manufacturing confectioner - Retail Confectioners International

NOVEMBER 2013
Vol. 93, No. 11
MANUFACTURING CONFECTIONER
G L OBAL SOURCE FOR CHOCOLATE , C O N F E C T I O N E R Y A N D B I S C U I T I N F O R M AT I O N
US CONFECTIONERY SALES
US REGULATION UPDATES
CONFECTIONERY ON THE INTERNET
WALNUTS, PECANS, HAZELNUTS & PEANUTS
Retail Confectioners International
Fall Regional in and around Buffalo
… where RCI members absorbed information like sponges …
he Retail Confectioners International (RCI)
regional event in Buffalo, New York, included tours
of seven confectionery-related companies. Sponge candy
is a regional favorite. During tours, each company had its
own production tips for this particular aerated confection. It is produced by some companies year-round,
while others limit manufacture of this treat to lowhumidity seasons. Beyond tours, the regional event
included formal and informal educational sessions.
T
Educational Sessions
Ganache for the Candymaker without
Scientific Training
Brian Donaghy (Tomric Systems) discussed ganache formulation with the understanding that many retail confectioners do not have a background in food science. Early in
his presentation he acknowledged that one major concern
for retailers is shelf life when trying to overcome the seasonal rush in this business.
Quality problems can occur with longer-term storage.
Some of these problems may be microbiological and some
may simply be product appearance, consistency and
mouthfeel.
Freezing can be a good way to alleviate the rush of seasonal production, but it must be done with care — in the
package sealing process, humidity levels and how the
product is defrosted.
Ganache is a stable emulsion of fat in water. “Chocolate
and water aren’t friends,” Donaghy reminded his listeners,
so candymakers must consider how these and other ingredients are blended in the structure of each confectionery
recipe. Water activity is not the same as water content.
Mold and bacteria grow quickly with high water activity,
which is a measure of how much moisture is available to
bind with other ingredients in the confection. One can
reduce available water by adding more sugar and other
solids in the formula. He shared some examples of recipes.
See article on water activity in this issue, page 59.
Leading with Emotional Intelligence
Geri Grossman (My Executive Coach) shared her
thoughts about management, beginning with the power of
listening that leaders can use in the workplace and at home.
Emotional intelligence refers to the capacity for recognizing our own feelings, for recognizing the feelings of
others, for motivating ourselves and for managing emotions well in ourselves and in our relationships. Emotional
intelligence is not about being nice all the time; it’s about
being honest. It is not about giving free reign to your feelings; it’s about being smart with emotions.
The professional benefits of emotional intelligence are improved Ten strategies to
improve emotional
communications, less workplace intelligence
stress, better problem-solving skills,
1. Learn to listen
2. Adapt to situations
improved conflict management
3. Never give up
4. Empathize
skills, effective leadership and
5. Communicate
improved relationships. One’s emo6. Set priorities
7. Go the extra mile
tional intelligence can contribute
8. Forgive
between 80 and 90 percent toward a
9. Show courage
10. Be optimistic
person’s success.
— Geri Grossman
The good news, Grossman said,
is that one can improve and develop one’s emotional
intelligence.
Business Transitions
David Jorgenson (Paramax Corp.) stressed that for family business succession, the most important advice is take
the time to plan for it.
In preparing a business for sale or other transition, it
may take an average of two or three years to complete the
exit process. For business transitions, there is an interesting balancing act required; on the one hand an owner
must promote the “wonderful company I’ve built” and on
the other hand the owner must acknowledge “I’m not
necessary for its continuing success.”
Other exit alternatives can be considered beyond outright sale: perhaps generational succession; employee or
The Manufacturing Confectioner • November 2013 19
RCI fall regional
inside sale; staged sale to outside party
(sale of portion of company in first
transaction with subsequent sale of
remainder); single transaction outside
sale (strategic sale to company already
in a similar business).
Effective preparation is the key to
a successful process.
History and Use of
Confectionery Moulds
Candy Clinic
Fruit jellies from the C Shop.
