by how many employees participated and how open and honest team people chose to “Collectively,be. we are Dawn, and individ ually we have such unique experiences and perspectives that make us who we are,” she said. “That diversity drives innovation. It drives differing opinions, and that opens up great questions and It’sdiscussions.”worthnoting that for DEI programs to be effective, leaders must commu nicate clearly and follow through on their promises.

If the pandemic has taught the baking industry anything, it’s that flexibility is key to staying relevant and finding success in the face of unforeseen obstacles. The future will always be full of ambigu ity, and the successful companies will be those that respond quickly when confronted with change. “Culture is never done being built,”

Gilbert said. “It’s something that lives and breathes. And as people come in and out of an organization, we have to be open to new ideas. If we ask for feed back, we have to listen.”

“When it comes to DEI, your leadership team all needs to be walking the walk, with everybody saying the same thing,” Bediako said. “It needs to come from the top down so your employees see that you’re serious about diversity, equity and inclusion. And all your managers or your supervisors, everybody on leadership is showing that and those initiatives; with out it, it’s not going to work.”

their statements with colleagues around the globe. To meet employees where they were, the company activated the initiative digitally and in-person at facil ities where digital communication isn’t the norm so leadership could facilitate engagement from all the different team Gilbertmembers.said

“It’s clear that Gen Z don’tcompaniesvaluesprioritizeaboveallelse,andthatunderstandorreflectthatwillfindthemselvesstrugglingtoattractandretainthebesttalent.”

Chris Lewis | CEO | LEWIS

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AUGUST 2022 Q3 70 Taste of WorldChanginga In a time of multifaceted disruption, flavor trends are a complex proposition for product developers. BY BELLA FOOTE UnsplashonJaszowskaMargaret©

According to a Mintel study from 2021, nearly three in five (58%) moms — often known as the purchasing decision-makers — are seeking more snacks with functional benefits. How does this impact flavor profiles?

“Consumers are putting a

Within the dessert and confection cate gory, consumers want to see more naturally sweetened products with ingredients like real fruit, honey and agave. Additionally, consumer interest in baked desserts with lighter textures such as whipped and airy desserts vastly outweighs dense, thick-textured indul gences, indicating a trend away from the previously popular indulgent treat

So far, 2022 has bestowed polarizing politics, post-pandemic alterations, skyrocketing inflation rates, supply chain disruption and a war with a ripple effect on virtually every business sector. It’s a difficult time for consumers to settle into a routine in this undulating climate, and it’s even harder for brands to understand — let alone predict — buying behavior as they estimate costs and potential inno vation during a time of unprecedented social, political and economic change.

Kathy Sheehan | SVP | Cassandra

COMMERCIAL BAKING71 PRODUCTFLAVORDEVELOPMENT:INNOVATION

People have turned to food as an outlet. It serves as a source of comfort, a medium for exploration and a means for change. They’ve looked outward in their search for new and exotic flavors as they seek out lesser-known international cuisines. But they have also looked inward as they uncover how their food choices impact their health — mental and physical. This is an exciting time for flavor innovation as consumers seek to discover all they can about food, demanding authenticity through nuanced, unique flavors. Before one can interpret and identify flavor trends, it is essential to understand modern consumer behavior. Why are consumers becoming more adventur ous? What is behind health-conscious buying habits? And how are cost and supply chain issues influencing these Onebehaviors?dominant behavior is healthconscious consumption and a trend toward healthy lifestyles. However, the focus is not on diet trends. In fact, only one in four American adults claim to be on a diet, as reported by The NPD Group, a global market information company. “Consumers are putting a greater emphasis on a holistic approach to food and using it as a way to express themselves,” said Kathy Sheehan, SVP of trend research firm Cassandra. The focus is not only on what’s good for their physical health but also what’s good for their mental health … with an added benefit if it’s healthy for the planet, too.

Since the beginning of the pandemic, consumers gravitated toward eating indulgent foods as a form of comfort. But stress-driven comfort food purchases are not likely to sustain the same growth seen during the pandemic, as Mintel reported that 53% of consumers would like to take better care of their health moving forward. A Dawn Foods 2021 Flavor Trends report found that in this post-pandemic world, “consumers are seeking out food and beverages that deliver both great taste and functional ingredients aimed at helping their overall health.”

And within the sweet baked goods sector, T. Hasegawa’s Food and Beverage Flavor Trends report found that 39% of consumers are motivated to buy because of healthier ingredients.

toholisticemphasisgreateronaapproachfoodandusingitasawaytoexpressthemselves.”

—Below Healthier versions of chips, often in a crisp form, are becoming increasingly popular better-for-you snacks.

AUGUST 2022 Q3 72 FLAVOR INNOVATION market. Seasonal fruit flavors and lighter citrus notes are also very popular. Some examples of naturally sweet ened, better-for-you baked goods on the market include Lenny & Larry’s Straw berry Shortcake Cookie, a vegan cookie packed with protein, fiber, non-GMO ingredients and natural sweeteners. This was quickly followed by the launch of Tastykake’s Banana Pudding Creme Glazed Pie, which takes a fruit-forward approach that merges classic flavors with banana and citrus. The pandemic caused many people to incorporate immunity-boosting nutrients into their daily intake. According to another Dawn Foods report, six out of 10 consumers are increasingly look ing for foods to support their immune health. Ingredients like turmeric, citrus fruits and probiotics have been welcome additions to product profiles, lending dynamic flavor and nutritional benefits to baked goods. This trend is taking form in products like Lenny & Larry’s The BOSS! Immunity Bar, full of plant protein and probiotics, as well as Smart Baking Company’s Smartcake, which has been recently reformulated to include 100% of the daily recommended vitamin C intake. Consumers are seeking out tastes that intermingle sweet with unex pected flavors. McCormick’s latest Flavor Forecast predicts that as more consumers move away from overly sweet indulgences, experimentation will reshape the notion. People want a balance with savory, smokey and spicy that yields unique, innovative complexi ties within the baked goods market.

“What our consumers appreciate is a more nuanced flavor,” she said. “Not an overwhelming single flavor, but some thing that can pair well with other food.”

Maine Crisp’s most recent variety, Savory Fig and Thyme, was a result of customer demand for savory, dairy-free crisps. Today, it’s the company’s most popular Unfamiliarityflavor. can be a barrier to new flavors, though. A study from T. Hasegawa noted that 45% of consum ers will be more likely to try a new cuisine if it is similar to one they’re familiar with.

One way to encourage new flavor exploration is to present them through a recognizable medium. For example, healthier versions of chips are becoming increasingly popular, with variations

Karen Getz, founder and president of New England-based specialty cracker company Maine Crisp, described her success in layering sweet and savory.

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For example, Unbelievabuns’ hamburger buns made with antioxidant-packed and fiber-rich sunflower flour, and pancake and waffle mix made with Amasar’s protein and vitamin-loaded breadfruit flour were just two of the standout prod ucts at the show.

Identifying a yearning for a return to classic flavors, woman-owned company Soozy’s Grain-Free recently launched Birthday Cake Donuts. The gluten-free donuts are sweetened with organic coconut sugar and maple syrup, free of refined sugar, processed ingredients and artificial colors. Many consumers will be more willing to try new flavors if they are presented in a familiar way. And that’s not exclusive to functional foods; it’s a popular way for any consumer to expand their culi nary palate, regardless of their dietary Forpreferences.example, many Asian ingredients and flavors are not yet a part of mainstream consumer culture outside of traditional Chinese cuisine. This presents a great opportunity for Asian fusion concepts — merging familiar flavors with foreign ones —or introducing new flavors within a familiar format. One such brand, Yishi Foods, introduced a variety of Asianinspired oatmeal flavors with functional benefits to the breakfast aisle, finding success in flavors like Red Bean Berry Oatmeal and Taro Bubble Tea Oatmeal. As consumers experience new flavor sensations, the oatmeal base lends a blanket of comfort. People crave adventure by way of flavor after years of being deprived of the ability to travel globally during the pandemic. However, consumers are no longer demanding flavors from the wellknown cuisines such as Italy, Mexico and China — those that have captivated tastebuds for decades. In contrast, some of the fastest-growing flavor concepts in the US are Asian and South American, including inspiration from India, Korea, Argentina, Vietnam and Brazil, accord ing to Datassential’s Fastest-Growing Restaurant Concepts report. Ube, a sweet purple yam, is commonly used in Asian cuisine. With its distinct coloring and with a nutty, vanilla taste, ube has grown into an international powerhouse flavor.

such as Sea Salt & Lime Chickpea Tortilla Chips by Hippeas and Cassava Chips by Turbana. This “familiar foods with a twist” trend saw dramatic growth at the Specialty Food Association (SFA)’s Summer Fancy Food Show in New York City, which high lighted tens of thousands of specialty food and beverage products. Trends are pointing to consumers seek ing out comforting treats as a coping mechanism during the pandemic. The Summer Fancy Food Show saw those same comfort-food trends. However, many now come with an updated twist that balances nostalgic favorites with something new, according to one Dawn Foods report. These days, “something new” often means functional benefits.

AUGUST 2022 Q3 74

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“Consumers’ pursuit of comforting foods with a slight twist in flavor, ingredients and nutritional benefits will drive the majority growth of the $170.4 billion specialty food industry in 2022,” accord ing to SFA’s Trendspotter Panel.

FLAVOR INNOVATION

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Mintel’s Trending on US Menus: Baked Goods report revealed that many consumers are taking notice of international spices that offer a dynamic, rich flavor profile. Some examples include Indian garam masala and Korean Dallas-basedgochugaru.

Younger consumers show the most interest in these emerging cuisines. The latest Dawn Foods report suggests that as this generation matures — and gains spending power — brands should focus on infusing international and regional flavors into snack foods to differ entiate and convey authenticity.

potato chip brand Green Sahara introduced consumers to interna tional spices by offering a range of salty snacks seasoned with African spice blends, differentiating between East African barbeque chili and the savory spices of North Africa.

