Baking & Snack - September 2020 - 92

BOTTLENECKS

High-speed packaging
systems provide
versatility while meeting
the need for increases in
packaging for the
retail market.
Syntegon Technology

to individual packs may limit manufacturers to specific
packaging lines and create more bottlenecks," he said.
"Therefore, reliable and efficient equipment offers a wide
range of formats."
For some bakeries, the torrent of change was too much
to handle.
"Probably the biggest impact was on the smaller and
mid-sized companies," said Steve McConnell, regional
sales manager for Matrix Packaging Machinery, a ProMach
product brand.
Others, Mr. McConnell added, also had the luxury of
turning to their co-manufacturers. In other cases, an old
production line became a new friend that saved the day.
"Many large companies just had to go into a room they
hadn't used or had to fire up an old line that had been sitting around for a couple of years," he said.
Bill Kehrli, vice president, sales and marketing, Cavanna
Packaging, noted that multi-plant companies could shift
capacity or simply put the pedal to the metal to ramp
up production of high-volume cookies, crackers and
other snacks.

CREATING A VERSATILE
PACKAGING DEPARTMENT
REQUIRES EXTENSIVE
PREPARATION, ESPECIALLY
FOR BREAD OR SNACK
OPERATIONS WITH
DOZENS OF SKUS.
"They just ran into some initial problems with the supply
chain," he said. "Instead of running five days a week, they
started to run seven days."
While the initial rush has subsided, many manufacturers are stuck in limbo as the pernicious pandemic prevents
some suppliers from installing major upgrades to packaging departments due to restrictions on allowing outside
personnel into bakeries and other health concerns. Still, Jeff
Almond, industry manager, snack food packaging for Heat
and Control, recommended several steps to enact new operational protocols while bridging the gap until new equipment gets delivered.
"During the interim period, bakers can continue to rationalize bag mix and tighten their specifications on corrugated for automation," Mr. Almond said. "They can also
review SKUs for consolidation opportunities to allow for
more efficient automation, invest in training tools for existing labor and embrace remote startups and service during
these restrictive times."

New bottlenecks occur
With the market's response to COVID-19, it was the speed
of change - and the complexity of the solution - that initially caught many operations off-guard.
"If a baker were running cookies and inclusions into a
bulk box, it was simple, but then all of a sudden, they had to
make a left turn and put them into trays. That takes months
of design and lead time," Mr. McConnell said. "And when
they put bodies in there to do the work, they needed 6 feet
of spacing, so the efficiencies just disappeared as they were
timing the new packaging with their oven and cooling."
Mr. Schildknecht said flowwrapping everything inundated many operations and slowed down efficiency.
"Packaging smaller, individual portions creates a bottleneck within the feeder," he said. "Individually packed
products have to be picked and placed into the flowwrapper without harming product quality. Packaging products
individually may also be limited by the shape of the product itself, whereas bulk packaging often does not require a
specific shape. Single-serve packaging, therefore, requires

