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Gonnella Baking Co.’s board of directors
are (from left to right) Thomas Mazukelli,
treasurer, Nicholas Marcucci, president
and Ron Lucchesi, secretary.
(From left to right) Catalino “Cuco” Quirarte, general
manager; Frank Puentes, distribution center/logistics
manager; Ricardo Baez, president; Evan Jaqua, national
tortilla category manager; and Mark Haig, Eastern region
category manager helped design and open Don Pancho’s
new Halifax, N.C., facility.
2 Snack Food & Wholesale Bakery - January 2011 www.snackandbakery.com
Happy
Anniversary,
Gonnella
Gonnella Baking Co. celebrates the major milestone of 125
years in the bread baking business, mixing high technology
with old world traditions. Once a small basement ‘shop,’ the
now-extensive, leading U.S. baker of hearth breads, rolls and
fresh-baked/frozen breads and doughs is still family-owned and
operated and still takes great pride in its product.
Lauren R. Hartman, Editor-in-Chief
A
lessandro Gonnella niques, Gonnella is ensuring its success
made his “dough” for the next 125 years.
like many Italian- As the sole employee of his business,
Americans: He baked Alessandro Gonnella quickly learned
it. He founded Gon- his trade of mixing doughs, baking
nella Baking Co. in bread, delivering the products and keep-
1886 in Chicago, and has enjoyed con- ing the books for the fledgling neigh-
sistent success ever since. So success- borhood enterprise. He began making
ful in fact, that this year, the company fresh Italian- and French-style specialty
is celebrating its 125th anniversary in breads, and his little bakery began to
business. And by combining traditional thrive, just as the large company still
goodness and modern production tech- does today. Its meager beginnings in a
Photos and product shots by Vito Palmisano.
www.snackandbakery.com
tiny basement shop on the Windy City’s De
Koven Street when Gonnella churned out a
few hundred loaves a week hardly compare
to the multi-product, multi-plant, high-
speed operations of today (there are cur-
rently six production facilities total), which
produce roughly three million pounds of
product a week.
But even after an incredible 125 years,
the breads continue to rival the quality of
Gonnella’s traditional Old World Italian
flair. “We’re planning to celebrate and
have some parties, do some things for our
employees, the city and our stockholders,”
says Ron Lucchesi, company secretary and a
director of Gonnella’s board. “Being in busi-
ness this long is quite an accomplishment.” the company’s board of directors. “There breadsticks for retail sales.
The event means a great deal to the were seven company principles. Now, we It has a national distribution footprint
company, adds Thomas Mazukelli, trea- have 150 stockholders, all descendants, in frozen products and in its contract
surer and another director of the board. so the base of the pyramid is getting a lot business. Its overall business consists of
“It is a testament to the hard work of all bigger, and depending on the family you’re one-third in frozen products, one-third in
our employees over the years. Not many in, you’re either fourth or fifth generation.” fresh and one-third in contract business.
companies reach this milestone of 125 years The families operate the bakeries much And it has expanded on both coasts over at
of service.” like their grandfathers and great-grandfa- least the last 20 years. “We started produc-
ther did all those years ago, using centu- ing frozen dough [today totally some 150
Too numerous to mention ries-old methods to create rustic breads different varieties] in the 1980s,” recalls
By 1896, Alessandro Gonnella moved to a and rolls with a European hearth oven. Nick Marcucci.
larger building and brought his wife, Mari- There are approximately 33 family mem- “That was really the birth of the fro-
anna Marcucci, over from the northern bers who work for the company today. zen business,” he says. “We then began
Italian village of Barga. In the early 1900s, Their breads include Italian, Vienna, expanding our boundaries. Prior to that,
his brothers-in-law, Lawrence, Nicholas French and Tuscan, as well as soft rolls, we were geographically located in the
and Luigi Marcucci, joined him in the sub rolls, Kaiser and sandwich rolls, buns Chicago market because the fresh product
United States to assist in the growing busi- and many others, and are available to had a one-day shelf life. But the frozen
ness. By 1915, the three brothers moved to grocers and restaurants in the Midwest. market was our first foray into the national
a location on Erie Street, which is now the The company’s route distribution covers market, and that allowed us to expand our
company’s corporate headquarters. Milwaukee to Indianapolis. horizons and our sales.”
