Baking & Snack - February 2020 - 50

KWIK TRIP

Left: The Kwik Trip
warehouse is a
metropolis that contains
automation for finished
product coming in from
packaging and going
out to the stores.
Right: Kwik Trip dialed
in automation on the
packaging lines to avoid
starving one line and
flooding another.

AMF bulk baggers and a Bosch individual bagger for hot
dog buns, followed by Burford Corp. bread and bun tiers.
"We spent a lot of time and effort to make sure each
individual line is getting product, and we're not starving
one and flooding another," Mr. Fonstad explained. The
bakery built in plenty of redundancy, so if one packaging
line goes down, it can fire up another.
Once products are bagged and tied, an AMF robotic
Versaloader loads bags into trays before they head over
to the warehouse, which takes up more than 1/3 of the
plant's square footage. In this 87,000-sq-ft space lives a
metropolis filled with somewhere in the neighborhood
of 80,000 trays stacked in towers up to 20 high. They're
managed by a Cimcorp order pulling system, the likes of
which is almost unseen in the baking industry.
The system manages the inbound and outbound items
with six gantries that are zoned inside three cells. Once
trays are stacked, product data leaves the AMF data control. "We transfer that data into Cimcorp," said Bruce
Burmeister, bakery production manager. "Cimcorp will
take trays and upstack them to 20 high, and the system
knows where to pick a spot on the outbound side to place
them. When the orders come in from the store, it will pull
those orders by store and route."
The system can grab a single tray or pull all 20 at once.
"It's like a sleeve over the trays," Mr. Fonstad said. "It clamps
onto them, picks them up, and off it goes."
Inventory is held no more than a day and a half before it's
transferred to the distribution center and loaded onto route
trucks for delivery to all 700 stores. To keep up with that,
the gantries move at 22 mph picking and placing product.
To ensure coworker safety, the cells are blocked off by fencing, and the system comes to a stop if anyone crosses inside.
Before, this was all was done manually, but skyrocket
growth made the sheer ergonomics a challenge for human hands. Kwik Trip discovered the Cimcorp system
in the dairy industry and is aware of just one other
bakery operation using this system. "This was an enormous job, and there weren't a lot of options out there,"

50 Baking & Snack February 2020 / www.bakingbusiness.com

Mr. Burmeister said. "Just imagine what it would take to
manage this many trays by hand."

How time flies
It's hard to believe that all this automation and data management was just two years in the making, even for those
who were directly involved.
"I never dreamed we'd be standing in this bakery today. After we built the one in 2009, I never thought we'd
build another one," Mr. Fonstad said. "But as Kwik Trip
has grown, we wanted to support vertical integration, so
our ownership - Don Zietlow and his family - knew we
needed to build another plant to support retail's growth."
While the new bakery may have been designed to accommodate four times the capacity of 2016 ... between
the c-store boom and the perseverance of the Wisconsin
work ethic, who knows how soon that day will come? Mr.
Fonstad isn't worried. "We have a lot of production hours
to fill up yet," he said.
One thing is for sure: No matter how fast it flies, Kwik
Trip has supplier relationships to stand the test of time
and a workforce that will prepare the bakery for the future. "The longevity of Kwik Trip coworkers is something we are very proud of," Mr. Fonstad said, noting Mr.
Walters' and Mr. Burmeister's combined experience of
more than 60 years and growth opportunities for younger
bakers such as Mr. Reimer. "Kwik Trip is the land of opportunity," he said. "If you stay here and work hard, you
can take on more responsibility and become a leader. Eric
[Riemer] is a great example of that."
At the rate Kwik Trip and the c-store market are growing - and as fast as the bakery is moving - opportunity
could knock at any time. "We knew the rates were going
to be extremely fast; that was the thing we were most impressed with," Mr. Fonstad recalled. "We asked ourselves,
'Can we build a plant that will make buns and bread that
fast?' You talk about it and hear about it, but when you
see the equipment installed and running ... it's simply remarkable how fast this plant is."

