Baking & Snack - April 2019 - 36

LECLERC FOODS

addition to this production line, a Cavanna Packaging
buffer system and flowwrappers. The first-in-first-out
buffer system creates space between production and
packaging departments, allowing for inevitable packaging events without slowing down production. Bars enter
the buffer system to be stored and are then retrieved by
the flowwrappers as they are ready to receive product.
With four decks, the buffer can store 8 minutes worth of
product without taking too much floorspace.
Without the buffer in place, the plant would need a
third backup wrapping lane and cartoner to prevent production interruptions. Costly downtime that could get
passed to the customer isn't a place Leclerc was willing
to compromise, and the buffer system frees the company
from having to make it. "Starting and stopping production is a domino effect, so our goal is to keep production moving at all times, even if it's at half speed, and the
buffer enables this," Mr. Carroll explained. "It's a necessity. The quicker you can provide product, the better the
profit margins are. Granola bars aren't a product with
big profit margins, so the volume of it helps us pad that
bottom line."
The buffer feeds two Cavanna flowwrappers that deliver product to a Cavanna cartoner. When designing the
packaging department, Leclerc wanted a compact footprint that only needed one operator. The slim, high-speed
wrapping system fits in half the space. Laid out in an
L-shape, the entire system can be managed by one person.
The flowwrappers feature auto-tracking that ensures
the film is perfectly aligned on the product. A scanner
checks the bar code on the packaging against the HMI
system's record of what bar is coming off the line. This
check prevents product from being wrapped in the
wrong film. The wrappers can run at a nominal speed of
1,000 bars per minute or a recovery speed of 1,100 bars
per minute.
After being individually wrapped, bars are inspected
by a Thermo X-ray machine at a speed of 600 bars per
minute. Because the film is metallized, metal detectors
inspect the product as it enters the wrappers. Once bars
are inspected, they head into the cartoner where two robots fill and seal cartons.
Pallets of finished product are stored in the automated warehouse, ready to be picked up by customers or
shipped to customers or the Leclerc distribution hub in
Pennsylvania.
Installed in 2010, the automated warehouse is another area Leclerc has found new technology to be a
boon. After seeing how successful automated warehousing was in other Leclerc facilities, Kingsport made the
leap, too. The 70,000-sq-ft space houses finished product
and ingredients. Automated cranes and forklifts hurry
down the aisles to fetch and store ingredients or finished

36 Baking & Snack April 2019 / www.bakingandsnack.com

"We're always trying to be
ahead of everybody and
find out what's new and
what can we get before
everybody else."
Lyne Normand, Leclerc Foods

Early adopting for better operations
In general, the baking industry has not
been quick to embrace new technology,
but that's not the case for Leclerc Foods.
For as long as Jeremy Carroll, plant
manager of the Kingsport, TN, facility,
and Lyne Normand, vice-president,
quality for US operations, can remember, Leclerc has always been quick to try
new technology.
"I think it's the Leclerc way," Ms.
Normand said. "We're always trying
to be ahead of everybody and find out
what's new and what can we get before
everybody else."
This affinity for the latest and greatest
isn't just for show, however. It's driven by
a need to constantly improve. This need
has been the heart of many investments
made at the Kingsport facility: an automated warehouse for improved control
and reduced labor, a packaging system
that prevents production slow-downs and
streamlines the department, the POKA
training tool and quality control app,
iPads for every employee. These innovations and investments have improved
Leclerc's product quality, production efficiency and worker safety.
Ms. Normand is constantly on the
lookout for ways they can improve
production, food safety, quality control
and worker safety. "If it can be done,
we'll look into it," she said. "What technology can we use to decrease the risk
of fruit flies? We're looking into how we
can use portable metal detectors, UV
lights, different IoTs. We're always open
to any suggestions."