Today, Gonnella is still all in the family Gonnella also produces fresh prod- A recently introduced Thaw ‘N Sell
and is owned by the family descendants, ucts, including hearth items for grocers, bakery solution gives retailers an easy,
who make hundreds of types of bread—so restaurants and contract customers out of freshly baked option. “The Thaw ’N Sell
many, that pages and pages of stock- its Chicago and Aurora, Ill., locations. It program was created out of market demand
keeping units fill the company’s catalogs, makes fresh-baked frozen breads, rolls, pan for retailers who wanted more flexibility,”
making it almost impossible for the owners breads, ryes in numerous sizes, flavors and Tom Mazukelli points out. “The program
to count all of the SKUs. But the fami- shapes, including Traditional and Wheat caters to retailers who don’t have a bakery
lies maintain tight bonds and established “families” for distribution to Midwest- or chains that don’t have bakeries in every
traditions that allow the luscious bread to ern in-store bakeries and restaurants. In store. Even if they have a bakery, Thaw ‘N
emerge from the ovens with the same qual- the 1980s, the company expanded even Sell helps them rotate stock, offer a wider
ity that Alessandro Gonnella produced in further, establishing a frozen dough plant variety and keep up with demand on busy
his small, wood-burning oven more than a in Schaumburg, Ill., which ships in-store days. The program also helps us expand dis-
century ago. bakery and foodservice products through- tribution to new areas, such as convenient
“We incorporated in 1923,” notes out the United States. The company also stores, club stores and grocery stores.”
president Nicholas Marcucci, the third of offers a variety of bread crumbs, rolls and Gonnella also has opened a second,
At a Glance
state-of-the-art, frozen products manufac- we’re also moving into Las Vegas, New
turing facility in 2008, located in Hazle Company: Gonnella Baking Co. Mexico and California. Since I started
Township, Pa. The 100,000-sq.-ft. opera- Headquarters: Chicago, Ill. working in the family business 28 years
tion boasts highly efficient production and Website: www.gonnella.com ago, the growth in the company has been
warehousing capabilities. Plant Size (Aurora location): 60,000-plus amazing. What we’re doing in terms of ex-
“We’re very excited to have the modern sq. ft. panding our fresh-baked/frozen and frozen
Hazle Township facility online,” says Annual revenue: $150-plus million dough businesses is great.”
Ron Lucchesi. “It allows Gonnella Frozen Production lines: Two bread and roll/bun Inspected regularly, the 60,000-plus-sq.-
Products to meet the rising demand for makeup lines feeding one oven ft. Aurora plant recently earned a superior
the highest quality frozen dough items for Employees (Aurora location): 80 rating from the AIB. There are several
which we are known. We are now centrally Years in Business: 125 quality control points located throughout
located to customers on the Atlantic Sea Product list: Hearth-baked breads and the facility and one Hazard Analysis and
Board, where Gonnella products have been rolls, pan-baked breads and rolls, frozen Critical Control Points (HACCP) valida-
very well received.” dough, frozen par-baked and fully baked tion.
There’s also a fresh-bread production breads, bread crumbs. “We’re working toward the GFSI (Glob-
plant in Chicago that produces baguettes al Food Safety Initiative), and one of our
and French bread and artisan products, KEY PERSONNEL: plants just became certified in that area,”
known as Plant Two. President: Nicholas Marcucci Mike Lucchesi points out. “Two more
V-P./Dir., Contract Sales: Paul Gonnella plants are working on this as we speak and
Keeping up with demand V-P., Mktg.: Thomas Marcucci a third will come online shortly. It’s excep-
To say that business is rising as quickly V-P., Prodn.: Mike Lucchesi tional that we’re at that level already.”
as Gonnella’s bread is an understatement. Delivering product six days a week,
Treasurer: Thomas Mazukelli
“We’re undergoing a resurgence in our the five facilities accommodate sustaining
Secretary: Ron Lucchesi
brand,” Tom Mazukelli adds. For Chicago orders and can take orders by phone or the
bread connoisseurs, the Gonnella name Internet. Orders are processed for the next
is quite familiar, conjuring up visions of our customers with our production capaci- day starting at 4 p.m.
