Baking & Snack - May 2019 - 36
PAN PEPIN
"We were able to add a lot
of capacity and just add a
few people to the line."
Mario Somoza, Pan Pepin
After running through
a two-pocket divider
and rounder, dough
balls are dusted with
flour before heading to
the sheeter-moulderpanner system.
Although the timeline experienced just a minor setback,
the installation was not without its hurdles. Perseverance
and partnership from the vendors as well as Ron Foster, the
Dallas-based third-party installer, were about the only ways
to survive an install without electricity.
The entire high-tech, fully automated bread line
was installed solely on backup generators. In fact,
when Pan Pepin celebrated the facility's grand opening, several areas, including parts of Bayamon, were
still without power, even though it had been more
than a year since the hurricanes. The lights - and
line - turned on just in time to do the testing and
training before the bakery officially started up. "That
was in November 2018," Mr. Somoza said. "We started
up the day after the opening, and we've been running
ever since."
Putting it on automatic
Pan Pepin was running at 90% capacity when the
master plan began, and although the expansion was
based on that need as well as the need to replace the
company's original bread line, efficiency became a
natural byproduct.
"One thing we discussed at the outset was moving
the volume products to this line so we can minimize
changeovers and make it as efficient as possible,"
36 Baking & Snack May 2019 / www.bakingandsnack.com
Mr. Somoza said. This way, the older lines would focus on smaller-volume and variety products.
The automated line also helped solve workforce issues. While many old-school bakers remained on the
older lines where products are still made with more
manual processes, the company strategically moved
a few workers who showed interest in tackling new
technology to the new line, where output speeds can
reach up to 150 loaves per minute over a 7-hour process. "We were able to add a lot of capacity and just
add a few people to the line," Mr. Somoza said. "It's almost tripled the capacity that we had on the old line,
but we didn't have to triple the staffing."
Running three products on one pan - white,
whole grain white and whole wheat - the bakery
boasts some of the most modern technology in the industry today; that's obvious before anyone steps foot
in the building. Towering outside stand Shick Esteve's
two 50,000-lb white whole grain flour silos and two
100,000-lb standard white flour silos that signal to all
who enter big things are ahead.
The company's first Shick Esteve system also includes two tanks for liquids, a super sack system for
the whole wheat flour and a bag dump station for minors, all new technology for Pan Pepin. This system
has helped streamline the bakery's method of bread
http://www.bakingandsnack.com
Baking & Snack - May 2019
Table of Contents for the Digital Edition of Baking & Snack - May 2019
Baking & Snack - May 2019
Contents
Contents
Editorial - Reflection on a legend
Newsfront - Kind highlights ‘hidden’ sweeteners in popular snacks
Mondelez to partner with food business incubator
News - Bundy Baking Solutions launches new company
Warburtons establishes apprenticeship program
Study disputes negative claims of refined grains
Venture capital fund takes stake in bar maker
In Memoriam
People/In Brief
Food Safety Series - Let's Talk FSMA
Pan Pepin - SURVIVAL OF THE FITTEST
What’s the next big thing in Puerto Rico?
