Baking&Snack - April 2012 - 40

ALESSI BAKERIES

Production of its tres leches and other premium desserts at Alessi Bakeries often combines automation and labor-intensive work.
Alessi Bakeries

Specifically, the bakery plans to make strategic equipment purchases and adjust its approach to scheduling by combining production runs to increase capacity, make new products and enhance efficiency in a way that

lowers the production costs per unit. “We won’t sacrifice quality,” he noted. “I don’t look at cheapening our products. I look at cost-reducing them. That’s everybody’s mentality. Our motto is, ‘Where quality ruled since 1912,’ and that’s something we live by.” About 120 employees work in the wholesale operation on a single shift, starting at 5:30 a.m. five days a week. All batches are assembled by hand either first thing in the morning or sometimes the previous day, especially for long-run products such as tres leche cakes. Four 140-qt Hobart spiral mixers create small batches that can provide better front-end control, according to Mr. Alessi Jr. The bakery uses four steam-jacketed, 240-qt kettles for making icings, fillings or even freshly brewed coffee for tiramisu. Depending on the product, the operation relies on a battery of de-

positors and icing machines, including a Polin depositor and a Fedco waterfall icing system. Alessi Bakeries plans to upgrade its depositing capabilities to reduce handwork and minimize waste, which now stands at 2.5%. It’s adding an enrober for a new product later this year, Mr. Alessi Jr. said. The bakery also uses a Hayon pan greaser and installed a Douglas Machines pan washing system that cleans 20 trays a minute. The 2-lane, continuous-cleaning tunnel washer includes a special gasheated, water-saving design, according to Kevin Lemen, vice-president at Douglas Machines. It features a recirculating wash tank, recirculating rinse tank, a final sanitizing rinse section and a high-pressure blow-off module. The system’s modified lanes can hold up to 3.5-in.-deep pans for added versatility.

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CALL 800-331-6870

for pricing, literature and specifications on a model suited to your needs.
2101 CALUMET ST. • CLEARWATER, FL 33765 • (727) 461-3477 (800) 331-6870 • FAX (727) 449-0029 • www.dougmac.com

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Baking&Snack - April 2012

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