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a sponge-and-dough process. Operators mix 2,800-lb batches that they then dump into troughs that feed two extruders on the Moline laminating line. After creating 36 layers by folding the dough and margarine — or, for a few high-end customers, butter — the dough sheet passes through a reduction station. To obtain the desired 108 layers, the sheet is folded over itself three more times before it passes through a series of flour dusters and reduction stations to make it 19 mm thick. The dough sheets are folded gently and placed on pans — with 32 pans on each double rack — and rolled into a first-in-first-out 34°F retarder where the dough books remain for up to 24 hours. The current retarder holds 243 racks, but with the boost in sales volume, Skinner Baking plans to add 40% more capacity. Operators attach a handwritten label to each rack to document the batch number, time produced, product variety and other information for traceability purposes. The time-consuming fermentation process is integral to making quality Danish and other sweet goods. In fact, Mr. Keaton noted, even the company’s non-laminated sweet doughs receive 2.5 hours of fermentation to develop their flavor prior to makeup. ▼ Cinnamon rolls bake in a 300-ft oven. After cooling, a dollop of icing is added to Skinner Baking’s premium products.
BLANE SUTTON

▶ After a depositor adds muffin batter, line workers manually sprinkle on toppings to provide a touch of indulgence to the products before baking.
BLANE SUTTON

After 24 hours of retarding, the laminated dough books are sheeted on one of the two Moline makeup lines. During Baking & Snack’s visit, Skinner Baking produced gourmet cinnamon rolls for a food service customer on line No. 2, which also makes sweet dough products such as mini-Danish and sticky buns. Line No. 3 typically produces larger products — strip Danish and coffee cakes. Line No. 1 makes muffins. On line No. 2, the dough initially travels through multi-roll reduction stations before a roller cutter slices the sheet into two. These

two strips are then filled with a 50:50 cinnamon-and-sugar paste. Torpedo rolls then curl the dough strips to seal in the cinnamon-andsugar filling. Next, a guillotine cuts the roll into individual pieces that are hand-placed into pans, racked and rolled into a proof box that is kept at 110°F and 95% relative humidity for 45 to 55 minutes.

New Products = New Equipment
When Skinner Baking Co. rolled out its branded muffin line, the company used existing capacity on its AutoBake line and other equipment. But the new product launch next year will likely be different. “Our next new product will involve a total expansion and new equipment,” said Audie Keaton, president of the Omaha, NE, company. “The lines we have now will support our growth, but we’re looking to add all-new lines with our new products.” As it expands its J. Skinner brand, the bakery plans to stay within its core competency of creating top-quality baked sweet goods, noted Gary Kyle, vice-president of marketing. “All of our products are born internally,” he said. “We have a gifted team of baking industry veterans who know what will work in the marketplace. Once we agree on a product or line of products, all departments take pricing into action. Recipes are created and tested, packaging design work begins, the purchasing department studies our commodity needs, and finance begins costing models. We are typically one year out on new product plans, so a lot of work and planning goes into every product launch.” Although the J. Skinner line currently has only 25 SKUs, Mr. Keaton said, the goal is to be the one-stop shop for the in-store bakery when it comes to baked sweet goods.

BAKING & SNACK / October 2011

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Baking&Snack - October 2011

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