Baking & Snack - November 2021 - 22

ROCKY MOUNTAIN PIES
" LABOR IS THE TOUGHEST THING
WE DEAL WITH HERE. IF YOU DON'T
HAVE WORKERS FOR THE LINE, IT
WILL ERODE PRODUCTION. "
Par Grandinetti, Rocky Mountain Pies
Infrared heat ensures a golden-brown hue.
For fruit pies, filling is deposited into the pie shells
on a Colborne pie line. The line operates with the threehead
depositor and can turn out 65 pies per minute.
Laying lattice by hand requires slowing down the line,
however, so the production team uses a foot pedal depositor
to bring things down to 35 pies per minute.
Lattice is hand cut from sheeted pie dough and five employees
lay the lattice in assembly line fashion. Fruit pies
are then sprayed with a sugar water solution to provide
browning before a photo sensor system loads the pies
into the tunnel oven automatically. Mr. Grandinetti estimated
that this system saved the company $270,000 in
labor annually when it was installed in 2006.
The rebuilt tunnel oven can turn out 1,500 to 3,000 pies
per hour depending on product type. Its 10 zones can be
adjusted to each pie's needs. Each type of pie comes with
a " traveler, " a document that informs operators of all the
settings necessary to bake that pie perfectly from size and
ingredients to oven settings and packaging.
After baking, the pies are automatically unloaded onto
a conveyor, then racked manually to cool in ambient temperature
for two to three hours before being frozen in one
of two blast freezers. Mr. Grandinetti said their next major
capital investment will be a spiral freezer. The bakery
has one that is used exclusively for holiday pies.
" You have to freeze pumpkin pies very fast or else the
tops will crack, " he said.
Once frozen, pies are packaged and driven to the offsite
frozen warehouse storage. Two Lantech box erectors
feed both packaging lines, which are largely manual
processes. Pies are packaged in crust saver shells on
one line and in cardboard boxes on the other, both by
hand. Loma metal detection ensures no foreign material
slipped into the product, and when necessary, a top and
bottom labeler will add a customer's label to the package.
After product is palletized, Lantech wrappers wrap
the products, and they are loaded onto trucks from three
dock doors. Rocky Mountain Pies has 300,000 square
feet of freezer warehouse space in Salt Lake City and
more in Belvidere, Ill., to supply the eastern half of the
United States. About 10 trucks leave for Illinois every
week loaded with frozen pies.
22 Baking & Snack November 2021 / www.bakingbusiness.com
For the few upscale restaurant accounts Rocky
Mountain Pies has, it creates pie kits on two utility lines
that mimic the back-of-house restaurant operations
from Mr. Grandinetti's Marie Callendar's days. At one
utility station, two Hobart mixers create the fillings that
are added by hand to pre-baked shells. These basic pies
can then be customized in the restaurant kitchen. The
other station features five Lucks deck ovens to bake off
pies for other restaurant and specialty accounts.
" With these two utility stations, we're slowing things
down to duplicate what they would do in the back of
their own restaurants, " Mr. Grandinetti said. " We just do
it for them. "
The company also has a quality assurance lab onsite.
Product is weighed and temperatures are checked at every
stage of the pie-making process. At the lab, samples
are tested for microbials daily and results will come back
the next day. The executive team scores product quality
every morning before pies are released to customers.
Next door to this production facility, in the same
building where ingredients are received and stored, is
a space for more production that Mr. Grandinetti plans
to expand into once the economy and labor market stabilize.
During the Western Country Pie days, that production
facility was fully operational. Though currently
emptied of equipment, the infrastructure is in place for
two new pie lines whenever Rocky Mountain Pies is
ready. With that facility operational to take on holiday
pie production, the company will be ready to take on
new business again.
" We're going to enhance our existing capabilities with
that extra building, " he said. " If our current production
line could focus on just fruit pies and we could put all
of our holiday pies in another building, we could have a
consistent run. It would make both buildings better, and
we could double our sales. "
Recruiting a team
While supply chain challenges and increased ingredient
prices are certainly putting limits on how much
Rocky Mountain Pies is willing to invest right now, Mr.
Grandinetti pointed to labor as being the most difficult
hurdle right now.
" Labor is the toughest thing we deal with here, " he
said. " If you don't have workers for the line, it will erode
production. "
With two Amazon distribution centers in Utah competing
for talent, the rules of the game have changed.
But Rocky Mountain Pies anticipated the change and
again, understood the rules and adapted in an attempt
to win more employees. Before the pandemic, the company
brought on Eric Carcellero as human resources director,
who Mr. Grandinetti credits with making Rocky
http://www.bakingbusiness.com