92 Baking & Snack September 2020 / www.bakingbusiness.com


http://www.bakingbusiness.com

Baking & Snack - September 2020

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

editorial - When 'unprecedented' becomes the status quo
newsfront
In brief/people
trends snapshot news
Special report: Incubators -- A brand-new beginning
Operations: Muffin Town -- New rules for schools
Trends: Pretzels -- back in the spotlight
Formulation: Fats & oils -- Dialing into functionality
Formulation: Sourcing & Supply Chain -- Global web of ingredients
Equipment: Pizza tech -- Piling it on
Equipment: Mixing -- Keep your cool
Equipment: Finishing -- Seeking the perfect touch
Operations: Augmented & virtual reality -- Playing pretend
Equipment: Bottlenecks -- Breaking the bottleneck
Events
Innovations
Featured technical expert
Ingredients & formulating
Equipment & packaging
Patents
New on the shelf
New product spotlight -- A change of pace
Baking & Snack - September 2020 - 1
Baking & Snack - September 2020 - 1
Baking & Snack - September 2020 - 2
Baking & Snack - September 2020 - 3
Baking & Snack - September 2020 - 4
Baking & Snack - September 2020 - 5
Baking & Snack - September 2020 - 6
Baking & Snack - September 2020 - 7
Baking & Snack - September 2020 - 8
Baking & Snack - September 2020 - 9
Baking & Snack - September 2020 - editorial - When 'unprecedented' becomes the status quo
Baking & Snack - September 2020 - 11
Baking & Snack - September 2020 - newsfront
Baking & Snack - September 2020 - 13
Baking & Snack - September 2020 - 14
Baking & Snack - September 2020 - 15
Baking & Snack - September 2020 - In brief/people
Baking & Snack - September 2020 - trends snapshot news
Baking & Snack - September 2020 - Special report: Incubators -- A brand-new beginning
Baking & Snack - September 2020 - 19
Baking & Snack - September 2020 - 20
Baking & Snack - September 2020 - 21
Baking & Snack - September 2020 - 22
Baking & Snack - September 2020 - 23
Baking & Snack - September 2020 - Operations: Muffin Town -- New rules for schools
Baking & Snack - September 2020 - 25
Baking & Snack - September 2020 - 26
Baking & Snack - September 2020 - 27
Baking & Snack - September 2020 - 28
Baking & Snack - September 2020 - 29
Baking & Snack - September 2020 - 30
Baking & Snack - September 2020 - 31
Baking & Snack - September 2020 - 32
Baking & Snack - September 2020 - 33
Baking & Snack - September 2020 - 34
Baking & Snack - September 2020 - Trends: Pretzels -- back in the spotlight
Baking & Snack - September 2020 - 36
Baking & Snack - September 2020 - 37
Baking & Snack - September 2020 - 38
Baking & Snack - September 2020 - 39
Baking & Snack - September 2020 - 40
Baking & Snack - September 2020 - 41
Baking & Snack - September 2020 - 42
Baking & Snack - September 2020 - Formulation: Fats & oils -- Dialing into functionality
Baking & Snack - September 2020 - 44
Baking & Snack - September 2020 - 45
Baking & Snack - September 2020 - 46
Baking & Snack - September 2020 - 47
Baking & Snack - September 2020 - 48
Baking & Snack - September 2020 - 49
Baking & Snack - September 2020 - 50
Baking & Snack - September 2020 - Formulation: Sourcing & Supply Chain -- Global web of ingredients
Baking & Snack - September 2020 - 52
Baking & Snack - September 2020 - 53
Baking & Snack - September 2020 - 54
Baking & Snack - September 2020 - 55
Baking & Snack - September 2020 - 56
Baking & Snack - September 2020 - 57
Baking & Snack - September 2020 - 58
Baking & Snack - September 2020 - Equipment: Pizza tech -- Piling it on
Baking & Snack - September 2020 - 60
Baking & Snack - September 2020 - 61
Baking & Snack - September 2020 - 62
Baking & Snack - September 2020 - 63
Baking & Snack - September 2020 - 64
Baking & Snack - September 2020 - 65
Baking & Snack - September 2020 - 66
Baking & Snack - September 2020 - 67
Baking & Snack - September 2020 - 68
Baking & Snack - September 2020 - Equipment: Mixing -- Keep your cool
Baking & Snack - September 2020 - 70
Baking & Snack - September 2020 - 71
Baking & Snack - September 2020 - 72
Baking & Snack - September 2020 - 73
Baking & Snack - September 2020 - 74
Baking & Snack - September 2020 - 75
Baking & Snack - September 2020 - 76
Baking & Snack - September 2020 - 77
Baking & Snack - September 2020 - 78
Baking & Snack - September 2020 - Equipment: Finishing -- Seeking the perfect touch
Baking & Snack - September 2020 - 80
Baking & Snack - September 2020 - 81
Baking & Snack - September 2020 - 82
Baking & Snack - September 2020 - 83
Baking & Snack - September 2020 - 84
Baking & Snack - September 2020 - 85
Baking & Snack - September 2020 - 86
Baking & Snack - September 2020 - Operations: Augmented & virtual reality -- Playing pretend
Baking & Snack - September 2020 - 88
Baking & Snack - September 2020 - 89
Baking & Snack - September 2020 - 90
Baking & Snack - September 2020 - Equipment: Bottlenecks -- Breaking the bottleneck
Baking & Snack - September 2020 - 92
Baking & Snack - September 2020 - 93
Baking & Snack - September 2020 - 94
Baking & Snack - September 2020 - 95
Baking & Snack - September 2020 - Events
Baking & Snack - September 2020 - 97
Baking & Snack - September 2020 - 98
Baking & Snack - September 2020 - Innovations
Baking & Snack - September 2020 - Featured technical expert
Baking & Snack - September 2020 - 101
Baking & Snack - September 2020 - Ingredients & formulating
Baking & Snack - September 2020 - 103
Baking & Snack - September 2020 - Equipment & packaging
Baking & Snack - September 2020 - 105
Baking & Snack - September 2020 - 106
Baking & Snack - September 2020 - 107
Baking & Snack - September 2020 - 108
Baking & Snack - September 2020 - Patents
Baking & Snack - September 2020 - New on the shelf
Baking & Snack - September 2020 - 111
Baking & Snack - September 2020 - 112
Baking & Snack - September 2020 - 113
Baking & Snack - September 2020 - 114
Baking & Snack - September 2020 - 115
Baking & Snack - September 2020 - 116
Baking & Snack - September 2020 - 117
Baking & Snack - September 2020 - 118
Baking & Snack - September 2020 - 119
Baking & Snack - September 2020 - 120
Baking & Snack - September 2020 - 121
Baking & Snack - September 2020 - New product spotlight -- A change of pace
Baking & Snack - September 2020 - 123
Baking & Snack - September 2020 - 124
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