Baking & Snack - March 2016 - 31
OPERATIONS
Gonnella Baking
ALL SYSTEMS GO
Gonnella's newly expanded Aurora,
IL, bakery fires up the engine to build
momentum now and launch the
business into the future.
by Dan Malovany
F
For the stars to align, it normally takes years - sometimes even decades - for a stalwart business to evolve
and complete a transition that sets the stage for the next
era of heightened growth.
As Schaumburg, IL-based Gonnella Baking discovered, making the gradual move from being a Midwestern
producer of fresh-delivered specialty breads and rolls to
becoming a national supplier of frozen premium baked
goods not only takes time but also a long-term strategic
plan. That's especially true when reinventing a business
that's been a Chicagoland institution for 130 years.
To respond to constantly shifting market dynamics and a
diversifying customer base, the company initially dove into
the frozen dough arena in the late 1970s. Later, it expanded
its capabilities by acquiring a manufacturing operation in
Schaumburg in 1980 and Hazle Township, PA, in 2007.
During that period of transition, Gonnella also purchased
an 80,000-sq-ft bakery in Aurora, IL, in 2001 and turned
the shuttered facility into a modern, high-speed operation
producing packaged bread, buns and rolls - and eventually par-baked and fully baked frozen items for the foodservice, c-store and in-store bakery channels.
Altogether, these three facilities provided ample capacity as the burgeoning baking company carved a
coast-to-coast presence. With success, however, came
growing pains. In recent years, Gonnella recognized that
steadily surging demand for its products could eventually outstrip its production capabilities - especially for
frozen bread and buns.
Firing up production
To respond to this challenge, Gonnella placed a
calculated bet - the company knows there's never a
sure thing - with a multi-million-dollar investment in
its Aurora bakery. Today, it's all-systems-go at its newly
expanded 107,000-sq-ft facility.
Following a 58,000-sq-ft addition completed last year,
the Aurora plant's new bread and bun line increases the
throughput of the original operation by more than 60%.
Buns seamlessly march out of the continuous proofer
and oven at 800 pieces a minute compared with 550
pieces a minute before.
But that's only half the story. The facility has been outfitted with the infrastructure to install a second bun line
that could quickly double bun production to 1,600 pieces a minute. Specifically, major systems - the ingredient handling, proofer, oven and automated pan handling
Three spiral coolers handle production from the upgraded hearth and new highspeed bread and bun lines.
Vito Palmisano
www.bakingandsnack.com / March 2016 Baking & Snack 31
http://www.bakingandsnack.com
Baking & Snack - March 2016
Table of Contents for the Digital Edition of Baking & Snack - March 2016
Baking & Snack - March 2016
Table of Contents
Table of Contents
Editorial - A whole new ballgame
Newsfront - Oprah’s bread claim underpinned by science
‘I LOVE BREAD’ gains momentum
Survey: Natural labels may mislead consumers
La Brea Bakery commits to non-GMO artisan bread
Mondelez positioning paying off
People/In Brief
Tax Credits - What a Relief!
IBIE 2016 - Taking a Vertical Leap
ABA tackles the ‘workforce gap’
Gonnella Baking - All Systems Go
Aurora shows off its colors
Hearth breads ‘bake to differ’
Bagels - Bagel Shake-Up
Convey the right message
Dietary Antioxidants - Adding Antioxidants
Specialty flour boosts antioxidant content
Food Safety - The Prevent Defense
FSMA timetables start now
Ingredient App - Cross-Over Trends
R&D Perspective - Clean and Safe...or not
Pizza Technology - A Lot of Crust
A matter of taste
What goes on top
Proofers - Proofed to Perfection
Ideal humidity for an ideal proof
Sanitation: The Final Frontier
Heat Recovery - Paths to Sustainability
Bulk Packaging - The Big Easy
Sanitation Strategies - The Year of Sanitation
Meeting Preview - TIA Goes SoCal
Events
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
Marketplace
Ad Index
New Product Spotlight
Baking & Snack - March 2016 - Baking & Snack - March 2016
Baking & Snack - March 2016 - 2
Baking & Snack - March 2016 - 3
Baking & Snack - March 2016 - 4
Baking & Snack - March 2016 - 5
Baking & Snack - March 2016 - 6
Baking & Snack - March 2016 - 7
Baking & Snack - March 2016 - 8
Baking & Snack - March 2016 - Table of Contents
Baking & Snack - March 2016 - 10
Baking & Snack - March 2016 - Table of Contents
Baking & Snack - March 2016 - Editorial - A whole new ballgame
Baking & Snack - March 2016 - 13
Baking & Snack - March 2016 - 14
Baking & Snack - March 2016 - 15
Baking & Snack - March 2016 - ‘I LOVE BREAD’ gains momentum
Baking & Snack - March 2016 - 17
Baking & Snack - March 2016 - La Brea Bakery commits to non-GMO artisan bread
Baking & Snack - March 2016 - People/In Brief
Baking & Snack - March 2016 - 20
Baking & Snack - March 2016 - Tax Credits - What a Relief!
