Baking&Snack - June 2012 - 34

J.S.B. INDUSTRIES

Training goes viral

Keeping staffers at J.S.B. Industries, Chelsea and Lawrence, MA, up to date on their skills involves continual training efforts. And increasingly, the training takes place via the Internet. The company’s corporate trainer takes every new hire through video instruction in Good Manufacturing Practices (GMPs), Hazard Analysis Critical Control Points (HACCP), food and employee safety, and a variety of similar programs. Then, the new staff member shadows a supervisor for a week to learn daily tasks on the job. The Anderson family recently gave Roger Piffer, J.S.B.’s e-commerce marketing director, a new assignment: to create a TV channel on the Web with company videos. “These are for the employees to watch, he explained. “We monitor their use of these materials, which are ” offered in multiple languages, including Spanish and Portuguese. ” He is exploring use of mobile apps that run on smartphones and tablets. “We are constantly training, Mr. Piffer said. “The more videos available, the better the ” training and the better the products that we provide our customers. ”

selection of the Veropack system, while accuracy in batter portioning that avoids spillage or tailing led to the choice of the Hinds-Bock depositor. A Mallet & Co. targeted spray system handles pan release oils. The high-tech approach continued with the choice of an ABB robotic product removal system. The end result is a minimal number of personnel in the baking area.

High volume, high speed
“This building is intended to do long runs and mass production while Chelsea is better at handling frequent changeovers,” Scott explained. “Anything we can make here, we can still make at Chelsea, but our efficiencies and labor costs are more favorable at Lawrence. The new line has been everything we expected and more.” J.S.B. sets its SKU threshold at 2,000 cases and schedules production at the new bakery for 1,500 to 2,000 cases per 8-hour shift. The bakery receives its eggs and vegetable oils in bulk tank totes that automatically dispense on call to the E.T. Oakes slurry mixer. The line operator adds Winona patent flour from Bay State Milling and Pillsbury bases as required. After mixing, the system pumps the batter to holding tanks that feed the depositor.

New “clipless” pans fit securely onto conveying mechanisms, even when inverted during washing and drying. At 155 ft long and 6 ft, 4 in. wide, the Auto-Bake line carries 505 pans, with 124 in the oven at any given time. Hourly output ranges from 24,000 muffin tops (3,250 lb) to 38,000 snack loaves (5,120 lb). Baking time is 16 to 30 minutes, depending on product type and size. The control system synchronizes the ancillary release oil sprayer, paper cup inserter and batter depositor. The operator needs only to push the start button. Pans filled with batter travel a serpentine path, back and forth,

/ Baking & Snack / June 2012

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Baking&Snack - June 2012

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