Baking & Snack - July 2024 - 24

CAROLINA FOODS
Left: Guided by a vision
system, robotic arms
pick honey buns for the
flow wrapper.
Right: After being
wrapped, product
travels through a
metal detector and
checkweigher for
quality control before
heading to secondary
packaging.
the secondary Schubert unit to be packed into trays. A
Loma checkweigher will also monitor tray weight, and
any individual piece or tray that is out of spec will be
rejected.
The Schubert secondary packaging unit constructs
the trays, and a robotic arm picks and places packaged
pieces to fill each tray. Similar to the primary packaging
unit, this unit's 10 robotic arms are guided by three
vision systems. The system was programmed with every
format and size, including exact dimensions, that
Carolina Foods will need. This thorough programming
enables the system to achieve the level of efficiency and
simplicity on display. Once trays are filled, they are
sealed and sent to be palletized.
Finished product is currently transferred to a consolidation
warehouse for shipping, which is done through
a freight broker, or customers pick up their orders.
Eventually there will be a warehouse onsite at the new
facility.
The entire bakery runs 24 hours a day for six days a
week. Production lines are cleaned as soon as they are
shut down, and the bakery reserves that seventh day for
sanitation and maintenance.
Carolina Foods designed this first honey bun line specifically
for long production runs, so it makes sense that
it features a high level of automation. The second honey
bun line will be designed for lower volume products.
New donut production lines will be designed similarly.
Having production lines dedicated to high-throughput
or flexibility enables the entire operation to run as effi24
Baking & Snack July 2024 / www.bakingbusiness.com
" OWNERSHIP AND
ACCOUNTABILITY ONLY WORK
WHEN BACKED UP BY FACTS. "
Dan Myers, Carolina Foods
ciently as possible while also being able to handle customers'
requests.
" We can then be strategic with what products run
on which line with production scheduling, " Smith said.
" Our donut lines will have a similar strategy. "
The donut line ready for installation featured a Topos
Mondial integrated mixer that feeds into a Unifiller
dough pump system. Myers explained that every donut
line will be able to run frosted or tumbled donuts
with one production line featuring the capability to do
crunch toppings.
" We have to have that flexibility, or we can't serve our
customers, " he said. " We want to be able to cater to our
customers' desire for LTOs. "
A Royal Houdijk packaging system with SPS flow
wrappers will automate packaging and be able to accommodate
different pack formations.
Safety is a team effort
Being committed to high quality and freshness for 90
years, Carolina Foods has a dedication to food safety
that is not new with the new facility. The South End bakery
has been SQF Level 3 certified for 13 years, and the
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
Baking & Snack - July 2024 - 4
Baking & Snack - July 2024 - 5
Baking & Snack - July 2024 - 6
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