Baking&Snack - July 2013 - 21

OPERATIONS
ACE Bakery

-in-class technology
Toronto-based ACE Bakery opens its new Gaffney, SC, facility with best
to serve growing US demand for par-baked breads.
by building a tiny backyard bakehouse at Caledon, ON.
Over the next several years, they visited artisan bakeries throughout North America and Europe, researching
methods and experimenting extensively.
That passion prompted the husband-and-wife team
to open to the public in 1993, establishing ACE Bakery
in Toronto. Demand grew, and the bakery did, too. It
moved into a larger facility in North York, ON, during 1997. Two years later, par-baked baguettes joined
the roster to meet the needs of in-store bakery clients.
Demand rose even higher as the company entered foodservice channels. In 2009, ACE opened an automated
facility at Vaughan to produce par-baked breads. The
company became part of Weston in 2010.
Vaughan paved the way for Gaffney. Less than 20 km
(about 12½ miles) from ACE’s fresh facility in Toronto,
the Vaughan bakery created a new paradigm for the
company. To achieve the high volume of par-baked
products that its business forecasts
predicted, the company
adopted automated systems that maintained
the characteristics of its
manual methods.

Brian Sisson, ACE’s vice-president of operations,
and company engineers thoroughly studied mixing,
makeup, proofing, baking and freezing options. They
did a massive amount of research to address the notoriously difficult problem of handling artisan doughs in
automated fashion. They sought best-in-class European
and North American technology. Everything they saw
indicated sheeting would be the way to go to prepare
artisan-quality breads.
“In 2004, we installed the first Fritsch sheeting line
in North America that made baguettes,” Mr. Sisson recalled. “We got into automatic proofing technology with
Gouet [now part of Mecatherm].
“We went to Europe several times to test ovens,” he
continued. “We knew we wanted
a stone-hearth sys-

Baked to 85% of finished state,
baguettes exit the oven. ACE’s
customers complete the baking
to ensure fresh flavor and
authentic taste.
ACE Bakery LLC

July 2013 / Baking & Snack / 21



Baking&Snack - July 2013

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