Commercial Baking August | Q3 2021 by AvantFoodMedia

ISSUE Q3 AUG 2021

STEVEN CHARLES’ REBECCA O’HARA

CULINARY INFLUENCE

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Steve Berne

Commercial Baking is published by Avant Food Media, 1625 Oak Street, Suite 201, Kansas City, MO 64108. 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.

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Commercial Baking magazine is published quarterly, along with two annual issues, in print and digital formats. Circulation is tightly controlled, and the print issues are sent free of charge only to hand-verified industry decision makers and influencers. To apply for a free subscription, please visit www.commercialbaking.com/magazine.

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AUGUST 2021 Q3

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IN THIS ISSUE

Features

Bakery Humanity: Built for the Future With three sister bakeries, Bakery Humanity is staking its claim in the Canadian and American markets.

PLUS: Look for QR codes that contain exclusive digital content throughout the issue.

Rebecca O’Hara: Leadership Contagion

Chef Talk: Culinary Trends in Baking

Emerging Market: Baking for Pets

COMMERCIAL BAKING

IN THIS ISSUE

Departments

TRENDS Category Outlook: Pastry

Category Outlook: Snacks

International Market: Pizza

I N N OVAT I O N S 73

Category Insight: Pastry Category Insight: Snacks Supplier Solutions Ad Index

96 104

QUICK READS

Editor’s Note

Seen and Heard

Business Intel

The Last Word

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ARTISAN BREAD & ROLLS

PIZZA & FLATBREADS

CAKES & PIES

PASTRIES & CROISSANTS

A N OTE FR O M TH E ED ITO R

On the Egg Hunt

Today, I heard someone call her coworker a “good egg.” For the young readers — or those who aren’t fans of musicals — it was a nod to the 1971 film Willy Wonka & the Chocolate Factory. In one scene, Wonka’s golden chocolate “good eggs” were shined up and shipped to candy stores around the world, and “bad eggs” were sent down the garbage chute. Remember when the labor shortage was just a problem? Now, it’s distinctly a crisis, and the hunt for good eggs is on. They’re hard to find and even harder to keep. Automation is helping, but people are still a critical component. I know so many of you are desperate to fill positions, but don’t let that keep you from developing the ones you have. Just ask some of the bakers featured in this issue. Dominique Bohec, CEO of Bakery Humanity, has spent his life in a bakery and treats every employee like family. And Rebecca O’Hara, president of Steven Charles – A Dessert Company, leads a contagious culture where top talent attracts more talent.

JOANIE SPENCER Editor-in-Chief | joanie@avantfoodmedia.com

AUGUST 2021 Q3

There’s no easy solution to this crisis, but there are strategies to consider. Be sure to check out the Last Word for advice on how to find fresh talent earlier than you might expect. Keep up the hunt; the good eggs are out there. And when you find them, be sure to help them shine.

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AND “The heart of The Women’s Bakery is to make our bread affordable because in many communities, affordability rhymes with accessibility.” Tessa Soni | South regional manager | The Women’s Bakery, Rwanda

“Conventional wisdom often has us turn to new time management skills to squeeze meetings into shorter time periods and group similar tasks together to reduce less productive actions. However, if we free up an hour, we quickly jump on another project that we have not prioritized. This is like digging a hole at the beach. It quickly fills up with water, and if you dig a wider or deeper hole, you just get more water.” Justin Spannuth | VP and COO | Unique Snacks via LinkedIn

“For candidates who may not possess all of the skills needed for higher-level positions, we have several entry-level and training programs positions available.” Chansidy Daniels | director of talent management | Flowers Foods during ABA’s Industry Careers Info Session

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“I fell in love with the association, the industry and, most specifically, the members. I’ve never felt the urge that most millennials do to change jobs; I’m forever learning.” Amanda Gonzalez | director of member relations | American Society of Baking

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SEEN AND HEARD

“One key focus for Publix is diversity across our organization. From local levels all the way to upper management, there’s been a significant effort to improve diversity across different departments.” Richard Ybarra | manager of manufacturing engineering and public management | Publix Super Markets during the Ask-A-Baker panel at BEMA Convention

“My daughter is a pescatarian and has been for about 13 years; she’s not going back to eating animalbased products. Now, we’re seeing it with our customers … the more innovative retailers, restaurants and coffee shops are adding plant-based offerings.” Brian Owens | CEO | Café Valley

“One of the greatest benefits of my role as past chair is having a hand in shaping the future of BEMA leadership. Joanie [Spencer]’s board appointment represents a step forward on gender equity within the industry, and I’m excited for the energy she will bring to the board. I’m also proud to see Clay [Miller] engage in his role on the executive committee.” Mark Hotze | 2020-21 immediate past chairman of BEMA and VP of Corbion on Spencer’s and Miller’s BEMA board and executive committee appointments, respectively

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F E AT U R E D B A K E R Y: B A K E R Y H U M A N I T Y

BUILT FOR THE FUTURE With three sister bakeries and a family orientation, Bakery Humanity stakes its claim in the Canadian and American markets.

BY J OAN I E S PEN C ER

In Quebec, Canada, Bakery H umanity is a new name. However, its brands — Maison Isabelle, Boulangerie Dumas and Aliments 2000 — are classics. And the company’s president, D ominique Bohec, is an industry veteran whose experience goes back to his childhood working at La Petit Bretonne, the Quebec-based commercial bakery owned and operated by Bohec’s family.

The first step was merging Maison Isabelle with Boulangerie Dumas, a manufacturer of croissants and puff pastry, with backing from Champlain Group, a Quebec-based investment firm.

These industry roots became the foundation of Bohec’s vision for a new kind of company ... one that focuses on respect for employees, the environment and society.

“We have a vision to consolidate bakeries in Canada,” Bohec said, noting that Bakery Humanity is first focused on growth through acquisition of small- to mid-size bakeries. The goal is to build a group that uses its respect-based values to create a sustainable business model … thus the name Bakery Humanity.

A master baker and certified pastry chef, Bohec first acquired Maison Isabelle, a small producer of cookies and loaf cakes, in 2016 as a side project while also leading international sales for the family business. But when the COVID-19 pandemic swept across North America, Bohec’s p erspective changed, and he took the entrepreneurial leap to leave behind a lifetime at La Petit Bretonne and pursue his dream of building Bakery Humanity. “I left to follow my vision and my passion,” Bohec said.

AUGUST 2021 Q3

The third company welcomed into the fold was Les Aliments 2000, which makes fully baked pizzas, crusts, frozen dough balls and raw-dough pie.

“I grew up in a bakery, and I know that every job — every single employee — is important. The people who are putting croissants in the bag are the ones paying our salaries.” Dominique Bohec | president | Bakery Humanity

In addition to developing a values-based corporate culture, Bakery Humanity has set its sights on dominating the supermarket freezer case. “My group and I have a vision for more acquisition in this market,” Bohec said. “Inside that frozen door, you find some puff pastry, pie dough or pizza balls. We want to create a one-stop shop. That’s our goal.”

—Right Leading the way with its frozen laminated dough products, Boulangerie Dumas is helping Bakery Humanity dominate the freezer case.

Photo courtesy of Bakery Humanity

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BAKERY HUMANIT Y

Currently, overall frozen sales including private-label programs account for about 80% of Bakery Humanity’s total b usiness, with the remaining 20% focused on fully baked croissants, puff pastry and loaf cakes. Bringing together a vision of sustainable business with a strategy for leading the freezer case requires serious innovation. This is a key platform for the company, with product development in areas such as vegan and other plantbased dough products like pizza dough balls and raw-dough pies. For the Bakery Humanity brands, innovation is more about incremental growth and development rather than skyrocketing straight to the top. Slow and steady wins the race, and it can also thoughtfully refine an operation.

But what we can do is understand every step we’re taking to become better every day.”

“What we are trying to do is become better step by step. We’ll never be 100% perfect; no one is perfect. But what we can do is understand every step we’re taking to become better every day.” Dominique Bohec | president | Bakery Humanity

This requires staying on top of consumer habits that have significantly evolved over the past 18 months. Prior to the pandemic, Canadian consumer trends centered around health and wellness. But, similar to other developed areas of the world, home baking and indulgence and comfort went through the roof. As COVID numbers began to wane, health-and-wellness trended upward again. But when the next wave of the pandemic hit, more lockdowns brought back that desire to indulge. “We got back to reality a little last summer, and everyone hit the gym,” Bohec recalled. “But then COVID came back, and it was sugar, sugar, sugar all over again.”

“What we are trying to do is become better step by step,” Bohec said. “We’ll never be 100% perfect; no one is perfect.

Watching the pendulum swing has inspired the Bakery Humanity team’s

Photo courtesy of Bakery Humanity

The Dumas plant currently houses one line for croissants and puff pastry with plans to break the bakery into new product development.

AUGUST 2021 Q3

BAKERY HUMANIT Y

“We have some pretty cool ideas coming, but it is a challenge,” Bohec said.

hybrid approach to product development with high-quality, indulgent products that also tout healthy attributes. This is where new products like vegan pies come into play, as well as a heightened focus on plant-based ingredients.

Some immediate solutions have included tapping into robotic technology such as in the Dumas plant. “For every potential packaging investment, we have to consider moving into better packaging with not only less plastic but also plastic that is better for the planet,” said Isabelle Pratte, VP of operations and integration for Bakery Humanity.

The better-for-you mindset doesn’t apply strictly to food consumption. Bohec also engages a holistic approach to efficiency as opposed to simply looking at operations as dollars and cents. For example, the traditional view of efficiency identifies wasted product as money lost. But, according to Bohec, this mindset no longer resonates with today’s workforce, who often want to understand how their jobs impact the greater good.

Although the bakeries are different from one another, these sister companies function much like siblings do: Each one has its own distinct personality while, at the same time, serving the same purpose of fulfilling Bakery Humanity’s mission.

“When I was young working in my father’s bakery, he would tell me, ‘That croissant on the floor cost us 5 cents,’” Bohec recalled. “Today, if I say that to my employees, they don’t understand. But if I tell them it’s creating pollution because we have to make more product, which requires more flour to be brought in by trucks, and it takes more electricity to run the equipment, that means something to them. When you bring this mentality into your bakery, you’ll be more efficient, make more profit and be better to the environment.”

“In the beginning the bakeries were totally different, but now we have a great synergy that brings out the best in each business to help them all improve,” Pratte said. “Many ingredients are similar, as well as the production lines. We want to come together so we can use one another’s strengths to improve not only production but also areas such as purchasing, sales, administration and personnel.”

These types of efficiencies are also considered in the packaging areas of the bakery plants, especially as Canadian regulations have plastic under intense scrutiny. Earlier this year, Bakery Humanity formed a task force to develop ideas for reducing packaging and improving the company’s carbon footprint.

One ERP system operationally ties the three facilities together for tracking all production numbers within a larger context. This enables the company to identify which facility is operating the most efficiently and what systems should be emulated everywhere. Because each brand creates its own distinct products through specific operations, a single

Photo courtesy of Bakery Humanity

With high flexibility on the line, Maison Isabelle creates a wide variety of loaf cakes.

AUGUST 2021 Q3

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BAKERY HUMANIT Y

ERP system allows Humanity to compare the three to one another, rather than likening “apples” with “oranges.”

The new line at Boulengerie Dumas will lead to growth in the US market.

“The base always remains the same with quantifiable and qualifiable objectives,” Pratte said. “We rely on visual systems that provide a general outline to each bakery’s leaders to easily indicate where the needs are. The leaders can then designate the proper resources to meet those needs.”

Photo courtesy of Bakery Humanity

Boulangerie Dumas is the largest plant at 39,600 square feet. Although it currently has just one laminated line to make frozen and baked products, it uses robotic automation to manufacture them at 1,000 kilos (approximately 2,200 lbs.) per hour. That said, Bakery Humanity recently invested $4 million in a second makeup line from Canol that will be dedicated to running laminated frozen dough products. The installation is scheduled for within the next year, and the plant also has a planned expansion of about 15,000 square feet, for which it will partner with Cominar Construction.

