Baking & Snack - August 2018 - 38
were such a vital ingredient in making its
cakes, and it needed an affordable, dependable supply to remain competitive in the
market. Today, that farm supplies 85% of the
company's eggs, and it's committed to cagefree breeding of its 500,000 hens within the
next five years. "We wanted to supply a key
raw material that had a good quality and low
price," Mr. Juan explained.
To further secure its supply chain, it also began making its own chocolate, another primary ingredient, and even purchased a packaging
company to expedite new product expansion
and speed to market. "It's very important because we have so many different types of packaging, and it allows us to be flexible and change
packaging very quickly to react to the market
in an affordable way," he observed.
Because Mr. Juan believes in continuous improvement throughout the organization, there are no sacred cows, even when it
comes to the products' most popular formulas. Dulcesol may "take care of its recipes,"
but that doesn't prevent it from changing
them for the better.
Take fairy cakes like the Glorias, perhaps
the most emblematic sweet good of the region. They're often compared to Americanstyle cupcakes, but they're smaller, lighter
and slightly less sweet. Additionally, fairy
cakes may be drizzled with buttercream icing. It's also a simple formula. They typically
contain butter, self-rising flour, sugar, eggs,
milk and vanilla, coconut or another flavor.
"The fairy cakes that we produce today are
similar to what we produced 5 or 10 years
ago, but we made small changes by adding
new technology in the plant that improved
the product over time," Mr. Juan said.
"The cakes are fairly easy to produce,"
he continued. "The difficulty is in producing 85,000 cakes an hour in our plant, then
individually wrapping all of them in a process that gives them a longer shelf life (about
2 months) and preserves their quality."
As a result, product development has become increasingly multidimensional. Mr.
Juan pointed out that R&D comprises more
Above: Buns pass through a combination of seeders, flour
dusters and water sprayers to produce a variety of products.
Below: Vacuum-batch mixing is one of the keys to producing
consistent buns on the high-speed production line.
Sosland Publishing Company
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