“The specialty, artisan food market has prospered amid two difficult years, with [the] latest research showing specialty continues to grow at a faster rate than all food,” said Denise Purcell, VP of content and education at SFA.

“I’m noticing more differentiation between southern and northern Indian cuisine and the specific spices used,” said Monica Saxena, owner and manager of aRoqa, a popular Indian restaurant in New York City. “It’s great to see people recognizing the regional varieties that I enjoyed while growing up.” Spices used in international fare are becoming more mai nstream as well.

In its 2022 Flavor Flash report, T. Hasegawa identified Mediterranean and Middle Eastern flavors as particularly popular with products like shawarma, harissa, peri-peri and za’atar gaining popularity over the past year. Maine Crisp also plans to release a new Olive & Za’atar Spiced Crisp soon. Fruit flavors from Asia and Latin America are also becoming increasingly popu lar in desserts and confections. Of such flavors, one Mintel study reports that lychee, yuzu, dragon fruit and ube — common in Asian cuisine — are poised for growth within the category.

For bakery and snack brands, one question remains: How long will consumers maintain their baked goods buying habits? As inflation shows no signs of slowing, many consumers may think about choosing private-label products to keep costs down.

That said, as inflation prices plague consumers, brands must seek out that balance between superior flavor and dollar value. It’s not just inflation vexing the baking industry. Supply chain disruption still impacts product availability, forcing many brands to prioritize their flavors or terminate those in lesser demand.

Some of the fastest growing [flavor] concepts in the US are Asian and South American, including India, Argentina,Korea,VietnamandBrazil.

Source: Datassential’s Fastest-Growing Restaurant Concepts report

“With consumers being so sensitive to pricing, we have seen a shift to privatelabel products in grocery stores,” said Tim Grzebinski, clinical insights principal at IRI Worldwide. “But this has not yet happened in the baking aisle. One thing we know for sure is that people do not want to sacrifice quality.”

AUGUST 2022 Q3 76 FLAVOR INNOVATION

Among these flavor trends, an underly ing behavior persists: Consumers are increasingly shopping for baked goods that fall within the handcrafted, specialty and artisan categories. Despite the rising food costs brought on by inflation, people are still willing to pay a premium for artisan baked goods.

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Some of the most prominent supply chain barriers and inflation rate factors are the results of the war in Ukraine. “Russia is a huge exporter of grain,” Grzebinski said. “Even if certain countries don’t source from there, it’s a demand on US supply and it has a huge impact on Accordingcost.”

to the World Bank’s Food Security Update reported as of June 16, the Agricultural Price Index is 14% higher compared to January 2022. Additionally, maize and wheat prices were up by 27% and 37%, respectively, compared to January 2022. Several countries are limiting sugar exports as well, representing one of the latest obstacles for the baking industry.

This is not to suggest that a supply chain system would benefit from entirely local and domestic sourcing but could better emphasize the benefits of support ing local food systems. Thriving local, decentralized supply chains decrease dependence on imports that are subject to global fluctuation; create greater food security; and promote seasonal, sustainable food procurement practices.

India, the world’s second-largest sugar producer and top sugar consumer, recently announced it would be imple menting a cap to maintain domestic availability and price stability, according to Business Insider

“We need to be able to rethink how the local space allows for that,” Berg said.

Local supply chains surely work for smaller brands such as Maine Crisp.

“When we look at bread and rolls, the assortment is down,” Grzebinski said. “The supply chain is impacting assort ment and variety. Add inflation to that, and if there are lines that aren’t as profitable, brands are walking away from those products.”

“We source locally, so we haven’t been as impacted by supply chain disruption,” Getz said. “Maine is a state with trees — and we have paper plants here — so our cartons are locally printed.”

In addition, sustainability within food is a major trend that’s captured consumers’ hearts. Holistically healthy consump tion practices also consider planetary health, and a shift toward seasonal consumption methods is on the rise. Approximately 36% of consumers are motivated to purchase a sweet baked good based on seasonal flavors, according to T. Hasegawa’s Food Flavor Trends report. As sustainability becomes more mainstream, the demand for seasonal ingredients will be sure to increase. Stone fruit in the summer, squash in the fall, and rhubarb in the spring can serve as a source of new flavor inspi ration. Could a return to sustainable supply chains and a renewed focus on long-ignored and neglected flavors offer new flavor innovation in this constantly changing world? Only time will tell. For now, the flavor trends currently emerging from these global disruptions are making waves in a positive way. CB

As supply chain issues continue, sourcing local ingredients has eased the burden on bakers.

AUGUST 2022 Q3 78 FLAVOR INNOVATION

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Political threats, economic disruption and natural disasters have always posed great risk to the global supply chain, and the pandemic exposed those vulnerabil ities. Robert Berg, founder of Iridescent Data and industry partner to Emerge CPG, mused on the potential bene fits of a supply chain revolution where local markets become more important, transportation costs are reduced and larger retailers call on smaller brands for white-label products.

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IBIE PERSPECTIVES

Advent of the Baking Influencer

Trendsetters and innovators in the baking industry have never been as accessible as they are now. The power of social media and influencer marketing is not one to be underestimated as the bakers behind the International Baking Industry Exhibition’s (IBIE) influencer program have proven. In addition to attending the Baking Expo, this select group of international bakers from a range of specialties were specifically chosen to create their own IBIE-related original content, bringing a century-old Expo into the modern day. But before there were bakers wellversed in the realm of social media — with major players like YouTube, TikTok and Instagram having taken off in just the last decade — there were bakers like Duff Goldman, renowned pastry chef and owner of Baltimore-based Charm City Cakes. He represents a generation of bakers who brought their expertise to the masses through the power of personality. Food Network’s Ace of Cakes , a reality television series that featured Goldman and his bakery employees, provided consumers and those interested in baking and cake decorating with an inside look at the creation of baked goods, from complex orders to day-today operations with a bit of fun mixed in. Social media has blown the doors wide open for bakers big and small to do the same online. In the advent of digital communication platforms available at the touch of a screen, influential figures like Goldman have adapted their strate With more bakery influencers sharing creations on social media, consumers are learning more about the industry and connecting to bakers directly.

From pastry chefs to viral creators, new and established names are leading influencerbaking’seconomy

BY ANNIE HOLLON

COMMERCIAL BAKING81

AUGUST 2022 Q3 82 IBIE PERSPECTIVES

Matthew James Duffy, a Toronto-based chef, baking professor and selfproclaimed bread fanatic, is among the select influencers partnering with the Baking Expo as part of its influencer program. More commonly known to his 300,000 followers as Sourdough Duffy, his primary platforms are TikTok, Instagram and YouTube,

“You’ve got to do things that make you excited and not necessarily things that you’ve already seen a million times,” Goldman said. “I think it’s cool to make stuff that you’re like, ‘Oh my god, this is delicious.’ And when you get to share that

There are plenty of consumer trends online, from mirror-glaze cakes to sprinkle-filled layer cakes, but bakers like Goldman and Duffy hone their trade and content around the kinds of baked goods and flavors that interest them.

“You’ve got to do things that make you excited and not necessarily things that you’ve already seen a million times.”

Duff Goldman | owner | Charm City Cakes gies and maintained their position as leaders in the baking industry by using these tools to their advantage. With the emergence of social media touch ing all kinds of industries, bakers can find opportunities to connect with consumers and one another as content creators and influencers. How bakers create niches for them selves with everything from photorealistic cakes and cronuts to vending machine-dispensed cupcakes provides a unique viewpoint into the future.

“It’s a cool thing that people are coming up with, and it’s like, ‘Let’s see what’s going to be around next year,’” Goldman said. The world of influencer marketing is vast and flourishing as social media maintains a preeminent digital pres ence. Whether it be on the viral video app TikTok, photo-forward Instagram or any other social media platforms domi nating internet usage, social media has the power to connect audiences and creators from all over to relish in si milar interests, hobbies and passions — including the baking industry.

“I’ve noticed that since then, the ques tions that I get are a lot more sophis ticated. You can tell by the questions they’re asking that they’ve run into a problem because they’ve actually been which serve a specific purpose and provide Duffy with different insights and opportunities.

“I have currently made TikTok my primary focus as I think it’s the best way to see organic growth and reach,” Duffy said. “It’s also a little bit more fun and less curated than Instagram.”

Combining personal content and behind-the-scenes footage of his unique bakes from his sourdough micro- ba kery, Duffy has found a way to balance craft with content curation. With videos that have garnered more than 3 million views on TikTok alone, his creations — which include unique flavor varieties and inclu sions such as chocolate, buckwheat, bacon, scallions, garlic and more — give his viewers a new perspective on the world of baking and sourdough in particular, which became home baking’s superstar during the pandemic. Goldman, who has been in the baking industry since the ’80s and was a pioneer in the digital documentation of bakery life, noted a shift in how thought leadership and trends are communicated. While the comment section of social media posts certainly provides feedback, it’s a baker’s own instincts and interests that drive authentic trends.

“I really don’t pay much attention to consumer trends,” Duffy said. “I’m in a fortunate position that my baking is shared with a small group of friends and family, and I can just bake whatever I want, when I want.”

Though his strongest following is on TikTok and Instagram, platforms like YouTube grant Duffy a different way to reach people. While he is currently in production for his upcoming cookbook, he plans to emphasize video content moving forward, as it serves an audi ence in search of answers to specific questions that he can address as a baker. Since the pandemic lockdown drove many amateur bakers into the kitchen, Goldman took to YouTube and Instagram livestreams to bake alongside them, providing insights and advice to viewers who quickly picked up on some of the finer aspects of the craft.

with people, and they’re like, ‘Oh man, this is really cool, I’ve never seen this before,’ I think that’s it.”