freshly baked, aromatic, crisp-crusted, ties and run a lot of volume each day at
hearth-baked bread that could be found most of the facilities to foresee the needs of A dedicated team
fresh baked every day of the year. But the our customers. We’re at the leading edge of Operating all of the plants, balancing
six sophisticated and extensive facilities are anything we need to be.” customer demands and daily deliveries and
producing bread that has quickly gained As the world has changed, so has Gon- staying competitive with the vast amount
enormous popularity nationwide. nella. The company is also enlarging its of products Gonnella makes every day
“Things over the last five years have route distribution for fresh-baked/frozen could be a logistical nightmare for any
become more competitive,” admits Tom products for both foodservice and retail company. But it works, Mike Lucchesi
Mazukelli. “Consumers have become more customers, says Paul Gonnella, vice presi- says. “It’s amazing how we get everything
health-, cost- and value-conscious, and we dent of contract sales, and “the oldest” of out the door everyday. And we’re in a
are baking fewer product varieties in our the fourth-generation of the family. “Some super-competitive—crazy competitive—
frozen division on the store level and see of our retail customers are really tak- market. But there are a lot of foundational
a greater demand for technical support. ing us on in a big way. But we have been building blocks here that employees should
Demand for Hispanic items has also grown expanding nationally for some time. Our have their names carved in. We have a
tremendously.” fresh breads are finding a national market, tremendous group of dedicated, loyal
Despite increased demands from cus- whether for restaurant chains or fresh- employees.”
tomers and consumers, as well as having baked/frozen retail. And we’re working Lots of family members work at the
to face increases in regulations and other with two of the biggest food distributors in manufacturing sites in Aurora, Schaum-
issues, the company somehow manages the country. So our Chicagoland distribu- burg and at the other plants as well as the
to balance its fast-paced production with tion base has spread out.” downtown Chicago headquarters location.
staying flexible. The company has been in the route Some of the employees have generations
“We bring a lot to the table,” points out business a long time, he says. “We have of family who have worked for Gonnella,
Michael Lucchesi, vice president of opera- made sure that all of the states around Mike Lucchesi adds. “It speaks volumes
tions, Fresh Division, who took Snack Food Illinois know Gonnella very well. Now, about the company that we inherited from
& Wholesale Bakery on the tour of the we’re heading down to Kentucky, Arizona, our family. The loyalty is wonderful. Times
Aurora facility. “We balance the needs of Arkansas and several other places. I think change and things change, but we’re still
a very tight-knit group. I started more whole grain loaves of bread.
working here in my teens. We have Our top sellers in the fresh group
one gentleman who worked here for are baguettes and rolls but in the
70 years.” frozen division it’s French and Ital-
While many bakers talk about ian breads, mini French bread and
trends such as different product types ethnic-style rolls.”
hitting the market, Ron Lucchesi What is the family’s secret to
says Gonnella has seen many busi- keeping it all together? Ron Luc-
nesses consolidate. “Our customers chesi says that each individual has
continue to consolidate,” he says. an expertise. “As a whole, all of
“There are more and more demands. this bolsters the company to move
Now we’re dealing with customers forward. We’re in this boat together
that buy millions of dollars worth of and we succeed together.”
product—that demand and rightly frozen and fresh product lines.” Nothing comes easy, adds Tom
so—to be our partner in this situation.” The current economic crisis doesn’t Mazukelli. Success comes only from hard
exactly sway the many generations of work and sacrifice. “You get out of the
Keeping things going employees. The ups and downs of the business what you put into it. We have
The company can also say that it has seen economy haven’t been as much of an issue good people and have to invest in the busi-
it all. “Just working in the company—it’s as the gyrations of the commodity pricing, ness with updated equipment to become a
inbred in us how important the family says Ron Lucchesi. “Over the last 10 years, better manufacturer.”