Baking & Snack - November 2021

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

Baking & Snack - November 2021 - Intro
Baking & Snack - November 2021 - 1
Baking & Snack - November 2021 - 2
Baking & Snack - November 2021 - 3
Baking & Snack - November 2021 - 4
Baking & Snack - November 2021 - 5
Baking & Snack - November 2021 - 6
Baking & Snack - November 2021 - 7
Baking & Snack - November 2021 - 8
Baking & Snack - November 2021 - 9
Baking & Snack - November 2021 - 10
Baking & Snack - November 2021 - 11
Baking & Snack - November 2021 - 12
Baking & Snack - November 2021 - 13
Baking & Snack - November 2021 - 14
Baking & Snack - November 2021 - 15
Baking & Snack - November 2021 - 16
Baking & Snack - November 2021 - 17
Baking & Snack - November 2021 - 18
Baking & Snack - November 2021 - 19
Baking & Snack - November 2021 - 20
Baking & Snack - November 2021 - 21
Baking & Snack - November 2021 - 22
Baking & Snack - November 2021 - 23
Baking & Snack - November 2021 - 24
Baking & Snack - November 2021 - 25
Baking & Snack - November 2021 - 26
Baking & Snack - November 2021 - 27
Baking & Snack - November 2021 - 28
Baking & Snack - November 2021 - 29
Baking & Snack - November 2021 - 30
Baking & Snack - November 2021 - 31
Baking & Snack - November 2021 - 32
Baking & Snack - November 2021 - 33
Baking & Snack - November 2021 - 34
Baking & Snack - November 2021 - 35
Baking & Snack - November 2021 - 36
Baking & Snack - November 2021 - 37
Baking & Snack - November 2021 - 38
Baking & Snack - November 2021 - 39
Baking & Snack - November 2021 - 40
Baking & Snack - November 2021 - 41
Baking & Snack - November 2021 - 42
Baking & Snack - November 2021 - 43
Baking & Snack - November 2021 - 44
Baking & Snack - November 2021 - 45
Baking & Snack - November 2021 - 46
Baking & Snack - November 2021 - 47
Baking & Snack - November 2021 - 48
Baking & Snack - November 2021 - 49
Baking & Snack - November 2021 - 50
Baking & Snack - November 2021 - 51
Baking & Snack - November 2021 - 52
Baking & Snack - November 2021 - 53
Baking & Snack - November 2021 - 54
Baking & Snack - November 2021 - 55
Baking & Snack - November 2021 - 56
Baking & Snack - November 2021 - 57
Baking & Snack - November 2021 - 58
Baking & Snack - November 2021 - 59
Baking & Snack - November 2021 - 60
Baking & Snack - November 2021 - 61
Baking & Snack - November 2021 - 62
Baking & Snack - November 2021 - 63
Baking & Snack - November 2021 - 64
Baking & Snack - November 2021 - 65
Baking & Snack - November 2021 - 66
Baking & Snack - November 2021 - 67
Baking & Snack - November 2021 - 68
Baking & Snack - November 2021 - 69
Baking & Snack - November 2021 - 70
Baking & Snack - November 2021 - 71
Baking & Snack - November 2021 - 72
Baking & Snack - November 2021 - 73
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Baking & Snack - November 2021 - 76
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Baking & Snack - November 2021 - 78
Baking & Snack - November 2021 - 79
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Baking & Snack - November 2021 - 81
Baking & Snack - November 2021 - 82
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Baking & Snack - November 2021 - 97
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Baking & Snack - November 2021 - 99
Baking & Snack - November 2021 - 100
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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
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https://www.nxtbook.com/sosland/bs/2015_12_01
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