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After years of social distancing and lock downs, the event allows people from every sector of the industry to come together face-to-face. As he enters his second IBIE show cycle — this year as a celebrity guest with AB Mauri at Booth #1832 and as part of Rockin’ Pint Night’s featured act, Foie Grock — Goldman looks forward to not only the innovations and opportu nities but also a chance to see his peers and other industry members in person.

Molly Robbins, a London-based cake decorator and CEO of Molly’s Creature Creator, is also involved in the influencer program. Goldman will get to meet her face-to-face for the first time after being online friends for nearly 10 years.

AUGUST 2022 Q3 84 doing this,” Goldman shared. “‘Why is my bread not rising?’ ‘Why is my crumb so tight?’ ‘Why isn’t my crust crusty?’ And you can tell people are really going for it and I love that.”

As an educator, Duffy will have the oppor tunity to connect with answer-seeking audiences at IBIEducate, where he will present a session called, “Intro to Rye Sourdough & Freshly Milled Grains: Presented by Bread Bakers Guild of America” on Sunday, Sept. 18 at 8:30 a.m.

“I will be taking a group of students from Centennial College to participate as volunteers and help out some of the conference presenters,” Duffy said. “I really look forward to networking and seeing some old friends. There are a lot of great companies and bakers that will be there, and it’s awesome to be a part of it.”

With IBIE bringing all kinds of influ encers to the Las Vegas Convention Center, this meeting of minds can now take place in a real-life social setting.

“We’ve been really good friends for so long, but we’ve never actually met in person,” Goldman said. “This will be the first time, so I’m really looking forward to that.” Influencers hold the power to connect with and educate their followers, a power that industries like cannabis can lever age to get their products into the hands of Cannabisconsumers.goods consulting firm The Vivid Team’s leaders — Jessica Cristadoro, president and CEO, and Steffen Weck, COO and Food Business Consulting president — shared that since cannabis brands can’t advertise in the traditional sense other bakeries do, influencers provide a way for brands to speak directly to consumers they’re trying to reach. “The only way we as an industry can communicate effectively to our products’ end consumers is through influencer marketing,” Weck said.

The session will guide attendees through the development of rye sourdough and help them understand the impact of different milling properties.

“I have currently made TikTok my primary focus as I think it’s the best way to see organic growth and reach. It’s also a little bit more fun and less curated than Instagram.”

Rather than through fiscal arrangements, cannabis companies are limited to trad ing product in exchange for content from influencers, Cristadoro shared. With each state having its own rules and regulations, edibles producers need to lean into modern marketing methods to connect to consumers. While influencers in cannabis range from online creators to the “budtenders” dispensing product, their impact and the feedback from their followers is direct. Working with creators who already have an audience — and the ability to create appealing content for that audience — can be a fraction of the cost of traditional “Bymarketing.engaging with different people, you don’t have to hire 15 new people,” she said. “All you have to do is work with influencers.” At its core, IBIE is about innovation, and the inclusion of influencers provides industry leaders, artisan bakers and others interested in a new way to market their products with a glimpse into what the future of connecting with consumers could look like. “I think we’re just in the beginning stages of the rapidly developing creator econ omy,” Duffy said, “and I really look forward to being a part of it.” CB

IBIE PERSPECTIVES

Matthew James “Sourdough” Duffy | chef, baking professor, social media influencer

“The reason why people do sweets is because there’s a charted path on how to do it, so everyone sees what works,”

Pot Brownie

Jovi Chen-Davis, founder and CEO of Munchy Co., is pioneering new territory within the cannabis industry.

I refuse to let it happen if there’s anything I can do about it,” she said.

With Munchy Co. set to officially launch in 2023, this ambitious CEO is set on paving a new path in cannabis.

“I lost everything, and I was like, ‘This cannot happen to other people of color.

For her, this sector’s great unknown was not an obstacle, but an opportunity.

Though traditional cannabis edibles involve the use of fat such as cannabisinfused oil or maltodextrin cannabis blends, the powder version of maltodextrin cannabis mixes with the seasoning process of snacks to create a new kind of edible. The Vivid Team, a product and brand creation consultant in the cannabis space, has helped Chen-Davis fill a share of the cannabis market that had not yet been tapped into. She is also leading the way through the core mission of her company.

BY ANNIE HOLLON What began as a side project for Jovi Chen-Davis is now a vibrant, vegan edibles brand changing the way cannabis can be used in food. As founder and CEO of Munchy Co., she’s bringing a savory innovation to the International Baking Industry Exposition (IBIE) this fall. Cannabis edibles more commonly take the form of brownies, cookies, gummies and other sweet options, leaving savory snacks in the white space. Following hefty R&D, Chen-Davis’ experimentation to merge the snack food and cannabis industries was a success in the form of an extruded snack. Munchy Co. is set to debut at IBIE 2022 in Las Vegas, previewing one of its three flavors — Vegan Barbecue — as a sample at Booth #7551 in the Cannabis Pavilion before the products launch in the Denver and Long Beach, CA, markets in 2023. Other flavors, which Chen-Davis expects to be received well in these first markets, include Vegan Cheddar Jalapeño and Vegan Hatch Chile Lime varieties.

Chen-Davis said. “In an industry that can be kind of volatile, I guess it could be easy to do what works. But I feel that this is feasible with the right team being me.”

Beyond the

CB StockAdobeonCreativefamily©

After facing her own issues getting Munchy Co. off the ground, ChenDavis plans to build a social equity fund from the proceeds of her company to help other entrepreneurs of color build their businesses.

“I know I’m on track with my thinking because cannabis is slowly being integrated into other types of products,” Chen-Davis said about her trailblazing path with Munchy Co. “And I feel like snack foods is the white whale — I’m going after it. It’s the next frontier.”

COMMERCIAL BAKING87 IBIE PERSPECTIVES

SEPT. 18-21, 2022

In the 52 weeks ending May 15, center store, which dominated sales during the pandemic, saw sales of $8.3 billion, a 7.1% change vs. a year ago. Perimeter sales of $2.3 billion, a 17.6% change from a year ago, demonstrate the ongoing rebound after a period marked by closures and labor shortages.

BAKING89 Source: IRI OmniMarket Integrated Fresh Latest 52 Weeks Ending May 15, 2022 COOKIESCOOKIESHOLIDAYCOOKIEMULTIPACKSPECIALTYCOOKIESICEDCOOKIESTRADITIONAL|FROSTEDCOOKIESCOOKIESTRAY|KIT|SEASONAL—ALLOTHER TOTAL DOLLAR SALES ($ IN MILLIONS) $ CHANGE VS. A YEAR AGO Perimeter Cookies By Type $2,296.$1,461.69$338.16$179.96$156.92$124.76$20.40$3.5589 22.9%20.7%18.2%15.6%1.1%67.7%-1.0%17.6%

Cookies flex their muscle

CATEGORY OUTLOOK: COOKIES

In center store, traditional cookies saw $685 million in current sales and $113 million in current sales of assorted/ multipack cookies. Traditional cookies recorded $1.5 billion in current sales in the perimeter, an impressive 15.6% change compared with a year ago. Unit sales of perimeter traditional cook ies were up 6.7%, and specialty cookies boasted $180 million in current sales. Iced/frosted perimeter cookies saw $338 million in current sales, an 18.2% change vs. a yearCOMMERCIALago.

The cookie category continues to show its resiliency with the global cookie market expected to grow at a CAGR of 5.43%, according to Mordor Intelligence. The importance consumers place on cookies translates into a category that sees little negative impact, even during a pandemic. Cookies found even more traction when lockdowns and stay-athome mandates further accelerated snacking behaviors.

Looking to fill the “almost- hom emade” category in center store is Pills bury’s new soft-baked cookies. The Minneapolis-based company, known for refrigerated cookie dough, now offers a shelf-stable version with no oven required. In the past year, the cookies have experienced tremendous growth with $91 million in sales and a 238% dollar sales change vs. last year.

Confetti, albeit a small sub-category, is finding some traction. Fun and flavorful confetti additions allow consumers to incorporate celebration and nostalgia into their cookie ple asure. Mintel found 72% of US consumers agree they enjoy things that remind them of childhood, and IRI research revealed that 67% of consumers look for fun-to-eat snacks.

$8,343.22$685.50$113.72$7.68$2.31$0.38 151.8%13.1%0.9%-0.2%8.2%7.1%

“Thirty percent of American households stated they struggle to afford needed groceries.” Looking at recent history, all indicators point to the fact that the category is well-positioned to not only survive but also thrive. Cookies are still in high demand despite an 8% price increase. Units are only down slightly, but Altobelli attributed this to out-of-stock products vs. true decline.

Other popular varieties include choco late chip, oatmeal, sugar and assorted.

If the past two years have taught us anything, it’s that consumers rely on comfort through accessible indulgence more than ever. Plus, those who set aside their baking mitts when mobility resumed are looking for new ways to get that fresh-baked fix.

When it comes to choosing flavors, traditional options dominate, especially chocolate, which also leads in growth from a dollar and volume perspective.

“Inflationary pressure can be seen in all food and beverage,” she said. “However, we do see that rewards or indulgent treat snacks are outpacing the categories of wellness and permissible snacking overall, and that is expected to continue.”

Another category top-seller is Burlington, ON-based Voortman Bakery, a manu facturer of cookies, sugar-free products and wafers. Known as “the real good, feel good treat,” its products contain whole grain oats, coconut and almonds and are free from artificial flavors and colors, HFCS, and trans-fat.

Sugar frosted, red velvet, snickerdoodle, gingerbread and M&M choc olate chip also show strong growth.

Limited-time offers (LTOs) also capture consumer attention. Offerings from East Hanover, NJ-based Nabisco demon strate consumers’ love of novelty with its Oreo LTOs in unique flavors such as Apple Cider Donut and Carrot Cake with cream cheese filling as well as holiday-related Oreos including Fourth of July and Pride-themed packs. The enjoyment of cookies is not limited to the young or young at heart. Cookie consumption spans across demograph ics, trending among larger families with children as well as seniors and Boom ers. From a volume index perspective, households with more than five people index at 138, households raising teens at 132 and four-person households at 119.

