Baking & Snack - May 2021 - 28

ANA & LA BREA BAKERY

Left: Baguettes leave
the oven to cool
before entering the
packaging area.
Right: Robotics enable
the Van Nuys bakery
team to keep up with
increased capacity.

The mixers are all fed by an ingredient management
system. Line 3 uses a Zeppelin system. Flour is stored
in two silos for Lines 1 and 2 and three silos for Line 3.
Additionally, the starter is held in a series of tanks feeding all lines. La Brea Bakery's starter ferments for several
hours before being added. This is one place where the
artisan method will not be compromised.
" Time is very critical to our process, and with expanding automation, we didn't lose sight of that, " said
Gilberto Gonzalez, production and packaging manager
at Van Nuys. " We stayed true to our tradition and legacy
of our signature starter. It still takes roughly 24 hours
from start to finish to make a La Brea Bakery product. "
Another critical element in the process is ice because
dough time and temperature of La Brea Bakery's products are tightly controlled. A new 10-tonne Northstar
machine can keep up with the bakery's demand for ice
during even the hottest California summers, saving the
bakery money.
" In the past, we would build pallets of ice and store it
in our freezer, and on many occasions, we had to purchase ice externally at a cost of $2,000 per pallet to keep
our bakery in operation, " Mr. Garcia explained.
Afterward, the dough is fed to one of three Rheon
makeup lines, which maintain the delicate structure
of the artisan doughs by using gravity to move them
through the system. Lines 1 and 2 are original Rheon
sheeting lines dating back to 1998, when La Brea Bakery
started the Van Nuys facility.
After makeup, product spends a number of hours
in the Iteca or Capway proofers before entering one of
several Daub or Heuft deck ovens the bakery has. After

28 Baking & Snack May 2021 / www.bakingbusiness.com

baking, the product is checked by the new Sightline vision system, an investment in Mr. Garcia's commitment
to efficiency and continuous improvement.
" My background is in Six Sigma lean manufacturing, so data is really important for making decisions and
having the right sample size, " he said. " Prior to this data
we were making decisions on a small sample size, and
we weren't able to make good decisions. "
The new vision system provides a sample size encompassing 100% of the product coming off all three
production lines and rejects product that is out of spec.
Monitors in the makeup and packaging departments
display visual guides to show operators if the product is
within specifications.
" Our employees love it, " Mr. Garcia said. " It's a communication tool to tell where we're at with waste in real time. "
After baking, product is cooled on an IJ White spiral cooler before traveling in the IJ White spiral freezer.
Product is then packaged manually on Line 1 or automatically on Lines 2 and 3 before being checked by metal detection and delivered to customers.

A culture of safety and sanitation
ANA's automation at La Brea Bakery's Van Nuys facility
is an outgrowth of the culture Mr. Garcia has instilled
in the bakery. Starting at La Brea Bakery in 2014 as the
bakery's first continuous improvement manager, Mr.
Garcia brought his Lean Six Sigma manufacturing background to bear on the artisan bakery. As bakery director,
he's implemented a culture of employee and food safety
first and streamlined operations using data and automation to always be improving efficiencies.


