Baking & Snack - August 2021 - 30
UNITED DAIRY FARMERS (UDF)
said. " The making of the donuts was the easy part. However,
we had vice presidents, family members and even spouses
helping us out because we had to pack and ship the donuts
to every store. "
Mr. Lindner noted that it took an all-hands-on-deck
approach to get the job done.
" Obviously, we had a deadline for when we were
transitioning from our supplier, " he said. " That was a
hard deadline for the transition, and by golly, everyone
pitched in and did yeoman's work to make that happen.
But that get-it-done attitude is not uncommon here. "
Before the brink of dawn
Overall, the bakery pumps out up to 30,000 donuts seven
days a week with a rotating days-off work schedule
that allows the nearly 30 employees to have at least one
weekend day off every other week.
" This allows us to maintain a more stable workforce, "
Mr. Lopez said.
In addition to Mr. Lopez, overseeing the day-to-day
operations are Daniel May, logistics and operations supervisor;
Tony Grote, production supervisor; Dennis
Fitch, chief engineer; James Allgeier, sanitation supervisor;
and Mark Wilson, human resources manager.
Production in the multi-functional, semi-automated
bakery runs on two staggered 8-hour shifts, starting at
3 a.m. followed by makeup and frying beginning around
4 a.m., and the remainder of the shift ramping up by 6
a.m. All products are shipped by mid-afternoon each
day on UDF-owned trucks, and an 8-hour sanitation
shift follows every evening. A Hildebrand tunnel washer
cleans its trays and other components.
Inside the temperature-controlled room with a filtration
system to purify the air, operators start producing a
small amount of cake donuts as they prepare for yeastraised
donut production. Typically,
it
takes about 70
minutes to make up and proof the yeast-raised dough.
Initially, two Escher spiral mixers turn out about a
dozen, 300-lb batches of dough daily. Production on
the versatile Rademaker USA makeup line starts with
Bismarks and Long Johns, which require a longer proofing,
followed by chocolate and iced donuts before a long
run of glazed donuts, cinnamon rolls and the kettle or
fried croissant dough variety.
After resting the yeast dough, an operator manually
chunks and feeds it onto a conveyor leading to a
sheeter on the makeup line. The sheet travels through
Top: After proofing, Long Johns travel through the fryer and flip
over halfway through the process.
Bottom: Dozens of freshly made yeast-raised donuts flow out of
the fryer and through an automatic glazer prior to being placed on
trays and racked.
30 Baking & Snack August 2021 / www.bakingbusiness.com
http://www.bakingbusiness.com
Baking & Snack - August 2021
Table of Contents for the Digital Edition of Baking & Snack - August 2021
Baking & Snack - August 2021 - Intro
Baking & Snack - August 2021 - 1
Baking & Snack - August 2021 - 2
Baking & Snack - August 2021 - vdg -1
Baking & Snack - August 2021 - vdg -2
Baking & Snack - August 2021 - 3
Baking & Snack - August 2021 - 4
Baking & Snack - August 2021 - 5
Baking & Snack - August 2021 - 6
Baking & Snack - August 2021 - 7
Baking & Snack - August 2021 - 8
Baking & Snack - August 2021 - 9
Baking & Snack - August 2021 - 10
Baking & Snack - August 2021 - 11
Baking & Snack - August 2021 - 12
Baking & Snack - August 2021 - 13
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Baking & Snack - August 2021 - 18
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