*


http://www.bakingbusiness.com

Baking & Snack - February 2020

Table of Contents for the Digital Edition of Baking & Snack - February 2020

Baking & Snack - February 2020
Contents
Editorial - What can bread learn from the little black dress?
Newsfront
People/In Brief
2020 Baking Hall of Fame - The history makers
2020 BAKING HALL OF FAME - The teacher
2020 BAKING HALL OF FAME - The engineer
2020 BAKING HALL OF FAME - The architect
2020 BAKING HALL OF FAME - The helper
Industry Confi dence Survey - Weathering the storm
Kwik Trip - Land of opportunity
Donuts - A hole in one
Health and wellness - Impacting consumer health
Protein - Blend for balance
Probiotics - Good for the gut
Snack processing - Story of the decade
Pan glazing - Life in the fast lane
Depositing - Bull's-eye
Production management - ERP software 101
Trays & baskets - Stacked for food safety
Meeting preview: ABA - A gold mine of information
Events
Innovations - Contents
Featured innovation center
Ingredients & formulating
Equipment & packaging
Patents
New on the shelf
Marketplace
Ad index
New product spotlight
Baking & Snack - February 2020 - Baking & Snack - February 2020
Baking & Snack - February 2020 - Baking & Snack - February 2020
Baking & Snack - February 2020 - 2
Baking & Snack - February 2020 - 3
Baking & Snack - February 2020 - 4
Baking & Snack - February 2020 - 5
Baking & Snack - February 2020 - 6
Baking & Snack - February 2020 - Contents
Baking & Snack - February 2020 - 8
Baking & Snack - February 2020 - 9
Baking & Snack - February 2020 - Editorial - What can bread learn from the little black dress?
Baking & Snack - February 2020 - 11
Baking & Snack - February 2020 - 12
Baking & Snack - February 2020 - 13
Baking & Snack - February 2020 - Newsfront
Baking & Snack - February 2020 - 15
Baking & Snack - February 2020 - People/In Brief
Baking & Snack - February 2020 - 17
Baking & Snack - February 2020 - 18
Baking & Snack - February 2020 - 19
Baking & Snack - February 2020 - 20
Baking & Snack - February 2020 - 2020 Baking Hall of Fame - The history makers
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The teacher
Baking & Snack - February 2020 - 23
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The engineer
Baking & Snack - February 2020 - 25
Baking & Snack - February 2020 - 26
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The architect
Baking & Snack - February 2020 - 28
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The helper
Baking & Snack - February 2020 - 30
Baking & Snack - February 2020 - Industry Confi dence Survey - Weathering the storm
Baking & Snack - February 2020 - 32
Baking & Snack - February 2020 - 33
Baking & Snack - February 2020 - 34
Baking & Snack - February 2020 - 35
Baking & Snack - February 2020 - 36
Baking & Snack - February 2020 - 37
Baking & Snack - February 2020 - Kwik Trip - Land of opportunity
Baking & Snack - February 2020 - 39
Baking & Snack - February 2020 - 41
Baking & Snack - February 2020 - 40
Baking & Snack - February 2020 - 42
Baking & Snack - February 2020 - 43
Baking & Snack - February 2020 - 44
Baking & Snack - February 2020 - 45
Baking & Snack - February 2020 - 46
Baking & Snack - February 2020 - 47
Baking & Snack - February 2020 - 48
Baking & Snack - February 2020 - 49
Baking & Snack - February 2020 - 50
Baking & Snack - February 2020 - 51
Baking & Snack - February 2020 - 52
Baking & Snack - February 2020 - 53
Baking & Snack - February 2020 - Donuts - A hole in one
Baking & Snack - February 2020 - 55
Baking & Snack - February 2020 - 56
Baking & Snack - February 2020 - 57
Baking & Snack - February 2020 - 58
Baking & Snack - February 2020 - 59
Baking & Snack - February 2020 - 60
Baking & Snack - February 2020 - 61
Baking & Snack - February 2020 - 62
Baking & Snack - February 2020 - 63
Baking & Snack - February 2020 - 64
Baking & Snack - February 2020 - Health and wellness - Impacting consumer health
Baking & Snack - February 2020 - 66
Baking & Snack - February 2020 - 67
