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facility reaches SQF Level 3, Mr. Keaton hopes to reduce the number of audits. “We’ve changed our entire culture — everything from traceability to HACCP to food safety and employee safety,” he added. Bulk flour is stored in two Pfening 105,000-lb silos. Moreover, a Pfening 65,000-lb high-fructose corn syrup tank and a 45,000-lb soy oil tank feed the operation. Most minor and micro ingredients as well as packaging supplies are stored at an offsite facility, and the company only brings a day’s worth of ingredients into the plant to maximize space for production. Inside the facility, a cooler stores butter, milk and other temperaturesensitive ingredients. Allergens, especially pecans and other tree nuts, are separated from other ingredients per the company’s HACCP plan. The plant’s tempering room brings margarine and butter up to optimum temperature, making the fats more malleable during the laminating process. A dedicated operator handscales all minor ingredients by batch in another room, then wraps each batch in pink plastic on a tray and tags it for traceability. The mixing and laminating room houses seven Shaffer horizontal mixers ranging in capacity from 1,600 to 3,000 lb. Skinner Baking recently purchased two Shaffer 3,000-lb horizontal mixers with glycol jackets to provide better front-end control of its dough temperature, Mr. Keaton said. In all, the bakery will have nine mixers feeding its production lines. For yeastraised sweet goods, the bakery uses

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Pit Crew Mentality
Because most of Skinner Baking Co.’s baked sweet goods are made with five — eggs, milk, soy, wheat and nuts — of the Big Eight allergens, the plant’s sanitation and maintenance crew needs to race into action to break down and set up equipment as the schedule changes from one product to another after each shift. “We call them the ‘pit crew’ because it only takes them 2.5 hours to break the equipment down, clean the line and set up new equipment for the next shift,” said Audie Keaton, president of the Omaha, NE, company. “They do it really fast and really well.”

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October 2011 / BAKING & SNACK

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Baking&Snack - October 2011

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