http://www.bakingandsnack.com

Baking & Snack - April 2019

Table of Contents for the Digital Edition of Baking & Snack - April 2019

Baking&Snack - April 2019
Contents
Contents
Editorial - Bread and butterflies
Newsfront - Grupo Bimbo, Kellogg, PepsiCo recognized for ethics
Walmart taking steps to drive grocery business
ADM, Cargill launch digital grain marketing venture
Global Bakeries expands in sweet goods category
News - RBS partners with Belgian snack systems supplier
Corbion to acquire Brazilian bakery ingredient company
In Memoriam
People/In Brief
Health & Wellness - HEALTH KICK
Are package callouts still effective?
Leclerc Foods - BAKING without compromise
Early adopting for better operations
Brand Loyalty - Digital DISCIPLES
Share it, and they will follow
Starches - DEMYSTIFYING THE MAGIC
Getting away from gluten
Fats & Oils - AN EXPANDED BOX
Collaborating to innovate
SANITATION STRATEGIES - REVISITING GOLDEN RULES
Cookie Processing - Cookie conundrums
Ovens - OPTIMIZED BAKING
Constructed for efficiency
Baking under pressure
Conveying - no STOPPING it now
Keeping the conveyor belt clean
Maximizing Efficiency - IN THE ZONE
Nothing fake about AI’s potential
Secondary Packaging - THINK INSIDE THE box
Industry Images - THE FUTURE IS NOW
Meeting Preview - FOUNTAIN OF KNOWLEDGE
Events
Featured Innovation Center
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
MARKETPLACE
AD INDEX
Baking & Snack - April 2019 - Baking&Snack - April 2019
Baking & Snack - April 2019 - Baking&Snack - April 2019
Baking & Snack - April 2019 - 2
Baking & Snack - April 2019 - 3
Baking & Snack - April 2019 - 4
Baking & Snack - April 2019 - 5
Baking & Snack - April 2019 - 6
Baking & Snack - April 2019 - 7
Baking & Snack - April 2019 - 8
Baking & Snack - April 2019 - Contents
Baking & Snack - April 2019 - 10
Baking & Snack - April 2019 - Editorial - Bread and butterflies
Baking & Snack - April 2019 - 12
Baking & Snack - April 2019 - 13
Baking & Snack - April 2019 - 14
Baking & Snack - April 2019 - 15
Baking & Snack - April 2019 - Global Bakeries expands in sweet goods category
Baking & Snack - April 2019 - 17
Baking & Snack - April 2019 - In Memoriam
Baking & Snack - April 2019 - 19
Baking & Snack - April 2019 - People/In Brief
Baking & Snack - April 2019 - 21
Baking & Snack - April 2019 - 22
Baking & Snack - April 2019 - Health & Wellness - HEALTH KICK
Baking & Snack - April 2019 - Are package callouts still effective?
Baking & Snack - April 2019 - 25
Baking & Snack - April 2019 - 26
Baking & Snack - April 2019 - 27
Baking & Snack - April 2019 - 28
Baking & Snack - April 2019 - 29
Baking & Snack - April 2019 - 30
Baking & Snack - April 2019 - Leclerc Foods - BAKING without compromise
Baking & Snack - April 2019 - 32
Baking & Snack - April 2019 - 33
Baking & Snack - April 2019 - 34
Baking & Snack - April 2019 - 35
Baking & Snack - April 2019 - Early adopting for better operations
Baking & Snack - April 2019 - 37
Baking & Snack - April 2019 - 38
Baking & Snack - April 2019 - 39
Baking & Snack - April 2019 - 40
Baking & Snack - April 2019 - 41
Baking & Snack - April 2019 - 42
Baking & Snack - April 2019 - 43
Baking & Snack - April 2019 - 44
Baking & Snack - April 2019 - Brand Loyalty - Digital DISCIPLES
Baking & Snack - April 2019 - Share it, and they will follow
Baking & Snack - April 2019 - 47
Baking & Snack - April 2019 - 48
Baking & Snack - April 2019 - 49
Baking & Snack - April 2019 - 50
Baking & Snack - April 2019 - 51
Baking & Snack - April 2019 - Starches - DEMYSTIFYING THE MAGIC
Baking & Snack - April 2019 - 53
Baking & Snack - April 2019 - 54
Baking & Snack - April 2019 - 55
Baking & Snack - April 2019 - Getting away from gluten
Baking & Snack - April 2019 - 57
Baking & Snack - April 2019 - 58
Baking & Snack - April 2019 - Fats & Oils - AN EXPANDED BOX
Baking & Snack - April 2019 - 60
Baking & Snack - April 2019 - 61
Baking & Snack - April 2019 - 62
Baking & Snack - April 2019 - 63
Baking & Snack - April 2019 - 64
Baking & Snack - April 2019 - 65
Baking & Snack - April 2019 - Collaborating to innovate
Baking & Snack - April 2019 - 67
Baking & Snack - April 2019 - 68
Baking & Snack - April 2019 - SANITATION STRATEGIES - REVISITING GOLDEN RULES
Baking & Snack - April 2019 - 70
Baking & Snack - April 2019 - Cookie Processing - Cookie conundrums
Baking & Snack - April 2019 - 72
Baking & Snack - April 2019 - 73
Baking & Snack - April 2019 - 74
Baking & Snack - April 2019 - 75
Baking & Snack - April 2019 - 76
Baking & Snack - April 2019 - 77
Baking & Snack - April 2019 - 78
Baking & Snack - April 2019 - Ovens - OPTIMIZED BAKING
Baking & Snack - April 2019 - Constructed for efficiency
Baking & Snack - April 2019 - 81
Baking & Snack - April 2019 - 82
Baking & Snack - April 2019 - 83
Baking & Snack - April 2019 - Baking under pressure
