Baking & Snack - May 2024 - 32

ANTHONY & SONS BAKERY
ANTHONY & SONS TAKES STEPS ON
line as backups for this larger line, " Baldo Dattolo said.
" We invested in the Rheon line because we needed capacity
and to modernize. "
After the doughs for the Italian Classic are fermented
on the floor, the troughs are wheeled to an automatic
trough hoist that adds the dough to the hopper of the extruder.
The extruder creates a continuous dough sheet,
which is then gently sheeted and moulded, depending
on the product being made. During Baking & Snack's
visit, ciabatta heroes were being processed. After the
ciabatta hero dough is sheeted to the appropriate thickness,
it's cut into three lanes of dough before a guillotine
divides the lanes into individual pieces. After makeup,
the heroes are baked in a 60-foot Mondial Forni Sistemi
tunnel oven.
All transfers and scoring are done by hand in the
Denville facility to keep things as nimble as possible.
It's also important to Anthony & Sons that the company
retains the hands-on feeling consumers expect from
Italian artisan bread. For the demi-baguette, which is
currently Anthony & Sons' No. 1 product, this oven runs
that one item for two 10-hour shifts a day.
The Avocado Bread Co. products are all created on
the high-speed bread line with a triple-deck Mondial
Forni Sistemi tunnel oven that was installed in 2022.
This is the second such oven for the bakery. The new
oven, slicing and packaging equipment for the avocado
bread were ordered just before COVID, and due to the
global logistics crisis, they were all held up in Italy.
" We're lucky we ordered it when we did because today
it would take too long to get to us, " Baldo Dattolo said.
The high-speed bread line currently dedicates 1.5
shifts to avocado bread, so Baldo Dattolo pointed out
there's still plenty of capacity. The line can produce 3,000
units per hour. After dough is mixed in the Peerless
mixer, it is divided by a WP divider that feeds a Benier
makeup line.
Dough is rounded before traveling through an overhead
proofer and then moulded. Then the avocado
breads are proofed in the final proofer for 2 hours.
The various rolls Anthony & Sons produces are all made
on one of two roll lines: a six-pocket Adamatic roll line with
a Gemini Bakery Equipment divider or an eight-pocket
Winkler line. Both are fully automated. Rolls and hoagies
are baked on a 105-foot-long Winkler tunnel oven.
Once products are baked, whether it's avocado
bread, Italian Classic or artisan bread, they cool on
one of four ambient spiral coolers: two IJ White coolers,
one G&F Systems cooler and one Vinak cooler.
Once bread is thoroughly cooled, it travels to one of
Demi-baguettes, currently Anthony & Sons' No. 1 product, cool on
a spiral conveyor before being packaged.
32 Baking & Snack May 2024 / www.bakingbusiness.com
SUSTAINABILITY JOURNEY
Five years ago, Anthony & Sons started
taking steps to pursue sustainability
initiatives to align itself with the goals its
retail customers have set.
" We're focused on all measures to be
ahead of sustainability for our customers, "
said Nick Sorresse, senior vice president,
relationship strategist.
Many of those steps have been to ensure
its products are aligned with its customers'
values. Eight of the company's products are
now Non-GMO Project verified. Anthony
& Sons is also a part of the Sustainable
Forestry Initiative that verifies ingredients
are sourced in a way that protects
biodiversity, water quality and other
environmental values. The company also
is committed to recycling its plastics and
cardboard through How2Recycle.
On the energy side, Anthony & Sons has
converted its fleet of delivery vehicles to
clean-burning fuel by using cleaner diesel
engines that are capable of operating on
bio-fuels and renewable diesel fuels. In the
bakery, the company is always looking for
ways to optimize energy consumption and
reduce energy usage.
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