Baking & Snack - April 2020 - 36

FIREKING BAKING CO.

After makeup,
dough retards in a
custom-built cooler.
Humidity prevents
the dough from drying out and cracking
on the surface.

receive the necessary gas in two phases, first in June 2019
and then in September. But as May rolled around, with
an open date of June 23, 2019, no action had been taken.
When asked, the utility company backtracked and offered
Mr. Acerra 3 PSI. After tapping contacts at the mayor's office, chamber of commerce and Governor Charlie Baker,
the gas company finally delivered on its promise, and
Fireking had the gas it needed in the new plant.
The move itself only took 30 hours. Because the
smaller facility was at capacity, Fireking couldn't make
the extra product to afford a two- to three-week shutdown, so the company made it happen over one weekend by employing lessons Mr. Acerra learned on the
previous move. He purchased extra equipment to set
up in the new space to bridge the production gaps. The
Monday and Tuesday before moving day, non-essential
equipment started getting shut down, cleaned and taken
apart so that by Thursday and Friday, the old plant was
running a bare-bones production. By Sunday, production was up and running in the new facility.
Manufacturer representatives from Rheon USA,
Koenig Bakery Systems and Miwe were all onsite to handle the installation of the newest equipment so Fireking
could focus on moving mixers and packaging equipment down the street.

A little elbow room
While the previous bakery had most production in one
large space, the new one gives each step of the process
plenty of room to breathe. Production loops throughout
the building. Twenty-two loading docks line the building:
half receiving ingredients and the rest loading distributors' trucks. Ingredients are stored in either an ambient
storage room or refrigerated cooler when necessary.
All ingredients are currently hand-scaled, but plans

are in place for an automated system later this year. Two
silos purchased from another bakery sit outside waiting
for certification for automated flour scaling and delivery.
Acuscale rebuilt the control panels on the silos and will
be providing automated minor ingredient scaling not
only for accuracy and consistency but also traceability
and lot tracking. Until the silos are certified, however,
Fireking is using bagged flour and manual scaling.
In the corner of the ingredient scaling room sit two
kettles prepping honey for the honey wheat breads.
Fireking has always cooked its own honey, but the previous space only had room for one smaller kettle.
After scaling, ingredients are moved to the mixing
room where 10 twin twist mixers from Koenig bring
together the doughs that will become Fireking's artisan
buns, rolls and breads. Each mixer can handle 240 kg
or 529 lbs of dough. Bowls are labeled to transport each
type of dough to the appropriate makeup line.
The makeup room houses seven production lines, set
up neatly side by side in the large bright room. There are
two Koenig industrial roll lines, one Koenig industrial
roll line with stamping capabilities, one Koenig Menes
stress-free line, one Koenig Rex Futura roll line with
proofing and stamping, one Rheon stress-free line purchased for the move and one smaller Rheon stress-free
line brought over from the old facility. Bowl lifts raise
and dump the dough into the hoppers at the beginning
of these production lines, which enable Fireking to make
a wide range of hearth breads, pan breads, and rolls of all
sizes and shapes.
On the roll lines, dough is divided and moulded to the
appropriate size. It's then placed on racks to be sent into
the retarder. Among the industrial roll lines, Mr. Acerra
has diversified the capabilities. The two Rex roll lines turn
out up to 24,000 pieces an hour of hamburger or hot dog

36 Baking & Snack April 2020 / www.bakingbusiness.com

B&S April book.indb 36

4/6/2020 11:17:25 AM


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Baking & Snack - April 2020

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