Baking&Snack - September 2013 - 47

OPERATIONS
Hearthside

B

by Dan Malovany
Big, fast and agile. Those three words not only describe the perfect 350-lb lineman who can make all
of the moves on the football field. Those qualities
also make Hearthside Food Solution’s flagship facility in McComb, OH, unique, according to Dwayne
Hughes, senior vice-president, supply chain, for the
Downers Grove, IL-based contract manufacturer.
“I’ve been working in the food industry for 25
years, and this is the biggest, most flexible plant that
I have ever been in,” Mr. Hughes said.
How big is big? Sitting on 41 acres, the 1.1 millionsq-ft operation allocates 750,000 sq ft to production,
200,000 sq ft to warehousing and 150,000 sq ft to office space and other operations, including a machinery design and maintenance center and the company’s main product development lab.
How fast is fast? The facility houses 14 production lines that can crank out 150 million lb of cookies, crackers, bars, brownies and other baked snacks
on an annual basis. To produce such high volume
requires about 1.3 million lb of flour, 800,000 lb of
bulk sugar and 750,000 lb of oil a week.
And what about its agility? That’s where the
plant’s versatility enters the picture. According to
Mr. Hughes, all a customer needs to do is look at
the packaging department where a spaghetti bowl
of conveyors and a maze of 27 packaging lines can
be reconfigured at any time and in any which way
to bag, carton, tray, wrap and even place snacks in
sealed to-go cups.
Specifically, the back end of the operation can
mix and match a wide variety of equipment, including 50 vertical form/fill/seal bagging machines, 46
horizontal wrappers, 25 horizontal cartoning systems, five bag-and-box lines and one go-cup system. In all, the maintenance department monitors
5,800 pieces of equipment throughout the facility.
Even the production area presents a balancing act between fast and flexible. The bakery has
19 dough mixers — most of them in the 2,000-lb
range — and seven creme mixers. Its 14 ovens range
from 220- to 250-ft long, but only two of them are
dedicated to a single product. Otherwise, how else
could a bakery output 660 SKUs of products in an
ever-changing portfolio as its customer base rolls
out new products?
“In some bakeries, you gear up for an item,
and you run it for 15 shifts. That’s not
our business,” explained John
Aldrich, vice-president
of
manufacturing,
Ohio region. “You’d

Some lines in the McComb, OH, bakery are so
versatile that they can produce wire-cut, die-cut,
extruded and other varieties of cookies.

Streams of crackers travel along a
conveyor to the versatile packaging
department, which has 27 different lines.

