Continued from Maximum Cool

PRODUCTION ON DEMAND. Falcone's currently operates its flatbread line on the low side of its nameplate capacity. Bakers can readily increase throughput rates as demand rises. Sanitation activities take place on Saturday, a down day.
"The system is very low maintenance and low labor," Mr. Falcone said of his flatbread line. Only two operators, including a foreman, are needed to handle mixing, makeup and baking tasks. And now that the spiral conveyor rack has eliminated manual loading and unloading, manpower for packaging has been cut to between five and eight people, depending on package style.
"We make to order, and the packing schedule can change daily," Mr. Falcone said. While the bakery makes several different varieties of flatbread, managers usually schedule the line to minimize formula changeovers and maximize the number of sizes ran on a given day. Flatbread sizes include retail, food service bulk-cuts and individually wrapped items.

The change in cooling method also prompted an improvement in Falcone's food service pack. Previously, the food service products, which also cool in clear plastic trays, were hand-loaded into a master case, lined with one largeplastic bag. Now the trays, longer than those for consumer-packed
"I would like us to be more automated upstairs in cookies," Mr. Falcone said. The company recently installed an 1J. White Constant-Radius Turn to move cookies out of the oven to cooling operations.
Demand for Falcone's cookies picked up considerably during the past year. The bakery recently added a small carton pack for its chocolate chip cookies and introduced individually wrapped biscotti. It also introduced fat-free and sugar-free items. But what has attracted the most attention is the bakery's new line of bulk-packed cookies, offered under the Falcone's Cookieland brand. The line has proved very popular.
"Our supermarket customers can hardly keep these on their shelves," Mr. Falcone said. "These cookies just blow out of the stores!"
So, what happened to all those mobile racks once needed to cool flatbread? The bakery kept 2 0 for emergency backup, but the racks didn't stand idle for long. "They're upstairs now," Mr. Falcone said, "in daily use on our cookie line."
An hour's ride through the six-tier spiral proceeds smoothly for all tray-packed flatbread. The extended cooling time also adjusts the flatbread's moisture level for best shelf life.
flatbread, are overwrapped like the consumer items. Six trays make up one 5-lb shipping case.

"The box is more compact than previously, but the product sustains far less damage," Mr. Falcone said.

BACK TO WORK. With Falcone's flatbread production facility now positioned for growth, what's next?
Baking & Snack - February 1997