Baking & Snack - May 2024 - 30

ANTHONY & SONS BAKERY
The bread is baked about 85% before being frozen and
packaged for consumers to take home and bake in the
oven for 5 to 8 minutes.
" Users just have to crisp up the crust with our product, "
Rizzitello said. " Most take-and-bake products can
feel heavy, but ours feels a lot lighter due to the opencell
structure. "
This open-cell structure is thanks to the high-hydration
dough and the fact that it is fermented for 2 hours on the
production floor, Baldo Dattolo explained.
The Italian Classic line features the standbys like
Italian bread as well as statement varieties like Italian
Bread with Everything Seasoning, Rosemary Olive Oil,
Sourdough Filoni, Sesame Semolina and a four-pack
Focaccia.
The demand seen in the sales data, both actual and
projected, led Anthony & Sons to invest in production
so the capacity will be there to support sales.
A nimble production
The Denville bakery has 65,000 square feet of production
space. Five lines - two artisan bread lines, two roll
lines and one high-speed bread line - create Anthony
& Sons' fresh bread and frozen product for its retail
and foodservice customers. The bakery operates two
10-hour shifts, nearly every day, with a few hours off
from Saturday to Sunday for maintenance. Sanitation is
conducted around the clock after every production run.
Baldo Dattolo estimated the bakery is running at 65%
capacity and has two 10-hour shifts available to handle
incoming demand.
Flour is delivered every day by truck throughout the
Anthony & Sons built
its reputation on
Italian-style breads
like these Italian heroes
waiting to enter
the tunnel oven.
growing its foodservice business but with a focus on frozen
rather than fresh delivery. The bakery will be bringing
The Avocado Bread Co. to the National Restaurant
Association show for the first time.
" Chefs love the creativity of the avocado bread, "
Rizzitello said.
In addition to the 5,000 retail stores and recent international
expansion into Mexico and Turks and Caicos
Islands, The Avocado Bread Co. has been picked up by
four major foodservice distributors. Chefs interested in
incorporating the new products into their menus will
have a supply waiting for them.
While The Avocado Bread Co. may be Anthony &
Sons' current crown jewel, it's not the only new product
line the baking company has up its sleeve. It saw consumer
demand for artisan Italian-style take-and-bake
bread and decided to bring its frozen bread expertise to
the consumer level. The company developed the Italian
Classic line, which will also make its debut at IDDBA.
30 Baking & Snack May 2024 / www.bakingbusiness.com
day to a KB Systems silo system that houses two 70,000-lb
bins. Other dry ingredients and packaging materials are
stored at an offsite 25,000-square-foot warehouse. Flour
and water are scaled and delivered to the four Peerless
mixers automatically.
While water and flour are automatically scaled and
added to the mixers, the rest of the ingredients are measured
and added manually. Each horizontal Peerless mixer
creates dough for the various lines in 1,000-lb batches,
which are left to ferment at ambient temperature in
troughs throughout the production room.
The latest addition to the Denville production is a
new high-speed Rheon makeup line, the latest technology
from the equipment supplier, that was installed in
November 2023 to handle the extra capacity brought in
by the Italian Classic products. The new line replaced a
smaller Rheon line and can produce 2 tonnes of product
per hour.
" We were doing the Italian Classic products on the
baby Rheon line that was having to run 22 hours a day,
and now we can use that line and our Italian makeup
http://www.bakingbusiness.com

Baking & Snack - May 2024

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

Baking & Snack - May 2024 - Intro
Baking & Snack - May 2024 - 1
Baking & Snack - May 2024 - 2
Baking & Snack - May 2024 - 3
Baking & Snack - May 2024 - 4
Baking & Snack - May 2024 - 5
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