September 2013 / Baking & Snack / 47



Baking&Snack - September 2013

Table of Contents for the Digital Edition of Baking&Snack - September 2013

Baking&Snack - September 2013
Table of Contents
Table of Contents
Editorial - Burning Down the House
Newsfront - Hostess to invest $70 million more in bakeries
Drake’s cakes return to the market
BBU to close Pennsylvania bakery
Snacking fuels Kellogg’s hunger for growth
Flowers secure in snack cake business
People/In Memoriam
Special Report - ACE Incubator
Construction Report - Expanding for Greater Flexibility
Striving for LEED Gold
Operations - Hearthside
What is co-manufacturing?
Gaining access to decision makers
Striving for ‘Best in Class’
Making strategic investments
Fast and Flexible
Scaling up new products
Q&A - Construction Management
Bread - No Pain, No Gain
Company values resonate with consumers
Flowers Foods sees growth, new markets from Hostess
BBU anticipates intense competition to continue
Formulation - Great Gluten-Free Expectations
Why add extra gluten anyway?
FDA makes it official
Frying Oils - Fry with Stability
Next up: high-oleic, high-stearic sunflower
Good news for palm
Ingredient App - Serve and Protect
Instead of One Good Egg
R&D Perspective - How Times Have Changed
Showcasing raisins on an international stage
Case Study - First in Flexibility
Ingredient Handling - Software’s the Solution
Calibrating load cells
Pizza Processing - As the Pizza Spins
Lightning-fast sanitation
Reducing waste
Tech Showcase - Delivering the Best Results
Q&A - The Road to FSMA
Be FSMA-ready with HACCP systems
Food Safety - FSMA on the Global Stage
IFT launches food traceability center
FDA concerned about tree nut safety
BEMA/BIF - Educating the Industry
B&CMA - New Chapter Opens
SFA - New Leader, New Strategy
SFA analyzes ‘Smart Snacks in School’ rule
TIA - All about Increasing Yields
Preventive maintenance reduces waste
Process Expo Meeting Preview - University-Style Learning
IBIE Meeting Preview - Last-Minute Matters
IBIE Education Preview
Events
Industry Images - Working the Show
Innovations
Products & Packaging
New on the Shelf
Marketplace
Ad Index
New Product Spotlight
Baking&Snack - September 2013 - Baking&Snack - September 2013
Baking&Snack - September 2013 - 2
Baking&Snack - September 2013 - FC1
Baking&Snack - September 2013 - FC2
Baking&Snack - September 2013 - 3
Baking&Snack - September 2013 - 4
Baking&Snack - September 2013 - 5
Baking&Snack - September 2013 - 6
Baking&Snack - September 2013 - 7
Baking&Snack - September 2013 - 8
Baking&Snack - September 2013 - Table of Contents
Baking&Snack - September 2013 - 10
Baking&Snack - September 2013 - Table of Contents
Baking&Snack - September 2013 - Editorial - Burning Down the House
Baking&Snack - September 2013 - 13
Baking&Snack - September 2013 - Newsfront - Hostess to invest $70 million more in bakeries
Baking&Snack - September 2013 - 15
Baking&Snack - September 2013 - BBU to close Pennsylvania bakery
Baking&Snack - September 2013 - 17
Baking&Snack - September 2013 - Flowers secure in snack cake business
Baking&Snack - September 2013 - 19
Baking&Snack - September 2013 - People/In Memoriam
Baking&Snack - September 2013 - 21
Baking&Snack - September 2013 - 22
Baking&Snack - September 2013 - Special Report - ACE Incubator
Baking&Snack - September 2013 - 24
Baking&Snack - September 2013 - 25
Baking&Snack - September 2013 - Construction Report - Expanding for Greater Flexibility
Baking&Snack - September 2013 - 27
Baking&Snack - September 2013 - 28
Baking&Snack - September 2013 - 29
Baking&Snack - September 2013 - 30
Baking&Snack - September 2013 - 31
Baking&Snack - September 2013 - 32
Baking&Snack - September 2013 - 33
Baking&Snack - September 2013 - Striving for LEED Gold
Baking&Snack - September 2013 - 35
Baking&Snack - September 2013 - Operations - Hearthside
Baking&Snack - September 2013 - 37