“In the beginning the bakeries were totally different, but now we have a great synergy that brings out the best in each business to help them all improve.”

“We are always consistent with the quality of our pastry shell,” Pratte said. “Our process ensures that it’s always flaky, and this equipment will ensure the quality of our new p roducts.” Meanwhile, the Aliments 2000 plant is a federally certified facility for Canadian pizza production with four lines and two inside silos.

Isabelle Pratte | VP, operations and integration | Bakery Humanity

The bakery produces frozen pizza dough balls and pressed crusts, raw-dough pies, and fully finished pizzas that are baked in a hearth oven. The lines are smaller than the Dumas line, but this outfit is fully automated.

In addition to the makeup line, the Dumas expansion includes a new Groupe Sinox bulk flour delivery system, which has a silo, sieve, air blowers and piping, as well as Leclerc technology to accompany the robotics that Dumas engineered internally about 10 years ago. Leclerc will act as an integrator between the older equipment and the new installation.

While Aliments 2000 is a player in private-label pizza products in the Canadian market, Humanity currently does not have plans for crossing south of the Canadian border. “We want to go national, but not in the US,” Bohec said. But that’s only the plan for Aliments’ private-label finished pizza brand, Pate 2000. Other pies, however, are a different story. The bakery is breaking into the vegan market, which is growing in Canada as well as the US.

While this operation focuses on croissants and puff pastry, the upgrades here will support future product development that will not only take Boulangerie Dumas into the US market but also create brand new, non-traditional pastry items with the same consistent quality.

AUGUST 2021 Q3

“We are the only Canadian manufacturer doing vegan raw pie,” Pratte noted.

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BAKERY HUMANIT Y

Additionally, Aliments is gaining momentum with pizza balls as well as thick pizza crusts with ambient temperature packaging. Similar to Dumas, Aliments 2000 is also innovating with tangential product development. This bakery also recently invested in a new tortilla line, and the operation is gearing up to produce filled tacos. Being federally regulated for meat production, Aliments 2000 developed a new finished taco filled with chicken and other meats that the bakery is producing for one customer. “We don’t manufacture the whole product just yet,” Bohec said. “But right now, we are filling it. This is just another area where we want to go, and we can integrate the taco production on the new line.” In the spirit of a family-like culture, Bakery Humanity will tap into the Aliments 2000 meat production capabilities for product development with Dumas. “Across the bakeries, we are fully integrated,” Bohec said. “We can make puff pastry filled with meats and have a unique product that is fully controlled from the first step to the last.”

Although this facility houses only one line, it’s also home to the company’s only tunnel oven, and equipment innovation inside this plant is a mixture of s upplier-developed and home-grown, including depositing equipment that was designed in-house. A few years ago, Maison Isabelle invested in Ultrason ultrasonic slicing technology (the second one for this operation) that throughputs nearly 1,000 loaf cakes per hour. Despite the speed and size — the total square footage here is roughly the size of the expansion at Dumas — flexibility is the gold standard at Maison Isabelle. “At this plant, especially versus other loaf cake plants, we’re baking the same product with different flavors that we can pack,” Bohec said. “The line may be slower, but we can pack two or three flavors with the same pack. That’s unique in Canada, and we’re very efficient with it. That’s why we’re leading the market on sliced loaf cakes.”

—Below Bakery Humanity’s strategy for Aliments 2000 includes national growth in the Canadian market.

Streamlined innovation inside this bakery that runs five days a week with two production shifts — plus a third shift for sanitation — will fast-track Bohec’s vision of a diverse portfolio inside the freezer case.

Photo courtesy of Bakery Humanity

“We want to be inside that frozen door with product innovation like this,” Bohec said, suggesting that integrating the two bakeries for filled products creates opportunities such as frozen breakfast. With production output up by about 35% in the past two months, the bakery is well on its way. Then there is Maison Isabelle. The smallest of the three bakeries, it’s Bakery Humanity’s first operation and arguably the most nimble.

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BAKERY HUMANIT Y

This bakery is also busy developing a new plant-based line of loaf cakes launching this month. Because the operation does not use mixes or bases, R&D is critical for a successful product launch. “It’s complicated to process a cake batter with several small ingredients,” Bohec explained. “It’s tough to do just one cake, but when you do thousands per hour, it’s even harder.” Because the US loaf cake market is relatively saturated, and this product accounts for about 20% of Bakery Humanity’s overall sales, the strategy is focusing on leading the Canadian market with new products such as b irthday-cake varieties and a licensing agreement with Sun Maid. “One day we might be the biggest player in loaf cakes in Canada,” Bohec suggested. “But that won’t happen without organically growing through acquisition.” Bakery Humanity is a new company, but it’s flourishing out of deep industry roots, and that is creating unlimited potential. “We want to be a platform with more than $100 million in sales,” Bohec said, noting his aggressive timeline with plans to break a new brand — Chef Dumas — into the US market. For distribution purposes, production stateside is a must, and acquisition is an efficient strategy in the post-pandemic landscape. Then again, US production won’t happen before the company increases capacity in Canada first. And Bohec still has a few tricks up his sleeve with acquisition targets on his home turf.

INNOVATIONS FROM THE BAKERY FLOORS Bakery Humanity has a strategy of growth through acquisition, and the first three bakeries to join the family bring different products to the group, all with Bakery Humanity’s commitment to quality. These are some of the innovations that can be seen throughout the three facilities. Canol laminating line Comas dough press Fanuc robotics Leclerc Robotique integration, automation and conveyors Picard ovens Refrigeration Jacques Guay air conditioning Rondo pastry makeup Shanklin shrink tunnel ADM flour Angropur butter Bunge shortening Christian Pellerin oils Groupe Prestige ingredient procurement

Regardless of how Bakery Humanity grows, or how many new bakeries join the family, Bohec will not forget his first goal.

Although Bohec said farewell to the bakery he grew up in, he is bringing those same family values into the future. “When I created Bakery Humanity, I wanted it to be a big family,” Bohec said. “The family business was my past life, but it’s still what I wanted to create for my company. I don’t work with my dad anymore, but we are all connected here, and it still feels like I’m creating a family business.” And who knows? Perhaps Bohec will be reunited with his roots one day. For this company set on changing the game, anything is possible. CB

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Photo courtesy of Bakery Humanity

“We respect our employees no matter how we integrate,” he said. “This is the key: Make sure our employees enjoy what we’re doing. If they don’t, we can’t succeed. I grew up in a bakery, and I know that every job — every single employee — is important. The people putting croissants in the bag are the ones paying our salaries.”

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Leadership Contagion An injection of courage, collaboration and competition can redefine a corporate culture. BY J OAN I E S PEN C ER

Photo courtesy of Steven Charles - A Dessert Company

Rebecca O’Hara | president | Steven Charles - A Dessert Company

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EXECUTIVE PROFILE: REBECCA O’HARA

Rebecca O’Hara may not have realized that the airline industry would lead her to bakery operations at Aurora, CO-based Steven Charles – A Dessert Company, but somewhere on that route, one thing became clear: What you lead is secondary to how you lead it. “Whether it’s an entire company or a specific aspect, once you break a certain barrier, leadership is leadership,” O’Hara said. Having spent more than two decades in airline operations and foodservice, including a dozen or so years leading two of the largest North American airline catering facilities, O’Hara developed skills that easily translated into commercial baking. While both industries focus on issues such as innovation, speed to market and food safety regulations, O’Hara noted that the airline industry — its catering side in particular — can be relatively more demanding in terms of stricter regulations and often with more individual SKUs. In many ways, it was boot camp for the baking industry. With that experience, O’Hara developed a business acumen that included not only sales, marketing and customer service but also a strong discipline for measurements and efficiencies. This ultimately led her to the baking industry as COO for Steven Charles. In that role, she was able to swiftly implement instant, yet lasting, operational improvements. “I’m always striving to do better with a constant pursuit to eliminate constraints,” O’Hara said. “My immediate learnings as COO included the need for resilience and agility with the team. I recognized that I had to strike a balance between maintaining the pride on which the company

“It has become my personal mantra to ensure that I encourage and inspire women to break down boundaries, even those we may place on ourselves.” Rebecca O’Hara | president | Steven Charles

was built and convincing the team that those processes — the ones that had led to our success at that time — would not get us where we needed to go.” Striking that balance required enough finesse to achieve predictable operational results through improved KPIs. “It’s about quickly understanding what’s going on and then immediately identifying what needs to be changed,” she said. “If you start by addressing the largest constraint, the efficiency picks up pace. When I came in, I focused on the big needs — and never stopped doing that. And now, our operational momentum is mind-boggling.” O’Hara’s focus on operational efficiency as well as a collaborative and diverse workforce culture landed her in the seat of president in 2020. That said, O’Hara stayed true to the company’s vision, and that maintained harmony among the business and operational aspects of the bakery.

“The corporate and manufacturing sides know what our vision is,” she said. “Our business plan is strong and concise with accountable objectives that reset as necessary.” While advances in automation set strides toward efficiency, O’Hara knows that people are still a big part of the process. Culture is a critical component for production at the company’s two SQF-certified facilities. Steven Charles has a policy of promoting from within, and O’Hara keeps an eye out for employees who exhibit strong leadership qualities. “I hire for attitude, so I can develop new leaders who are rarely satisfied with where we stand against the competition,” O’Hara said. “The key is turning discipline into execution.” Vanessa Ridley-Gray, who replaced O’Hara as COO, embodies those very qualities, which made for a smooth transfer when O’Hara was promoted to president. “Vanessa is a sharp, experienced leader with a people-first mentality,” O’Hara said. “She took the foundational changes from my first year and not only continued to sustain the new operating models but also improved every measurable KPI.” This isn’t just a c-suite mentality. Steven Charles maintains high standards that go hand-in-hand with collaboration and respect, and O’Hara is driving this culture throughout the entire company, especially as the baking industry faces an epic workforce shortage. “We strive to be agile, collaborative and dynamic while also being demanding, fast-paced and, at times, healthy with conflict,” O’Hara said. “We believe success is contagious, and good people attract good people.”

COMMERCIAL BAKING

EXECUTIVE PROFILE

Photo courtesy of Steven Charles - A Dessert Company

“It’s about quickly understanding what’s going on and then immediately identifying what needs to be changed. If you start by addressing the largest constraint, the efficiency picks up pace.” Rebecca O’Hara | president | Steven Charles

Rebecca O’Hara (left) with COO Vanessa Ridley-Gray.

In this company, hard work looks more like a contact sport than touch football. “The retention of great team members comes from our encouragement to bring different ideas to the table, to be willing to rumble for the right solution and to always know that we’re collectively driving toward the same mission,” she said. “Our performance ethic combines the ambition to do the unthinkable and the discipline to deliver what would have been previously believed impossible.” Achieving the impossible seems like just another day on the job for this leader who spent the first half of her career as one of the few — if not only — women in leadership positions. And that’s what made her a good fit for Steven Charles, a minority-owned company known for diversity that starts in the c-suite.