Source: IRI

OmniMarket Integrated Fresh | Latest 52 Weeks Ending May 15, 2022 Center Store Cookies By Type TRADITIONAL COOKIES ICED | FROSTED COOKIES MULTIPACK COOKIES SPECIALTY COOKIES COOKIE TRAY | KIT TOTAL DOLLAR SALES ($ IN MILLIONS) $ CHANGE VS. A YEAR AGO

CATEGORY OUTLOOK: COOKIES AUGUST 2022 Q3 90 Despite the ever-present hurdles of labor shortages and ongoing supply chain issues, the category shows tremendous strength. What remains to be seen is if cookies can successfully weather the inflation ary shock inside the bakery and the unknown impact of changing consumer purchasing behavior. A survey conducted in May by IRI found that 95% of consumers are concerned about rising prices, with 48% being very concerned. “The widespread nature and height of inflation is pressuring spending for many consumers, including 38 percent who described their financial health as strained,” said Melissa Altobelli, principal, strategic solutions group for IRI.

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Heightenedsales.

Across all snack categories, multi/ variety packs are up 26%, demonstrat ing the many benefits of on-the-go convenience and the desire of multiple family members to have the snacks they want with built-in portion control. The 25-oz. party-size varieties recorded unit sales of 294 million, and 30-oz. multi packs saw unit sales of 268.3 million.

CATEGORY OUTLOOK: COOKIES AUGUST 2022 Q3 92

“Consumers still prefer freshness over packaged, which was curbed when we had to cut grocery store visits,” Frossard said. “On the other hand, center-store items are convenient. We remain optimistic with the perime ter perspectives and also reaffirm the need for the center aisle to compete directly with them.”

Protein is another important theme, as IRI found 41% of consumers “sometimes” look for high protein in their snacks, and 32% “always” or “usually” look for high protein. That said, claims for proteinenhanced cookies remain modest: $177.7 million in sales, a 2% dollar share of cookies and a 14.8% dollar sales change vs. a year ago. Although shelf-stable products were prioritized during 2020, consumers still reassert their preference for fresh, according to JP Frossard, VP, consumer foods analyst for Rabobank Group.

With inflation impacting consumers in numerous ways, some may choose shelf-stability and quantity over a more expensive fresh-baked cookie. On the other hand, it might also result in consumers purchasing in-store as an in-the-moment splurge.

While the majority of growth in the category comes from indulgent cook ies, there is some traction in healthier versions with simple ingredient profiles.

When it comes to opportunities in the category, Altobelli recommends capitalizing on snacking. Consumers are looking for variety through multi packs, ensuring everyone gets what they want, with the added bonus of portion control. Hotter flavors, often more associated with snacks than cookies, might actually offer another option for differentiation and innovation in the category, Altobelli concluded. From flavor bonanzas to family affairs, cookies clearly remain a strong category in the industry.

CB CHOCOLATECHOCOLATE CHIP OATMEAL SUGAR ASSORTED Source: IRI OmniMarket Integrated Fresh | Latest 52 Weeks Ending May 15, 2022 Top Cookie Varieties By Dollar Sales ($ in Millions) 2022 2021 $1,710.24 $1,436.81 $421.68 $347.40 $234.38 $ 1,834.27 $1,582.07 $474.50 $417.23 $294.73

Inclusions of whole grain oats, no artificial colors or flavors, no HFCS, low-carb, low-sugar, high protein, and fiber prove indulgence and health aren’t mutually exclusive. Enhanced awareness of what one is eating is a lingering aftereffect of the pandemic, and it’s giving rise to greater demand for cookie products that are keto-friendly and grain-free. Gluten-free is smaller but gaining in distribution and growth rates. Demands for zero- and no-sugar claims are also expected to expand in snacking, and depending on the right formulation, this could also be applicable to cookies. Items with vegan/ vegetarian claims saw around 7% growth, accounting for less than 2% of cookie

IRI is seeing innovation in lines like Chicago-based brand Simple Mills, which features fewer ingredients and a tagline of “ingredients that nourish you, nothing artificial ever.”

health concerns don’t inhibit the continuation of the snack ing habits that accelerated during the pandemic. This explains the ongoing interest in multipacks for variety and portion control. Food waste, another hot topic, offers an opportunity to upcycle fruit or veggies into betterfor-you cookies. Products made with less or reusable packaging are growing double digits in dollars and units.

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Source: IRI OmniMarket Integrated Fresh | Latest 52 Weeks Ending May 15, 2022 Perimeter Tortillas | Wraps WRAPS | TORTILLASFLATBREADS DOLLAR SALES ($ IN MILLIONS) $ CHANGE VS. A YEAR AGO $288.11$17.90 9.2%3.7%

OUTLOOK: TORTILLAS

CATEGORY

The company announced Keto Pita and Keto Wraps at the IDDBA 2022 tradeshow and currently carries three gluten-free tortilla wraps.

All Wrapped Up

Change starts at the ground level, and ingredients become even more important to help flatbread producers make the switch to creating gluten-free and keto goods. These trends don’t come without their trials as new ingredients impact production and require bakers to try again and again to find solutions that work with the equipment and resources they currently have.

Jim Kabbani, CEO of the Tortilla Industry Association (TIA), shared that impacts from the supply chain and the war in Ukraine — which until early August had halted the export of grain — have forced tortilla companies to find alternative ingredients and substitutions.

BY ANNIE HOLLON

Greg Toufayan, owner of Toufayan Bakeries, shared that the rising trend around health and wellness, while new to some, has been around in a number of ways for a long time … and it’s always been a “Healthdisruptor.andwellness, and people’s opinions as to what’s good for them, is always going to change, and so that disrupts everyone’s business,” Toufayan said. “Disruption to us equals opportunity, and it’s a little bit easier for us to quickly jump and do something.”

On the tortilla side, the industry benefits from corn — one of the most popular varieties of tortilla — already being a gluten-free ingredient. However, a major influx in growth due to the pandemic has caused tortilla manufacturers to seek new varieties to appease and fulfill consumer demand.

INSIGHT: TORTILLA | FLATBREAD

Toufayan Bakeries produces a number of flatbread products and varieties across cultural cuisine types in its product portfolio, including naan, pita bread, tandoori flatbread, tortillas and wraps, in addition to other baked goods offerings. With a range of traditional flatbread types, newer trends like keto-friendly and gluten-free varieties are opening doors for Toufayan.

Toufayan noted that even though the company’s equipment works well, when it comes to adapting to keep up with consumer trends, bakers have to do the modifications and work from what they have at their disposal. “If you have to do something quick,” he said, “you’ve got to be able to make something on your own.”

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“A lot of the work that we’ve done in this regard at TIA has been to help them find alternative ingredients and figure out things like, ‘Does that particular alternative present any challenges in and of itself?’ in regard to either formulation or appliance pricing, and how to deal with that,” Kabbani said.

Victor Hugo | director of operations | Pan Pepin

UnsplashonMontanoChad© CATEGORY INSIGHT: TORTILLA | FLATBREAD

Yet that growth didn’t slow when foodservice outlets restarted their kitchens for pickup and delivery. Though restaurants were beginning to reopen, consumers continued to purchase tortillas for at-home consumption.

Among the alternative ingredient options, flour derived from lentils, chickpeas and cauliflower have helped tortilla manufacturers keep up with demand, which caused major growth in the category due to the pandemic. Kabbani noted that when the pandemic lockdowns hit, a huge shift in tortilla consumption directed business away from restaurants and toward retail.

With the inclusion of nontraditional flours and ingredients, R&D in tortillas has centered around replacement and substitution ingredients and how they affect formulation. As a result, tortilla manufacturers had to ramp up production but faced a challenge seen broadly across baking: labor shortages and supply chain issues. “It made things a little crazy,” Kabbani said. “The demand for labor increased, and the ability to meet that demand has been rather difficult.”

“I believe that [supply

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“The demand for the retail side of tortilla has just skyrocketed and pretty much doubled,” he said. “It kind of filled up an emptiness on the food service side.”

“The types of tortillas in demand have maintained their projected ratios prior to the pandemic,” Kabbani said, “but the volumes have increased quite a bit.”

thatonedisruption]chainisofthemostdifficultissueswearehavingrightnow,notonlyintortilla,butalsoinbread.”

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CATEGORY INSIGHT: TORTILLA | FLATBREAD

“I believe that this is one of the most difficult issues that we are having right now, not only in tortilla but also in bread,” said Victor Hugo, Pan Pepin’s operations director. Beyond issues with the supply chain, increased labor costs have also impacted the bakery’s operation.

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With a company that produces an array of flatbreads ranging from shelf-stable pizza crusts to premium frozen pizzas to products for foodservice, disruption in the supply chain has hit particularly hard in the form of raw ingredients.

“Wheat prices have gone through the roof,” Sterl said, also noting that oils and non-GMO and organic ingredients have become more difficult to obtain. “On the premium side of the category, some manufacturers that were producing ingredients chose not to make organic ingredients or some of those more premium ingredients. And they’ve started focusing on the items they can produce at higher volumes and higher margins.”

Outside the continental US, labor shortages and supply chain issues still impact bakeries like Pan Pepin. The Puerto Rico-based bakery faces similar challenges in its operation but faces steeper cost issues due to the need for importing ingredients from the mainland.

For Brad Sterl, president and founder of Pittsfield, NH-based Rustic Crust, issues with the supply chain have impacted every aspect of his business.

Beyond wheat and other ingredients, Sterl also noted that corrugated packaging costs, which impact nearly everyone in the pizza space, have gone up due to fuel indexes. With prices increasing from 20 to 30%, companies are forced to put in larger orders than normal in hopes of getting a higher percentage of packaging in on time.

