Baking & Snack - August 2022 - 46
consistency of the doughs just leveled out, " Mr. Benton
said. " When you have a human being scaling these ingredients,
they may make mistakes. The minors are really expensive
ingredients, but they are also really active ingredients.
You can't make mistakes with those ingredients. "
A sustainable renovation
As Flowers has grown its DKB business, it's looked for
bakeries that can take on production to support the
brand's blossoming popularity. Geographically, the
Lynchburg facility was in the perfect spot to add to the
DKB capacity from Tuscaloosa and support consumer
demand in the Northeast and mid-Atlantic regions. On
top of that, the bakery had a stable, high-quality workforce
already in place, which has only become more critical
in today's labor market.
" We could have gone to a bigger city and built a new
bakery, but the biggest hurdle with that plan is you have
to start with a workforce that doesn't know the bakery
business, " Mr. Benton explained. " We had a good management
team already here, and we only had to relocate
a few people. "
During the renovation, the workforce was furloughed,
and all but one returned to work when the bakery
opened, speaking to the loyalty Lynchburg's team has for
its bakery.
" The team you see today is mostly the same team that
started up the bakery, " Mr. Luciano explained.
Flowers acquired the building in 1978 from Kerns
and expanded and renovated it in 1981 to increase the
administrative offices and add a shipping area. The bakery
was producing Sunbeam bread and housed a small
Nature's Own bun line. The Sunbeam process is a continuous
mix line and converting to the DKB process required
a total renovation as well as retraining the staff on
the new process.
Robert Ray, vice president, network optimization, was
the project manager who oversaw the complete dismantling
and modernization process of the more-than-acentury
old facility.
" Due to its age, this was an incredibly complicated
project, " Mr. Benton commented. " Working with an accelerated
timeline, Robert did an outstanding job converting
an aging facility into a high-performing modern
bakery. "
In addition to installing new equipment to produce
DKB, Mr. Ray coordinated all of the day-to-day activiTop:
Bread loaves are sheeted, rolled and then seeded before
being panned for the proofer.
Bottom: The cooler brings down the temperature of dense DKB
bread loaves quickly and consistently, which ensures every loaf is
ready for slicing and packaging.
46 Baking & Snack August 2022 / www.bakingbusiness.com
http://www.bakingbusiness.com
Baking & Snack - August 2022
Table of Contents for the Digital Edition of Baking & Snack - August 2022
Baking & Snack - August 2022 - Intro
Baking & Snack - August 2022 - 1
Baking & Snack - August 2022 - 2
Baking & Snack - August 2022 - FCa
Baking & Snack - August 2022 - FCb
Baking & Snack - August 2022 - 3
Baking & Snack - August 2022 - 4
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Baking & Snack - August 2022 - VDGa
Baking & Snack - August 2022 - VDGb
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