Baking & Snack - July 2024 - 20

CAROLINA FOODS
which we solve problems accelerates when everyone is
a problem solver. "
With so many variables monitored and controlled,
Carolina Foods also invested in Schubert packaging
systems for primary and secondary packaging for
honey buns. Robotic arms pick and place honey buns
into a flow wrapper and finally into trays for packing.
Robots demand precise products to deliver the expected
efficiencies from such a system. The upstream
investments Carolina Foods has made ensure the
product delivered to the robotic arms is consistent
and in spec.
" When you feed a precision system a precise product,
it's a beautiful thing, " Smith said.
Designed for precision
The honey bun line is designed for long production runs
that turn out the highest-quality products every time.
Ingredient handling is housed in its own room: the
nervous system of the operation, Myers said. A Pfening
bulk ingredient system consists of outdoor silos for
flour and sugar and bulk liquid tanks. The silos are
outfitted with dehumidifiers to prevent mold growth.
Ingredient storage was sized so that the bakery doesn't
have to rely on daily flour deliveries in an effort to head
off any future supply chain issues.
Flour is sifted by Great Western Manufacturing
The automated
ingredient handling
system is the
nervous system of
the entire bakery.
orbital sifters and delivered into day-use tanks. From
there the flour is automatically added to the scale
hoppers over the mixers. Super sacks hold minor ingredients,
which are blended in-house before being
delivered pneumatically to the mixer. For a touch of
quality control, the ingredient handling room includes
CAROLINA FOODS
invests in a team mentality
Anytime a baking company changes hands,
there's an opportunity that some employees
are lost to the change, but that hasn't been
the case at Carolina Foods. Chief Executive
Officer Dan Myers said the company is very
aware of the value of the institutional knowledge
its workforce holds.
It was critical that the site for the new
building was close enough to the South End
bakery that the company's 400 to 450 employees
could transition to the new bakery
when South End eventually closes. A new
facility also means new hires. Thankfully, a
state-of-the-art bakery that's well-lit, climatecontrolled
and features high-tech automation
makes hiring easier.
" We do bring potential candidates to the
new facility, and they recognize that there
aren't a lot of opportunities to work in a facility
like this, " Myers said. " We're growing, and
I like to think that people want to work for a
growing company. "
When hiring, Carolina Foods looks for
people with technical expertise, but cultural
fit is key: The company wants people who are
inquisitive and team players. All team members
are onboarded with a multi-week orientation
with training on food and employee
safety. More technical roles like engineering
and maintenance are provided with further
education.
The company also prioritizes internal
promotions when positions are open. This
empowers employees to visualize a future
career with Carolina Foods.
" We have a lot of management who
started out as frontline employees, " said
Sonya Yalla, director of quality assurance and
R&D, who started her career at the company
on the production room floor.
To create a sense of unity, Stuart Smith,
vice president of operations, pointed out
that even salaried hires spend time working
on the production room floor learning the
ins and outs of honey buns as a part of their
training. This not only connects them to what
Carolina Foods does, but it fosters empathy
with hourly employees.
20 Baking & Snack July 2024 / www.bakingbusiness.com
http://www.bakingbusiness.com

Baking & Snack - July 2024

Table of Contents for the Digital Edition of Baking & Snack - July 2024

Baking & Snack - July 2024 - Intro
Baking & Snack - July 2024 - 1
Baking & Snack - July 2024 - 2
Baking & Snack - July 2024 - 3
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