As Toufayan Bakeries looks to the future for more product innovation, the company is focused on equipment that can use mother dough in its pita bread, combining trends like sourdough with traditional pita techniques. In 2019 Toufayan visited the stilloperating bakery in Eqypt where his grandfather once baked more than 100 years ago, and he has visited Armenian bakeries where their techniques spark “Myinspiration.dream

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CATEGORY INSIGHT: TORTILLA | FLATBREAD line ingredients more efficiently grants greater accuracy in portion control. Kabbani also noted that due to the uptick in tortilla demand, an increase in automation is still needed even with significant equipment backlogs, upwards to a year in some cases. New innovations like high-pressure water jet mixing have also piqued the interests of tortilla manufacturers.

Flatbreads of every variety have stood the test of time across cultures, and all sectors of the category see continued

The pandemic caused the demand for retail tortillas to nearly double.

[production] line would be fully automated and could use the same starter/mother dough technique for a super high hydration dough that they do in the old world,” he said. The move toward automation in bakery continues an upward tick as challenges with labor shortages remain the industry status quo. Hugo shared that though Pan Pepin has a machine that can move more than 800 packages an hour, the bakery is looking to buy another line that can move nearly twice as many in the same “Throughouttime.

the last two years from staffing shortages, we’ve really invested a lot more in equipment where we were running short staffed or areas where we would normally have hourly workers or production workers,” Sterl said, pointing to the critical need for labor solutions. While a lot of hand application is involved in his production, investment in equipment that feeds people on the growth in store for the future, even if the amount of growth might remain a “Imystery.dosee the idea of consumers moving more into some of these types of products and, depending on what happens with the economy as they go forward, I would say the category moving forward in the next 12 to 18 months would be stable,” Sterl said. “I don’t see any magic increases, but I do see, from our end of it anyway, the pretty stable potential for some customers to shift into this category.”

In the face of supply chain shortages, Hugo looks to increase efficiency in the bakery and replace ingredients as needed. To overcome some of these challenges, Pan Pepin relies on solutions from suppliers like Corbion and J&K Ingredients to keep R&D running smoothly and also ease labor.

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Health and immunity concerns considered, Euromonitor estimated cakes recorded the biggest increase, with approximately 6.3% YOY growth last year, followed by a 5% uptick this year, according to forecast data. The bread product segment enjoyed a similar growth last year, with a 5.6% expansion, which is expected to settle into a 4.2% growth value this year. Frozen baked goods were among the favorite categories during various levels of lockdowns, after an initial decline (from 7.1% in 2019-20 to 5.4% last year). Euromonitor estimated this segment to have grown by 5.4% in 2020-21. As restrictions are lifted, frozen goods are expected to slow to half this level at 2.8% YOY Pastriesgrowth.are a promising category for consumers and manufacturers with strong growth: 4.4% YOY last year and an estimated 4.7% growth worldwide, up from 1.9% YOY growth pre-pandemic. Dessert mixes are rebounding after a sharp drop in 2020-21. The YOY evolution in the past four years is estimated to go from 1.9% to 4.4% and reach 4.7% this year, according to Euromonitor. International content provided by baking+biscuit international, an F2M publication.

Consumer Trends That Take the Cake

After putting consumer resilience and adaptability to the test in 2021, access and action are driving worldwide trends this year. Euromonitor International analyzes market sizes, with historical and forecast data, and finds consumers favor their cakes and more. The global market for baked goods has emerged with newfound strength: Euromonitor International estimates a 5.5% year-on-year (YOY) growth for the 2020-21 period, followed by a 4.4% YOY forecast for 2021-22. For comparison, the pre-pandemic baked goods market grew by 1.7% (2019-2020).

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Tracking European consumer trends and predicting the future, according to Euromonitor.

The Self-Love Seekers, and The Socialization Paradox. Among these, Backup Planners will be key for baking and the bakery market. Faced with challenges in securing their usual or desired products and services, Backup Planners are looking for ways to purchase similar items or finding creative solutions to obtain alternatives. While supply chains should start to stabilize and access to products should revert to pre-COVID-19 levels by late 2022, the new shopping habits consumers have acquired will dictate how Backup Planners discover and select products. Goods that emphasize local sourcing and offer direct-toconsumer or subscription options will hold appeal here.

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Another global consumer trend of particular relevance will be the SelfLove Seekers. For these consumers, acceptance, self-care and inclusion are at the forefront of their lifestyles. This group prioritize their happiness, feeling comfortable in their own skin,

“Businessesactivities. need to transform alongside rapidly evolving consumer preferences,” said Alison Angus, head of lifestyles at Euromonitor International. “Reverting to a pre-pandemic playbook is not likely to generate the same results moving forward.”

Finally, the global consumer trend of The Socialization Paradox will be important as it tracks how consumers are approaching a return to prepandemic life in different ways based on their comfort levels. Certain consumers are eager, while others are hesitant, to resume their normal

and indulging in goods and services that elevate their sense of self. In food — bakery, in particular — these consumers are not necessarily looking for standardissue permissible indulgence (claims that seek to assuage guilt over sugar, fat, calorie intake, etc.), but rather tastes that align with their ideas of who they are, allowing them to simply be happy before, during and after eating.

By market share, the world’s top five players are Grupo Bimbo SAB de CV, Yamazaki Baking Co., Flowers Foods, Shikishima Baking Co. and Fuji Baking Co. Every year, Euromonitor identifies those trends expected to gain traction in the year ahead, providing insight into changing consumer values and exploring how behavior shifts can cause disruption for businesses globally. Access and action are the driving forces behind the top 10 global consumer trends in 2022. Resilience and adaptability were tested in 2021, forcing consumers to relinquish control and embrace ambiguity. This year, consumers are taking back the reins and paving a path forward based on their passions and values. The top 10 global consumer trends identified for 2022 are Backup Planners, Climate Changers, Digital Seniors, Financial Aficionados, The Great Life Refresh, The Metaverse Movement, Pursuit of Preloved, Rural Urbanites,

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Jorge Zarate, global SVP of opera tions and engineering at Mexico Citybased Grupo Bimbo and IBIE 2022 vice chairman, sat down with baking + biscuit for a discussion on what’s shap ing the international industry at present and how it’s impacting mindsets of inter national attendees for the International Baking Indusry Exposition (IBIE), taking place Sept. 17-22 in Las Vegas. With a host of challenges happening not only in the US but also in areas like Mexico, South America and Central America, IBIE will be showcasing solutions for automation, equipment to bypass supply chain issues and training opportunities to help with workforce challenges. As international bakers navigate these issues plight in Europe, IBIE visitors will find inspiration throughout the show. Digital solutions are bound to garner interest as well, given their recent spike in popularity as they provide valuable tools for handling staff shortages, sanitation solutions and sustainability. Throughout Europe and other corners of the globe, adoption of digital solutions in bakeries will see a significant increase, dictated by need on both sides of the Atlantic Ocean, according to Zarate. For example, he noted that Grupo Bimbo is making efforts to increase its own

For international attendees, the anticipation is building around returning to Baking Expo.

There’s No Place in the World like IBIE

COMMERCIAL BAKING119 INTERNATIONAL MARKET

digitalization level, taking new s olutions launched in the past two years into account.

“Consumers have had the time to reflect, and they are now asking for innovation,” Zarate added. “As a result, innovations are rolling out faster and are more focused than ever now. The plant-based trend is currently boom ing and is not only driven by vegetarian consumers but also by all consumers’ personal ideals, in cluding diet, health and sustainability goals. We see products such as keto-friendly and low-carb ranges coming back. After two years of at-home cooking, consumers appreciate treats in a new light. Often, this means artisanal-style bread or finishing baking at home but not necessarily committing to the time and effort to bake from scratch.”

To support international participation, the show has worked with the US government and embassies to facil itate the visa issuing process.

To accomplish this, Grupo Bimbo’s commercial depart ments and heads of business units will come together in- person at the show to get inspired, analyze issues together and get a clear overview of the current status of the industry, as well as discover new manufacturing and distribution solutions. Despite immense pandemic-, inflation- and supply chain-related challenges, attendee figures at present are a perfect match with those from the previous IBIE.

“I think that we’re going to have good international atten dance,” Zarate said. “We already have the exhibitors who confirmed their participation, and it’s a similar share to previous IBIE expos.”

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Along with the known challenges facing the industry, international consumers are going through transforma tions of their own, becoming more sophisticated and more demanding, Zarate observed.

Even though active lifestyles has now resumed outside of homes, many pandemic-driven consumption behavior changes will remain, and bakeries have to accommodate them.

In addition to visa renewals, the task force behind IBIE’s international delegation program has been working to provide international attendees benefits that include

The European and American markets share more similarities in trends than differences, so international visi tors will find relevant solutions and inspiration.

“Bakers are looking into health and wellness products, keto and low-carb products,” Zarate said. “And they are looking for ways to improve on sustainability.” Differences come from the products themselves as well as the needed eq uipment.

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discounted exhibition hall registration, IBIEducate partic ipation, even lower rates for hotels and assistance at the international booth, including Wi-Fi. Through the corpo rate meeting program, space can be reserved in meet ing rooms at the Las Vegas Convention Center before or after show hours.

Meet AZO’s solution for minor and micro ingredient automation

Learn more at:

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“North American products are more the soft, pan-molded types, what we call ‘Pullman,’” Zarate said, noting that Europeans also prefer crusty breads, creating a differ ence in fermentation times for artisan-style breads, which tend to be longer in Europe. Product flavors are stronger in Europe, too. These differences lead to different technology require ments. While America is starting to manufature more European-style products, bakery products remain mainly on the soft side. IBIE is supporting European participation and facilitating the transfer of ideas through its collabora tion with its European counterpart, iba. The partnership has been beneficial for both sides, according to Zarate.

