Baking & Snack - December 2017 - 30
TREEHOUSE FOODS
Investing in flexibility
Since 2009, significant improvements have been made to
this 985,000-sq-ft facility to make product types ranging
from rotary die, rotary moulded, seasoned, glazed, and
sweet and savory cookies and crackers. All told, more
than $100 million have been invested in capital expenditures to increase throughput and flexibility on multiple
production lines. Today the bakery, which runs 24/7
and employs nearly 600 people, cranks out an average
of 575,000 lb of product that ship out on about 45 to 50
semis every day.
When RBS designed the most recent cracker line, flexibility was at the heart. While many TreeHouse cracker
products are laminated doughs, that's not always the case.
"The newest line was built with a cut-sheet laminator, but it
also has a bypass so we can run a non-laminated product,
as well," Mr. Allen noted. On other lines, it's one or the other, but this one provides the option to run both as needed.
In addition to typical sheeting, this line can run rotary
moulded product as well. "We can slide the conveyor out
and a rotary moulder in," Mr. Allen said. "The new line has
a lot of flexibility - laminate, non-laminate, rotary mould,
rotary cut - as well as different topping applications for savory or sweet."
After the bake, flexibility is still a critical factor for production. For example, some products get a sweet sugar
glaze post-bake from a GOE-Amherst system, while others, like oyster crackers that are offered in a variety of
flavors, get attention further down the line in a Heat and
Control tumble drum application.
It was designed - and installed downstream closer to
packaging - to address the side effects that come with
adding seasonings upstream. Much of the application falls
off as it travels 300 to 400 ft on the conveyor, so operators
would over-season to compensate for the loss. Then they'd
have to clean the whole line during changeovers. Without
seasonings all over the line, the new drum not only provides ingredient cost savings but also reduces changeover
time. "Now, we just have to clean the tumble drum," Mr.
Melton said.
The system can accommodate three different applications at once. "With short runs, changeover is important,
as is supplying customers with a lot of different things. This
now allows us to divide the product stream so we can create
smaller runs that aren't so painful."
The mathematics of packaging
While large-scale private-label contract manufacturing
requires consistency in product processing, the opposite
is true in the packaging area. One customer might reTop: Cut-sheet laminating makes for saltine crackers' light and airy texture.
Bottom: Time, temperature and turbulence rule in the five-zone hybrid ovens.
30 Baking & Snack December 2017 / www.bakingandsnack.com
http://www.bakingandsnack.com
Baking & Snack - December 2017
Table of Contents for the Digital Edition of Baking & Snack - December 2017
Baking & Snack - December 2017
Contents
Contents
Editorial - Cookies, karaoke and continuous improvement
Newsfront - Kellogg partners with ABA for cookie and cracker training
Corbion fights hunger during holiday season
Bunge simplifying organizational structure
Possible revisions coming to GMO regulations
People/In Brief
Operations Executive of the Year - MR. FIX-IT
People skills and family ties
TreeHouse Foods - KENTUCKY GOLD
Marketing to Millennials - more than a STEREOTYPE
Putting faces to the facts
Emulsifiers - Stability in Transition
Cleaning up the label … or not
Flavors - FINDING YOUR FLAVOR
Ingredient App - Mind the GAP
R&D INSIGHTS - MYSTERIES of baking
Flatbread Technology - extreme SHEETING
PANS - Lightening the LOAD
Food Safety Management - recipe for SUCCESS
Striving for a new world of safety
Packaging Innovations - chalahead of the curve
INDUSTRY IMAGES - TECHNICALLY SPEAKING
Meeting Preview: ASB - Sustainability THROUGH THE PEOPLE
Meeting Preview: SNAXPO - IMAGINATION MEETS INNOVATION
Events
ingredients & formulating
equipment & packaging
patents
new on the shelf
MARKETPLACE
AD INDEX
NEW PRODUCT SPOTLIGHT
Baking & Snack - December 2017 - Baking & Snack - December 2017
Baking & Snack - December 2017 - Baking & Snack - December 2017
Baking & Snack - December 2017 - 2
Baking & Snack - December 2017 - 3
Baking & Snack - December 2017 - 4
Baking & Snack - December 2017 - 5
Baking & Snack - December 2017 - 6
Baking & Snack - December 2017 - 7
Baking & Snack - December 2017 - 8
Baking & Snack - December 2017 - Contents
Baking & Snack - December 2017 - 10
Baking & Snack - December 2017 - Contents
Baking & Snack - December 2017 - Editorial - Cookies, karaoke and continuous improvement
Baking & Snack - December 2017 - 13
Baking & Snack - December 2017 - 14
Baking & Snack - December 2017 - 15
Baking & Snack - December 2017 - Bunge simplifying organizational structure
Baking & Snack - December 2017 - 17
Baking & Snack - December 2017 - People/In Brief
Baking & Snack - December 2017 - 19