In times of trouble, the baking industry rallies
Fringe Baking - BEYOND THE BROWNIE
An evolving consumer base
Sweeteners - Stacking the Sweet
Dairy and Eggs - Farm Fresh Convenience
TECHNICALLY SPEAKING - REASSESS AND REDUCE
Specialty Bread - CREATING THAT SPECIAL BOND
Saving money with precision seeding
Specialty baking sprouts opportunities
Ingredient Handling - GOING THE DISTANCE
Co-extrusion - FILLED TO THE BRIM
Flexibility to innovate
Startups - TIPS FOR A SMOOTH STARTUP
Starting with a clean slate
Wrappers - NO FILM LEFT BEHIND
A wrapper’s seal of approval
Route Accounting - Kill the Chaos
INDUSTRY INSIGHT - NOT-SO-EASY LIVIN'
Industry Images - DISCOVERIES MADE
Meeting Preview - A WORLD OF OPPORTUNITY
Tour bakeries around the world
Events
Featured Innovation Center
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
Baking & Snack - May 2019 - Baking & Snack - May 2019
Baking & Snack - May 2019 - Baking & Snack - May 2019
Baking & Snack - May 2019 - 2
Baking & Snack - May 2019 - FC - 1
Baking & Snack - May 2019 - FC - 2
Baking & Snack - May 2019 - 3
Baking & Snack - May 2019 - 4
Baking & Snack - May 2019 - 5
Baking & Snack - May 2019 - 6
Baking & Snack - May 2019 - 7
Baking & Snack - May 2019 - 8
Baking & Snack - May 2019 - Contents
Baking & Snack - May 2019 - 10
Baking & Snack - May 2019 - Contents
Baking & Snack - May 2019 - Editorial - Reflection on a legend
Baking & Snack - May 2019 - Newsfront - Kind highlights ‘hidden’ sweeteners in popular snacks
Baking & Snack - May 2019 - Mondelez to partner with food business incubator
Baking & Snack - May 2019 - 15
Baking & Snack - May 2019 - Study disputes negative claims of refined grains
Baking & Snack - May 2019 - 17
Baking & Snack - May 2019 - In Memoriam
Baking & Snack - May 2019 - 19
Baking & Snack - May 2019 - People/In Brief
Baking & Snack - May 2019 - 21
Baking & Snack - May 2019 - 22
Baking & Snack - May 2019 - Food Safety Series - Let's Talk FSMA
Baking & Snack - May 2019 - 24
Baking & Snack - May 2019 - 25
Baking & Snack - May 2019 - 26
Baking & Snack - May 2019 - 27
Baking & Snack - May 2019 - 28
Baking & Snack - May 2019 - 29
Baking & Snack - May 2019 - Pan Pepin - SURVIVAL OF THE FITTEST
Baking & Snack - May 2019 - 31
Baking & Snack - May 2019 - 32
Baking & Snack - May 2019 - 33
Baking & Snack - May 2019 - What’s the next big thing in Puerto Rico?
Baking & Snack - May 2019 - 35
Baking & Snack - May 2019 - 36
Baking & Snack - May 2019 - 37
Baking & Snack - May 2019 - In times of trouble, the baking industry rallies
Baking & Snack - May 2019 - 39
Baking & Snack - May 2019 - 40
Baking & Snack - May 2019 - 41
Baking & Snack - May 2019 - 42
Baking & Snack - May 2019 - 43
Baking & Snack - May 2019 - 44
Baking & Snack - May 2019 - Fringe Baking - BEYOND THE BROWNIE
Baking & Snack - May 2019 - 46
Baking & Snack - May 2019 - 47
Baking & Snack - May 2019 - An evolving consumer base
Baking & Snack - May 2019 - 49
Baking & Snack - May 2019 - 50
Baking & Snack - May 2019 - 51
Baking & Snack - May 2019 - 52
Baking & Snack - May 2019 - 53
Baking & Snack - May 2019 - 54
Baking & Snack - May 2019 - Sweeteners - Stacking the Sweet
Baking & Snack - May 2019 - 56
Baking & Snack - May 2019 - 57
Baking & Snack - May 2019 - 58
Baking & Snack - May 2019 - 59
Baking & Snack - May 2019 - 60
Baking & Snack - May 2019 - 61
Baking & Snack - May 2019 - 62
Baking & Snack - May 2019 - 63
Baking & Snack - May 2019 - 64
Baking & Snack - May 2019 - Dairy and Eggs - Farm Fresh Convenience
Baking & Snack - May 2019 - 66
Baking & Snack - May 2019 - 67
Baking & Snack - May 2019 - 68
Baking & Snack - May 2019 - 69
Baking & Snack - May 2019 - 70
Baking & Snack - May 2019 - 71