“We are sharing trends and knowledge,” Zarate said. “We intend to take part in iba next year. Our European colleagues have shown great interest in learning and seeing how we do business, and how we manufacture products. This interest goes both ways. Through our part nership with iba, we gain access to voices from bakeries and equipment manufacturers. Our coordination will benefit both industries, in Europe and the US.” Commercial Baking has developed a cooperative ag reement with the leading Euro pean / international baking journal baking+biscuit international from the publish ing house F2M. This magazine is the English- la nguage sister to the acclaimed German language journal brot+backwaren and is published six times per year with 5,000 hard copies delivered per issue and thousands reading the editions digitally.

Precise dosing Highly accurate and flexible automation for unique solutions Automated weighing Ultimate scale accuracy

At the root of the commercial baking industry is the widely shared belief that almost everyone has a healthy appetite for an amazing cake, warm bread or a good old-fashioned chocolate chip cookie. Certainly, those within the industry have a passionate interest in their products and the customers who crave them. But when it comes business-essential topics like insurance — and the commercial risks that make it an important part of a bakery’s bottom line — a baker’s appetite is not so hearty. While the task of reviewing insurance needs can often be seen as necessary but unpleasant, it doesn’t have to be that way. Rather than being seen as a “sales” persona, an insurance broker could — or, perhaps, should — assume the role of an advisor with the primary goal of guiding insurance choices for a client to arrive at the best possible fit at the best possible rate. But without proper guidance, many bakery professionals too often immediately scroll to the last page of an insurance proposal to focus only the premium. “What’s it going to cost me” is a natural first inclination. But the devil is, indeed, in the details. Insurance premiums are derived from exposures multiplied by a given rate. When considering the options, the most important decision is in considering how much you can afford to fund yourself. In effect, that’s the appetite for risk.

Policies can be designed with large deductibles or self-insured retentions that result in ultimate savings.

Appetite for Risk

BY JOE BUICK, OSWALD COMPANIES

As a business grows, the ability to absorb larger losses usually grows with it. With proper guidance, the opportunity to reduce the net rate should also increase. By managing claims internally and accepting a large deductible, for example, premium credits of up to 75% can be applied, depending on risk parameters and loss history. For companies with a strong safety culture and years of experience including hard loss data, coverage adjustments can accommodate that changing appetite for risk to drive bottom-line savings.

One of the best examples lies in workers’ compensation insurance. Many businesses have been insured with “first dollar” coverage since their inception. Often, their premiums started at just a few thousand dollars per year but have grown to more than $250,000 for this coverage line alone.

Part of this concept is self-explanatory: Choose a deductible that’s reasonable and that can be absorbed at the time of loss. However, a larger business can drive costs down with a loss-sensitive approach.

Consider a company with five locations and a Total Insured Value (TIV) per location of $20 million. The combined total insured value for all locations would be $100 million, and the company would normally carry blanket coverage of $100 million to fully cover their total risk. This blanket limit would be rated based on the fact that simultaneous total loss is unlikely.

How baking companies can avoid biting off more insurance costs than they can chew.

Expanding companies with a larger appetite for risk can also realize cost savings by reexamining their commercial property insurance. Many underwriters have the ability to apply a (per location) loss limit, so for businesses with significant geographic spread across multiple locations, this could be an option worth exploring.

COMMERCIAL BAKING123 BUSINESS INTEL

Joe Buick, a certified insurance counselor and certified risk manager, has more than 25 years of experience in the commercial insurance industry. He and his wife, Rebecca, own D’Vine Cookies in Ferndale, MI. Contact him at jbuick@oswaldcompanies.com

Further, if a company is paying more than $500,000 for casualty lines (commercial auto, general liability and excess liability), it should be hearing about captive insurance options. Captives, in simple terms, are programs designed and paid for by members. Businesses that pursue a captive option are very interested in controlling and managing risk. They often have a higher appetite for it based on their culture and experience. Because of this, they can pay a lesser net rate as well as enjoy returns that reflect losses not incurred.

Ideally, each line of insurance coverage — including health benefits — can be approached in this same way. Sometimes, for no reason other than lack of a recent policy review, a buyer’s risk appetite can appear to vary greatly from one coverage area to the next. For instance, why else would a business self-insure the first $100,000 of a workers’ compensation loss but keep their auto physical damage deductible at $1,000 if they average fewer than three accidents per year? These inconsistencies develop over time, but if reviewed annually to match a business’ overall appetite for risk, savings can be achieved. In risk management circles, there’s an expression: “They’re outgrowing their agent or broker.” This is often true for large, risk-laden clients. The agency that is selling “cookie-cutter” products is an agency that For companies with a strong safety culture and years of experience including hard loss data, coverage adjustments can accommodate that changing appetite for risk

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would indeed pay an insurance premium based on the entirety of this value. Assuming the insured is confident that simultaneous loss is unlikely as well, why not cap the per occurrence property loss limit at $20 million? It’s a method that is commonly used with multi-state or multi-region companies to reduce the total cost of risk. The commonality and application of these examples has a direct correlation to how much risk a company is willing to take to reduce overall costs. The larger a company grows, the more latitude it has to consider such risk management techniques.

With insurance as a shield meant to protect a business’ balance sheet, baking companies should ensure their coverage is consistently designed across all lines or types. Measuring the appetite for risk is a great place to start the conversation with an insurance advisor, whether growing a business or launching one CB

normally does not design or have access to insurance programs that include loss-sensitive options. It’s important for a growing bakery business to consider the possible options.

Thank you for supporting IBIE, which is co-owned by ABA The wholesale baking industry’s most established and largest business network offers corporate membership with individual benefits. Learn more about how an ABA membership can benefit your company. Stop by our booth in the West Hall Lobby of the LVCC. BECOME A MEMBER OF ABA MEMBER EXCLUSIVE PROGRAMS PROFESSIONALDEVELOPMENT CONNECTIONSBUSINESS ADVOCACYSOLUTIONSAND

Solutions

Synova, a Bundy Baking solution, released the AccuTech Pan Greaser, which uses exclusive design technology to provide bakeries with accurate, sanitary and automated pan greasing technology. Bakeries can expect to reduce release agent usage, decrease sanitation needs and downtime, and increase throughput. Recipe-driven technology and simple changeover also reduce labor requirements. www.synovaoil.com

Sanitary automated greaser

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SUPPLIER SOLUTIONS

Precise fine powder coverage Axis Automation’s patented AXIS Duster delivers precise, uniform coverage for fine powders without using screens or vibra tion, which eliminates surging, streaking, bare spots, and waste or scrap products. It helps bakers maximize ingredient yield and eases supply chain strain. Customers report up to a 50% decrease in flour consumption. Standard sizes are available for faster d elivery. www.axisautomation.com

Dual-fuel tunnel ovens

Babbco’s line of CleanBake tunnel ovens incorporates Dual-Fuel Hybrid Technology (gas and electric) for clean energy and reduced carbon footprint. This oven technology provides the same baking performance that customers have come to depend on. Bakers can achieve net-zero and sustain ability objectives while enjoying low risk of entry for existing processes. www.babbcompanies.com

User-friendly, industrial cobot Apex Motion released a new industrial, user-friendly cobot, the Baker-Bot MAX. It boasts double the payload (44 lbs.) of the Baker-Bot 10, is designed with greater reach of 67 in., and has a pallet height capacity of 96 in. This cobot can handle applica tions outside the threshold of other Baker-Bot models, is well suited for demanding industrial tasks and has minimal guarding requirements. www.apexmotion.com

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When production lines collide Allied Bakery & Food Service Equipment announces its latest advancement in pizza production. A collaboration between two of its suppliers, this complete, fully automated high-production industrial line can produce artisan, restaurant-quality pizza using highly hydrated, long fermented, natural dough with full topping capabilities. This gives bakers the chance to create high-quality pies such as Neapolitan style pizza or get in on trends like pinsa, a Roman-style pizza. www.alliedbake.com

High-performance film sealing

Cavanna Group’s ZERO5BMF is designed to work with thick, innovative films that require a longer sealing time. The machine can be applied to bakery applications where thick film is used as an oxygen barrier for products such as specialty breads or baked products that use a gas flush to increase shelf life. With BoxMotion film sealing technology, it reaches speeds over 300 pieces per minute.

SUPPLIER SOLUTIONS

Updated bagger design

www.cavanna-usa.com

Formost Fuji GTS Bagger will boast a new mechanical design that allows the machine to run quieter, smoother and more effi ciently. These changes — including a newly designed over head, improved bag hold-down and auto bag change design — reduce downtime and create efficiency on the plant floor.

Mixing system flexibility

www.formostfuji.comAUGUST2022

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Spiromatic’s AGV-based mixing bowl handling system enables a fully automated batch mixing system that offers new levels of flex ibility. The AGV runs 24 hours while being continuously charged through induction lines and can be allocated to multiple mixers/ lines. During the dough mixing process, the area where the AGV operates is accessible and available for cleaning or maintenance on parts of the system not running. www.spiromatic.com

Optimized manufacturing and maintenance DIOSNA introduces its IoT interface function to optimize process flows and maintenance planning. With condition and product quality monitoring through live data, the system transforms existing processes into Industry 4.0. Bakery-specific advan tages include cross-machine recipe editor and integrated account management. Rapid data analysis enables optimized processes for companies with an existing PLC control system.

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Heavy-duty, long-lasting radius belt

Henry & Sons developed the ZERO Contact device, which will stop metal-to-metal contact with VEMAG screws and housings. The new device can improve weight consistency, stop product giveaway and the wearing process of double screws and hous ings, and reduce temperature rise. www.dhenryandsons.com

From micro to Maxowave

Avoid metal-to-metal contact

Intralox’s new Series 2400 Radius belt reduces belt breakage and increases belt life. With a heavy-duty edge, it is a lo ng-lasting, fault-tolerant radius conveyor belt for the food industry.