business is and how important it is to con- it has gotten to the point that commodity But as the world changes, so do we,
tinue,” Ron Lucchesi explains. “That’s the pricing is totally unpredictable. That has says Nick Marcucci. “It’s not our grand-
challenge we have is to grow the business really changed the business for us. We’re fathers’ company. But it has been a gift
with the future generations coming up. dealing with things overseas that control handed down, and we’re kind of like the
We’re doing that by making major invest- the commodity markets–that part of the stewards now. We’d like to keep it going,
ments in plants here and in Pennsylvania business has changed dramatically.” and I would love to see it last at least
to be able to compete in the marketplaces Paul Gonnella says it’s sad to see how another 50 years.” Paul Gonnella smiles,
we’re in.” many of the little bakeries and great restau- adding, “My son is 10 years old and
Ron Lucchesi, Tom Mazukelli and Nick rants have closed. “But we always remember recently asked me if he could work in the
Marcucci say that over the decades, the that you’re never a big shot here. You do bakery someday. So we hope things keep
original bakery of course has gone from what you have to do for the business, even if on going.” SF&WB
being a “hand operation” to a mechanized that means delivering buns at 3 a.m. in a van
one, and then to multiple production facili- to make this as successful as we can.”
ties, and that means challenges. “We face
challenges, as any other baker does today, The trends
regarding financing, commodity costs and The core consumers the company targets
labor—it’s a much more complicated, have also changed, which is why Gonnella
hard-to-understand business,” says Ron continues to develop a variety of products
Lucchesi. that appeal to them, such as different types
Sustainabilty plays a role at the compa- of rolls and breads. “It’s what has taken us
ny, and it hopes to save energy by changing nationally,” says Nick Marcucci.
its plant lighting. It’s also looking at har- “We see a greater demand for quality
nessing wind energy at its plant in Hazle products and are targeting different ethnic
Township. Robotics for some of its packag- groups with bolito rolls, telera rolls, ciabi-
ing operations are also being considered, atta bread and artisan-type breads,” adds
and updated packaging graphics unify the Tom Mazukelli. “Our goal is to make good
enormous line of items with a contempo- quality products at a reasonable price.
rary, consistent and unified message. We’re trying to broaden our sales base
“We hope to expand our frozen dough by giving the consumers what they want.
division and put a facility on the West Families are smaller, so they’re looking for
Coast in the near future,” adds Tom smaller package sizes. They’re also looking
Mazukelli. “We also want to expand our for health-conscious products, so we bake
They
‘Bake’ to
Differ
Celebrating 125 years in business, Gonnella
Baking Co. operates sophisticated baking/
manufacturing facilities that produce breads,
rolls and more at rates exceeding three mil-
lion pounds a week. Join us on a tour of the
80,000-plus-sq.-ft. Aurora, Ill., facility that in-
cludes high-tech equipment, superior operating
standards and two makeup lines that provide
plenty of product to major U.S. companies.
Lauren R. Hartman, Editor-in-Chief
W
hen Gonnella acquired a plant in Aurora,
Ill., more than six years ago, it installed
new production equipment and overhauled
much of the facility, which now produces
eight luscious bread varieties—four consis-
tently each day —and assorted bread and
Gonnella’s Aurora plant produces assorted
bun products. Eight is really a drop in the bucket considering fresh bread and bun products for some of the
Gonnella’s massive stock-keeping units list. According largest, most popular food companies in the
United States. These small loaves were being
to Michael Lucchesi, vice president of operations, fresh made for nationally distributed childrens’
meal kits.
Photos by Vito Palmisano
division, the total product list for the entire
company is about 14 pages long. “We make
close to a thousand SKUs total, but we pro-
duce them at the various locations,” he says.
Employing 80 people, the Aurora fresh-
product plant supplies contract custom-
ers, including two of the largest “soup”
companies in the country. The plant starts
its baking shift at 11 p.m. There are two
makeup lines—one for bread and another
for buns—that feed a 125-ft.-long tunnel
oven. Production starts off with bread-bak-
ing and then migrates to producing buns,
then back to bread and back to buns. “We
change over the product on the lines on a
daily basis,” Lucchesi explains. “We have
Top left, dough is mixed at the front of the line on one of two mixers that accommodate the bread and the
a significant national presence in frozen
bun line. Top right, the formed meal kit buns are automatically scored on the tops after being proofed.
dough and achieve the same type of pres- Above, dough balls are dusted with flour and are deposited directly into pans.
ence in fresh-baked items.”