Baking&Snack - September 2013 - What is co-manufacturing?
Baking&Snack - September 2013 - 39
Baking&Snack - September 2013 - 40
Baking&Snack - September 2013 - Gaining access to decision makers
Baking&Snack - September 2013 - 42
Baking&Snack - September 2013 - Striving for ‘Best in Class’
Baking&Snack - September 2013 - Making strategic investments
Baking&Snack - September 2013 - 45
Baking&Snack - September 2013 - Fast and Flexible
Baking&Snack - September 2013 - 47
Baking&Snack - September 2013 - Scaling up new products
Baking&Snack - September 2013 - 49
Baking&Snack - September 2013 - 50
Baking&Snack - September 2013 - 51
Baking&Snack - September 2013 - 52
Baking&Snack - September 2013 - 53
Baking&Snack - September 2013 - 54
Baking&Snack - September 2013 - 55
Baking&Snack - September 2013 - 56
Baking&Snack - September 2013 - Q&A - Construction Management
Baking&Snack - September 2013 - 58
Baking&Snack - September 2013 - 59
Baking&Snack - September 2013 - Bread - No Pain, No Gain
Baking&Snack - September 2013 - 61
Baking&Snack - September 2013 - Company values resonate with consumers
Baking&Snack - September 2013 - 63
Baking&Snack - September 2013 - 64
Baking&Snack - September 2013 - 65
Baking&Snack - September 2013 - Flowers Foods sees growth, new markets from Hostess
Baking&Snack - September 2013 - 67
Baking&Snack - September 2013 - 68
Baking&Snack - September 2013 - 69
Baking&Snack - September 2013 - 70
Baking&Snack - September 2013 - 71
Baking&Snack - September 2013 - 72
Baking&Snack - September 2013 - 73
Baking&Snack - September 2013 - BBU anticipates intense competition to continue
Baking&Snack - September 2013 - 75
Baking&Snack - September 2013 - 76
Baking&Snack - September 2013 - Formulation - Great Gluten-Free Expectations
Baking&Snack - September 2013 - Why add extra gluten anyway?
Baking&Snack - September 2013 - 79
Baking&Snack - September 2013 - 80
Baking&Snack - September 2013 - 81
Baking&Snack - September 2013 - 82
Baking&Snack - September 2013 - 83
Baking&Snack - September 2013 - 84
Baking&Snack - September 2013 - 85
Baking&Snack - September 2013 - FDA makes it official
Baking&Snack - September 2013 - 87
Baking&Snack - September 2013 - 88
Baking&Snack - September 2013 - 89
Baking&Snack - September 2013 - 90
Baking&Snack - September 2013 - Frying Oils - Fry with Stability
Baking&Snack - September 2013 - 92
Baking&Snack - September 2013 - 93
Baking&Snack - September 2013 - 94
Baking&Snack - September 2013 - Next up: high-oleic, high-stearic sunflower
Baking&Snack - September 2013 - Good news for palm
Baking&Snack - September 2013 - 97
Baking&Snack - September 2013 - 98
Baking&Snack - September 2013 - 99
Baking&Snack - September 2013 - Ingredient App - Serve and Protect
Baking&Snack - September 2013 - 101
Baking&Snack - September 2013 - Instead of One Good Egg
Baking&Snack - September 2013 - 103
Baking&Snack - September 2013 - R&D Perspective - How Times Have Changed
Baking&Snack - September 2013 - Showcasing raisins on an international stage
Baking&Snack - September 2013 - 106
Baking&Snack - September 2013 - Case Study - First in Flexibility
Baking&Snack - September 2013 - 108
Baking&Snack - September 2013 - 109
Baking&Snack - September 2013 - 110
Baking&Snack - September 2013 - 111
Baking&Snack - September 2013 - 112
Baking&Snack - September 2013 - Ingredient Handling - Software’s the Solution
Baking&Snack - September 2013 - 114
Baking&Snack - September 2013 - 115
Baking&Snack - September 2013 - 116
Baking&Snack - September 2013 - 117
Baking&Snack - September 2013 - 118
Baking&Snack - September 2013 - 119
Baking&Snack - September 2013 - Calibrating load cells
Baking&Snack - September 2013 - 121
Baking&Snack - September 2013 - 122
Baking&Snack - September 2013 - Pizza Processing - As the Pizza Spins
Baking&Snack - September 2013 - Lightning-fast sanitation
Baking&Snack - September 2013 - 125
Baking&Snack - September 2013 - 126