http://www.bakingbusiness.com

Baking & Snack - May 2021

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

Baking & Snack - May 2021 - Intro
Baking & Snack - May 2021 - 1
Baking & Snack - May 2021 - 2
Baking & Snack - May 2021 - 3
Baking & Snack - May 2021 - 4
Baking & Snack - May 2021 - 5
Baking & Snack - May 2021 - 6
Baking & Snack - May 2021 - 7
Baking & Snack - May 2021 - 8
Baking & Snack - May 2021 - 9
Baking & Snack - May 2021 - 10
Baking & Snack - May 2021 - 11
Baking & Snack - May 2021 - 12
Baking & Snack - May 2021 - 13
Baking & Snack - May 2021 - 14
Baking & Snack - May 2021 - 15
Baking & Snack - May 2021 - 16
Baking & Snack - May 2021 - 17
Baking & Snack - May 2021 - 18
Baking & Snack - May 2021 - 19
Baking & Snack - May 2021 - 20
Baking & Snack - May 2021 - 21
Baking & Snack - May 2021 - 22
Baking & Snack - May 2021 - 23
Baking & Snack - May 2021 - 24
Baking & Snack - May 2021 - 25
Baking & Snack - May 2021 - 26
Baking & Snack - May 2021 - 27
Baking & Snack - May 2021 - 28
Baking & Snack - May 2021 - 29
Baking & Snack - May 2021 - 30
Baking & Snack - May 2021 - 31
Baking & Snack - May 2021 - 32
Baking & Snack - May 2021 - 33
Baking & Snack - May 2021 - 34
Baking & Snack - May 2021 - 35
Baking & Snack - May 2021 - 36
Baking & Snack - May 2021 - 37
Baking & Snack - May 2021 - 38
Baking & Snack - May 2021 - 39
Baking & Snack - May 2021 - 40
Baking & Snack - May 2021 - 41
Baking & Snack - May 2021 - 42
Baking & Snack - May 2021 - 43
Baking & Snack - May 2021 - 44
Baking & Snack - May 2021 - 45
Baking & Snack - May 2021 - 46
Baking & Snack - May 2021 - 47
Baking & Snack - May 2021 - 48
Baking & Snack - May 2021 - 49
Baking & Snack - May 2021 - 50
Baking & Snack - May 2021 - 51
Baking & Snack - May 2021 - 52
Baking & Snack - May 2021 - 53
Baking & Snack - May 2021 - 54
Baking & Snack - May 2021 - 55
Baking & Snack - May 2021 - 56
Baking & Snack - May 2021 - 57
Baking & Snack - May 2021 - 58
Baking & Snack - May 2021 - 59
Baking & Snack - May 2021 - 60
Baking & Snack - May 2021 - 61
Baking & Snack - May 2021 - 62
Baking & Snack - May 2021 - 63
Baking & Snack - May 2021 - 64
Baking & Snack - May 2021 - 65
Baking & Snack - May 2021 - 66
Baking & Snack - May 2021 - 67
Baking & Snack - May 2021 - 68
Baking & Snack - May 2021 - 69
Baking & Snack - May 2021 - 70
Baking & Snack - May 2021 - 71
Baking & Snack - May 2021 - 72
Baking & Snack - May 2021 - 73
Baking & Snack - May 2021 - 74
Baking & Snack - May 2021 - 75
Baking & Snack - May 2021 - 76
Baking & Snack - May 2021 - 77
Baking & Snack - May 2021 - 78
Baking & Snack - May 2021 - 79
Baking & Snack - May 2021 - 80
Baking & Snack - May 2021 - 81
Baking & Snack - May 2021 - 82
Baking & Snack - May 2021 - 83
Baking & Snack - May 2021 - 84
Baking & Snack - May 2021 - 85
Baking & Snack - May 2021 - 86
Baking & Snack - May 2021 - 87
Baking & Snack - May 2021 - 88
Baking & Snack - May 2021 - 89
Baking & Snack - May 2021 - 90
Baking & Snack - May 2021 - 91
Baking & Snack - May 2021 - 92
Baking & Snack - May 2021 - 93
Baking & Snack - May 2021 - 94
Baking & Snack - May 2021 - 95
Baking & Snack - May 2021 - 96
Baking & Snack - May 2021 - 97
Baking & Snack - May 2021 - 98
Baking & Snack - May 2021 - 99
Baking & Snack - May 2021 - 100
Baking & Snack - May 2021 - 101
Baking & Snack - May 2021 - 102
Baking & Snack - May 2021 - 103
Baking & Snack - May 2021 - 104
Baking & Snack - May 2021 - 105
Baking & Snack - May 2021 - 106
Baking & Snack - May 2021 - 107
Baking & Snack - May 2021 - 108
Baking & Snack - May 2021 - 109
Baking & Snack - May 2021 - 110
Baking & Snack - May 2021 - 111
Baking & Snack - May 2021 - 112
Baking & Snack - May 2021 - 113
Baking & Snack - May 2021 - 114
Baking & Snack - May 2021 - 115
Baking & Snack - May 2021 - 116
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-may-2022
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-april-2022
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-march-2022
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-january-2022
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-december-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-november-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-october-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-september-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-august-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-july-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-june-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-may-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-april-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-march-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-february-2021