Baking & Snack - December 2017 - 20
Baking & Snack - December 2017 - Operations Executive of the Year - MR. FIX-IT
Baking & Snack - December 2017 - People skills and family ties
Baking & Snack - December 2017 - 23
Baking & Snack - December 2017 - 24
Baking & Snack - December 2017 - 25
Baking & Snack - December 2017 - 26
Baking & Snack - December 2017 - 27
Baking & Snack - December 2017 - TreeHouse Foods - KENTUCKY GOLD
Baking & Snack - December 2017 - 29
Baking & Snack - December 2017 - 30
Baking & Snack - December 2017 - 31
Baking & Snack - December 2017 - 32
Baking & Snack - December 2017 - 33
Baking & Snack - December 2017 - 34
Baking & Snack - December 2017 - 35
Baking & Snack - December 2017 - 36
Baking & Snack - December 2017 - 37
Baking & Snack - December 2017 - 38
Baking & Snack - December 2017 - 39
Baking & Snack - December 2017 - 40
Baking & Snack - December 2017 - Marketing to Millennials - more than a STEREOTYPE
Baking & Snack - December 2017 - 42
Baking & Snack - December 2017 - 43
Baking & Snack - December 2017 - 44
Baking & Snack - December 2017 - 45
Baking & Snack - December 2017 - 46
Baking & Snack - December 2017 - Putting faces to the facts
Baking & Snack - December 2017 - 48
Baking & Snack - December 2017 - Emulsifiers - Stability in Transition
Baking & Snack - December 2017 - 50
Baking & Snack - December 2017 - Cleaning up the label … or not
Baking & Snack - December 2017 - 52
Baking & Snack - December 2017 - 53
Baking & Snack - December 2017 - 54
Baking & Snack - December 2017 - Flavors - FINDING YOUR FLAVOR
Baking & Snack - December 2017 - 56
Baking & Snack - December 2017 - 57
Baking & Snack - December 2017 - 58
Baking & Snack - December 2017 - 59
Baking & Snack - December 2017 - 60
Baking & Snack - December 2017 - 61
Baking & Snack - December 2017 - 62
Baking & Snack - December 2017 - Ingredient App - Mind the GAP
Baking & Snack - December 2017 - 64
Baking & Snack - December 2017 - R&D INSIGHTS - MYSTERIES of baking
Baking & Snack - December 2017 - 66
Baking & Snack - December 2017 - Flatbread Technology - extreme SHEETING
Baking & Snack - December 2017 - 68
Baking & Snack - December 2017 - 69
Baking & Snack - December 2017 - 70
Baking & Snack - December 2017 - 71
Baking & Snack - December 2017 - 72
Baking & Snack - December 2017 - PANS - Lightening the LOAD
Baking & Snack - December 2017 - 74
Baking & Snack - December 2017 - 75
Baking & Snack - December 2017 - 76
Baking & Snack - December 2017 - 77
Baking & Snack - December 2017 - 78
Baking & Snack - December 2017 - 79
Baking & Snack - December 2017 - 80
Baking & Snack - December 2017 - Food Safety Management - recipe for SUCCESS
Baking & Snack - December 2017 - 82
Baking & Snack - December 2017 - Striving for a new world of safety
Baking & Snack - December 2017 - 84
Baking & Snack - December 2017 - Packaging Innovations - chalahead of the curve
Baking & Snack - December 2017 - 86
Baking & Snack - December 2017 - 87
Baking & Snack - December 2017 - 88
Baking & Snack - December 2017 - 89
Baking & Snack - December 2017 - 90
Baking & Snack - December 2017 - INDUSTRY IMAGES - TECHNICALLY SPEAKING
Baking & Snack - December 2017 - 92
Baking & Snack - December 2017 - 93
Baking & Snack - December 2017 - 94
Baking & Snack - December 2017 - Meeting Preview: ASB - Sustainability THROUGH THE PEOPLE
Baking & Snack - December 2017 - 96
Baking & Snack - December 2017 - Meeting Preview: SNAXPO - IMAGINATION MEETS INNOVATION
Baking & Snack - December 2017 - Events
Baking & Snack - December 2017 - 99
Baking & Snack - December 2017 - ingredients & formulating
Baking & Snack - December 2017 - 101
Baking & Snack - December 2017 - 102
Baking & Snack - December 2017 - 103
Baking & Snack - December 2017 - equipment & packaging
Baking & Snack - December 2017 - 105
Baking & Snack - December 2017 - 106
Baking & Snack - December 2017 - 107
Baking & Snack - December 2017 - patents
Baking & Snack - December 2017 - 109
Baking & Snack - December 2017 - new on the shelf
Baking & Snack - December 2017 - 111
Baking & Snack - December 2017 - MARKETPLACE
Baking & Snack - December 2017 - 113
Baking & Snack - December 2017 - 114
Baking & Snack - December 2017 - 115
Baking & Snack - December 2017 - 116
Baking & Snack - December 2017 - 117
Baking & Snack - December 2017 - 118
Baking & Snack - December 2017 - 119
Baking & Snack - December 2017 - 120
Baking & Snack - December 2017 - AD INDEX
Baking & Snack - December 2017 - NEW PRODUCT SPOTLIGHT
Baking & Snack - December 2017 - 123
Baking & Snack - December 2017 - 124
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http://digitalbs.bakingbusiness.com/sosland/bs/2004_05_01
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https://digitalbs.bakingbusiness.com/sosland/bs/2004_03_01
https://digitalbs.bakingbusiness.com/sosland/bs/2004_02_01
https://digitalbs.bakingbusiness.com/sosland/bs/2003_12_01
https://digitalbs.bakingbusiness.com/sosland/bs/2003_11_01
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