Baking & Snack - December 2021 - 25

Doughnut Peddler
OPERATIONS
As Doughnut Peddler pushes out its expansion plans,
it turns its attention to updating its oldest bakery in Arizona.
by Charlotte Atchley
A
After Doughnut Peddler, Chandler, Ariz., built four new
bakeries in two years, it was time for a break. When
the Houston facility opened in 2019, all agreed that the
company would take a yearlong hiatus and go back and
fine-tune those four bakeries. As Jon Dairman, director
of innovation, facilities and equipment, tells it, the company
got really close to reaching that goal. The bakeries
were starting to click and staffing issues were getting resolved,
but then the coronavirus (COVID-19) pandemic
happened.
" People who were starting to ask about new markets
stopped asking; everyone was just worried about keeping
their business open, " he said. " What started as a
one-year hiatus became a two-and-half year hiatus. We
still have hope that the pandemic will end or resolve to a
point that we're comfortable to build new plants. "
Instead, Doughnut Peddler decided to bring some automation
and fine-tune its oldest facility in Chandler.
A beautiful friendship
Doughnut Peddler moved into the 24,000-square-foot
facility in Chandler, Ariz., about seven years ago, two
years after Jason Duffy and Bert Hayenga built the donut
bakery for their Dunkin' Donuts Central Manufacturing
Location (CML) to support their franchises.
Doughnut Peddler had a cycle of moving buildings
every seven years to accommodate growth and was eyeing
a $5 million build-out when the Smiths, owners of
Doughnut Peddler at that time, were approached by Mr.
Duffy to merge.
" We thought we could spend a bunch of money and
build something, or we can go into this bakery that happens
to be empty at the time of day we need a bakery, "
Mr. Dairman said. " So that partnership made sense. "
The current layout of the building and equipment is
pieced together. Instead of purchasing all the equipment at
once and finding the most efficient way to lay out production,
operations came together wherever there was space.
" It's not exactly perfect, but it's served us well, " Mr.
Dairman said. " We've gotten all the stores delivered for
seven years, for 1,000-plus convenience stores and almost
100 Dunkin' stores. "
That said, the Arizona facility is due for an upgrade,
and that is Mr. Dairman's next project. Part of the decision
to upgrade Arizona rather than expand into new
markets was influenced by the pandemic, but also the
bakery just needs it, and Doughnut Peddler had a serendipitous
opportunity.
" One of the tenants next to us, it just so happens that
their lease is up, and we had an opportunity to get that
spot, " Mr. Dairman explained. " We know we're too big
for the area we're in. We're too crammed in, and we see it
more and more every day. "
So the Arizona facility next year will catch up to
the other facilities in the East. With the new space,
Doughnut Peddler will be able to stretch out into about
42,000 square feet of production space.
Opportunities to automate
Before Doughnut Peddler leapt into automation with its
Charlotte, NC, facility, every production line was essentially
the same. Only the size varied. Those same lines
still serve Arizona today.
The facility houses three lines and a small fourth station
with multiple kettle fryers for smaller business. The
larger lines produce donuts, cinnamon rolls, bars and
other pastries.
Production moves in a circle: Racked finished product
comes up into the space where ingredients are stored.
This illustrates the need for more room as the company
looks to remodel. One of Doughnut Peddler's key initiatives
in the past few years is to hone in on food safety,
and that is true of the remodel as well.
Ingredients are weighed and scaled manually into two
small mixers that will be replaced by larger industrial
Topos Mondial mixers. Makeup is done almost entirely
by hand. Dough is hand-cut and sheeted on Rondo
reversible sheeters, which will be replaced by a Radini
line from Rademaker USA. Rotary cutters slice the bars
and donuts from the dough sheet. Product is then placed
on peel boards before being manually loaded onto the
Belshaw Adamatic proofer.
For cinnamon rolls, multiple employees hand roll and
chop the rolls all day.
" In Houston, that takes one hour and one person, " Mr.
Dairman said.
www.bakingbusiness.com / December 2021 Baking & Snack 25
The makeup
process for
cinnamon rolls
is completely
manual, but new
automation in other
Doughnut Peddler
plants showed
how efficiently this
process can be
done with the right
equipment.
Photos by James Dyrek
http://www.bakingbusiness.com

Baking & Snack - December 2021

Table of Contents for the Digital Edition of Baking & Snack - December 2021

Baking & Snack - December 2021 - Intro
Baking & Snack - December 2021 - 1
Baking & Snack - December 2021 - 2
Baking & Snack - December 2021 - 3
Baking & Snack - December 2021 - 4
Baking & Snack - December 2021 - 5
Baking & Snack - December 2021 - 6
Baking & Snack - December 2021 - 7
Baking & Snack - December 2021 - 8
Baking & Snack - December 2021 - 9
Baking & Snack - December 2021 - 10
Baking & Snack - December 2021 - 11
Baking & Snack - December 2021 - 12
Baking & Snack - December 2021 - 13
Baking & Snack - December 2021 - 14
Baking & Snack - December 2021 - 15
Baking & Snack - December 2021 - 16
Baking & Snack - December 2021 - 17
Baking & Snack - December 2021 - 18
Baking & Snack - December 2021 - 19
Baking & Snack - December 2021 - 20
Baking & Snack - December 2021 - 21
Baking & Snack - December 2021 - 22
Baking & Snack - December 2021 - 23
Baking & Snack - December 2021 - 24
Baking & Snack - December 2021 - 25
Baking & Snack - December 2021 - 26
Baking & Snack - December 2021 - 27
Baking & Snack - December 2021 - 28
Baking & Snack - December 2021 - 29
Baking & Snack - December 2021 - 30
Baking & Snack - December 2021 - 31
Baking & Snack - December 2021 - 32
Baking & Snack - December 2021 - 33
Baking & Snack - December 2021 - 34
Baking & Snack - December 2021 - 35
Baking & Snack - December 2021 - 36
Baking & Snack - December 2021 - 37
Baking & Snack - December 2021 - 38
Baking & Snack - December 2021 - 39
Baking & Snack - December 2021 - 40
Baking & Snack - December 2021 - 41
Baking & Snack - December 2021 - 42
Baking & Snack - December 2021 - 43
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Baking & Snack - December 2021 - 45
Baking & Snack - December 2021 - 46
Baking & Snack - December 2021 - 47
Baking & Snack - December 2021 - 48
Baking & Snack - December 2021 - 49
Baking & Snack - December 2021 - 50
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Baking & Snack - December 2021 - 107
Baking & Snack - December 2021 - 108
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https://www.nxtbook.com/sosland/bs/2016_12_01
https://www.nxtbook.com/sosland/bs/2016_11_01
https://www.nxtbook.com/sosland/bs/2016_10_01
https://www.nxtbook.com/sosland/bs/2016_09_01
https://www.nxtbook.com/sosland/bs/2016_08_01
https://www.nxtbook.com/sosland/bs/2016_07_01
https://www.nxtbook.com/sosland/bs/2016_06_01
https://www.nxtbook.com/sosland/bs/2016_05_01
https://www.nxtbook.com/sosland/bs/2016_04_01
https://www.nxtbook.com/sosland/bs/2016_03_01
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https://www.nxtbook.com/sosland/bs/2015_12_01
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https://www.nxtbook.com/sosland/bs/2014_12_01
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https://www.nxtbook.com/sosland/bs/2013_12_01
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https://www.nxtbook.com/sosland/bs/2013_06_01
https://www.nxtbook.com/sosland/bs/2013_05_01
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https://www.nxtbook.com/sosland/bs/2012_12_01
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