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This culture of inclusion has existed at Steven Charles for years. O’Hara may not have been its creator, but she certainly is its champion. “It has become my personal mantra to ensure that I encourage and inspire women to break down boundaries, even those we may place on ourselves,” she said. “I want to empower other women to have the courage to get into the uncomfortable space where we’re paving a path for the young women coming up behind us.” Rather than looking at diversity in terms of a quota needed to achieve, O’Hara looks deeply at people, ideas and solutions to think about it as a bigger part of the culture. “It’s holistic,” O’Hara said. “It takes a little longer to achieve diversity, but the hard

work to get there makes the prize feel bigger. When you have a group of people who think that way — and hire and lead that way — it becomes quite contagious, too. That holistic feel resonates through the company.” This is how diversity becomes infectious across the supply chain. “The challenge in every industry is to look at what’s important to customers,” O’Hara observed. “And our customers want to be connected with suppliers that have the same values they do. We’re fortunate to be aligned with our customers in that regard, and it’s also our own practice to give first consideration to our suppliers who do the same.” It takes strategy to recognize opportunity, and it takes courage to make the difficult choices that lead to change. But these are the choices that can transform a company or even an industry … especially one that is so rooted in tradition through processes that have remained fundamentally unchanged. “The owners needed to have some faith,” O’Hara said. “They were already successful and respected in this space, but they knew we needed to make some changes, and we’re reaping significant rewards because of it.” Leaps of faith are rarely easy, but important lessons can come from that which might seem painful. “I am so grateful to have been chosen to pioneer through the uncomfortable times that I now consider to be the catalyst of my own growth,” O’Hara said. “I’m so proud of the incredible company that Steven Fabos and Charles Kosmont have built and grateful that they have entrusted me to grow it above the industry average.” CB

Chef Talk Translating culinary trends into the bakery aisle. BY MAGG I E G LI SAN

In 2020, dining in became the new dining out. As restaurants shut their doors during the pandemic, consumers looked for ways to replicate those dishes at home, whether it was enjoying a home-cooked fine dining experience, exploring exotic ingredients and flavors despite the inability to travel, or trying products that supported the latest trends in health and wellness. As the restaurant and travel industries reopen and consumers are no longer homebound, these culinary behaviors

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have varying degrees of staying power that will influence bakery and snack product innovation. Comfort and indulgence were hallmarks of the pandemic, which triggered growth across nearly every baked good category. It also drove consumer proclivity to the familiar — with a twist — that could well maintain its stronghold. A recent survey conducted by the Harris Poll suggests that 28% of Americans are eating more baked goods, with 42% citing a sense of comfort and 41% citing

a way to induce happiness as their reasons, respectively. And flavors like chocolate, fruit and citrus — those with nostalgic familiarity — are also resonating with consumers, especially when elevated to a fine dining-like experience in quality of ingredients and execution. Such is the case for London-based Pots & Co, which sells its products in Costcos across the US. The company crafts Michelin-quality desserts in its signature ceramic pots using single-origin Fino de Aroma chocolate sourced from farms in Colombia. “We’ve translated a basic fine dining philosophy to our products: Keep things simple and search the world for the best possible ingredients,” said Pots & Co’s founder, Chef Julian Dyer. “We know that people want the classics done really well. Our products tend to be a bit more expensive because of that, but that’s the tradeoff for raising the bar.” Bringing these small luxuries into consumers’ homes is also a factor driv-

CONSUMER TRENDS: CULINARY INFLUENCE

ing innovation at Richmond, CA-based Brioche Pasquier | Galaxy Desserts. One of its newest products, Freezer to Oven Croissants, was crafted by Master Pastry Chef Jean Yves Charon and doesn’t need proofing. They can be baked straight from frozen, which provides convenience and indulgence. However, consumers are also counterbalancing their desire to indulge with their interest in consuming functional foods that contribute to overall mental and physical health and wellness. The plant-based “revolution” is now mainstream — in restaurants and home kitchens — and plays directly to that consumer need. According to the Specialty Food Association’s State of the Specialty Food Industry 20202021 report, the category is expected to increase 10 to 20% annually through 2024. And SPINS data showed that the total plant-based market is growing 29% year over year, nearly double the 15%

growth rate of the food-and-beverage market as a whole. The chip category has been an innovation leader of plant-based alternatives (think Tia Lupita Cactus Tortilla Chips, Plant Snacks Beet with Vegan Goat Cheese Cassava Root Chips, and Farmhouse Culture Dill Pickle Kraut Krisps Snack), but desserts and snacks are untapped opportunities for plant-based alternatives, though product innovators are aware of the potential in the space.

expertise and create unique and tasteful new products,” said Guillaume Perruchet, R&D manager.

“The plant-based trend is one that is really powerful and picking up across categories,” Dyer said. “In baking, we’re seeing experimentation with alternative milks like coconut and oat, and even plant-based chocolates.”

Mushrooms are hot in the plant-based culinary trend, though they have not yet reached their full potential in the baking space. Adaptogenic mushrooms, known for their benefits like improving cognitive function, stress and immunity, have been prized among health circles for years, but the culinary world is starting to take note as well, with many hailing them as the “it ingredient” of 2021. Datassential information revealed that on 80% of restaurant menus, mushrooms are one of the top appearing ingredients. And the functional mushroom market is expected to grow 8% by 2024 per a recent ReportLinker. com report.

Brioche Pasquier | Galaxy Desserts is also exploring vegan alternatives to eggs and dairy, as well as new chocolates. “As a principle, we are trying to integrate American trends into our French culinary

Commercial bakeries looking to take advantage of this trend would be wise to explore the use of mushroom powders and extracts in their baked goods. For example, Earthlight Whole Vitamin D,

COMMERCIAL BAKING

CONSUMER TRENDS

28%

of Americans are eating more baked goods, with 42% citing a sense of comfort and 41% citing a way to induce happiness as their reasons, respectively. Source: Harris Poll

which is produced under PLT Health Solutions, is a mushroom powder that delivers 1000 μg (40,000 IU) of Vitamin D per gram and has received approval of its Food Additive Petition from the USDA for use in a broad range of products including breakfast cereals and baked goods. Chickpeas are also having a moment thanks to the interest in all things plantbased. The legume, which is rich in protein and fiber, was singled out by Whole Foods Market in its Top Food Trends for 2021 as “the new cauliflower,” noting its versatility for use in snacks and baked goods. According to the Mintel Global New Product Database, the number of US product launches with chickpeas increased 74% in 2019 versus 2018. The number of launches fell 22% in 2020, when compared with the same time in 2019, though that decrease likely has more to do with innovation cutbacks in light of the pandemic.

Austin, TX-based Siete Family Foods introduced Chickpea Flour Tortillas, which gives consumers a convenient way to add nutritional value to favorites like tacos and wraps. Boston-based Biena Snacks now offers a variety of both grain-free and keto-friendly Chickpea Puffs in the baked snack category. And Denver-based 34 Degrees recently released Snaps Baked Chickpea Thins, which include 3 grams of plant-based protein per serving. In addition to plant-based, global flavors are expanding their reach and becoming more approachable as bigger CPG players introduce products that push the culinary envelope. According to Datassential, one-third of consumers are looking forward to trying new global foods and/or flavors this year, and 42% are seeking out spicy foods. Latin flavors still enjoy popularity in the US, and according to Mintel, many of the flavors that gained traction — spicy,

Photo courtesy of Galaxy Desserts

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Honey bees are responsible for one-third of the foods we eat. Almonds, apples, cinnamon, garlic, sunflowers and onions are just a handful of the 90+ fruits, vegetables, herbs and spices that require honey bee pollination. These products represent a fraction of the thousands of food and beverage products that would be impacted with the loss of honey bees. When you formulate products with honey, you’re supporting beekeepers and their efforts to keep honey bees healthy. That’s a cause the entire food industry can get behind. Email keith@honey.com to learn how you can support honey bee health.

CONSUMER TRENDS

smoky and citrus — are already foundations of Latin cuisine. Additionally, more than a third of consumers also expressed interest in trying foods from lesser-known regions such as Oaxaca, Peru, Brazil and Argentina.

Take fonio, an ancient grain from S enegal gaining traction in the Western world. It can be prepared similarly to couscous, cooking in about 5 minutes, and can be ground into a (gluten-free) flour for use in a variety of baking applications. Founded by chef, restauranteur and cookbook author Pierre Thiam, Brooklyn, NY-based Yolélé is one such company. It connects smallholder farmers with global markets and offers products including fonio pilafs and chips. McCormick & Company’s Flavor Forecast 21st Edition also identified “Humble Nosh” as one of its four flavor themes for innovation this year. The theme is “inspired by the Yiddish word ‘nashn,’ meaning to nibble on, and combines rising global flavors with the means to ‘travel locally’ via our plates.” And according to the report, a few key flavors to keep top of mind include the Indian spice blend chaat masala, pandan kaya (Malasian jam) and crisped chiles.

Photo courtesy of GFF

This trend for greater diversity in taste exploration expands beyond Latin flavors. “I’m seeing more prominence and appreciation of regional ingredients from parts of the world often overlooked, specifically an interest in West African ingredients and cuisine,” said Dawn Padmore, VP of culinary marketing and events with Karlitz and Co.

¡EL TIEMPO ES AHORA! With Hispanic and Latino Americans accounting for almost 20% of the current US population and expected to comprise nearly a third of it by 2050, brands and businesses of all types need to start catering to these ethnic groups today. For the baking industry, this means not only creating specific products that appeal to different ethnicities but also, perhaps even more importantly, developing recipes that allow these consumers to incorporate grain foods into healthy, culturally appropriate eating patterns. I have dedicated most of my career to developing such recipes and promoting them to diverse audiences. I’ve always focused on making these foods accessible to as many people as possible and also helping Hispanic and Latino consumers retain their traditional cultural foodways while helping industry partners attract and build brand affinity with their customers. For example, when working with the Grain Foods Foundation (GFF) during its recent research on the nutritional value of whole grains and enriched refined grains, I developed the Refried Bean Breakfast Flatbread Wrap. It uses a flatbread, but consumers can use any grain food as the base and whatever toppings fit their taste or dietary choices. Promoting your baked goods with recipes that are delicious, authentic, nutritious and appealing to diverse audiences will be good for them and you. iBuen apetito! — Sylvia Melendez-Klinger

For companies looking to expand their culinary flavor offerings in a global sense, the snack category offers a low barrier to entry. Consumers are snacking more than ever and are more willing to

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Award-winning author and global nutrition entrepreneur Sylvia Melendez-Klinger is the founder of H ispanic Food Communications, a nutrition communications and culinary consulting company, and a member of the GFF Scientific Advisory Board.

CONSUMER TRENDS

experiment with new flavors and ingredients in the category, due to a limited cost commitment, according to Mintel’s Regional and International Flavors and Ingredients November 2020 report. Health trends also remain top of mind for restaurants and chefs. Kimpton Hotels & Restaurants’ 7th Annual Culinary & Cocktail Trend Forecast for 2021 expects a shift from the comfort food that so many turned to in 2020 to a renewed interest in healthful eating. “We know that diners’ needs have changed,” said Scott Gingerich, Kimpton’s senior VP of restaurants and bars. “The pandemic brought out the foodie or home chef in many of us. While diners first leaned into comfort and nostalgia, heading into the new year we’re seeing a return to health-and-wellness-inspired culinary and cocktail creations.”

“I’m seeing more prominence and appreciation of regional ingredients from parts of the world often overlooked, specifically an interest in West African ingredients and cuisine.” Dawn Padmore | VP of culinary marketing and events | Karlitz and Co.

Clean labels and “free from” claims on packages are still top of mind for c onsumers. Four in 10 Americans

(43%) say it is important to them that a food or beverage include only a few ingredients, and 54% say it is important the ingredients don’t have “chemicalsounding names,” per the 2021 International Food Information Council’s Food & Health survey. Foods and beverages carrying a “lifestyle” diet claim grew 13% in dollar sales for the year ending Dec. 27, 2020, per IRI data. In looking at overall bakery and snack trends, it might seem there is a strong disconnect in consumer behaviors influencing culinary trends in new product development. Do they want to indulge or eat more healthfully? Do they want familiar comfort food or new and exotic global flavors? Individual brands will have to make the call as to how to stay up-to-date with the latest trends, ingredients and flavors that best fit their unique audience. But in this space, there is more than enough room to play. CB

Photo courtesy of Pots & Co.