http://digitalbs.bakingbusiness.com/sosland/bs/2020_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_11_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_10_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_09_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_08_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_07_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_06_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_05_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_04_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_03_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_02_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_11_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_10_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_09_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_08_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_07_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_06_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_05_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_04_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_03_01
http://digitalbs.bakingbusiness.com/sosland/bs/2019_02_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_11_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_10_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_09_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_08_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_07_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_06_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_05_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_04_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_03_01
https://www.nxtbook.com/sosland/bs/2018_02_01
https://www.nxtbook.com/sosland/bs/2017_12_01
https://www.nxtbook.com/sosland/bs/2017_11_01
https://www.nxtbook.com/sosland/bs/2017_10_01
https://www.nxtbook.com/sosland/bs/2017_09_01
https://www.nxtbook.com/sosland/bs/2017_08_01
https://www.nxtbook.com/sosland/bs/2017_07_01
https://www.nxtbook.com/sosland/bs/2017_06_01
https://www.nxtbook.com/sosland/bs/2017_05_01
https://www.nxtbook.com/sosland/bs/2017_04_01
https://www.nxtbook.com/sosland/bs/2017_03_01
https://www.nxtbook.com/sosland/bs/2017_02_01
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
https://www.nxtbook.com/sosland/bs/2016_02_01
https://www.nxtbook.com/sosland/bs/2015_12_01
https://www.nxtbook.com/sosland/bs/2015_11_01
https://www.nxtbook.com/sosland/bs/2015_10_01
https://www.nxtbook.com/sosland/bs/2015_09_01
https://www.nxtbook.com/sosland/bs/2015_08_01
https://www.nxtbook.com/sosland/bs/2015_07_01
https://www.nxtbook.com/sosland/bs/2015_06_01
https://www.nxtbook.com/sosland/bs/2015_05_02
https://www.nxtbook.com/sosland/bs/2015_04_01
https://www.nxtbook.com/sosland/bs/2015_03_01
https://www.nxtbook.com/sosland/bs/2015_02_01
https://www.nxtbook.com/sosland/bs/2014_12_01
https://www.nxtbook.com/sosland/bs/2014_11_01
https://www.nxtbook.com/sosland/bs/2014_10_01
https://www.nxtbook.com/sosland/bs/2014_09_01
https://www.nxtbook.com/sosland/bs/2014_08_01
https://www.nxtbook.com/sosland/bs/2014_07_01
https://www.nxtbook.com/sosland/bs/2014_06_01
https://www.nxtbook.com/sosland/bs/2014_05_01
https://www.nxtbook.com/sosland/bs/2014_04_01
https://www.nxtbook.com/sosland/bs/2014_03_01
https://www.nxtbook.com/sosland/bs/2014_02_01
https://www.nxtbook.com/sosland/bs/2013_12_01
https://www.nxtbook.com/sosland/bs/2013_11_01
https://www.nxtbook.com/sosland/bs/2013_10_01
https://www.nxtbook.com/sosland/bs/2013_09_01
https://www.nxtbook.com/sosland/bs/2013_08_01
https://www.nxtbook.com/sosland/bs/2013_07_01
https://www.nxtbook.com/sosland/bs/2013_06_01
https://www.nxtbook.com/sosland/bs/2013_05_01
https://www.nxtbook.com/sosland/bs/2013_04_01
https://www.nxtbook.com/sosland/bs/2013_03_01
https://www.nxtbook.com/sosland/bs/2013_02_01
https://www.nxtbook.com/sosland/bs/2012_12_01
https://www.nxtbook.com/sosland/bs/2012_11_01
https://www.nxtbook.com/sosland/bs/2012_10_01
https://www.nxtbook.com/sosland/bs/2012_09_01
https://www.nxtbook.com/sosland/bs/2012_08_01
https://www.nxtbook.com/sosland/bs/2012_07_01
https://www.nxtbook.com/sosland/bs/2012_06_01
https://www.nxtbook.com/sosland/bs/2012_05_01