Baking & Snack - April 2019 - 85
Baking & Snack - April 2019 - 86
Baking & Snack - April 2019 - 87
Baking & Snack - April 2019 - 88
Baking & Snack - April 2019 - 89
Baking & Snack - April 2019 - 90
Baking & Snack - April 2019 - 91
Baking & Snack - April 2019 - 92
Baking & Snack - April 2019 - 93
Baking & Snack - April 2019 - 94
Baking & Snack - April 2019 - Conveying - no STOPPING it now
Baking & Snack - April 2019 - 96
Baking & Snack - April 2019 - 97
Baking & Snack - April 2019 - Keeping the conveyor belt clean
Baking & Snack - April 2019 - 99
Baking & Snack - April 2019 - 100
Baking & Snack - April 2019 - 101
Baking & Snack - April 2019 - 102
Baking & Snack - April 2019 - Maximizing Efficiency - IN THE ZONE
Baking & Snack - April 2019 - Nothing fake about AI’s potential
Baking & Snack - April 2019 - 105
Baking & Snack - April 2019 - 106
Baking & Snack - April 2019 - 107
Baking & Snack - April 2019 - 108
Baking & Snack - April 2019 - Secondary Packaging - THINK INSIDE THE box
Baking & Snack - April 2019 - 110
Baking & Snack - April 2019 - 111
Baking & Snack - April 2019 - 112
Baking & Snack - April 2019 - 113
Baking & Snack - April 2019 - 114
Baking & Snack - April 2019 - Industry Images - THE FUTURE IS NOW
Baking & Snack - April 2019 - 116
Baking & Snack - April 2019 - 117
Baking & Snack - April 2019 - 118
Baking & Snack - April 2019 - 119
Baking & Snack - April 2019 - 120
Baking & Snack - April 2019 - 121
Baking & Snack - April 2019 - 122
Baking & Snack - April 2019 - Meeting Preview - FOUNTAIN OF KNOWLEDGE
Baking & Snack - April 2019 - Events
Baking & Snack - April 2019 - 125
Baking & Snack - April 2019 - 126
Baking & Snack - April 2019 - 127
Baking & Snack - April 2019 - Featured Innovation Center
Baking & Snack - April 2019 - 129
Baking & Snack - April 2019 - Ingredients & Formulating
Baking & Snack - April 2019 - 131
Baking & Snack - April 2019 - 132
Baking & Snack - April 2019 - 133
Baking & Snack - April 2019 - Equipment & Packaging
Baking & Snack - April 2019 - 135
Baking & Snack - April 2019 - 136
Baking & Snack - April 2019 - 137
Baking & Snack - April 2019 - Patents
Baking & Snack - April 2019 - 139
Baking & Snack - April 2019 - 140
Baking & Snack - April 2019 - New on the Shelf
Baking & Snack - April 2019 - 142
Baking & Snack - April 2019 - MARKETPLACE
Baking & Snack - April 2019 - 144
Baking & Snack - April 2019 - 145
Baking & Snack - April 2019 - 146
Baking & Snack - April 2019 - 147
Baking & Snack - April 2019 - 148
Baking & Snack - April 2019 - 149
Baking & Snack - April 2019 - 150
Baking & Snack - April 2019 - 151
Baking & Snack - April 2019 - 152
Baking & Snack - April 2019 - AD INDEX
Baking & Snack - April 2019 - 154
Baking & Snack - April 2019 - 155
Baking & Snack - April 2019 - 156
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-may-2024
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https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-november-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-october-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-september-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-august-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-july-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-june-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-may-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-april-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-march-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-february-2021
http://digitalbs.bakingbusiness.com/sosland/bs/2020_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_11_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_10_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_09_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_08_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_07_01
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http://digitalbs.bakingbusiness.com/sosland/bs/2019_12_01
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http://digitalbs.bakingbusiness.com/sosland/bs/2019_10_01
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http://digitalbs.bakingbusiness.com/sosland/bs/2018_12_01
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http://digitalbs.bakingbusiness.com/sosland/bs/2018_10_01
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https://www.nxtbook.com/sosland/bs/2018_02_01
https://www.nxtbook.com/sosland/bs/2017_12_01
https://www.nxtbook.com/sosland/bs/2017_11_01
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https://www.nxtbook.com/sosland/bs/2016_12_01
https://www.nxtbook.com/sosland/bs/2016_11_01
https://www.nxtbook.com/sosland/bs/2016_10_01
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https://www.nxtbook.com/sosland/bs/2015_12_01
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