Baking & Snack - May 2019 - 72
Baking & Snack - May 2019 - 73
Baking & Snack - May 2019 - 74
Baking & Snack - May 2019 - TECHNICALLY SPEAKING - REASSESS AND REDUCE
Baking & Snack - May 2019 - 76
Baking & Snack - May 2019 - 77
Baking & Snack - May 2019 - 78
Baking & Snack - May 2019 - Specialty Bread - CREATING THAT SPECIAL BOND
Baking & Snack - May 2019 - 80
Baking & Snack - May 2019 - 81
Baking & Snack - May 2019 - Saving money with precision seeding
Baking & Snack - May 2019 - 83
Baking & Snack - May 2019 - 84
Baking & Snack - May 2019 - 85
Baking & Snack - May 2019 - 86
Baking & Snack - May 2019 - 87
Baking & Snack - May 2019 - 88
Baking & Snack - May 2019 - 89
Baking & Snack - May 2019 - Specialty baking sprouts opportunities
Baking & Snack - May 2019 - 91
Baking & Snack - May 2019 - 92
Baking & Snack - May 2019 - Ingredient Handling - GOING THE DISTANCE
Baking & Snack - May 2019 - 94
Baking & Snack - May 2019 - 95
Baking & Snack - May 2019 - 96
Baking & Snack - May 2019 - 97
Baking & Snack - May 2019 - 98
Baking & Snack - May 2019 - 99
Baking & Snack - May 2019 - 100
Baking & Snack - May 2019 - 101
Baking & Snack - May 2019 - 102
Baking & Snack - May 2019 - Co-extrusion - FILLED TO THE BRIM
Baking & Snack - May 2019 - 104
Baking & Snack - May 2019 - 105
Baking & Snack - May 2019 - Flexibility to innovate
Baking & Snack - May 2019 - 107
Baking & Snack - May 2019 - 108
Baking & Snack - May 2019 - 109
Baking & Snack - May 2019 - 110
Baking & Snack - May 2019 - 111
Baking & Snack - May 2019 - 112
Baking & Snack - May 2019 - Startups - TIPS FOR A SMOOTH STARTUP
Baking & Snack - May 2019 - Starting with a clean slate
Baking & Snack - May 2019 - 115
Baking & Snack - May 2019 - 116
Baking & Snack - May 2019 - 117
Baking & Snack - May 2019 - 118
Baking & Snack - May 2019 - Wrappers - NO FILM LEFT BEHIND
Baking & Snack - May 2019 - A wrapper’s seal of approval
Baking & Snack - May 2019 - 121
Baking & Snack - May 2019 - 122
Baking & Snack - May 2019 - 123
Baking & Snack - May 2019 - 124
Baking & Snack - May 2019 - 125
Baking & Snack - May 2019 - 126
Baking & Snack - May 2019 - Route Accounting - Kill the Chaos
Baking & Snack - May 2019 - 128
Baking & Snack - May 2019 - 129
Baking & Snack - May 2019 - 130
Baking & Snack - May 2019 - INDUSTRY INSIGHT - NOT-SO-EASY LIVIN'
Baking & Snack - May 2019 - 132
Baking & Snack - May 2019 - Industry Images - DISCOVERIES MADE
Baking & Snack - May 2019 - 134
Baking & Snack - May 2019 - 135
Baking & Snack - May 2019 - 136
Baking & Snack - May 2019 - 137
Baking & Snack - May 2019 - 138
Baking & Snack - May 2019 - Meeting Preview - A WORLD OF OPPORTUNITY
Baking & Snack - May 2019 - Tour bakeries around the world
Baking & Snack - May 2019 - 141
Baking & Snack - May 2019 - Events
Baking & Snack - May 2019 - 143
Baking & Snack - May 2019 - 144
Baking & Snack - May 2019 - 145
Baking & Snack - May 2019 - Featured Innovation Center
Baking & Snack - May 2019 - 147
Baking & Snack - May 2019 - Ingredients & Formulating
Baking & Snack - May 2019 - 149
Baking & Snack - May 2019 - 150
Baking & Snack - May 2019 - 151
Baking & Snack - May 2019 - Equipment & Packaging
Baking & Snack - May 2019 - 153
Baking & Snack - May 2019 - 154
Baking & Snack - May 2019 - 155
Baking & Snack - May 2019 - Patents
Baking & Snack - May 2019 - 157
Baking & Snack - May 2019 - New on the Shelf
Baking & Snack - May 2019 - 159
Baking & Snack - May 2019 - 160
Baking & Snack - May 2019 - 161
Baking & Snack - May 2019 - 162
Baking & Snack - May 2019 - 163
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Baking & Snack - May 2019 - 172
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