SUPPLIER SOLUTIONS

Performance-based control system Multivac/Fritsch has a new performance-based control system for lines in the PROGRESSA range to make operations easy and intuitive. With the PROGRESSA Control, operators input the target production number, and the line will calculate all parameters necessary to achieve the desired output. With no highly technical settings or adjustments, mid-sized bakers can achieve superior results on their lines. www.fritsch-group.com

www.jkingredients.com

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J&K Ingredients has taken the microwave to the max. Maxowave is a dough conditioner specifically for use in yeast-raised baked goods that are heated in the microwave. This solution can be used to keep sandwiches, breads and rolls, stuffed pockets, pizza crust, biscuits, and more from becoming rubbery and to maintain their overall quality. It can be applied to any existing dough condition ing system to enhance the tolerance of microwaved baked goods.

The newest addition to the company’s line of radius conveyor belts, its design is paired with Intralox’s patented load-sharing edge technology, which reduces downtime and extends belt life by decreasing fatigue failures. www.intralox.com

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High-quality 3-D printer

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SUPPLIER SOLUTIONS

Schubert Additive Solutions has launched its new PARTBOX 3-D printer. It delivers consistently high print quality to improve process reliability within packaging machines and efficiency in the packaging process. With its own streaming platform and printer, PARTBOX is a complete system that enables manufac turers to produce components directly in their own operations.

www.schubert.groupAUGUST2022

Croissant creation innovation

A wirecut machine with an array of capabilities

Rexfab has partnered with Mekitec to offer North American bakeries an X-ray system with data reporting software that opti mizes lines to run more efficiently and require less maintenance. The system records, classifies and organizes production data to be easily interpreted and gives bakeries an exceptional quality control system that minimizes food waste, achieves better trace ability, and reduces costs and paperwork. www.rexfab.com

Software-supported x-ray system

Reading Bakery Systems introduces a new Thomas L. Green WCX Wirecut Machine with improved flexibility, control, safety features and sanitation. The expanded range of product capabilities includes standard and filled bars, multi-color prod ucts, filled and encapsulated cookies, pet treats, frozen dough applications, and more. Capable of producing throughput yields of up to 300 cuts per minute while maintaining a high accuracy and consistent piece weights. www.readingbakery.com

Rademaker’s Radini croissant system is an add-on to the Radini makeup line. The system is made up of three mobile units: spreading, turning and align unit, and a croissant moulder. This enables bakers to create croissants of different shapes and sizes in a consistent way. The flexibility of this module offers a minimum impact in terms of surface area, while bakers’ product range can be expanded. www.rademaker.com

TechTalk with Ton van der Pas, Kaak Ton van der Pas, product sales manager for mixing at Kaak, dives into the the benefits of mechanical dough development (MDD). Listen into the conver sation to hear how Kaak has refined the pressure and vacuum mixing processes in the MDD field. www.kaak.com

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Our multimedia collection is full of videos, podcast episodes and more, where you can get a deep look — and listen — into the exciting shifts happening in the baking industry.

Commercial Baking Channel

TechTalk with John McIsaac, Reiser Joanie Spencer, editor-in-chief for Commerci al Baking , talks with John McIsaac, VP of strategic business development for Reiser, about the latest advancements in the company’s high-speed cutting systems. www.reiser.com

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TechTalk with Nico Roesler, RBS Nico Roesler, pretzel and snack equipment sales manager for Reading Bakery Systems, discusses the newest generation of the Thom as L. Green WCX Wirecut Machine and how its versatility lends itself to a wide variety of cookie and bar products. www.readingbakery.com

Linxis Group’s Tim Cook on key industry trends

TechTalk with Christy Pettey and Stephanie Jackson, Kwik Lok

TechTalk with Pieter Van Hoecke, Spiromatic Listen to a conversation between Joanie Sp encer, Commercial Baking editor-in-chief, and Pieter Van Hoecke, Spiromatic’s business development manager for North America. They discuss process automation as a whole concept, from ingredient intake to dough on the line. www.spiromatic.com

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Commercial Baking catches up with Tim Cook, pres ident and CEO of Linxis Group and 2021-22 BEMA board chair, during BEMA Convention 2022 in San Diego, CA. Cook explores trends he’s seen in the bak ing industry this year, including cultural shifts in the workforce and an evolution in collaboration methods.

Fresh Faces at BEMA Convention 2022

Kwik Lok’s chief people officer Christy Pettey and co-owner Stephanie Jackson explain how they’re transforming their company with diversity, equity and inclusion initiatives like their ex plosively popular DuoLingo language learning program. www.kwiklok.com

The world is changing, and so is the baking industry, especially as the pandemic’s workforce disruptions have helped usher in a new wave of diverse talent. In this video, you’ll get to meet some of the fresh faces making their first appearance at BEMA 2022.

Kerwin Brown, president and CEO of BEMA, shares his insight on how the pandemic shifted the industry into adopting more remote methods of communica tion and virtual customer support.

Chris Prociv on elevating brunch through bread Commercial Baking catches up with Chris Prociv, senior VP of marketing, R&D and innovation for A spire Bakeries. See her take on what was displayed at this year’s IDDBA convention, especially around brunch and at-home entertaining. Prociv shares how Aspire Bakeries is strategizing to meet the moment and elevate the brunch experience for its consumers.

COMMERCIAL BAKING CHANNEL

Kerwin Brown on the pandemic’s impacts to baking

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Robb MacKie on the state of the industry

Robb MacKie, president and CEO of the American Bakers Association, discusses the key shifts that he is seeing in the commercial baking industry and the important role that leadership positions have in man aging them. need

for companies to thoroughly evaluate their methods of reducing waste. By collecting data on moisture con tent throughout the manufacturing process, baked goods producers can improve efficiency, quality and overall plant production. www.moisttech.com www.unifiller.com18887338444 We design and manufacture processing and portioning equipment to bakeries and food plants worldwide. Join us at Booth #1025 for IBIE in Vegas, Sept 18-21 More PRODUCTION. Less WASTE.

The benefits of moisture control This video from MoistTech highlights the

Jennifer Caro on the meaning of “grit” The team at Steven Charles — A Dessert Company is known for what president Rebecca O’Hara calls the “rumble.” It means fighting for what works and a willingness to let go of what doesn’t. And it requires grit. Hear Jennifer Caro, chief commercial officer for Steven Charles, on what “grit” really means.

The International Dairy Deli Bakery Association (IDDBA) held its 2022 convention June 5-7 in Atlanta. Watch this Commercial Baking exclusive video of the showfloor to see some of the industry’s top compa nies, innovations and new products on display.

COMMERCIAL BAKING CHANNEL

IDDBA convention recap

Troubleshooting Innovation Welcome to season 4 of Commercial Baking ’s podcast. Join Stephen Hallam, brand ambassador for Dickinson & Morris and chair of judges for the Tiptree World Bread Awards, as he explores the elements of artisan baking that can — and should — be incorporated into commercial bread production. Listen to episode 1 by scanning the QR code below. COBOTS . ROBOTS . AUTOMATION Decorating & Writing . Dough Cutting . Tray Handling . Pre & Post Bake Equipment Automation for Bakery Applications Cookie dough cutting and placing. Decorating for high volume & seasonal. Cake layering and custom conveyors. Tray loading and unloading. ROBOTICS & AUTOMATION FOR FOOD & BAKERY apexmotion.com | info@apexmotion.com1-778-298-8292 High volume robotic decorating. BAKER-BOT Multi-task Cobot Visit Us at Booth 612 Industrial Cobot with increased reach and payload. COBOTS . ROBOTS . AUTOMATION Decorating & Writing . Dough Cutting . Tray Handling . Pre & Post Bake Equipment Automation for Bakery Applications Cookie dough cutting and placing. Decorating for high volume & seasonal. Cake layering and custom conveyors. Tray loading and unloading. AUTOMATION FOR FOOD & BAKERY apexmotion.com | info@apexmotion.com1-778-298-8292 DECO-BOT High volume robotic decorating. BAKER-BOT Multi-task Cobot Visit Us at Booth 612 Industrial Cobot with increased reach and payload. COBOTS . ROBOTS . AUTOMATION Decorating & Writing Dough Cutting Tray Handling Pre & Post Bake Equipment Automation for Bakery Applications Cookie dough cutting and placing. Decorating for high volume & seasonal. Cake layering and custom conveyors. Tray loading and unloading. ROBOTICS & AUTOMATION FOR FOOD & BAKERY apexmotion.com | info@apexmotion.com1-778-298-8292 DECO-BOT High volume robotic decorating. BAKER-BOT Multi-task Cobot Visit Us at Booth 612 BAKER-BOT MAX Industrial Cobot with increased reach and payload. COBOTS . ROBOTS . AUTOMATION Decorating & Writing Dough Cutting Tray Handling Pre & Post Bake Equipment Automation for Bakery Applications Cookie dough cutting and placing. Decorating for high volume & seasonal. Cake layering and custom conveyors. Tray loading and unloading. ROBOTICS & AUTOMATION FOR FOOD & BAKERY apexmotion.com | info@apexmotion.com1-778-298-8292 DECO-BOT High volume robotic decorating. BAKER-BOT Multi-task Cobot Visit Us at Booth 612 BAKER-BOT MAX Industrial Cobot with increased reach and payload.

IBIE Booth Trailers

Intralox is the leading conveyance solutions provider whose extensive portfolio includes equipment and technologies for food processing, manufacturing, and handling. Come by the com pany’s booth at IBIE to witness a variety of sanitary design conveyance solutions in-action, including the new AIM Glide technology. www.intralox.com

Get an exclusive sneak peek into some of the booths that will be present at IBIE 2022. Before stepping foot on the tradeshow floor, take a look at some of the most innovative exhibitors at this year’s Baking Expo.

