Baking & Snack - October 2021 - 38

UTZ BRANDS, INC.
core products and the company grew geographically
" BEHIND THE CURTAIN, WE GET THE
PRODUCT TO WHERE IT NEEDS TO
BE. WE'RE UNDERSTANDING OUR
NETWORK BETTER AS WE HAVE
GOTTEN BIGGER. "
Brian Greth, Utz Brands
while venturing into new snack categories over the years.
" It was a fun time for everyone because we were
growing constantly, and you don't realize what you accomplished
until you're done and look back at it and see
what everyone within the company built and how big it
became during that period, " Mr. Livelsberger observed.
At the High Street plant, more than 20 trucks arrive
daily, each carrying nearly 50,000 lbs of potatoes.
They feed the five potato chip lines that together produce
more than 17,000 lbs an hour. Dusty Lehr, plant
manager, noted a Spudnik sorter separates the large
potatoes from small ones with the bigger potatoes feeding
family-pack lines while the little ones go to small
bag operations.
After sorting, the potatoes enter a peeler to remove
the potato skin using a material like an " industrial grade
sandpaper, " Mr. Lehr said. Then the potatoes enter a rotor
slicing system, which uses a measuring system to
ensure thin slivers of potatoes are cut consistently to
1/1,000 of an inch.
After rinsing off excess starch that would have created
a darker, less tender chip, the potatoes fry for 2 to 7 minutes
and are salted immediately afterward so that some
of the flavor is immediately absorbed into the chips.
Mr. Lehr noted that a Key Technology optical sorter
then purges chips with blemishes beyond product specifications
before they enter the updated Heat and Control
turnkey system that includes conveyance to the seasoning
area and then the packaging department including
Mettler Toledo metal detection.
On an upper level, the chips travel along a FastBack
horizontal motion conveyor that feeds them to multiple
seasoning systems. Mr. Lehr said the systems monitor
the amount of chips entering the seasoner to ensure the
precise amount is applied to the chips to obtain the optimum
flavor. The chips then enter Ishida scales that precisely
weigh the amount of chips for the vertical form/
fill/seal bags below.
After forming, filling and sealing, the bags are casepacked
for DSD distribution in reusable boxes or in
tape-sealed cases for warehouse distribution before palletizing
and traveling to the distribution center.
Technology for the future
Mr. Lehr showed off the plant's new robotic system that
automates the normally labor-intensive variety pack
Top: The company produces a wide variety of potato chips that
come in dozens of different flavors and are available under Utz,
Zapp's and other brands.
Bottom: One of four Hanover, Pa., snack plants produces its multiple
types of pretzels that are sold nationally under the Utz brand.
38 Baking & Snack October 2021 / www.bakingbusiness.com
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Baking & Snack - October 2021

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