Baking & Snack - November 2006 - 48

toppings as required. The Werner & Pfleiderer Ecotherm
Plus Duo indirect-fired oven supplied by Gemini quickly
bakes both boiled and steamed bagels. From the oven, bagels ride a conveyor upstairs to a spiral cooling system.
"Boiled bagels are new to us, so it's been a learning experience," Dan Mulloy said. "With this oven, we doubled
capacity and achieved more control. But we needed to
retrain our people to deal with different constraints."
During the early weeks of startup, Ginsburg's bagel
customer spent a week at the bakery. "Also, Atlantic City
is close to a couple of our major vendors, so we can call
them in to help," Dan Mulloy observed.
VOLUME RATED. Rye bread styles include unseeded,
seeded, pumpernickel and marble in bulk, rounds, split
loaves and sliced for retail and food service use. Bagel
varieties - plain, cinnamon raisin, onion, pumpernickel, marble, sesame, poppy, "everything," blueberry
and whole-wheat - come in 2-, 3- and 4-oz sizes and are
available in bulk, fresh, frozen, sliced and bagged for retail. The company also produces rolls tailored to specific
customer needs.
Making its rye breads, rolls and bagels, Ginsburg consumes 13 million lb of flour annually, using 250,000 lb
a week. It stores flour in two 1990s-era 110,000-lb silos,
one for roll flour, the other for bread flour. Rye flour is
received in bags and dumped into internal flour silos.
The bakery's second floor houses the dough mixing
room and its Peerless Royal horizontal mixers. "We use a
new-style trough to move doughs from the mixer to the
floor chutes," Dan Mulloy said. "It's basically a motorized
conveyor on wheels, designed for us by G&F."
The mixers discharge their dough into the mobile
trough, and the operator pushes it into place over one
of the two dough chutes leading to the downstairs W&P
bread and variety roll lines. A conveyor serves as the floor
of the trough. The operator switches it on, and it moves
the dough ahead to drop through the dough chute.
Three processing lines occupy the bakery's main floor:
a roll line, a bread line and the bagel line. Cooling operations involve both ambient and enclosed spiral coolers.
"We recently added the ambient cooler to give us an extra
hour of dwell time," Dan Mulloy explained. This is used
primarily for rye, whole-wheat and white bread supplied
fresh to casino food service operations.
Packaging offers a slicing option, and all products
travel through Goring Kerr metal detectors before release
from the bakery.
Fresh products are made early in the day, while frozen
items are done at night, going through a BOC Gases liquid nitrogen freezer before being cased for distribution.
Frozen products are then palletized, stretch-wrapped
and held briefly before transfer to the company's off-site
freezer warehouse.

50 / BAKING & SNACK / November 2006

ᮡ Housed on the second floor, mixing operations supply doughs to the three
processing lines downstairs.
Ginsburg operates three over-the-road trucks for fresh
delivery, while two reefer trucks manage transportation
to the warehouse and common carriers. "Most of our
business is handled through distributors," Dan Mulloy
said. "Some of our co-pack customers pick up their
products directly from here. One customer, for example,
leaves a trailer here on a continuing basis and picks up
five days a week."
The busy bakery employs 120 to 160 persons, depending on the season.
SUPERIOR STANDARD. Ginsburg positions itself as a
custom baker, serving customers as both consultant and
baker, "helping to identify, develop and produce the breads,
rolls and bagels that consumers crave, with custom formulations and distinctive packaging solutions," as noted by
the company's Web site, www.GinsburgBakery.com.
This means striving for, attaining and maintaining
the highest standards. The bakery consistently earns the
Superior rating from AIB International inspections.
"AIB is a tool for us to stay up to date," Dan Mulloy
said. The annual inspections help the bakery staff stay
on their toes, according to him. "AIB helps us and our
customers with the changing food safety rules that
affect operations."
He noted that AIB inspections often go into greater
detail than those done by regulatory officials. Ginsburg
takes advantage of the institute's correspondence courses and has sent several staff members to classes held at
Manhattan, KS. "Industry wise, AIB sets the standard,"
Dan Mulloy said.

http://www.GinsburgBakery.com

Baking & Snack - November 2006

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