Baking & Snack - July 2005 - 42

The right choice
themselves, tearing down office walls to make room for the new equipment.
With the corporate restructuring, the headquarters operation moved from
the site it shared with the commissary to a new location a few miles away.
Plant staff also assisted vendor technicians during installation.
The new equipment and systems came in from vendors on their
specified delivery dates. Much was actually on-site two or three weeks
ahead of time, according to Mr. Mare. The facility continued manufacturing during construction, halting for only a few days during the
dusty work of wall reconstruction.
The changes at Bake One have not gone unnoticed by its major
client, Atlanta Bread Company. "Our main customer tells us that our
products' consistency and quality has changed dramatically for the
better," Mr. Mare said. "Consistency was always an issue with our previously semi-automated facility.
"Take freezing, for example," he continued. "Blast freezing could require
up to three hours. Now it's a 30-minute process in the spiral freezer. This
shocks the yeast faster, and that helps proofing time at store level. Consistency is absolutely essential for our customer's stores."
PLANT IN ACTION. As Bake One heads into the summer months,
it operates a Monday-through-Thursday schedule. Each of the four
days uses two shifts for production and one full shift for sanitation.
The plant is completely air conditioned and kept at a year-round
75°F (24°C). The pastry room, however, is held at 50°F (10°C). "That
temperature keeps butter at proper condition, so it won't melt into the
dough," Mr. Mare explained.
The plant consumes 250,000 lb of flour on a weekly basis, and its
two existing silos stock patent flour in one and high-gluten flour in the
other. All flour is sifted on delivery.
As part of the plant upgrade, Bake One acquired a water filtration
system for ingredient water. Mr. Mare explained, "Filtration removes
minerals that retard the yeast - a factor especially important for frozen dough performance."
A 500-hp compressor, housed outside the plant, supplies the ammonia coolant for the bakery's freezing system. "We sized the ammonia system to run two spiral freezers," Mr. Mare revealed.
Along with all the changes during the past year, the company also
bought the entire building that houses the bakery. It previously leased the
space. This opens up an additional 60,000 sq ft for storing ingredients and
supplies. "Now that 4 Seasons distribution moved out to a new location,
we can re-do the space used for warehousing," Mr. Mare said. "But by the
end of 2006 or 2007, this area will be given over to manufacturing." There
are plans to totally automate cheesecake production with a tunnel oven,
deck oven and second spiral freezer.
AIB-READY. "The next thing will be to get the plant ready for inspection by the American Institute of Baking," Mr. Mare said. "Bake One
wants to be dairy kosher and AIB certified, so we are stepping up a
notch to achieve these standards."
"We want to use these certifications to build our image with our
customers," Mr. Couvaras added.
By applying such regulatory polish to the new facility, Bake One has
moved out fast from its starting position. Winning new customers for
this versatile plant is "a goal we have been striving for during the past
six years," Mr. Mare said.
Ⅲ

Fine pastry production

Whether an individual laminating line, a pastry make-up line,
a Pizza line, a croissant
machine or a fully automatic
/

9* -/

production line, we have for
decades been specialists in
the development of innovative,
customer-oriented solutions.
By using modular systems we
are able to devise production
lines that meet all of the wishes
and requirements of our worldwide clientele.
www.rondodoge.com

Rondo Inc.
51, Joseph Street
Moonachie, N.J. 07074
USA
Tel. +1 201 229 97 00
Fax +1 201 229 00 18
info@us.rondodoge.com

RONDO

DOGE®

July 2005
/ BAKING & SNACK
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information,
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Baking & Snack - July 2005

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