Equipment efficiencies and reliability in place “and the lines can talk to each quality control inspection operator.
are critical to this large-volume plant, he other,” notes Lucchesi. “The plant was laid Delivering product six days a week,
adds, which can output as much as 12,000 out very effectively. It’s very spacious here, the Aurora plant, like the other Gonnella
lbs. of product an hour. Safety is also of ut- compared to some of our smaller, land- facilities, accommodates sustaining orders
most importance, and the company aims to locked facilities in the city [of Chicago], so and can take orders by phone or the Inter-
achieve the highest standards in customer we have a lot of room to operate here.” net. Orders are processed for the next day
safety, including top inspection scores. There are several quality control points starting at 4 p.m.
Inspected regularly, the 80,000-plus-sq.-ft. located throughout the facility and one On the morning of Snack Food &
Aurora plant recently earned a superior Hazardous Analysis Critical Control Point Wholesale Bakery’s visit, the bun line was
rating from AIB. (HACCP). Each line receives daily main- producing aromatic, buttery sandwich rolls
Programmable logic line controls are tenance and inspection, the latter from a for childrens’ meal kits.
Mixing, rounding, dusting
At the head of the line is a mixing area,
equipped with two mixers that accom-
modate the bread line and the bun line,
with one mixer used for each line. In full
production, both mixers are used for each
line. Located on the outside of the plant
are three flour silos that each hold about
100,000 lbs. for production of the fresh
products, which carry a three-day shelf life
but last for as long as 14 days, depending
The buns are baked in a large oven at 400-410ºF for 30 minutes. Times and temperatures vary with the many
on the item. different fresh products produced at the facility.
Minor ingredients are scaled and manu-
ally dumped into one of the mixers. Flour 98ºF (this also varies with the product a metal detector system and are bagged in
and other ingredients are conveyed directly being made) for an hour. the packaging area. The clear bags are au-
into a scaling (weigh) hopper located above “This line can produce hamburger, hot tomatically clipped closed with a bread bag
each mixer. The hopper, which can hold dog, sub buns and several other items,” clip that incorporates a production code.
1,200 to 1,300 lbs. of dry ingredients, Lucchesi notes. “A quality control test is performed
opens directly into the mixers. Water and Just prior to proofing, line operators every hour of production,” says Lucchesi.
other liquid ingredients are pumped into check the rolls for proper pan placement. The buns can also move through a set of
the mixers and the dough is then mixed “If the bun is overlapping or not centered indexers and rotary or band slicers as well
for several minutes. The mixed dough then properly in the pan, it’s unacceptable and as orienters if they are to be sliced, Luc-
drops through a “slide” and into a dough it’s removed,” he says. chesi says. A quality check is also made
pump. After the buns are proofed, they are at this stage to inspect for any rolls with
The dough then conveys on a long belt automatically scored on the top and are imperfections. Measurements of the prod-
to the roll makeup line and heads to a bun conveyed to a staging area. “This gives the ucts are also taken to ensure they’re the
divider system. At this point, the line turns buns some time to skin over on a circulat- proper height, weight and size. “This is
at a 90-degree angle and progresses in a ing conveyor before they go to the oven,” done every 15 minutes to make sure each
long continuous flow into two hoppers says Lucchesi. product fits into the packaging properly
leading to the divider. The dough then Then, the scored buns make their way and is made to our and our customers’
moves under a set of rounding bars to a into the large oven, which bakes at 400- requirements to ensure that the customer
flour duster chute that prevents the dough 410ºF, for nine to 30 minutes, again de- gets the best possible product,” Lucchesi
from sticking (the flour dust is re-circulated pending on the product. “We’re equipped points out.