Baking & Snack - March 2016 - 22
Baking & Snack - March 2016 - 23
Baking & Snack - March 2016 - 24
Baking & Snack - March 2016 - IBIE 2016 - Taking a Vertical Leap
Baking & Snack - March 2016 - 26
Baking & Snack - March 2016 - ABA tackles the ‘workforce gap’
Baking & Snack - March 2016 - 28
Baking & Snack - March 2016 - 29
Baking & Snack - March 2016 - 30
Baking & Snack - March 2016 - Gonnella Baking - All Systems Go
Baking & Snack - March 2016 - 32
Baking & Snack - March 2016 - 33
Baking & Snack - March 2016 - Aurora shows off its colors
Baking & Snack - March 2016 - 35
Baking & Snack - March 2016 - Hearth breads ‘bake to differ’
Baking & Snack - March 2016 - 37
Baking & Snack - March 2016 - 38
Baking & Snack - March 2016 - 39
Baking & Snack - March 2016 - 40
Baking & Snack - March 2016 - 41
Baking & Snack - March 2016 - 42
Baking & Snack - March 2016 - 43
Baking & Snack - March 2016 - 44
Baking & Snack - March 2016 - 45
Baking & Snack - March 2016 - 46
Baking & Snack - March 2016 - Bagels - Bagel Shake-Up
Baking & Snack - March 2016 - 48
Baking & Snack - March 2016 - 49
Baking & Snack - March 2016 - Convey the right message
Baking & Snack - March 2016 - 51
Baking & Snack - March 2016 - 52
Baking & Snack - March 2016 - 53
Baking & Snack - March 2016 - 54
Baking & Snack - March 2016 - Dietary Antioxidants - Adding Antioxidants
Baking & Snack - March 2016 - Specialty flour boosts antioxidant content
Baking & Snack - March 2016 - 57
Baking & Snack - March 2016 - 58
Baking & Snack - March 2016 - 59
Baking & Snack - March 2016 - 60
Baking & Snack - March 2016 - 61
Baking & Snack - March 2016 - 62
Baking & Snack - March 2016 - 63
Baking & Snack - March 2016 - 64
Baking & Snack - March 2016 - Food Safety - The Prevent Defense
Baking & Snack - March 2016 - 66
Baking & Snack - March 2016 - 67
Baking & Snack - March 2016 - 68
Baking & Snack - March 2016 - FSMA timetables start now
Baking & Snack - March 2016 - 70
Baking & Snack - March 2016 - Ingredient App - Cross-Over Trends
Baking & Snack - March 2016 - R&D Perspective - Clean and Safe...or not
Baking & Snack - March 2016 - 73
Baking & Snack - March 2016 - 74
Baking & Snack - March 2016 - Pizza Technology - A Lot of Crust
Baking & Snack - March 2016 - A matter of taste
Baking & Snack - March 2016 - 77
Baking & Snack - March 2016 - 78
Baking & Snack - March 2016 - 79
Baking & Snack - March 2016 - 80
Baking & Snack - March 2016 - 81
Baking & Snack - March 2016 - What goes on top
Baking & Snack - March 2016 - 83
Baking & Snack - March 2016 - 84
Baking & Snack - March 2016 - 85
Baking & Snack - March 2016 - 86
Baking & Snack - March 2016 - Proofers - Proofed to Perfection
Baking & Snack - March 2016 - Ideal humidity for an ideal proof
Baking & Snack - March 2016 - 89
Baking & Snack - March 2016 - Sanitation: The Final Frontier
Baking & Snack - March 2016 - 91
Baking & Snack - March 2016 - 92
Baking & Snack - March 2016 - 93
Baking & Snack - March 2016 - 94
Baking & Snack - March 2016 - 95
Baking & Snack - March 2016 - Heat Recovery - Paths to Sustainability
Baking & Snack - March 2016 - 97
Baking & Snack - March 2016 - 98
Baking & Snack - March 2016 - 99
Baking & Snack - March 2016 - 100
Baking & Snack - March 2016 - Bulk Packaging - The Big Easy
Baking & Snack - March 2016 - 102
Baking & Snack - March 2016 - 103
Baking & Snack - March 2016 - 104
Baking & Snack - March 2016 - Sanitation Strategies - The Year of Sanitation
Baking & Snack - March 2016 - 106
Baking & Snack - March 2016 - Meeting Preview - TIA Goes SoCal
Baking & Snack - March 2016 - 108
Baking & Snack - March 2016 - Events
Baking & Snack - March 2016 - 110
Baking & Snack - March 2016 - 111
Baking & Snack - March 2016 - Ingredients & Formulating
Baking & Snack - March 2016 - 113
Baking & Snack - March 2016 - Equipment & Packaging
Baking & Snack - March 2016 - 115
Baking & Snack - March 2016 - 116
Baking & Snack - March 2016 - 117
Baking & Snack - March 2016 - Patents
Baking & Snack - March 2016 - New on the Shelf
Baking & Snack - March 2016 - Marketplace
Baking & Snack - March 2016 - 121
Baking & Snack - March 2016 - 122
Baking & Snack - March 2016 - 123
Baking & Snack - March 2016 - 124
Baking & Snack - March 2016 - 125
Baking & Snack - March 2016 - 126
Baking & Snack - March 2016 - 127
Baking & Snack - March 2016 - 128
Baking & Snack - March 2016 - 129
Baking & Snack - March 2016 - 130
Baking & Snack - March 2016 - 131
Baking & Snack - March 2016 - 132
Baking & Snack - March 2016 - Ad Index
Baking & Snack - March 2016 - New Product Spotlight
Baking & Snack - March 2016 - 135
Baking & Snack - March 2016 - 136
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http://digitalbs.bakingbusiness.com/sosland/bs/2004_06_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_05_01
https://digitalbs.bakingbusiness.com/sosland/bs/2004_04_01
https://digitalbs.bakingbusiness.com/sosland/bs/2004_03_01
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