https://www.nxtbook.com/sosland/bs/2012_04_01
https://www.nxtbook.com/sosland/bs/2012_03_01
https://www.nxtbook.com/sosland/bs/2012_02_01
https://www.nxtbook.com/sosland/bs/2011_12_01
https://www.nxtbook.com/sosland/bs/2011_11_01
https://www.nxtbook.com/sosland/bs/2011_10_01
https://www.nxtbook.com/sosland/bs/2011_09_01
https://www.nxtbook.com/sosland/bs/2011_08_01
https://www.nxtbook.com/sosland/bs/2011_07_01
https://www.nxtbook.com/sosland/bs/2011_06_01
https://www.nxtbook.com/sosland/bs/2011_05_01
https://www.nxtbook.com/sosland/bs/2011_04_01
https://www.nxtbook.com/sosland/bs/2011_03_01
https://www.nxtbook.com/sosland/bs/2011_02_01
https://www.nxtbook.com/sosland/bs/2010_12_01
https://www.nxtbook.com/sosland/bs/2010_11_01
https://www.nxtbook.com/sosland/bs/2010_10_01
https://www.nxtbook.com/sosland/bs/2010_09_01
https://www.nxtbook.com/sosland/bs/2010_08_01
https://www.nxtbook.com/sosland/bs/2010_07_01
https://www.nxtbook.com/sosland/bs/2010_06_01
https://www.nxtbook.com/sosland/bs/2010_05_01
https://www.nxtbook.com/sosland/bs/2010_04_01
https://www.nxtbook.com/sosland/bs/2010_03_01
https://www.nxtbook.com/sosland/bs/2010_02_01
https://www.nxtbook.com/sosland/bs/2009_12_01
https://www.nxtbook.com/sosland/bs/2009_11_01
https://www.nxtbook.com/sosland/bs/2009_10_01
https://www.nxtbook.com/sosland/bs/2009_09_01
https://www.nxtbook.com/sosland/bs/2009_08_01
https://www.nxtbook.com/sosland/bs/2009_07_01
https://www.nxtbook.com/sosland/bs/2009_06_01
https://www.nxtbook.com/sosland/bs/2009_05_01
https://www.nxtbook.com/sosland/bs/2009_04_01
https://www.nxtbook.com/sosland/bs/2009_03_01
https://www.nxtbook.com/sosland/bs/2009_02_01
https://www.nxtbook.com/sosland/bs/2008_12_01
https://www.nxtbook.com/sosland/bs/2008_11_01
https://www.nxtbook.com/sosland/bs/2008_10_01
https://www.nxtbook.com/sosland/bs/2008_09_01
https://www.nxtbook.com/sosland/bs/2008_08_01
https://www.nxtbook.com/sosland/bs/2008_07_01
https://www.nxtbook.com/sosland/bs/2008_06_01
https://www.nxtbook.com/sosland/bs/2008_05_01
https://www.nxtbook.com/sosland/bs/2008_04_01
https://www.nxtbook.com/sosland/bs/2008_03_01
https://www.nxtbook.com/sosland/bs/2008_02_01
https://www.nxtbook.com/sosland/bs/2007_12_01
https://www.nxtbook.com/sosland/bs/2007_11_01
https://www.nxtbook.com/sosland/bs/2007_10_01
https://www.nxtbook.com/sosland/bs/2007_09_01
https://www.nxtbook.com/sosland/bs/2007_08_01
https://www.nxtbook.com/sosland/bs/2007_07_01
https://www.nxtbook.com/sosland/bs/2007_06_01
https://www.nxtbook.com/sosland/bs/2007_05_01
https://www.nxtbook.com/sosland/bs/2007_04_01
https://www.nxtbook.com/sosland/bs/2007_02_01
https://www.nxtbook.com/sosland/bs/2006_12_01
https://www.nxtbook.com/sosland/bs/2006_11_01
https://www.nxtbook.com/sosland/bs/2006_10_01
https://www.nxtbook.com/sosland/bs/2006_09_01
https://www.nxtbook.com/sosland/bs/2006_08_01
https://www.nxtbook.com/sosland/bs/2006_07_01
https://www.nxtbook.com/sosland/bs/2006_06_01
https://www.nxtbook.com/sosland/bs/2006_05_01
https://www.nxtbook.com/sosland/bs/2006_04_01
https://www.nxtbook.com/sosland/bs/2006_03_01
https://www.nxtbook.com/sosland/bs/2006_02_01
https://www.nxtbook.com/sosland/bs/2005_12_01
https://www.nxtbook.com/sosland/bs/2005_11_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_10_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_09_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_08_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_07_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_06_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_05_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_04_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_03_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_02_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_11_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_10_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_09_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_08_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_07_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_06_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_05_01
https://digitalbs.bakingbusiness.com/sosland/bs/2004_04_01
https://digitalbs.bakingbusiness.com/sosland/bs/2004_03_01
https://digitalbs.bakingbusiness.com/sosland/bs/2004_02_01
https://digitalbs.bakingbusiness.com/sosland/bs/2003_12_01
https://digitalbs.bakingbusiness.com/sosland/bs/2003_11_01
https://www.nxtbookmedia.com