The C Shop (Birch Bay, Washington) had given seasonal employees an assignment of developing a
fruit pectin jelly. They created six
flavors: raspberry, strawberry, watermelon, lemon, orange and lime. The
company also produces wine jellies
for Christmas using products of a
local winery.
Chocolate Fetish Asheville, North
Carolina described its recent
Beth Kimmerlee shared her excitement about historic moulds in a special display at Tomric Systems.
With her is Diana Gould of Chocolate Rain Shop.
Author and collector of vintage confectionery miscellany Beth Kimmerlee spoke about the diversity of
confectionery moulds and some of
the history of their use. She presented photos of hammered metal
moulds and highly detailed moulds
for ice cream or chocolate.
Sugar boards are another type of
mould; confectioners would use a
thick sugar paste similar to royal
icing on handcarved boards to make
wedding favors. Often sugar “baskets” would be filled with Jordan
almonds at banquet tables.
Cleartoy moulds are filled with
cooked syrup. When the toy hardens
and is demoulded, light shines brightly
through the colored hard candy.
attempts at staff training and development, especially for college-aged
employees. Using handouts inspired
by training company ZingTrain,
Chocolate Fetish owners developed a
program to help employees understand that the customer is their first
priority.
“I’ve learned that people will
forget what you said, people
will forget what you did, but
people will never forget how
you made them feel.”
— Maya Angelou
Four Steps to Awesome
Customer Service
• Greet and engage every customer
• Find out what the customer wants
• Get it for them (efficently, politely,
enthusiastically)
• Go the extra mile
20 November 2013 • The Manufacturing Confectioner
New fall items from Chocolate Spike.
Chocolate Spike (Blacksburg, Virginia) offers these new confections
this season: peanut butter pretzel
haystacks and six flavors of salty
crunch bark (using combinations of
bits of almond toffee, sea salt, caramel,
red hots, potato chips, graham crackers and marshmallows).
Apple pecan caramel bark from Hilliard’s
House of Candy.
Hilliard’s House of Candy (North
Easton, Massachusetts) presented its
apple pecan caramel bark using white
chocolate, cinnamon oil, dried apples,
caramel and cinnamon sugar. Those in
attendance could take the recipe to try
at their own shops.
Marie’s Candies (West Liberty,
Ohio) presented a sample of their
latest vehicle of staff communication, their newsletter. Too often,
employees feel that information is
not shared or that bits of news spread
haphazardly, changing as they are
passed on. To assure appropriate
communication and to augment the
RCI fall regional
staff meetings and policy book, the
newsletter is produced regularly.
Tours
Ranging from an 800 sq ft production space in a shopping mall to a
10,000 sq ft facility in an industrial
park, the confectionery businesses
RCI visited during the fall regional
showed innovation and efficiency,
successful family transitions and
smart planning for new shops.
Martha Stewart Living magazine and Morkes
Chocolates’ Rat Pack.
Morkes Chocolates (Palatine,
Illinois) heard from Martha Stewart Living magazine staff who had
noticed a confectionery snake on
Morkes’ website. They asked about
producing confectionery bugs or rats
in conjunction with
the magazine’s focus
on unique Halloween
treats.
Morkes staff brainstormed and produced five chocolate
rats in a box (RatPack) and a chocolate Rat in a Trap. In
Morkes Chocolates’
addition to mention
Rat Trap.
in the magazine, the company developed a Facebook campaign to capitalize on the recognition.
Stephen Libs Finer Chocolates
(Evansville, Indiana) wanted to run
a coupon promotion because summertime is slow for them. They simply printed three coupons on a sheet,
slipped one (for 15% off ) into every
customer’s bag upon purchase and
watched for return customers. The
promotion gave a boost to sales.
Stever’s Candies
Hostess gift idea from Wahl’s.
Wahl’s Candies (Buffalo, New
York) offers a Thanksgiving centerpiece for fall holidays consisting of a
hollow moulded chocolate turkey
fastened with melted chocolate onto
a plate, decorated with fall novelties,
wrapped in cellophone and tied with
a festive bow. This product is appropriate as a hostess gift also.