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Treat Yo’ Pet Commercial baking opportunities spike for man’s best friend … or feline. BY MAGG I E G LI SAN

Photo by Glenn Han on Unsplash

“Happy Birthday Rosie!” reads the top of a bubblegum-pink iced cake in white icing. Neat circular pink frosting puffs adorn the top, while colorful sprinkles dance around the sides. It could be a birthday cake for just about anyone. A slice into this cute confection doesn’t reveal layers of vanilla or chocolate, but a mixture of pumpkin puree, whole wheat flour, egg, peanut butter and honey.

dogs and cats — have become full-fledged members of the family. Charlie the golden doodle has a $46 collar with matching bowtie for any occasion from Crew La La. Maisie the tabby loves to play in her “mid-size” 49-inch wooden condo from Wayfair. Eleanor the lab goes through a 6-pack of polka-dotted Boots & Barkley tennis balls every week. Since 2015, the market for pet care products and services — including pet food, pet supplies, veterinary and pet services (grooming, boarding, training, etc.) — has grown steadily by 30%, according to Mintel research. And that growth has been driven predominantly by spending on pet food, treats and other supplies.

This cake isn’t for just anyone. Little Rosie happens to be a 5-year-old dachshund. In the past several decades, particularly in the US, the concept of pet ownership has shifted significantly. Pets — specifically

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E M E R G I N G M A R K E T: BAKING FOR PETS “Dogs and cats no longer live in the backyard but are often considered members of the family, and pet owners feed them as such,” said Pat Tovey, director of technology and regulatory compliance for the Pet Food Institute. Mars, which is one of the world’s largest suppliers of pet food, reported that 70% of American households are pet owners. And the height of the pandemic saw a spike in pet adoptions and ownership, with 10% of cat owners and 9% of dog owners reporting they had adopted a pet specifically because of the coronavirus, according to market research firm Packaged Facts in the recent report Pet Food in the US, 15th edition.

“Companies looking to enter the pet food and treat market have a responsibility to understand their food safety and regulatory obligations.” Pat Tovey | director of technology and regulatory compliance | Pet Food Institute

Accompanying the surge in pet ownership — and the evolution of the human-pet relationship — is a significant shift in the way consumers think about feeding their furry friends. “Pet owners increasingly gravitate toward purchases they might enjoy themselves,” said Kristen Boesel, senior lifestyles and leisure analyst at Mintel. “For example, decadent treats like pet-friendly ice cream appeal to human palates.” Kurt Stricker called this the “humanization” of pets. After 15 years at the helm of his family’s wholesale bakery, he switched gears and started Pedigree Ovens, a Harvard, IL-based manufacturer of pet food and treats. “Companies have really started to take baked pet treats to the next level,” he said. “They’re making cakes and cupcakes or treats that resemble sandwich cookies … the kind of special treats people would enjoy.” There is no doubt about the immense growth potential for the baked pet treat market, but there are some critical considerations for commercial bakers to cover before making the leap. “It’s important to remember that ingredients used in pet food and treat recipes are carefully

COMMERCIAL BAKING

BAKING FOR PETS

defined and accepted for that use, and some ingredients used in food for human consumption can be dangerous or harmful to cats or dogs,” Tovey said. “There are, however, some helpful resources available for commercial bakers if they are considering entering the pet treat market.” The Business of Pet Food website from the Association of American Feed Control Officials (AAFCO) outlines the obligations and questions that manufacturers must consider. Tovey noted that it’s critical for businesses looking to bake pet treats to understand the laws governing animal food, labeling and ingredients in their state.

©Art Kevorkov - stock.adobe.com

Stricker agreed that navigating the stateby-state regulations can be extremely challenging. “You don’t have just one entity; you have 50 different government guidelines that you need to address,” he said. This is due largely in part to matters of quality and safety. People may not realize that pet food is also one of the most highly regulated food product types in the US, according to Tovey. “Companies looking to enter the pet food and treat market have a responsibility to understand their food safety and regulatory obligations,” Tovey cautioned. “For example, pet food and treats are regulated under the US Food and Drug Administration (FDA)’s Food Safety Modernization Act, which means manufacturers must identify known foreseeable hazards in the manufacturing process and take documented steps to address them in a food safety plan. This may mean ensuring that a treat is baked to a certain temperature to help control for the presence of pathogens as well as auditing an ingredient supplier.”

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“Vegan, superfoods, organic, better ingredients, clean label, functional … people are scrutinizing what they feed their pets, perhaps even more than what they feed themselves.” Kurt Stricker | owner | Pedigree Ovens

BAKING FOR PETS

Jumping through these hoops can be challenging, both for smaller pet treat bakeries looking to expand and for mid-size commercial bakeries looking to crossover into baking for pets. Currently, the baked pet treat space is dominated by just a few large pet food producers. But still, baked treats only comprise roughly 5% of the pet food market at this point. That said, several smaller operators are figuring out the next steps needed to break into this market with a steep barrier to entry from cost and regulatory perspectives. Despite all the challenges, baking for pets is a market to keep an eye on, and there are some trends that should be closely followed. According to Stricker, if it’s popular for humans, it’s likely trending on the pet side, too. “Vegan, superfoods, organic, better ingredients, clean label, functional … people are scrutinizing what they feed their pets, perhaps even more than what they feed themselves,” he said.

Consumer demands that impact human food production can sometimes be mirrored in pet food production as well. “This is largely in part to the evolving relationship we have with our pets,” Tovey said. “Shoppers may be looking for certain ingredients in a dog or cat treat or expect it to more closely resemble the food that humans eat.” The move toward a limited-ingredient philosophy and clean labels in human CPG is just as important, if not more so, when it comes to manufacturing and marketing baked pet treats. Pet owners are gravitating toward products that include only simple, natural ingredients and “free from” claims — wheat-free, grain-free, corn-free, soy-free, non-GMO — as they scrutinize labels. Plant-based and superfoods are also big trends in the pet food and treat market. Kale, spinach, bone broth, chia seeds and turmeric are just a few ingredients that have gone mainstream in pet products. For example, New York,

NY-based Bocce’s Bakery recently released Turmeric Latte Biscuits as a special edition flavor, and San Diegobased The Honest Kitchen has a full line of Bone Broth Bites, which are savory protein cookies slow baked with chicken broth and vegetables such as pumpkin and sweet potato. Functional health is also of massive importance in the pet food and treat market. Benefits like gut health, joint health, dental care, immunity, skin and hair support, and longevity are just as important for pet owners when shopping for Fido as they are when shopping for themselves. Brands like The Honest Kitchen and Lowell, MA-based Old Mother Hubbard appeal directly to consumers through their marketing of wellness-boosting and naturally wholesome treats. And just as CBD (cannabidiol) is seeing massive growth in bakery for human consumption, CBD pet products are also gaining considerable traction. According

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BAKING FOR PETS

©Barbara Helgason - stock.adobe.com

23% of dog owners and

24% of cat owners

agreed they’re especially concerned about their pet’s anxiety and stress.

to Nielsen data presented by Hemp I ndustry Daily in 2020, the CBD for pets market could reach $175 to $225 million across all channels by 2025, which will make up 3% of the total CBD consumer products category. Pet owners purchase CBD products for their pets for a variety of reasons, including easing hip and joint pain and promoting relaxation. According to Packaged Facts’ November/December 2020 survey of pet owners, 23% of dog owners and 24% of cat owners agreed that they’re “especially concerned” about their pet’s anxiety and stress. Although cannabis has not yet been approved by the FDA for use in animals, some manufacturers have already leaned into the category — particularly with CBD oils and chews designed for pets. But CBD baked pet treats are now starting to emerge as well, such as Paw CBD, a brand that makes crunchy baked cheese- and peanut butter-flavored treats. During an April 2021 Petfood Industry Webinar, Euromonitor’s head of packaged food, Jared Koerten, noted that premiumization trends focus on things like sustainability, locally sourced ingredients, minimal processing and functional health. But macro trends such as environmental and social impacts should also be taken into consideration. According to the Packaged Facts report, close to 70% of pet owners are concerned about the treatment of animals used to make pet food and treats. And the firm’s February/March 2020 Survey of Pet Owners showed that a pet retailer’s participation in pet welfare and rescue plays a role in where 48% of pet owners will shop. Transparency in pet food — what’s on the label, how it’s sourced or how it’s made — is just as important as it is for human consumables.

Source: Packaged Facts

Upcycled treats could also be an area of opportunity for manufacturers, especially those looking to help combat food waste. Chicago-based Shameless Pets has been a leader in this space. The company, which launched in 2018, turns misfit and surplus produce and

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BAKING FOR PETS

ingredients (think sunflower meal, bananas, beets, carrots, blueberries, apple pomace) into healthy treats for pets, like its line of soft-baked dog treats. Whole Foods, Chewy.com and Thrive Market are just a few places already carrying Shameless Pets products.

of consumers are buying groceries online, and the same frequency of consumers plan to do so when COVID-19 ultimately subsides. So as long as it’s healthful, functional and nutritional (and available for purchase online), pet treat “indulgence” — whether in the form of an everyday biscuit or a special occasion birthday cake — is here to stay with plenty of room to grow, especially in the baked treat market. Eighty percent of owners say they enjoy spoiling their pet, per Mintel data, and three in five believe a good pet parent buys only the best.

There are a few overarching trends to consider, as well. Just as snacking for humans spiked during the pandemic (there was a 79% increase in core snacking, per IRI data), it did so among canines and felines, too. In fact, labeling pet treats as “pet snacks” creates new opportunities. Baked biscuits, cookies and the like are no longer just a tool to train but now also a reward to be given for companionship throughout the day. This shouldn’t be discounted, given that more of the workforce is likely to work remotely (or flexibly) post-pandemic.

Tovey summed it up by pointing to the steady growth in the market in recent years, often seen in the premium segment. “Market research predicted there was an 8% increase in dog and cat treat sales in 2020,” he said. “As people spent more time at home with their pets over the past year — and even brought home new pets for companionship — feeding habits will continue to change as we give our pets special treats. While it’s important for pet owners to treat responsibly and avoid overfeeding, they are still looking for increased choice and availability when selecting treats for their pets.” CB

Another matter to note is the channel of delivery. Packaged Facts predicted US online pet product sales will account for 35% of the total share by 2024. This is no doubt due to convenience and changed combinations of habits post-pandemic. A new study by Coresight Research said about 60%

©Jiri Hera - stock.adobe.com

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Pastries playing catch-up Center Store Dollar Share Morning Bakery

For the 52 weeks ending June 13, 2021, dollar sales of center store morning bakery hit $3.52 billion, with pastry, Danish and coffee cakes capturing $1.08 billion of the sales in the category. This represents just a 0.2% increase from a year ago.

MUFFINS 24.2%

DONUTS 4 6 .1 %

PASTRY | DANISH | COFFEE CAKES 29.7%

Overall, the center store held a 29.7% dollar share of the category, a -1.3% drop from a year ago. But with unit sales hitting 526 million, the slightly larger drop represented a -7.9% change versus a year ago, according to IRI Integrated Fresh. The morning bakery perimeter, however, saw more action this year. Dollar sales were $3.34 billion with current dollar sales in the pastry category at $1.45 billion, a 7.4% change versus a year ago.

Latest 52 Weeks Ending 06-13-21 Total US Multi-Outlet w/ C-Store (Grocery, Drug, Mass Market, Convenience, Military and Select Club & Dollar Retailers) Source: IRI Market Advantage - Integrated Fresh

This past year, unit sales in the centerstore morning bakery dropped by

7.9% Source: IRI

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C AT E G O R Y O U T L O O K : P A S T R Y

Pastry, Danish and coffee cakes claimed 43.5% of the dollar share of the perimeter, a 2.4% change versus a year ago. Unit sales in the perimeter broke relatively even, up just 0.3% from a year ago with 463 million units sold.

Perimeter Dollar Share Morning Bakery

While laminated and pastry products tend to skew toward the Baby Boomer generation, IRI has seen an uptick in purchasing from millennials, especially those young families with kids, as well as Asian American and Hispanic shoppers.

