Baking & Snack - May 2009 - 38
40
1,200 stores in 11 Southeast and
Mid-Atlantic states; a new Web site
with online sales; and media exposure through contests, festivals and
community events have helped get
the company noticed.
Recently, Apple Baking began contract manufacturing for
customers such as Tasty Baking
Co., producing sliced, individually packaged 3.75-oz pound cake
wedges. Tasty found the company
through a Web search.
"The mini Bundt cakes may be
one of our most promising products," Mr. DeBoer noted. "It crosses
category lines by being great for
convenience stores, vending machines and upscale food service."
REFINED UGLINESS. Investments
are only beginning at Apple Baking. On the Ugly side of operations,
the company may soon install a
new extruder to provide enhanced
consistency in weight, length and
width but not in appearance.
"This was a hurdle that had to be
overcome because machines are
normally designed to produce a
consistent appearance," Mr. DeBoer
explained. "Part of the overall investment is a feedback system from
the checkweigher to the extruder to
maintain consistent weight."
Consistency in length, width and
weight will save on product giveaway and also save on packaging
film. "The current setup produces a
wide range in product size - short
and fat to long and skinny," Mr.
DeBoer said. "It creates havoc with
wrapping and packaging." He estimated the weight variance resolution could yield close to $1 million
annually or nearly 30% in savings.
"With the new system, we hope
to achieve a product appearance
that is even more inconsistent," Mr.
DeBoer noted. "We also eliminated
proof time by changing to an auger
versus gravity feed system. While
the surface of the continuous extruded dough is smooth, when
BAKING & SNACK / May 2009
ᮡ Line operators spread apple filing over a 100-lb dough portion and then randomly run roller knives
through the dough, folding it on itself before feeding it into the extrusion hopper to create uniquely
shaped Uglies.
ᮡ Pastry dough exits the extruder as a log.
it is guillotine portioned, it is the
cut surface that becomes the top
and bottom of the pastry and that
makes the Ugly, well, ugly."
PHAT AND UGLY. Uglies are produced in Apple, Blueberry, Raspberry, Chocolate Chip and Raisin
Honey varieties. The business is
split almost evenly between Cstores and vending with a small but
growing retail presence.
The 1.5-hour production process
for Uglies starts with hand-scaled
ingredients added to the Triumph
400-lb-capacity mixer. After mix-
ing, dough is portioned into totes,
each holding approximately 100 lb
and allowed to rest.
After resting, portions of dough
are dumped on a work table where
a specific measure of apple or other
filling is added and spread across
the dough. The operator then
takes a 5-blade rotary cutter and
randomly runs the roller blades
through the dough, folding the
dough on itself several times during the process.
The dough mass is hoisted to
the hopper and extruded as a
continuous solid round ribbon. After
Baking & Snack - May 2009
Table of Contents for the Digital Edition of Baking & Snack - May 2009
Contents
Baking & Snack - May 2009 - 1
Baking & Snack - May 2009 - 2
Baking & Snack - May 2009 - 3
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https://digitalbs.bakingbusiness.com/sosland/bs/2004_02_01
https://digitalbs.bakingbusiness.com/sosland/bs/2003_12_01
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