Baking & Snack - June 2020 - 34

DITSCH USA

"WE SAY, 'BETTER BETTER.'
WE WANT TO KEEP OUR
STANDARDS AND QUALITY,
BUT EACH TIME MAKE THE
PROCESS BETTER."
Gary Gottenbusch, Ditsch USA

Two outdoor silos provide flour to the two high-volume soft pretzel lines, and
there is room for expansion as the bakery's business grows.
(RBS) caustic bath, which determines the color and texture
of the final product.
"It's my personal recipe," Mr. Gottenbusch said. "We
create simple, clean label products that taste great."
The pretzels bake in an AMF DenBoer oven.
"Working with one manufacturer for the makeup,
proofing, caustic bath and baking provided us with a
turnkey solution," Mr. Gottenbusch said of the Markel
Food Group, the parent company of AMF Tromp, AMF
DenBoer and RBS. "They provided the integrated communication between the components and just one number to call in case there were any issues, and they had the
right philosophy for us. We're craft master bakers looking
to efficiently supply the nation with traditional pretzels."
After ambient cooling, the pretzels travel through a spiral freezer set at -15˚F before metal detection and packaging. Here, the pretzels may enter two vertical form/fill/
seal systems, Bettendorf Stanford baggers with Burford
twist tyers or flowwrappers before being cartoned, palletized and stored in a freezer.
"Our packaging needs to change daily, based on demand," Mr. Goldie said.

Scaling up artisan baking
All mixing allows the operators to document the process
for variability and traceability, mainly because most of the
pretzels contain only five ingredients - flour, water, yeast,
salt, malt - along with a dab of oil. Overall, the bakery is
SQF Food Safety and SQF Food Quality certified.
Looking forward, Ditsch USA already plans to add another line and possibly expand production even further.
In fact, Mr. Goldie has already drawn up six different versions of potential lines.
"We had hoped to order our third line this year, but all
these events may push us back about six to 12 months,"
Mr. Gottenbusch said. "And down the line, who knows?
We may be looking at another facility within the next
three to five years."
In the meantime, he added, the company is not waiting for opportunity to knock at the bakery's door. Rather,
it's ready to take on any challenge, no matter what twist
of fate comes next. Not surprisingly, he still believes the
bakery will top last year in annual revenue.
"Our family's business always did better in tough times
because people wanted to still eat great bakery products,"
Mr. Gottenbusch said. "Sure, it is much different this time,
but I'm still keeping a positive attitude. We're growing and
making fun products, and we offer a fun place to work.
I'm looking at everything as an opportunity to build a
team for the future."

*

34 Baking & Snack June 2020 / www.bakingbusiness.com


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