Baking&Snack - September 2013 - 127
Baking&Snack - September 2013 - Reducing waste
Baking&Snack - September 2013 - 129
Baking&Snack - September 2013 - 130
Baking&Snack - September 2013 - 131
Baking&Snack - September 2013 - 132
Baking&Snack - September 2013 - Tech Showcase - Delivering the Best Results
Baking&Snack - September 2013 - 134
Baking&Snack - September 2013 - 135
Baking&Snack - September 2013 - 136
Baking&Snack - September 2013 - 137
Baking&Snack - September 2013 - 138
Baking&Snack - September 2013 - 139
Baking&Snack - September 2013 - 140
Baking&Snack - September 2013 - Q&A - The Road to FSMA
Baking&Snack - September 2013 - Be FSMA-ready with HACCP systems
Baking&Snack - September 2013 - 143
Baking&Snack - September 2013 - 144
Baking&Snack - September 2013 - Food Safety - FSMA on the Global Stage
Baking&Snack - September 2013 - 146
Baking&Snack - September 2013 - 147
Baking&Snack - September 2013 - IFT launches food traceability center
Baking&Snack - September 2013 - FDA concerned about tree nut safety
Baking&Snack - September 2013 - 150
Baking&Snack - September 2013 - BEMA/BIF - Educating the Industry
Baking&Snack - September 2013 - 152
Baking&Snack - September 2013 - 153
Baking&Snack - September 2013 - 154
Baking&Snack - September 2013 - 155
Baking&Snack - September 2013 - 156
Baking&Snack - September 2013 - 157
Baking&Snack - September 2013 - 158
Baking&Snack - September 2013 - B&CMA - New Chapter Opens
Baking&Snack - September 2013 - 160
Baking&Snack - September 2013 - 161
Baking&Snack - September 2013 - 162
Baking&Snack - September 2013 - SFA - New Leader, New Strategy
Baking&Snack - September 2013 - SFA analyzes ‘Smart Snacks in School’ rule
Baking&Snack - September 2013 - 165
Baking&Snack - September 2013 - 166
Baking&Snack - September 2013 - TIA - All about Increasing Yields
Baking&Snack - September 2013 - Preventive maintenance reduces waste
Baking&Snack - September 2013 - 169
Baking&Snack - September 2013 - 170
Baking&Snack - September 2013 - Process Expo Meeting Preview - University-Style Learning
Baking&Snack - September 2013 - 172
Baking&Snack - September 2013 - 173
Baking&Snack - September 2013 - 174
Baking&Snack - September 2013 - IBIE Meeting Preview - Last-Minute Matters
Baking&Snack - September 2013 - 176
Baking&Snack - September 2013 - 177
Baking&Snack - September 2013 - 178
Baking&Snack - September 2013 - 179
Baking&Snack - September 2013 - 180
Baking&Snack - September 2013 - 181
Baking&Snack - September 2013 - 182
Baking&Snack - September 2013 - IBIE Education Preview
Baking&Snack - September 2013 - 184
Baking&Snack - September 2013 - 185
Baking&Snack - September 2013 - 186
Baking&Snack - September 2013 - 187
Baking&Snack - September 2013 - 188
Baking&Snack - September 2013 - 189
Baking&Snack - September 2013 - 190
Baking&Snack - September 2013 - Events
Baking&Snack - September 2013 - Industry Images - Working the Show
Baking&Snack - September 2013 - 193
Baking&Snack - September 2013 - Innovations
Baking&Snack - September 2013 - 195
Baking&Snack - September 2013 - 196
Baking&Snack - September 2013 - 197
Baking&Snack - September 2013 - Products & Packaging
Baking&Snack - September 2013 - 199
Baking&Snack - September 2013 - 200
Baking&Snack - September 2013 - 201
Baking&Snack - September 2013 - 202
Baking&Snack - September 2013 - New on the Shelf
Baking&Snack - September 2013 - 204
Baking&Snack - September 2013 - Marketplace
Baking&Snack - September 2013 - 206
Baking&Snack - September 2013 - 207
Baking&Snack - September 2013 - 208
Baking&Snack - September 2013 - 209
Baking&Snack - September 2013 - 210
Baking&Snack - September 2013 - 211
Baking&Snack - September 2013 - 212
Baking&Snack - September 2013 - Ad Index
Baking&Snack - September 2013 - New Product Spotlight
Baking&Snack - September 2013 - 215
Baking&Snack - September 2013 - 216
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