Packaging preferences

Highland offers many packaging styles.

“Pretty much every customer has their own case or package configuration, determined by how they run their operations,” Mr. Galenson explained.

For those preferring rolls in 6-count bags, a laned conveyor sorts the finished products into rows. The loading system for the Formost Fuji bagger creates two layers of three buns in each package. A Kwik Lok system applies clip closures. When running loaf bread, a gate located after the spiral towers diverts cooled loaves to a Bettendorf slicer ahead of the bagger.

Bulk-packed buns are routed to the LeMatic line with a horizontal slicer and a center-seal bulk packer. Each pack gets a lot code, and cases are loaded with two packs each, separated by a layer of cardboard.

Two Loma metal detectors monitor packaged goods before casing. North American box formers, case sealers and pallet wrappers finish the packaging job. Operators stack cases onto pallets, which are then stabilized with stretch wrap before they enter the freezer. The packaging line also has Atlantic poly-bag and case printers.

To better manage so many packaging styles, the company has ordered a new racking system for these materials.

While all Spartanburg products are made for food service clients and all sent to various distribution centers, some is transported by the bakery, but most goes out on the customer’s own trucks.

Ready for more

Spartanburg’s latest addition was Line No. 2, completed in July 2014 to double bun capacity. That’s when Highland Baking added a Rondo Doge line for ciabatta, folds and other stress-free products. The bakery now has the capacity to do egg wash and other pre- or post-bake wash treatments on both lines at the same time.

Stu revealed plans to expand the freezer and add a third oven in the next two or three years.

“It’s already designed,” he said. “We’re waiting for the growth that will support it.”

Those plans involve floor space already available, but there’s still more to Spartanburg. Mr. Galenson pointed to a door in the wall next to the spiral cooling towers.

“This building has another bay, 30 feet wide and the full length of the building, behind that wall,” he said.

Highland Baking takes pride in the fast pace it brings to food service product development, service and supply.

“Our speed and reaction time is across everything — developing products, taking them to market, meeting customer requirements,” Stu said. “And to be quick and nimble, you have to combine a superior staff and flexible production. Like my father has said many times: With good people, we can make anything happen.

“So far, Spartanburg has answered what we’ve needed phenomenally. For us, it’s all about the customer. And the new bakery allows us to respond to customer needs in two major ways. First, it offers freight efficiency. Second, it gives us redundancy.