MUFFINS 26.9%

The growing shopper demographic of 55.4 million Hispanic consumers boasts $1.8 trillion in purchasing power. By 2025, more than 69.5 million Hispanic Americans will live in the US, representing approximately 20% of the US population, according to research firm Claritas.

PASTRY | DANISH | COFFEE CAKES 43.5%

DONUTS 29.6%

Latest 52 Weeks Ending 06-13-21 Total US Multi-Outlet w/ C-Store (Grocery, Drug, Mass Market, Convenience, Military and Select Club & Dollar Retailers) Source: IRI Market Advantage - Integrated Fresh

As the pastry category is drawing in more diversity to its consumer base, interest in traveling the world through flavor is ushering in international pastry influences in the form of buñuelos, churros, baklava, torta and paczki.

PASTRY | DANISH | COFFEE CAKE DOLLAR SALES

CURRENT DOLLAR SALES ($ IN BILLIONS)

% CHANGE VS. A YEAR AGO

In addition, nostalgia still remains as a powerful purchase driver for many c onsumers who are looking to indulge in sweet goods like pastries.

PERIMETER PASTRY

$1.45

7.4%

CENTER-STORE PASTRY

$1.09

0.2%

Traditional household brands remain as some of the top-ranked items and strongest sellers. Some familiar flavor favorites include chocolate in the form of coatings and fillings and fresh seasonal fruit flavors of apple, peach, cherry and guava.

Latest 52 Weeks Ending 06-13-21 Total US Multi-Outlet w/ C-Store (Grocery, Drug, Mass Market, Convenience, Military and Select Club & Dollar Retailers) Source: IRI Market Advantage - Integrated Fresh

AUGUST 2021 Q3

With consumer mobility increasing every day as more people begin to work outside the home again, on-the-go eating is roaring back with strong sales growth and a desire for convenient,

C AT E G O R Y O U T L O O K : P A S T R Y

single-serve and handheld options.

PASTRY | DANISH | COFFEE CAKE UNIT SALES

CURRENT UNIT SALES (IN MILLIONS)

% CHANGE VS. A YEAR AGO

PERIMETER PASTRY

463

0.3%

CENTER-STORE PASTRY

526

-7.9%

IRI’s 2021 Snacking Survey revealed that consumers indulge in bakery snacks throughout the entire day: 31% in the morning, 29% during the afternoon and 27% at night. Transparency is another factor driving consumer choices, and that’s also impacting the pastry category as consumers seek to purchase products aligning with their values. Brands that allow shoppers a view behind the scenes create o pportunities to attract and retain new and loyal consumers. This includes those offerings touting features such as non-GMO, natural and organic ingredients as well as straight-forward nutrition labeling of calories, sugar and fat.

Latest 52 Weeks Ending 06-13-21 Total US Multi-Outlet w/ C-Store (Grocery, Drug, Mass Market, Convenience, Military and Select Club & Dollar Retailers) Source: IRI Market Advantage - Integrated Fresh

Pastries are falling behind in center store, with only

29.7% of dollar share, compared with 43.5% dollar share in the perimeter. Source: IRI

Year-to-date numbers from IRI feature an increasing number of products made without dairy, soy, gluten, shellfish, tree nut, peanut or other allergens. More and more, “free from” claims suit consumers looking to make food purchases in alignment with lifestyle choices of diet, environment and other aspects of sustainability. Across categories, strong dollar growth is being delivered by p roducts noting their sustainability practices on the package, providing an opportunity for sales increases. This is especially true when it comes to not only p ackaging materials but also the messaging included for a product’s on-pack claims. These types of opportunities can help bridge growth gaps happening in the category. Compared with other categories across the center store, pastries and laminated products have some catching up to do. CB .

AUGUST 2021 Q3

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Riding the tailwinds of snacking For the 52 weeks ending June 13, 2021, total snack category sales were $28.50 billion, a 5.8% increase, while unit sales of 10.48 billion remained unchanged from this time last year. Within the category, the largest dollar sales percent change was in the Other Salted Snacks segment (corn/potato, onion, crisps and multi-grain) at 12.8%. This was followed by ready-to-eat (RTE) Popcorn/Caramel Corn (9.1%), Cheese Snacks including crisps (4.9%) and Corn Snacks (4.9%). Crackers registered a -0.1% change vs. a year ago with unit sales down -3.5% and $7.90 billion in sales, according to IRI Integrated Fresh. Snacks are seeing increased dollar sales for core categories in brick-andmortar and online channels, as well as elevated snacking occasions throughout the day. Licensed products, flavor innovations, international flavors and new takes on hot and spicy drive category interest, along with continued consumer expectations for better packaging innovations and sustainability practices. According to IRI’s 2021 Snacking Survey, snacking throughout the day is on the rise; snacking five or more times per day is up 3 percentage points vs. 2016. This is driven primarily by Gen Z (ages 18-24) whose demographic result is up 7 points since 2018, alongside Millennials up 12 points for ages 25-34 and up 13 points for ages 35-44. IRI forecasted these levels to decline a bit moving into 2022, but

Salty Snacks Dollar Share

CORN SNACKS: 4.9%

PRETZELS: 5.0%

PORK RINDS: 2 .1 %

RTE POPCORN | CARAMEL CORN: 5.8%

POTATO CHIPS: 29.2% CHEESE SNACKS: 1 0 .1 %

OTHER SALTED SNACKS (NO NUTS): 20.2%

TORTILLA | TOSTADA CHIPS: 22.7%

Latest 52 Weeks Ending 06-13-21 Total US Multi-Outlet w/ C-Store (Grocery, Drug, Mass Market, Convenience, Military and Select Club & Dollar Retailers) Source: IRI Market Advantage - Integrated Fresh

Gen Z consumers (ages 18-24) snacking five or more times a day is up 7 percentage points vs. 2018. Source: IRI

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snacking across all dayparts will remain elevated compared to older consumers. The global snack market was valued at nearly $440 billion in 2018, according to data from Grand View Research, and the compound annual growth rate is predicted to hit 6.2% from 2019 to 2025. According to Grand View, the category also includes crackers, rice cakes and pita chips, which have seen popularity in many Latin American regions. Prior to the pandemic, the cracker segment had its work cut out for it, but in 2020, it saw a 7% sales increase, according to Mintel. Looking ahead, consumer preferences will focus on freshness and texture or crunch, as well as organic and health claims, the research firm noted. Snacking patterns obviously changed during the pandemic with accelerated snacking at home. Consumers gravitated to larger package sizes designed to feed more people in the home. As the pendulum swings back toward mobility, the category is returning to smaller sizes for some products, while others are balancing between small and large sizes. Tortilla chips, potato chips and corn snacks are seeing the smaller sizes growing and larger sizes declining. The combination of more on-the-go consumers with the decrease of at-home occasions is likely contributing to the size shift. “Using analytics to gain an optimal price/ pack architecture is critical for snacking success,” said Sally Lyons Wyatt, EVP and practice leader for IRI. “We’re estimating that large and smaller sizes will find growth going forward for many snack categories because of the hybrid working models and preferences for snacking, but it will take CPG and retailers to collaborate on the o ptimal mix.”

AUGUST 2021 Q3

SALTY SNACKS DOLLAR SALES

CURRENT $ SALES (IN BILLIONS)

% CHANGE VS. A YEAR AGO

SALTY SNACKS

$28.49

5.8%

POTATO CHIPS

$8.33

2.9%

TORTILLA/ TOSTADA CHIPS

$6.29

0.6%

OTHER SNACKS (NO NUTS)

$5.75

12.8%

CHEESE SNACKS

$3.05

4.9%

Latest 52 Weeks Ending 06-13-21 Source: IRI Market Advantage - Integrated Fresh

Continuing emphasis on lower-carb lifestyles is making protein attractive in salty snacks.

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Continuing emphasis on lower-carb lifestyles is making protein attractive in salty snacks. Viewed as an added benefit across many snacking categories, p roducts with protein claims have done well over the past 18 months, according to IRI. Lyons Wyatt suggested manufacturers of these products could attract consumers looking for snacks that provide more protein and offer added energy. Protein can deliver high satiety, great flavor and a robust nutritional profile, particularly for plant-based eaters and those following keto diets. Plant-based offerings are topping the new product lists by leveraging better-for-you ingredients like mushrooms and okra, offering a feel-good element when it comes to diet, lifestyle and the environment. As brands amp up the nutrition, those better-for-you snacks must deliver on

“Using analytics to gain an optimal price/ pack architecture is critical for snacking success.” Sally Lyons Wyatt | EVP and practice leader | IRI

US Snacks Market Size, By Type, 2019-2025 ($ in billions) $150

$150

$100

$50

$0.0 2019

Source: Grand View Research

2020

2021

2022

2023

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consumers’ expectations for taste and texture. Manufacturers will also need to balance the earthy off-notes of plant protein sources with options that offer a neutral flavor profile. Crisps and crackers made from real cheese are attractive to those on low-carb diets. Of course, sodium is inherent in the salty snack. In the most recent Dietary Guidelines for Americans 2020-2025, salty snacks are once again under fire with recommendations to select foods with reduced sodium or no added salt. Packed with protein, boosted by plants or balanced with sweet notes, the sky’s the limit with salty snacks. Mintel predicts that over the next two years, snacks will be repositioned into items that provide mood food with health benefits. Likewise, IRI’s predictions have the salty snack category maintaining its foothold. “Our predictions are that salty snacks will do well for the rest of 2021 and for 2022 at a minimum,” Lyons Wyatt said. “Salty snacks serve multiple roles for consumers. Whether as an accompaniment for a meal, snacking alone or snacking with others, salty snacks is a ‘go to’ category for consumers. In addition, salty snacks provide indulgence and comfort which continues in vogue with consumers.” CB

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The pastry evolution BY LIZ GOO DWI N

Consumer trends may come and go, but the love of sweets is eternal. Whether the guilty pleasure is a warm chocolate croissant or an iced strawberry turnover, people pine for a dose of sugar. But as consumer trends collide with evergreen cravings, sweet goods and pastry producers are shifting their R&D and operation strategies. When it comes to satisfying their sweet tooth, consumers want it all — something that tastes great and is keto, gluten-free or plant-based. It’s challenging for bakeries to create pastries that deliver balance on taste and health factors, but this is a space with serious potential for growth. For Brian Owens, CEO of Phoenixbased Café Valley, it’s about embracing all things plant-based, especially as younger consumers gain increasing buying power.

Photo by Nathan Dumlao on Unsplash

“People want something fantastic like an authentic pain au chocolate, or they want something plant-based or keto or at least with some connotation to it,” Owens said. “We get a lot of requests for those, and we’re dipping our toe into the plant-based market. Younger consumers are keen on plant-based, and they’re not going back to eating animal products. It has a lot of promise.” That promise can have a price tag, but if consumers believe it’s worth

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C AT E G O R Y I N S I G H T: P A S T R Y

the money, some bakers say it’s a good investment. “There are definitely implications, but you have to be willing to invest the time and resources upfront,” Owens said. “It’s a trade-off — if you believe that’s where the profitability and the consumer is, you’ve got to make that trade. And that means you have to find suppliers that are specializing in plant-based fats to satisfy that customer demand.” Pastry producers are also capitalizing on demand for clean-label products. Anna Maria Fritsch, head of marketing for Bridor, North America, noted that creating a high-quality, clean pastry is a top focus for this global bakery. The company makes its fillings in-house and has rigorous standards, with more than 300 ingredients banned to ensure its

“Different types of doughs like multigrain or those with inclusions can be challenging on the lines ... We need equipment that is not only flexible but also user-friendly with a hygenic design.” Anna Maria Fritsch | head of marketing, North America | Bridor

products are as pure as possible. That adds a layer of complexity when it comes to ingredient sourcing. “There are always new flavor trends emerging, and that challenges us to discover new ingredients available for use in industrial production,” Fritsch said. To add to that challenge, as consumer cravings for flavor innovation increase, their demand for clean-label ingredients never wanes. And even ingredients that are technically considered clean according to bakers and suppliers might not be perceived as clean by labelconscious shoppers. Bridor prides itself on having one of the highest clean label standards in the industry, which can add an extra step in ensuring the ingredients aren’t just clean, but Bridor clean.