into the system). here to use pans or peel boards for certain Just before bagging, a bun stacker
Each divider creates four portioned types of hearth breads,” he continues. groups the buns into multiples. During
balls of dough at a rate of about 400 pieces In the first stage of the oven, the scores Snack Food & Wholesale Bakery’s visit,
per minute. The dough balls are dusted open on the tops of the rolls while a gold- the system placed six buns on top of anoth-
with flour using the zig-zag dusting chute. en-brown crust sets in the second stage of er six buns for a 12-pack. A final quality
At this point, if the product is to become baking and the rolls achieve a warm golden control check is made in this area. The
a round bun, it’s deposited directly onto color, or bloom, Lucchesi explains. clear film bags are then loaded in counts
a pan. If it’s molded, the dough balls are of five into the shipping trays while sen-
immediately conveyed to an intermediate Quality control checks sors help control bag pattern feeders that
(pocket) proofer. After baking, the buns are then automati- orient the bags of buns for placement into
After a short resting time, the dough cally de-panned and placed on spiral cool- the trays. The trays convey to the shipping
pieces drop out of the proofer pockets ing conveyors where they cool at ambient area where they’re stacked and loaded onto
and onto a molding board and are then temperatures for approximately an hour. trucks ready for shipment. The closed-loop
indexed into pans that hold 40 buns each Meanwhile, the empty pans convey back system requires that the trays returned
(the amount varies, depending on the size to the front of the line to be re-circulated from customers be washed in an automatic
and shape of the bun or other item being into the system. Before the pans are rein- tray washer before being reused.
made). The large pans continue conveying troduced into the line, they are tilted and “The bread line operates almost the
downstream to the final proofer, which blown off with air to remove any residu- same way, and we can place six bags of
proofs the dough at temperatures of 96- als. After cooling, the buns move through bread on a tray,” he says. The plant runs
two shifts, eight hours a day, five days a have various new things on the drawing used in the systems are sent to recyclers.
week. board, and have customers who we’re talk- “We’re a pretty light footprint of an
Even though it’s very well established, ing to right now on things that could take industry. We use a lot of power, but only
Gonnella isn’t set in its ways. “We are in- us into new levels of production. But at this at optimal times,” he continues. “We don’t
novative,” Lucchesi continues. “In terms of plant, we’re most concerned with maximiz- operate in the high-energy-use hours and
our production, there is a lot of innovation ing product throughput, one efficiency at a we wind down production at mid-day, so
in this world-class plant. We’re dealing time. As we expand into different markets, our power profile is ideal. At our other
with some of the biggest food manufactur- our next big investment could be on the plants, it’s also ideal and our frozen dough
ers in the world and we’re competitive. We packaging end, in terms of robotic pallet- plants try to balance out their energy pow-
win their business because we’re dedicated, izing and getting things ready for shipment er needs with respect to the community.”
compassionate, innovative and high-capac- without missing a stroke.”
ity. A lot of blood, sweat and tears end up As far as the packaging itself goes, the The beat goes on
culminating at this plant.” retail packaging recently got a graphic The lines at this facility hum along every
revise, and Gonnella as a company is inves- day (and night), without missing a beat.
What’s ahead? tigating ‘green’ or sustainable packaging. That’s the whole idea, says Lucchesi. “If our
Aside from adding two new indexers on Other environmental initiatives include customer wakes up and doesn’t see his bags
the bun lines to pick up 1-2% percent of adopting more energy-efficient lighting of bread delivered to his shop or store, he’s
additional throughput, and some packing systems and upgrading to more environ- in trouble,” Lucchesi says. “We can’t allow
pattern conveyors, the Aurora facility is still mentally-friendly motors, Lucchesi says. that to happen. We’ve gone through a lot
new enough that major equipment changes “We recycle plastics, paperboard, food and over the years and survived all sorts of cir-
or additions are not necessary for the other materials. Food that doesn’t make it cumstances—we even ran out of flour once
foreseeable future. “We upgrade equipment to end users is reprocessed into animal feed —but the bread gets out. We have always
on a continuous basis,” Lucchesi says. “We and other things. Used motor oil and oils maintained the operation.” SF&WB
Reprinted with permission from Snack Food and Wholesale Bakery January 2011
www.snackandbakery.com