Baking & Snack - February 2020 - 68
Baking & Snack - February 2020 - 69
Baking & Snack - February 2020 - 70
Baking & Snack - February 2020 - Protein - Blend for balance
Baking & Snack - February 2020 - 72
Baking & Snack - February 2020 - 73
Baking & Snack - February 2020 - 74
Baking & Snack - February 2020 - 75
Baking & Snack - February 2020 - 76
Baking & Snack - February 2020 - 77
Baking & Snack - February 2020 - 78
Baking & Snack - February 2020 - 79
Baking & Snack - February 2020 - 80
Baking & Snack - February 2020 - Probiotics - Good for the gut
Baking & Snack - February 2020 - 82
Baking & Snack - February 2020 - 83
Baking & Snack - February 2020 - 84
Baking & Snack - February 2020 - 85
Baking & Snack - February 2020 - 86
Baking & Snack - February 2020 - 87
Baking & Snack - February 2020 - 88
Baking & Snack - February 2020 - Snack processing - Story of the decade
Baking & Snack - February 2020 - 90
Baking & Snack - February 2020 - 91
Baking & Snack - February 2020 - 92
Baking & Snack - February 2020 - 93
Baking & Snack - February 2020 - 94
Baking & Snack - February 2020 - 95
Baking & Snack - February 2020 - 96
Baking & Snack - February 2020 - 97
Baking & Snack - February 2020 - 98
Baking & Snack - February 2020 - Pan glazing - Life in the fast lane
Baking & Snack - February 2020 - 100
Baking & Snack - February 2020 - 101
Baking & Snack - February 2020 - 102
Baking & Snack - February 2020 - 103
Baking & Snack - February 2020 - 104
Baking & Snack - February 2020 - 105
Baking & Snack - February 2020 - 106
Baking & Snack - February 2020 - Depositing - Bull's-eye
Baking & Snack - February 2020 - 108
Baking & Snack - February 2020 - 109
Baking & Snack - February 2020 - 110
Baking & Snack - February 2020 - 111
Baking & Snack - February 2020 - 112
Baking & Snack - February 2020 - 113
Baking & Snack - February 2020 - 114
Baking & Snack - February 2020 - Production management - ERP software 101
Baking & Snack - February 2020 - 116
Baking & Snack - February 2020 - 117
Baking & Snack - February 2020 - 118
Baking & Snack - February 2020 - 119
Baking & Snack - February 2020 - 120
Baking & Snack - February 2020 - 121
Baking & Snack - February 2020 - 122
Baking & Snack - February 2020 - Trays & baskets - Stacked for food safety
Baking & Snack - February 2020 - 124
Baking & Snack - February 2020 - 125
Baking & Snack - February 2020 - 126
Baking & Snack - February 2020 - 127
Baking & Snack - February 2020 - 128
Baking & Snack - February 2020 - Meeting preview: ABA - A gold mine of information
Baking & Snack - February 2020 - Events
Baking & Snack - February 2020 - 131
Baking & Snack - February 2020 - 132
Baking & Snack - February 2020 - Innovations - Contents
Baking & Snack - February 2020 - Featured innovation center
Baking & Snack - February 2020 - 135
Baking & Snack - February 2020 - 136
Baking & Snack - February 2020 - Ingredients & formulating
Baking & Snack - February 2020 - 138
Baking & Snack - February 2020 - 139
Baking & Snack - February 2020 - Equipment & packaging
Baking & Snack - February 2020 - 141
Baking & Snack - February 2020 - 142
Baking & Snack - February 2020 - 143
Baking & Snack - February 2020 - 144
Baking & Snack - February 2020 - 145
Baking & Snack - February 2020 - 146
Baking & Snack - February 2020 - 147
Baking & Snack - February 2020 - Patents
Baking & Snack - February 2020 - 149
Baking & Snack - February 2020 - New on the shelf
Baking & Snack - February 2020 - 151
Baking & Snack - February 2020 - Marketplace
Baking & Snack - February 2020 - 153
Baking & Snack - February 2020 - 154
Baking & Snack - February 2020 - 155
Baking & Snack - February 2020 - 156
Baking & Snack - February 2020 - 157
Baking & Snack - February 2020 - 158
Baking & Snack - February 2020 - 159
Baking & Snack - February 2020 - 160
Baking & Snack - February 2020 - Ad index
Baking & Snack - February 2020 - New product spotlight
Baking & Snack - February 2020 - 163
Baking & Snack - February 2020 - 164
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