Gonnella Celebrates 125th Anniversary by wuxiangyu


									            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
                             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

                                                   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.

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
‘Bake’ to
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

                 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

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