Baking&Snack - October 2013 - 32

RUDI’S GLUTEN-FREE

Because of the glutenfree dough’s consistency,
operators slide a five-strap
pan back and forth so that
the dough piece lies in the
center of each pan. Proper
depositing is key to making
consistent products.

applied, and the product passes through a Safeline metal
detector before manual casepacking. A Videojet printer
adds production information and logos to the cases.
Black “popcorn” spacers (sheets of black plastic with
bubbles) are placed between each level of cases as the
pallets are built. The spacers allow the products to freeze
quickly and evenly. Every four hours, two shuttles take
the pallets to an off-site holding freezer.
“Our learning curve was gradual, just like we did with
organic,” Mr. Holm said. “We started out pretty manual
then figured out the best way to automate production
without compromising on the quality.”

In the gluten-free bakery, that means automation
started in the packaging area and is working its way
back to the divider. “Dividing will be the last thing we
automate because it’s so hard to do, and it’s so critical
to the quality of the final product,” he noted. “We don’t
want to lose control of the process.”
Automating will double the bakery’s capacity. Rudi’s
plans to add five double-rack ovens as demand warrants.
Mr. Holm estimated the gluten-free operation has three
years of capacity before it needs to be expanded. “We’re
a slow-growth-curve organization,” he said. “We want to
make sure we get an ROI before we invest more.”

What’s next for Rudi’s?
In four years, Ms. Miller said she expects Rudi’s will double the size of its current business again. Why so bullish?
Three strategic initiatives drive sales. First, Rudi’s plans
to work closely with its natural food customers — its
core business — to custom design products and develop
marketing programs that have big growth potential.
The second plank involves broadening its reach in
conventional supermarket channels. Third, Rudi’s wants
to be a product leader in the natural, gluten-free and
organic arenas with more tortillas, soft pretzels, sweet
goods and even snacks. Today, bread comprises 85% of
Rudi’s revenues. “My guess is that in four years, bread
may account for 25% of our business,” she said.
Recently, the company added seeded and sprouted
breads. “Based on some extensive consumer research,
we know that the Rudi’s name is such a great platform
for expanding into other products,” Ms. Miller added.
That’s thinking on the bright side.

•

Pan &
Product
Systems

INNO•BAKE•TION
CUTTING EDGE SOLUTIONS FOR THE INDUSTRIAL BAKER

PALSUS Pan & Lid
Stacker – Unstacker
• 70% Fewer Moving Parts than Conventional Magnetic Units
for Reduced Maintenance
• “Soft Touch” End-of-Arm-Tool for Quieter, More Gentle Pan
Handling
• Handles Multiple Bread
or Bun Pans at one
time for Smoother
Operation at Higher
Speeds
• Direct Replacement
of Conventional Units
with Minimal Layout
Modiﬁcation

/ Baking & Snack / October 2013

WWW.AMFBAKERY.COM
AMF is a Markel Bakery Group Company
For more information, see Page 113

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Baking&Snack - October 2013

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