Baking & Snack - October 2021 - 98

RUNNING BEYOND CAPACITY
Top: Scheduling
less overlap on shift
changes can help
bakeries extend their
labor and optimize
production uptime.
Ryan Alcantara
Bottom: A retarder
can allow bakeries
to consolidate
production runs.
Wayne Dion
lines, " Mr. Arnold explained. " Ensuring that backup suppliers
of ingredients and raw materials are included in
the planning process can help if primary suppliers are
having difficulty meeting demand. "
To further exacerbate the situation, supply chain delays
and labor crunches are making it difficult for bakers
to meet that demand. Mr. Kline pointed out that bakeries
sometimes find themselves turning away business because
they simply don't have the workforce or capacity to take it
on. To prevent that, he stressed the importance of a plan.
" The best thing to do is have an awareness about your
customers, what's going on in the marketplace and understanding
where you want to be with your business, "
he said. " You have to know if you want to sustain your
business or grow because sustaining still takes planning.
And if you want to grow, how do you sufficiently grow
and keep doing what you're doing. You have to have an
idea of where you want to be and have a plan. Those who
do are handling this really successfully. "
Outside of preparation, bakers can also take steps
to maximize the efficiency of their production lines.
Changeovers, for example, create speedbumps and
prevent bakeries from reaching their full throughput
potential. Producing a wide range of SKUs with many
changeovers helped bakers meet consumer demands for
variety. But today, things have changed.
" Trying to run a bunch of short runs with long
changeovers isn't going to pay the bills, " Mr. Brixey said.
To optimize production, operations may have to have
a heart-to-heart with sales about what products can be
cut or consolidated. Mr. Brixey offered some difficult
questions bakers will need to address as they rationalize
their SKUs. " Can I consolidate that run and run it once a
week instead of five days? Do we outsource it? Where do
we make our money, and what do we keep, and what do
we cut? Do we raise prices? "
This last question may be controversial, but it holds
an upside. On the surface, increased volume may seem
good. But without the resources to produce that volume,
bakers find themselves in a potential conundrum,
running equipment and employees into the ground. By
raising prices, bakers could stem ever-climbing demand
without impacting sales growth, while also providing
some much-needed breathing room to the operations
and maintenance teams.
When consolidating SKUs into one production run,
Mr. Kline said retarders can be an asset.
" Specialty bakers have restaurant customers who may
want product first thing in the morning, and others want
them at 6 p.m., " he said. " With a retarder you can produce
Kaiser rolls for the entire day and then pull out of
the retarder exactly what you need when you need it. "
Reaching out to a co-manufacturer to take on extra
98 Baking & Snack October 2021 / www.bakingbusiness.com
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Baking & Snack - October 2021

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

Baking & Snack - October 2021 - Intro
Baking & Snack - October 2021 - 1
Baking & Snack - October 2021 - 2
Baking & Snack - October 2021 - 3
Baking & Snack - October 2021 - 4
Baking & Snack - October 2021 - 5
Baking & Snack - October 2021 - 6
Baking & Snack - October 2021 - 7
Baking & Snack - October 2021 - 8
Baking & Snack - October 2021 - 9
Baking & Snack - October 2021 - 10
Baking & Snack - October 2021 - 11
Baking & Snack - October 2021 - 12
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Baking & Snack - October 2021 - 17
Baking & Snack - October 2021 - 18
Baking & Snack - October 2021 - 19
Baking & Snack - October 2021 - 20
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Baking & Snack - October 2021 - 33
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Baking & Snack - October 2021 - 36
Baking & Snack - October 2021 - 37
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Baking & Snack - October 2021 - 60
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Baking & Snack - October 2021 - 62
Baking & Snack - October 2021 - 63
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Baking & Snack - October 2021 - 76
Baking & Snack - October 2021 - 77
Baking & Snack - October 2021 - 78
Baking & Snack - October 2021 - 79
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Baking & Snack - October 2021 - 81
Baking & Snack - October 2021 - 82
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Baking & Snack - October 2021 - 90
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Baking & Snack - October 2021 - 97
Baking & Snack - October 2021 - 98
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Baking & Snack - October 2021 - 100
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Baking & Snack - October 2021 - 140
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