Photo by Mink Mingle on Unsplash

Café Valley is seeing requests from its customers for plant-based offerings.

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C AT E G O R Y I N S I G H T: P A S T R Y

“This is nothing new, but it strongly affects us and is going into the pastry category,” Fritsch said. Consumers are also seeking big flavor in small packages. Bitesized products that invite permissible indulgence are surging in popularity, and pastry producers are answering this demand through smaller portions and snack sizes. But smaller bites can have a big impact on the production line. “It has a lot of implications in terms of your run speeds and how you package things on the back end,” Owens said. It even has the bakery looking into more automation for manufacturing the smaller-sized products being requested by Café Valley’s customers. Today’s consumers struggle to reconcile — perhaps now more than ever — the desire for healthfulness, the urge to indulge and the need to tighten the pocketbook strings. While that is clearly driving much of the innovation on the

ingredient and formulating side, it’s also impacting product sizes and, ultimately, packaging needs. According to Fritsch, Bridor also has its sights set on smaller sizes, but wants to keep the distinction between small and mini. She noted that consumers want to scale back only enough to justify the purchase and the calories while still getting a bang for their buck. “We are seeing a demand for going smaller, but not all the way to mini products,” Fritsch observed. “I would say reducing the product size by 20% gives the impression of a more responsible indulgence.” Where shape, size and flavor innovation go, operational challenges will follow. Finding suppliers that can help bakers innovate with new concepts on an industrial scale is key, especially when it comes to serving QSR customers that are looking for highquality products, whether they’re classics or new additions.

Café Valley’s experience with producing sweet goods has helped the bakery when it comes to processing doughs with decadent ingredients that are also classified as clean label. Laminated dough products by their very nature require very specific process controls; even the slightest deviation in temperature could throw the process off when the dough enters the makeup line. “If the butter melts, you don’t get the layering you want, and you lose that flaky texture,” Owens said. Conversely, if the dough is too cold, it won’t machine properly on the line. For Café Valley, the first step is having the right staff who understands all the idiosyncrasies that come with laminated sweet goods. Even while the workforce shortage in the industry is at crisis levels, Café Valley has a core team, some of which are 25-year veterans, working on the line. “We have one guy in particular who is an absolute ‘dough whisperer,’” Owens said. “He can work wonders, even if there’s a problem on the line. And we have an entire R&D team that spends a lot of time working with the production team.”

Photo courtesy of Bridor North America

Bridor has rigorous clean-label standards with more than 300 ingredients banned from its products.

AUGUST 2021 Q3

The company has programs in place where production workers are trained to become bona-fide bakers, then move up into operations roles as supervisors or production managers in roughly two years. A strong workforce is critical, but in today’s labor shortage, strong supplier partnerships — and even stronger communication — are everything.

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C AT E G O R Y I N S I G H T: P A S T R Y

“There are limitations on robotics — they’re not people — but with automation technology, suppliers are starting to figure it out.”

Photo courtesy of Café Valley

Brian Owens | CEO | Café Valley

Along with the partnerships, bakers are also in need of flexible and efficient lines that can handle the variety of ingredients they’re incorporating into their formulations. “Different types of doughs like multigrain or those with inclusions can be challenging on the lines,” Fritsch said. “Specialized recipes like vegan

AUGUST 2021 Q3

“Automation can be very rigid, as in, ‘You can have any color you want as long as its black,’” Owens said. “But you want to have that flexibility for different product packaging. There are limitations on robotics — they’re not people — but with automation technology, suppliers are starting to figure it out.” The ultimate dream is to get to the point where machines can be easily adjustable in all areas of the pastry process with the ability to handle rapid growth.

Café Valley is seeing requests from its customers for plant-based offerings.

“Having relationships and setting expectations and then getting the right service support that you need is key. We have suppliers who come into our facilities regularly to make sure equipment is running well and that our people are trained properly.” Owens noted that Café Valley has benefitted from partnerships with various suppliers such as AMF Tromp and Rademaker.

there’s room for further innovation to bring efficiency and flexibility to the packaging area as single serving and smaller sizes dominate.

doughs or fillings with allergens require additional cleaning cycles, which impact the efficiency of the lines. We need equipment that is not only flexible but also user-friendly with a hygienic design.” For maximum efficiency, especially as the industry faces critical workforce shortages, automation is key — especially with technology that can take on labor such as repetitive-motion tasks. “Automating manual processes like the bending and pinching of croissants has been a major innovation,” Fritsch said. “It’s incredible how this market has developed, especially for creating that artisanal design on an industrial scale.” Owens also noted that while automation on the makeup line has been a godsend,

“Improving the equipment in terms of design, handling and changeovers is the main challenge right now,” Fritsch observed. But her ultimate wish would be to discover automated equipment that could ensure that perfect half-moon shape for croissants. “If it could manage to stay in that shape after proofing and baking without pans, then we would definitely be seeing the next innovation in the market.” Owens echoed the importance of maintaining quality and flexibility all the way through the process. And although it seemed impossible five years ago, he envisions a future where packaging automation and flexibility can live in harmony. “Doing different packaging sizes with clamshells or for foodservice, isn’t quite there yet,” Owens said. “But the demand is there, and I think that’s the change.” As pastry manufacturers lean into the challenges and potential success of flavor innovation, clean labels and smaller sizes, one thing remains clear: There’s no sign of slowing on the need for speed. CB .

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Inside the baked snack shift BY LIZ GOO DWI N

Salty snacks have always had a place in the hearts of consumers. But these days, they’re searching for something more to their chips, crisps, crackers and mixes … a snack with impact. Whether it’s new ingredients, climate-conscious production or innovative flavors and shapes, consumers are craving bold savory bites. And bakeries need to keep up as demand soars.

Photo courtesy of HighKey

Here’s how some snack bakeries are navigating the challenges of goal setting for baked snack production … and what’s needed to take conscious crunching to the next level. Breaking down what elevates a consumer’s snack choice goes straight to the basics: the ingredients. As things like major allergens, gluten and carbohydrates wane in popularity, some bakeries find themselves switching up their product formula. Gone are the days when traditional flour was the default, and that’s had serious impact on the baking process.

entire commercial production process at almost every step. But, with persistence and care, most challenges can be largely overcome. Anything that slows down a commercial line is unpopular with the engineers, so accommodating their concerns is always at the forefront of our considerations.”

“When you remove gluten, carbs and other binders, you fundamentally change the nature of the product, in this case our crackers,” said John Gibb, co-founder of Orlando, FL-based HighKey, a low-carbohydrate and low-sugar snack brand. “That adds complexity in the

Foods such as chickpeas, potatoes, rice, lentils and even alfalfa are gaining attention on the cracker scene, each one for having its own unique health benefits. They take time to master, but with the right technology, these ingredients have the potential to shine.

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Photo courtesy of HighKey

“The recent developments in baking technology are awesome,” Gibb said. “Many new products will emerge from [these technologies].” He noted that these advances present the opportunity to offer different tastes, textures and nutritional attributes to some otherwise very traditional products. Another snack ingredient powerhouse is oats. Saint Louis-based Airly, a climatefriendly cracker company with a focus on sustainability, uses oats as the dominant ingredient in its “Oat Cloud” crackers. The variety used in the formula physically removes carbon dioxide from the air, giving Airly the brand points with consumers who are passionate about stopping climate change. That said, it also presents challenges when making products with such delicate formulas and intricate shapes on a large scale. “We’ve had to do a lot of work on getting the right formulation that will mix, sheet and die cut equal to or better than a

AUGUST 2021 Q3

“You want to make sure you have the capacity to manufacture the snacks, because people are eating. If demand gets any higher, we’re going to have to bust a wall out and people can eat products right off the line.” Mark Lindsley | director of research and development | Hearthside Food Solutions

conventional cracker,” said Kris Corbin, co-founder and chief supply chain officer at Airly. “It’s critically important for us to not create a tremendous amount of scrap and increase our carbon footprint, so the sheeting and die cutting is important to us in the baking process.” As demand increases for crispstyle crackers often made with more non-traditional ingredients, so does the need for equipment that can handle these new formulas. Finding the sweet spot when it comes to sheeting cracker dough, especially one made with alternative ingredients, often requires special attention to factors such as gauge roll differentials to optimize the process. “Most all non-wheat-based formulas pose problems for current high-speed cracker equipment,” said Mark Lindsley, director of research and development at Downers Grove, IL-based Hearthside Food Solutions. “That has to be overcome

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by either modifications in process or in the equipment or the formula or all three.” While factors such as dough consistency, piece weight and finished product moisture are always important, crisptype products require a simpler process than traditional crackers because the straight-dough doesn’t require steps such as lamination and fermentation.

Before that, though, there’s still the oven. And Airly is also looking for the best way to get its product baked to perfection while keeping the environment in mind. The company is seeking a cutting-edge oven system — one with zero emission — to join the ranks of the operation’s

Photo courtesy of Airly

“It’s simpler, but that doesn’t make it easier,” said Brandon Heiser, president and COO of Grand Rapids, MI-based Roskam Baking Co. The bakery invested in a Reading Bakery Systems Baked Multi-Crisp line to streamline its process for these types of products .

direct gas-fired oven. The technology is still in its infancy, but Corbin noted that as the importance of sustainability grows worldwide, he’s excited to see it come to fruition. “The zero-emissions oven would be a huge innovation that would match the efforts we’re doing with carbon on the farms,” he said. “It’s the coolest thing I’m working on right now. There are some early prototypes in Europe, but we really want to be the first ones to pioneer that here in North America. I love the idea of bringing it to the states.”

Photo courtesy of Airly

AUGUST 2021 Q3

With all these new ingredients and flavor concepts, bakers also have to make sure their formulas can beat the heat during the baking process. Kaitlin Sass, senior R&D manager for Reno, NV-based Mary’s Gone Crackers, said that’s something she and her team have to keep in mind when developing new products. “The ovens at Mary’s bake at a really high heat, and that can unfortunately cause

flavors to flash right off in the oven,” Sass said. “You can add ingredients and flavors all day long, but at the end of day if the heat is too high, the flavor may not come through on the finished crackers. And that makes development tough.” As bakeries become more conscious of how new formulas run on the lines — and what equipment will fit those unique needs — technology has become the name of the game. Seasoning non-traditional crackers can require automation that must be easy to clean. At Roskam, the operation relies on equipment such as Heat and Control’s vibratory conveyors to keep the process moving smoothly after the oven and through seasoning, where a combination of oils and topicals creates the need for great sanitary design. And then there’s striking a balance between the workforce shortage and increasingly intricate customer demands. For many, it’s been robots to the rescue.

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Lindsley said this is something his company is heavily focusing on … with all its triumphs and challenges. Although machines can’t replace a human touch, they can help with repetitive motion tasks that allow for maximum production turnout. “What’s driving the need for automation now is the inability to get human beings, and we’re having a hell of a time filling those critical lower-level positions,” he said. “You want to make sure you have the capacity to manufacture the snacks, because people are eating. If demand gets any higher, we’re going to have to bust a wall out and people can eat products right off the line.” Corbin also noted that rapid demand yielded Airly’s need for large capacity.

equipment, which is not easy to do,” Sass noted. “That means a lot of research, a lot of R&D and a lot of material exploration to see if we can even run it.”

“In the old days we had the liberty of testing things for nearly six months,” Lindsley said. ”Those days are gone. Speed to market is enormous, but it’s also collapsed, and something has got to give. We’ve got to know how to make that formula and how to make it function within those high speeds.”

