Baking & Snack - April 2020 - 42

ture from the previous plant where baked
product filled the space between ovens and
packaging, heating up the entire bakery.
Cool air is pumped and circulated throughout the room, creating a current to pull
heat out of products. Eventually, Mr. Acerra
hopes to install two spiral coolers with a
conveyor feeding them product from above.
After finally cooling for 20 minutes to two
hours, product enters the packaging department, which is as big as the previous bakery
altogether.
"Packaging takes a lot of space," Mr.
Acerra said.
It also takes a lot of labor, and the majority
of employees work in this department. Here,
Mr. Acerra has ensured comfort in natural
lighting from skylights and air conditioning
for more ideal working conditions. Employees
run seven packaging lines from UBE, Lematic,
Bettendorf-Stanford, Ilapak and Formost Fuji,
mostly baggers for rolls, buns and bread loaves.
Crusty rolls are bulk packaged by an OK bulk
packer. Three Robopac robot pallet wrappers
cover pallets for distribution.
For the frozen business, the packaging
room ends at two freezers, also custom-built
by the engineering staff. The freezers can
hold up to 1,100 pallets total. Another offsite
freezer handles overflow. Product is frozen,
packaged and then stored in the freezer before shipping out. There's room for one more
freezer in the future.
It's also in this area of the new facility
where the engineering room is, a large office space and shop that houses all the tools
Fireking's engineers and mechanics could
need. As the business has grown, Mr. Acerra
has also expanded his staff of engineers and
mechanics and not just because the amount
of equipment has proliferated.
"With smaller buildings, you just need
mechanics for the equipment, but with a
bigger building you need mechanics for the
equipment and engineers for the building,"
he explained.
Top: Fireking's new facility is only operating at 20% capacity,
and that leaves more than enough space for dough to travel
between processes.
Middle: Dough is prepped for the oven manually after proofing.
Bottom: After cooling, finished product is bagged on one of
seven packaging lines. Frozen product is stored in one of two
freezers, while the rest is staged for distribution pickup.
42 Baking & Snack April 2020 / www.bakingbusiness.com

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Baking & Snack - April 2020

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

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