Belshaw | Booth 3031 Belshaw has served the baking industry for 99 years as a leading supplier of donut fryers, donut production equipment, bakery ovens and bread makeup lines to customers big and small. Stop by the company’s booth at IBIE to talk with the Belshaw team of experts about your bakery’s custom needs and how their innovations can fit your operation. www.belshaw.com

COMMERCIAL BAKING141 IBIE BOOTH TRAILERS

HaF Equipment designs innovative solutions for powder and bulk material handling, dust col lection, and batching systems that meet today’s manufacturing challenges head-on. The compa ny is best known for its commitment to partnership and excellence through service with integrity, pur pose and ingenuity, which attendees can witness first-hand at the booth. www.hafequipment.com

HaF Equipment | Booth 7305

Intralox | Booth 3453

LeMatic’s focus on sustainability, automation, increased capacities and improved operational efficiencies will be on full display in Booth #2601. LeMatic has been a global leader in slicing and packaging manufacturing for the baking industry since 1972, and the company is looking to the future as it strengthens its role of robotics and cutting-edge technology in its equipment design. www.lematic.com

WP Bakery Group USA | Booth 1633 WP Bakery Group USA designs, manufac tures, installs and services equipment for all as pects of the baking industry. Step inside their booth to experience the full WP world of possi bilities. From mixers and makeup lines to ovens, proofing equipment and much more, WP has a complete turnkey solution for a bakery’s specific needs.

www.wpbakerygroupusa.com Watch Booth

AUGUST 2022 Q3 142 IBIE BOOTH TRAILERS

Trailers, scan the QR code now.

the full collection Interested in learning more? To view all of the

LeMatic | Booth 2601

Visit ASB! Booth 1255 at the Sept. 17-21, 2022 LAS CONVENTIONVEGASCENTER

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does not assume any liability for errors or omissions. Please send any updates or corrections to info@commercialbaking.com GOLDPARTNERMEDIA

Food Business Consulting 140 www.thevividteam.com info@thevividteam.com Formost Fuji 99 www.formostfuji.com sales@formostfuji.com

Doran Scales www.doranscales.com sales@doranscales.com E.T. Oakes www.oakes.com info@oakes.com

Sifting through the noise Print DigitalmagazineseditionsWebsiteNewslettersMultimedia AUGUST 2022 Q3 The following advertisers appear in this issue. We encourage readers to reach out to these companies through the listed website or email for further information. This index is provided as a service to readers and advertisers, but

144 SUBSCRIBE Fresh insights on trends innovationsand www.commercialbaking.com/subscription Ad Index AA Bakery Services 136 www.aabakeryservices.com patrick@aabakeryservices.com AB Mauri 85 www.abmna.com customerservice.abmauri@abmauri.com ABI LTD 69 www.abiltd.com inquiry@abiltd.com Allied Bakery & Food Service Equipment 47 www.alliedbaking.com steve@alliedbake.com American Bakers Association 125 www.americanbakers.org info@americanbakers.org American Society of Baking 143 www.asbe.org kvanamburg@asbe.org AMF Bakery Systems 3 www.amfbakery.com sales@amfbakery.com Apex Motion Control 139 www.apexmotion.com info@apexmotion.com Ashworth 31 www.ashworth.com sales@ashworth.com Avant Food Media 120 www.commercialbaking.com info@avantfoodmedia.com Axis Automation 100 www.axisautomation.com info@axisautomation.com AZO 121 www.azo-inc.com info-azo-usa@azo.com Babbco 42-43 www.babbco.com sales@babbco.com Belshaw 65 www.belshaw.com info@belshaw.com Bettendorf Stanford 83 www.bettendorfstanford.com jatkins@bettendorfstanford.com BluePrint Automation 33 www.blueprintautomation.com sales@blueprintautomation.com Brabender 111 www.brabenderti.com golmes@brabenderti.com Brolite 79 www.bakewithbrolite.com s.delghingaro@broliteproducts.com

Bundy www.bundybakingsolutions.com info@bundybakingsolutions.com www.cainfood.com sales@cainfood.com Capway Automation 16-17 www.capwayautomation.com sales@capwayusa.com Cavanna Group 93 www.cavanna.com sales@cavannagroup.com Corbion 148 www.corbion.com foodus@corbion.com Diosna 8 www.diosna.com info@diosna.com

Cain Food Industries 147

Baking Solutions 13

Gold Coast Ingredients Inc. www.goldcoastinc.com info@goldcoastinc.com

Great Western Manufacturing www.gwmfg.com eharrison@gwmfg.com Commercial Baking

Kaak 118 www.kaak.com jlaros@kaak.com

145 ADVERTISE Download the media kit www.commercialbaking.com/advertise Paul Lattan paul@avantfoodmedia.com 816.585.5030 steve@avantfoodmedia.com 816.605.5037 It’s time to perform rather than just spend. AD COMMERCIALINDEXBAKING

IJ White 53 www.ijwhite.com pwhite@ijwhite.com Imperial 138 www.imperialind.com morgan@imperialind.com Intralox 5 www.intralox.com

Moline 108 www.moline.com sales@moline.com Multivac/Fritsch 94 us.multivac.com matt.zielsdorf@multivac.com

Harpak-Ulma www.harpak-ulma.com info@harpak-ulma.com

PMMI 115

IPCO 105 www.ipco.com sales.us@ipco.com

sales@peerlessfood.com

hobartcorp.com/products/food-prep/mixers carolyn.bilger@itwfeg.com

Henry & Sons 20www.dhenryandsons.com info@dhenryandsons.com

Handtmann www.handtmann.de/en patrick.mcgady@handtmann.us

moisttech.com/applications/human-food-moisture info@moisttech.com

Rademaker

customerservice.bakery@intralox.com

Zeppelin Systems USA 39 zeppelin-systems.com/us/industries/food-industry info@zeppelin-usa.com

Middleby Bakery Group 54-5 7 www.middlebybakery.com nicole.plantenis@middlebybakery.com

Equipment 27

Mecatherm 122 www.mecatherm.fr/en info@mecatherm.fr

Peerless Food www.peerlessfood.com

MIWE 131 www.miwe.com/roll-in contact@miwe.de MoistTech 41

National Honey Board www.honey.com honey@nhb.org Newsmith www.newsmiths.co.uk bwoods@newsmiths.co.uk

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Fred D. Pfening Co. www.pfening.com sales@pfening.com www.pmmi.org info@pmmi.org www.benchmarkautomation.net benchmark.sales@promachbuilt.com 29 www.rademaker.com sales@rademaker.com Reading Bakery Systems 61 www.readingbakery.com info@readingbakery.com Reading Thermal 51 www.readingthermal.com info@readingthermal.com Reiser 49 www.reiser.com sales@reiser.com Repco 97 www.repcoworld.com/bakery info@repcoworld.com Rexfab 4 www.rexfab.com rexfab@rexfab.com Schubert 103 www.schubert.group sales@schubert-na.com Shaffer 7 www.shaffermixers.com info@shaffermixers.com Shick Esteve 34-35 www.shickesteve.com info@shickesteve.com

J&K Ingredients 2 www.jkingredients.com sales@jkingredients.net

Promach 10

Spiromatic 25 www.spiromatic.com info@spiromatic.com Tonelli 88 www.tonelli.it kevin@tonelli.com Unifiller 137 www.unifiller.com info@unifiller.com Univar Solutions 77 www.univarsolutions.com getstarted@univarsolutions.com WP Bakery 86 www.wpbakerygroupusa.com patk@wpbakerygroupusa.com

IBIE 133 www.bakingexpo.com info@bakingexpo.com

Hobart 80

GiveNeverUp

Relentless perseverance was the best decision of my Thelife.obstacles won’t stop appearing before us. As businesses, there will always be something to get in our way. But steadfast commitment to the science and beauty of our industry will allow us to continue bringing the art of baking to our communities and customers. Every time things get tough, whether a pandemic, supply chain issues or staffing, remembering the importance of what we bring to the table — literally — keeps us moving forward.

AUGUST 2022 Q3 146

THE LAST WORD FROM CORDIA HARRINGTON

Cordia Harrington is the founder and CEO of Crown Bakeries and board chair for the American Bakers Association

The experience is nothing short of fantastic. It is art.

The bread we make is the bread people break when they come together for comfort and celebrations. We’re impacting lives every day … the lives of our current and future employees, our customers, our consumers, and our own families. Never forget and never give up on this beautiful, artful industry that is baking. CB

One of my biggest lessons has become one of my greatest convictions. Study, determination and relentless persever ance — despite all the obstacles and shortfalls — are the inspiration for us to deliver something truly special. Ford went broke five times. Thomas Edison made 1,000 tries before the lightbulb was discovered. Jordan was cut from his high school basketball team. It takes many rejections and failures, but we persevere.

Henry Ford, Michael Jordan and Walt Disney all had multiple failures preceding fabulous success. Collapsed dough and rock-hard biscuits are mere stepping stones to a beautiful baked good. And when we finally do get it right, wonderful aromas and beautiful visuals lead us to the first bite of a buttery biscuit, bun or croissant.

Baking, like music or photography, is an amazing combination of science, creativity and perseverance. Anyone who has attempted learning how to bake knows the patience required to “get it right.” We aren’t alone in the effort to succeed. In fact, we are in very good company.

It took me four years and 31 interviews to become a McDonald’s bun supplier, but every step was worth it.

The right partner can change what’s possible. Supported by Corbion’s technological innovation, hands-on problem-solving, unique marketing insights and time-saving online tools, the baking industry continues to edge consumers’ expectations higher. Today, a single ingredient choice can help create and preserve consistent product quality, prolong the taste and texture of freshness, reduce formulation costs, and produce friendlier labels. What comes next starts when we reimagine together.

Re:

theReimaginePossibilities

Commercial Baking August | Q3 2022

Articles inside

The Last Word

IBIE Booth Trailers

Category Insight

Commercial Baking Channel

Category Insight

Supplier Solutions

Editor’s Note

Featured Brand

Business Intel

IBIE Perspectives