More new flavor concepts come with more health and environmental implications, so producers of baked snacks need ingredient and equipment suppliers that can keep those wheels turning. Demand for innovation is still spiking, and bakeries are dreaming of groundbreaking products with new textures and flavor profiles made on flexible, efficient machines.

Packaging is another level where salty snack producers are feeling the pressure. As consumer demand spikes for different package styles like singleserve, flexibility is critical to keep things running smoothly. “We have a few staple carton sizes, but if we want to branch out and explore new capabilities, we have to order additional

This high demand can put pressure on a bakery’s speed to market, especially from its customers. But if a formula doesn’t hit the mark, that could turn into even more time and money for the bakery. If that happens, some call out an SOS to the big guns: ingredient suppliers. “We have ended up having to clean up some epic messes because it can be difficult for formulators to understand our limitations,” Lindsley said, recalling formulating challenges that have come with the trial-and-error for new product development, especially with starches that come in several different forms. “We can’t run something with 30% scrap rate because the formula was off. That’s beyond unacceptable. Sometimes we have to tap into experts to help us out.”

AUGUST 2021 Q3

Conscious consumers are causing bakeries to narrow the focus on what’s next … and to become more conscious about their own production needs. As the baked snack market evolves, rest assured that with the right supplier innovation, bakeries will keep churning out snacks to meet any demand. CB

Photo courtesy of Mary’s Gone Crackers

“With COVID and the huge spike in demand for snacks and baked goods in general, our big need is bakery capacity,” he said. “We’ve partnered with contract manufacturers for help with our cracker sheeting along with baking and bagging.”

Even when the formula is right, as long as consumer palates expand as fast as their appetites, operations and speed to market are like an accordion.

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Around the World, Pizza Brings the Innovation

International content provided by baking+biscuit international, an F2M publication.

AUGUST 2021 Q3

I N T E R N AT I O N A L M A R K E T

B Y C ATA L I N A M I H U , EDITOR-IN- CHIEF B A K I N G + B I S C U I T I N T E R N AT I O N A L

While pizza restaurants around the world are working to regain their footing, pizza brands are riding the innovation wave, launching new offerings that meet diverse preferences, lifestyles and diets. Many try to replicate the authentic, almost elusive, dining-out quality, while better-for-you options explore all sides of what “better” stands for. A universal choice for comfort food, pizza is enjoying a generous uptick in innovation. Retail brands, bolstered by the newfound interest of homebound consumers, are revamping the preparation process to replicate the quality of restaurant and delivery pizzas. Innovation has centered around highlighting quality and authenticity credentials on packaging, thereby raising consumers’ expectations, according to Mintel research. In the UK, Crosta & Mollica Pizzeria Bosco adds restaurant-quality claims on its packaged pie. The Wood-Fired Sourdough Pizza with Mushrooms and Truffle & Garlic Cream Sauce features traditional sourdough baked in a woodfired oven for an authentic pizzeria taste. In September 2020, Zizzi, a chain of Italian restaurants in the UK and Ireland, partnered with Sainsbury’s to launch its first at-home pizzas after a number of its restaurants closed due to lockdown measures. The popular Rustica pizzas, with varieties like Piccante Pepperoni, Margherita Classic and Vegan Jackfruit Pepperoni, are said to feature restaurant-quality ingredients.

Plant-based goes with everything Improved nutritional profiles also spell quality, and Mintel found that consumers are game to try better-for-you pizza, opening the door to a new range of possibilities. “Brands are enriching recipes with nutritious ingredients that may provide protein, fiber or functional benefits,” said Stefania Apostol, innovation analyst at Mintel. “Similarly, vegetarian and vegan brands are highlighting the nutritional benefits of plant-based ingredients.” Globally, consumers are looking for healthier pizzas: Since the COVID-19 outbreak, 74% of adults in Spain have found pizzas with healthier toppings to be appealing, as European consumers are eager to try better-for-you products made with healthier ingredients. Innovating around functional benefits can also appeal to health-conscious consumers. “Pizza and pie brands have an opportunity to tap into this consumer interest in healthier alternatives by highlighting functional claims or nutritious and healthier ingredients like wholemeal flour or vegetables used as toppings and in crusts,” Apostol added. One Planet Pizza, a British manufacturer of plant-based pizza, launched the No Clucks Pizza to celebrate National Fried Chicken Day in the UK in July, in partnership with vegan chick*n brand VFC. The pizza is topped with VFC’s vegan Southern fried chick*n popcorn pieces and features One Planet Pizza’s “secret family recipe” tomato sauce. The producer estimated that one chicken’s life will be saved for every 20 No Clucks Pizzas purchased in lieu of a regular chicken pizza, and 50 pence (approximately 62.5 cents) from every purchase is donated to the Big Red Rooster Cockerel Rescue. When selecting ingredients for its pizzas, the most important aspect is the taste for One Planet Pizza.“They have to taste as good, if not better, than meat and dairy alternatives,” Hill said. “Once we’ve nailed the taste, the aim is to make them as healthy and sustainable as possible. Our pizza range on average has at least 25% less salt and sugar.” Toronto, Canada-based GA Pizza caters to the Canadian flexitarian consumers with its own plant-based launch: the naturally-leavened, New York-inspired Impossible Pizza, a collaboration with Impossible Foods. Its recipe features housemade tomato sauce and Impossible “meat” made from plants that is seasoned with chili, garlic and toasted fennel seed. Fresh Anaheim chilis and thinly shaved white onions complement the fennel-spiced plant-based protein. The pizza is finished with three types of cheese: premium fior di latte, grass-fed mozzarella and grana padano. The plant-based trend is reaching new heights, and vegetarian and vegan pizza brands are on board as they trade dairy for exciting topping combinations among vegetables and plant protein. UK-based Asda’s Plant Based Chargrilled Veg Flatbread Pizza is a vegan product that is low in saturated fat, which contributes to the maintenance of normal blood cholesterol levels and is high in fiber.

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I N T E R N AT I O N A L M A R K E T

A cause for pizza Ethical and environmental claims are also on the rise in pizza aisles across Europe as consumers’ concerns about the climate crisis intensify. Mintel reported that 44% of UK consumers say the amount of packaging used for ready meals discourages them from buying them more often. As a result, there has been an increase in launches with ethical and environmental claims in recent years dominated by environmentally friendly packages and recyclable claims.

“This relates to the Mintel trend ‘Rethink Plastic’, which outlines how plastic in itself is not bad, but our throwaway culture of it is,” Apostol said. “Brands and consumers are therefore reviewing their own behaviors to prevent plastic pollution.” This environmental awareness and consumers’ increased concern over packaging’s impact on the environment are giving way to the debut of fully recyclable and plastic-free packs.

Mintel also highlighted new environmentally friendly entries in Europe’s market. Mix Créateur de Goût Pizza del Gusto! Goat’s Cheese, Walnut & Honey Pizza retails in a partly recyclable pack made with a 100% recycled carton and printed with vegetable ink in France. In the UK, Pieminister Gluten Free Moo Beef Steak & Ale Pie has been repackaged in a newly designed p lastic-free, fully recyclable and biodegradable pack with a pack window made from wood pulp.

Out-of-home pizza party While the US is home to the largest number of pizza restaurants worldwide with 90,817 pizza restaurants as of 2020 — more than the top four markets combined (88,100) according to B oldData — Italy comes in second, with 42,288 pizzerias, and Brazil completes the top three with 32,283 pizza places. Australia, ranking eighth on the list, is an interesting mention with 5,598 pizza restaurants. That amounts to one of the highest numbers of pizza outlets per capita. Germany also continues to see growth. This is due in part to many chains opening stores throughout the country. Close to 700 restaurants have opened since 2016, bringing the total count to 13,521 as of this year. Berlin is also the country’s pizza capital, with almost 500 stores, more than twice the number of those in Munich (232). Cologne and Hamburg are the other major pizza centers with more than 200 dedicated businesses each.

AUGUST 2021 Q3

BoldData: number of pizza restaurants by country in 2020 USA 90,302

OTHER 56,386

GERMANY 13,529 BRAZIL 32,283

ITALY 42,288

Source: BoldData Food Database / Created with Datawrapper

As foodservice picks up the pace all over the world, pizza maintains its reign in consumers’ choices, offering plenty to be experienced either at home or at the local pizza place.

Commercial Baking has developed a cooperative agreement with the leading European / international baking journal baking+biscuit international from the publishing house F2M. This magazine is the English- language sister to the acclaimed German language journal b rot+backwaren and is published six times per year with 5,000 hard copies delivered per issue and thousands reading the editions digitally.

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BUSINESS INTEL

Data in the Age of Disruption The Internet of Things has led to ‘Bakery 4.0’ and the next generation of data usage, just in time to navigate a supply chain crisis. B Y A N I R B A N B H AT TA C H A R Y YA

The Industry 4.0 revolution is changing the face of manufacturing and supply chain across industries. The baking industry is no exception ... in fact, the rise of “Bakery 4.0” is already underway. For many people, Bakery 4.0, the interactive communication between semi-autonomous machines, may sound like science fiction, but it’s the inevitable future of commercial baking. According to the Federal Ministry of Economics and Technology in Germany, a third of production is fully networked, a third partially networked and a third not yet networked in mid-sized companies. Digitalization can decrease workloads and provide numerous benefits without adding complexity. Most bakery processes — including recipes, refrigeration control and even the overall operation — can be automated and networked. Online services are already used widely in oven design and refrigeration systems. The Internet of Things (IoT) has applications in product and process monitoring, labeling, packaging, logistics and maintenance.

use of lean manufacturing strategies that minimized the inventory held in global supply chains. A recent Accenture survey revealed that 94% of Fortune 1000 companies are seeing supply chain disruptions from COVID-19, while 55% of companies plan to downgrade their growth outlooks. There is a dire need for leaders to accelerate the adoption of agile strategies and value chain transformation to help outmaneuver uncertainty. The scale of COVID-19 impact requires continuous end-to-end assessment, optimization and monitoring. Strong data and analytics capabilities are crucial to understanding complexity, anticipating disruption and quickly responding to issues such as demand drops and surges by segment, supply shortages, inventory placement challenges and reduced productivity.

Although efficiency and simplicity are the goal, COVID19 made the past year anything but. The pandemic triggered widespread disruption. The Institute for Supply Management found that nearly 75% of the companies surveyed reported some kind of supply chain disruption due to COVID-19.

Bakery 4.0 entails several disruptive tools that can be leveraged by most organizations across the industry. Big-data analytics enables the storage and processing of vast quantities of information. Blockchain allows the direct transfer of assets while documenting each transaction. IoT uses sensors to monitor and track products as they move through production and delivery. Digital supply chains transmit digital media from content providers to consumers. Advanced robotics use artificial intelligence and machine learning to increase operational speed and accuracy.

Manufacturers are now facing greater pressure to increase domestic production, grow employment, reduce dependence on risky sources and rethink the

Needless to say, the pandemic has knocked the baking industry’s balance of supply, demand and labor off its axis. It’s also led to compounding bottlenecks.

COMMERCIAL BAKING

BUSINESS INTEL

94%

of Fortune 1000 companies are seeing supply chain disruptions from COVID-19. Source: Accenture

For Robb MacKie, president and CEO of the American Bakers Association, it’s reminiscent of the wheat crisis the industry faced about a dozen years ago when flour prices saw increases higher than 150%. “The price of flour is pretty close to what it was at that time,” Mackie said during a group discussion with Commercial Baking.

of progress and results, as well as initial and refresher training. The analysis of energy efficiency, control, maintenance, the import of software updates and even networking can also be accomplished through remote maintenance using real-time data. Value-stream mapping can be used to accurately regulate and track variables such as oven heat, product feed rate and ingredients for continuous improvement and pinpoint control of operations. Additionally, smart factory software can be used to shape data into actionable insights to optimize manufacturing and identify causes of downtime and least-profitable products to maximize productivity, efficiency and quality.

