Baking & Snack - September 2022 - 21

" THERE AREN'T MANY COMPANIES THAT USE A
RETARDED LAMINATED DOUGH PROCESS. MOST
COMPANIES ARE CONTINUOUS DOUGH PROCESS. "
Tom Lensing, James Skinner Baking Co.
customers and consumers but is also important
with employees.
" I talk about sustainability, and everybody's engaged,
which is great, " Mr. Keaton said. " That's how life has
changed over the past 10 years in terms of people's perceptions
and what they care about. "
Sweet steps to success
The 120,000-square-foot Omaha bakery runs four processing
lines, which produce 22 million cases of sweet
goods each year. The Red Line makes strip coffee cakes,
the White Line produces muffins, and the Blue Line
makes cinnamon rolls, individually wrapped Danish,
bow ties and braids.
A fourth line, started earlier this year in another
building, makes family-pack cinnamon rolls, strawberry
rolls and topped rolls in a variety of flavors.
The lines are fed by two Pfening 105,000-lb bulk flour
silos and a 140,000-lb Shick Esteve flour silo that was recently
installed. The bakery has two high-fructose corn
syrup tanks, including a Pfening 65,000-lb tank and
a 75,000-lb Columbian TecTank. The bakery also has
a 45,000-lb soy oil tank. The rest of the ingredients are
scaled by hand and added manually.
The bakery has seven mixers, including five Peerless
mixers and two Shaffer mixers that support the production
lines. The company also uses a Breddo Likwifier to
make icing and an AMF smear mixer for fillings.
The bakery produces 60 laminated doughs - creating
its signature 108 layers of dough and butter - every day
to make coffee cakes and individual Danish. The laminated
dough is placed in a retarding box for 24 hours at
36°F to begin the fermentation process.
" That's what's unique about Skinner, " Mr. Lensing
said. " There aren't many companies that use a retarded
laminated dough process. Most companies are continuous
dough process. "
After the retarding box, the doughs are sheeted on a
Moline Machinery line. Attachments fill and then form
the dough into the shape of the Danish. The Danish for
the Red and Blue Lines are put on a carrier before proving
for 55 minutes, and are then topped and streusel is
applied. Coffee cakes are baked in a 960 Baker Perkins
thermal tunnel gas oven and travel through the Baker
Perkins overhead cooler for 30 minutes. Danish on the
Blue Line are baked in a Baker Perkins 970-tray oven,
www.bakingbusiness.com / September 2022 Baking & Snack 21
and a RockTenn case erector supplies case packing.
The Red Line has a Schubert robotic depanner, and
the Danish on the Blue Line are manually removed from
the pans. Glaze and icing are applied to the products before
freezing. Mr. Lensing said the pans get cleaned after
each depanning cycle.
From the I.J. White spiral freezer, the coffee cakes go
through the Schubert pick-and-place packaging machine,
which handles 160 strip Danish each minute.
Product enters the machine through a central conveyor,
then are picked and placed in clamshells on belts traveling
in the opposite direction. The clamshells go through
a PMC closer, a Branson welder, Safeline metal detector
and Markem printer. A CTM labeler applies the
top and bottom label, then the product travels into the
Schubert case packer. The entire process of case forming,
erecting, loading and closing is automated with limited
changeovers. Blue Line depanning and packaging are all
done manually.
The palletized cases either go into a 35,000-squarefoot
onsite freezer, which holds 800 pallets, or are
Skinner Baking's
strip Danish travel
into robotic packaging
equipment,
which picks up the
delicate pastry in
foil pans and places
them in clamshells
moving in the opposite
direction on
either side of the
belt.
http://www.bakingbusiness.com

Baking & Snack - September 2022

Table of Contents for the Digital Edition of Baking & Snack - September 2022

Baking & Snack - September 2022 - Intro
Baking & Snack - September 2022 - 1
Baking & Snack - September 2022 - 2
Baking & Snack - September 2022 - 3
Baking & Snack - September 2022 - 4
Baking & Snack - September 2022 - 5
Baking & Snack - September 2022 - 6
Baking & Snack - September 2022 - 7
Baking & Snack - September 2022 - 8
Baking & Snack - September 2022 - 9
Baking & Snack - September 2022 - 10
Baking & Snack - September 2022 - 11
Baking & Snack - September 2022 - 12
Baking & Snack - September 2022 - 13
Baking & Snack - September 2022 - 14
Baking & Snack - September 2022 - 15
Baking & Snack - September 2022 - 16
Baking & Snack - September 2022 - 17
Baking & Snack - September 2022 - 18
Baking & Snack - September 2022 - 19
Baking & Snack - September 2022 - 20
Baking & Snack - September 2022 - 21
Baking & Snack - September 2022 - 22
Baking & Snack - September 2022 - 23
Baking & Snack - September 2022 - 24
Baking & Snack - September 2022 - 25
Baking & Snack - September 2022 - 26
Baking & Snack - September 2022 - 27
Baking & Snack - September 2022 - 28
Baking & Snack - September 2022 - 29
Baking & Snack - September 2022 - 30
Baking & Snack - September 2022 - 31
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Baking & Snack - September 2022 - 33
Baking & Snack - September 2022 - 34
Baking & Snack - September 2022 - 35
Baking & Snack - September 2022 - 36
Baking & Snack - September 2022 - 37
Baking & Snack - September 2022 - 38
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Baking & Snack - September 2022 - 42
Baking & Snack - September 2022 - 43
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Baking & Snack - September 2022 - 46
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Baking & Snack - September 2022 - 49
Baking & Snack - September 2022 - 50
Baking & Snack - September 2022 - 51
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Baking & Snack - September 2022 - 53
Baking & Snack - September 2022 - 54
Baking & Snack - September 2022 - 55
Baking & Snack - September 2022 - 56
Baking & Snack - September 2022 - 57
Baking & Snack - September 2022 - 58
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Baking & Snack - September 2022 - 65
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Baking & Snack - September 2022 - 70
Baking & Snack - September 2022 - 71
Baking & Snack - September 2022 - 72
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https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-september-2022
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-august-2022
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-july-2022
https://digitalbs.bakingbusiness.com/sosland/bs/-baking-snack-june-2022
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https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-april-2022
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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
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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
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