Restricted access to materials like lumber created ripples across supply chains, disrupting the supply of pallets and shipping cartons. Monthly changing lead times created a dependence on secondary materials needed to manufacture final products. Interrupted domestic transportation led to labor shortages, impacting available drivers. There was also difficulty finding and shipping ingredients, with even substitutes entailing a hefty price tag.

High volumes of data involved with the industry can be processed and simulated to develop data-led strategies using AI and digital twins, enabling a “control tower” where leadership, employees and partners can review the impediments for a certain configurable time horizon.

Moving forward in 2021, it’s important to understand that the shortcomings exposed in the 2020 supply chains largely stemmed from an over-dependency on the concept of resiliency. The model relied on outdated technology that hampered visibility and decision making, while also preaching impractical recommendations. As a result, supply chains buckled when demand increased.

With design and data-led tools, Bakery 4.0 sets the stage for a new marketplace that will open new opportunities for business and innovation. CB — Anirban Bhattacharyya is CEO of Amplo Global, Inc. He has more than 18 years of experience in strategy, research and development, and implementation in physical and digital operations manufacturing, supply chain process improvement, and process automation services. He holds a bachelor’s degree in engineering from the Birla Institute of Technology and Science in India and an MBA in strategy and marketing from Duke University’s Fuqua School of Business.

Current forecasts predict this lasting well into 2022. Manufacturers with digital platforms, accessible data and advanced analytics will be able to respond more quickly, accurately and successfully to disruptions. A variety of industry-specific data tools are available to streamline operations in the face of disruption. Hygiene-management apps enable the digital transformation of analog processes, documentation

AUGUST 2021 Q3

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Solutions

Topping Applicator AXIS Automation’s Rake Topper is at the core of an integrated system for applying moist or sticky toppings to your products. It delivers consistent, uniform distribution across the entire deposit width. When coupled with conveyors to transport product, feed toppings and reclaim excess material, it is the perfect solution for applying streusel, cheese or other challenging toppings. www.axisautomation.com AUGUST 2021 Q3

SUPPLIER SOLUTIONS

Dual Robotic Decorator Apex Motion’s Dual Baker-Bot robotic decorator can decorate everything from cookies to cakes and cupcakes. Top rosettes, bordering swirls, drizzle and even writing can easily be set up using the touch screen drawing pad. Aside from consistent, continual decorating, the Dual Baker-Bot robotic decorator also helps with labor shortages and repetitive strain injuries. www.apexmotion.com

Gravity Case Packer BluePrint Automation’s Gravity 100r case packer top loads a variety of products directly into the secondary container. Now offered for high caustic washdown environments, it’s built with minimum static flat surfaces to drain all liquid. With high efficiency IP69K stainless steel permanent motors, the new sanitary Gravity 100r provides easy access for cleaning and inspection. www.blueprintautomation.com

Automated Stacking and Unstacking Capway’s RoboStack automatic handling system with pan storage cart integration is designed for the stacking, unstacking and storing, of pans/lids/trays/etc. within medium to high-output industrial food and bakery operations. It replaces the manpower required to stack or unstack pans, lids, trays, or peel boards on the production line. www.capwayautomation.com

Full Washdown Feeder Cavanna has developed a new solution that is able to regulate the irregular arrival of products, delivering a continuous flow to the downstream metering belt of the flow wrapper ensuring optimal OEE. It features individual product control, full caustic wash-down execution, toolless accessibility and is ideal for baked products requiring gentle handling and allergen cleaning. www.cavanna.com

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SUPPLIER SOLUTIONS

Smart Applicator Solution AMF Tromp brings automated quality and quantity control for pizza toppings through AI-based regulation with its Smart Applicator Solutions. With cloud-based software that allows AI to analyze real-time photographs, the software can adjust pizza topping applicator speed and volume settings to deliver the optimal cheese distribution. This minimizes waste and giveaway of toppings. www.amfbakery.com

Sourdough Production Line Diosna’s presents its stainless-steel plant RW 650 for a variety of leavened doughs, wheat, rye, and gluten-free sourdough production. It comes with cooling and temperature control and a fermenter volume of 170 US gal (650 l). An anchor agitator, wall and bottom scrapers allow for fast mixing. www.diosna.com

COBOTS, ROBOTS & AUTOMATION Robotic Packing . Smart Conveyors . Robotic Decorating . Tray Management Equipment automation built to help you with: BAKER-BOT Versatile, userfriendly Cobot.

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AUGUST 2021 Q3

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Stainless Steel Replacement Parts Henry & Sons has introduced cutting edge stainless-steel replacement parts for VEMAG’s. Included parts are a 36lb Stainless-Steel ERGO Housing (vs the 64lb competitors) and Stainless-Steel Double Screws. They can help reduce rust in your housings and double screws, are corrosion free, 48% lighter weight, and made of USDA-approved materials with a 100% sanitary finish. www.dhenryandsons.com

Granola Production Line Reading Bakery Systems introduces a new Granola Production Line. The system includes an RBS Omega IV Dispenser with overhead kibbler and Emithermic Oven. The line offers the flexibility to incorporate topping conveyors after the oven, and a guillotine cutter and slitter for bar applications. www.readingbakery.com

Complete Mixing Automation

Escher has specifically designed their bottom discharge mixers for continuous batch production. This compact system of two or more mixers allows smaller, more frequent batch sizes of 250 to 1,300 pounds of dough. By utilizing bottom discharge spiral mixing technology, finished dough is automatically unloaded and transferred to production lines for seamless, constant production. Schedule your demo today and put our claims to the test.

doughtech.com 1-800-896-3706 sales@doughtech.com Dough production experts offering: Mixing, Dividing, Rounding, Intermediate Proofers, Bread Moulders, Make-Up Equipment and Silos

CONTINUOS BATCH PRODUC TION 99

SUPPLIER SOLUTIONS

Spiral Conveyer Monitoring System Ashworth offers the SmartSpiral® Monitoring System – an innovative application that provides real-time remote monitoring using predictive analytics to minimize production downtime. The SmartSpiral allows access to multiple spiral/plant locations from your phone and tablet to continuously monitor spiral temperature, belt tension, cage power and features the industry’s first, patented bottom bearing wear sensor. www.ashworth.com

Electrical Ovens Kaak’s new electrical ovens emit no CO2 and distribute even heat over the baking chamber, allowing for control over the baking process. Offering a wide range of baking temperatures allows robust flexibility in production. The compact construction is available in continuous, batch and multideck ovens with widths up to 4 meters. www.kaak.com

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Conveyor System Upgrade IPCO, a world leading manufacturer of bake oven belts, also supplies a full range of conveyor components. When faced with problem lines, the company offers solutions including a complete system upgrade with replacement steel belts, new tracking systems, drums, scrapers, spring guide rollers and skid bars. This can minimize downtime, and create more reliable line performance. www.ipco.com

Modified Protein REPCO debuts the new technology eLentil to strengthen wheat flour doughs. Enzymatically modifying lentil protein creates adhesive properties that bind and strengthen gluten, native in flour. As a clean-label replacement for costly emulsifiers, dough conditions and vital wheat gluten, eLentil is the perfect solution for pan bread, rolls, buns, bagels, and artisan whole grain loaves. www.repcoworld.com

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SUPPLIER SOLUTIONS

Tight Transfer Belt Intralox releases a new high-strength tight transfer belt. The Intralox® Series 560 belt provides smooth, gentle product handling to improve yield and minimize damaged product. Its design helps simplify cleaning, eliminate mistracking, and maintain product orientation. With a belt strength of 300 lb per foot, it’s one of the strongest, most durable tight-transfer modular plastic conveyor belts available. www.intralox.com

Low Stress Laminator Multivac Fritsch’s Laminator 300 can now be configured with even more flexibility thanks to the “Low-Stress” dough sheet former “TBP.” In addition to the gentle processing of the dough, high system availability and ease of operation is of great importance. An automatic, permanent cascade control now makes operation even easier. www.fritsch-group.com

INGENIOUS

What can you expect from the largest trade event for the grain-based foods industry in the Western Hemisphere? A launch of everything you need to further your ingenuity. With the latest innovations, new ingredient formulations, game-changing insights and an unbeatable sense of community, it’s a one-stop shop for all baking professionals. Join the global industry in Las Vegas, where you’ll find the power to keep your business going strong.

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Bread Rack The Henry Group Bread Rack combines convenience and durability. Made from 100% 304 stainless steel and fully-welded construction, the reinforced shelves carry up to 130 lbs. per shelf. Dual pull-handles and top/bottom bumpers allow effective product handling and protect protection. The design can be customized to suit specific needs. www.thehenrygroup.com

Rotary Divider Handtmann introduces the SE 442-1 Rotary Divider. It reduces giveaway and rework and is designed to make sanitation simple and changeovers fast. The servo-driven rotary divider scales a range of dough products with +/-1 % accuracy at up to 200 ppm. Its undercut function reliably increases precision to let you adjust cutting speeds for different dough densities. www.handtmann.us

There is no need to sacriﬁce quality for cost. L AUR A A ND RON A LD R IJK A A R T

More than make-up lines, Rijkaart are experts with pie, laminating and bread lines, too.

doughtech.com 1-800-896-3706 sales@doughtech.com CROI S S A N T S

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Rijkaart’s philosophy is to work toward the best solution for the best price, and it has been that way since 1963. We value customer feedback, ﬂexibility and integrity with all our customers. It’s these guiding principles that makes all of us at Dough Tech proud to partner with Rijkaart.

Dough production experts oﬀering: Mixing, Dividing, Rounding, Intermediate Proofers, Bread Moulders, Make-Up Equipment and Silos

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ISSUE Q1 FEB 2021

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CATEGORY TRENDS

Ad Index 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 Commercial Baking does not assume any liability for errors or omissions. Please send any updates or corrections to info@avantfoodmedia.com.

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It’s time to outperform rather than just outspend.

COMMERCIAL BAKING

THE LAST WORD FROM JENNIFER BAUER

Bridging the Gap

It’s no secret that there is a crisis for talent acquisition, training and retention in the baking and food science industries. This problem has only been exacerbated by the pandemic, and commercial bakeries are now among the economy’s mostneeded workforces. Tracing back the talent development pipeline shows the problem originates in post-secondary degree programs, which are uniformly under-enrolled.

the under-enrollment in these programs. We have to make students aware of these opportunities much, much sooner. National programs from the Center for Advanced Professional Studies (CAPS) propel high school students toward STEM-related degrees and careers. CAPS blends business, science and engineering disciplines, and in Kansas City, Blue Valley CAPS has leaned on partners like Corbion to generate awareness for food science, as well.

Kansas State University has one of the top food science, milling and baking programs — perhaps one-of-a-kind in the country — with students who are almost guaranteed to graduate with a job in the industry. But many students enter K-State (and other universities) unaware of those opportunities. They understand careers in business or engineering, but not as they relate to food production.

The next generation may have a general awareness of food production and agriculture, but the baking industry can help them understand the role they can play in the food supply chain. Programs like CAPS are building the bridge, and when baking companies start the conversations with students at the high school or even middle school level, it’s a big step toward crossing it. CB

As students consider STEM-related education, food or bakery science programs housed in the school of agriculture aren’t typically on the radar. They assume that department only consists of farming or veterinary science, when in reality it’s so much more.

— Jennifer Bauer is the business development specialist for Blue Valley (BV) CAPS in Overland Park, KS. She works with partners across several STEM-related industries, including food and baking. In 2014, BV CAPS launched the Future of Food course in conjunction with K-State and its food-related business partners.

I see this disconnect all the time. I have conversations with baking companies and associations about the lack of people available to hire, and I hear from K-State about

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Commercial Baking August | Q3 2021

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