Rochester, New York
When RCI toured this family business it was just beginning its peak
season — September through Easter.
“Birthday cake” decorated Oreos from Stever’s
“Bliss” from Winfrey’s.
Winfrey’s Fudge and Chocolate
(Rowley, Massachusetts) developed
its own Bliss product in response to
the book Salt Sugar Fat by Michael
Moss. The investigative reporter
wrote that a “bliss point” of beverages or food is created by food and
beverage companies by concentrating fat, salt and sugar in products to
addict consumers. Winfrey’s Bliss is
penuche fudge swirled with caramel
and sprinkled with sea salt. The candymakers at Winfrey’s suggest cooking the fudge and caramel at the
same time, then swirling them
together and sprinkling with sea salt.
Within a 3,000 sq ft production area
and 1,200 sq ft retail space, meltaways,
peanut brittle and sponge candy are
signature confections at Stever’s. In
this former residence, efficient use of
space is a high priority. Several years
ago an expansion project included the
addition of a product elevator. Some
production occurs on the second
floor, some on the first, and storage is
on the third floor, so they must plan
and adapt to each season. Candymakers roast nuts, make moulded chocolates, produce marshmallows and
other confections. Easter is the biggest
holiday for this business.
One sign seen in the shop during the
September visit: “Sponge Candy season
is almost here! … It takes its name
because it absorbs moisture …. season
starts as soon as the weather changes in
the fall, usually by October 1.”
The Manufacturing Confectioner • November 2013 21
RCI fall regional
Spacing and lighting in the showroom allows for easy
customer shopping in the attractively decorated area.
An innovation demonstrated in this shop was the special paper-cutting device to wrap different size boxes.
Mike Wahl’s father developed the Peppy Pumper pneumatic metering pumps for accurate chocolate depositing.
Stever’s Candies’ well-lit and well-organized displays include many
chocolate moulded items.
The Palace of Sweets Blasdell, New York
With the swift movements of experience,
Mike Wahl showed RCI
visitors how the exterior edges of each
batch of sponge candy
are removed with this
bandsaw blade. More
than 50 percent of
every batch is insufficiently aerated so
it must be disposed of.
Easter is a major holiday for Wahl’s. They estimate 40 percent of their business is during that season. They have a
separate room reserved for Easter treats.
One of Wahl’s confections is the Charlie Chaplin, a
marshmallow, chocolate and coconut treat.
Oliver’s Candies Batavia, New York
Willing staff ready to serve with chocolate, ice cream or gift purchase from
the Palace of Sweets
With only 800 sq ft production space, the Palace of
Sweets has to be efficient. Sponge candy, butter crunch,
peanut brittle and chocolate-covered pretzels are some of
their signature items. The multifunctional space behind
the retail area of the McKinley Mall location is used to
produce all the candies. The retail space is beautifully presented with gifts, ice cream, candy and a display of antique
candy moulds.
This family-owned business was founded in 1895.
Wahl’s Candies Buffalo, New York
After Wahl’s Candies was founded in 1938, it experienced
growth and several moves. In 2004, third-generation
owner Mike Wahl and his wife Kathy planned for and
built a new facility with great attention to detail. Its current 6,000 sq ft of production space accomodates a
smooth flow of raw materials through production and
packaging.
22 November 2013 • The Manufacturing Confectioner
Oliver’s Candies store displays feature prepackaged boxes, baskets
and gifts at a large range of price points.
Starting by blanching peanuts in their home and selling
them directly to stores and gas stations, Oliver’s Candies was
established in 1932. Eventually the company developed
other products to offer, such as cashew glaze. Oliver’s is now
owned by the Quincey family. They hand-dip, mould,
enrobe and package. They are known for ribbon candy
and candy canes, also.
RCI fall regional
Joseph Fowler created and sold confections for the 1901
Pan American Expo in Buffalo. He and brother Claude
started a candy store together. Later, Claude started his own
business focused on taffy and candied apples. Succeeding
generations continued the chocolate business after Joseph’s
passing. In 1968 the company moved operations to a
10,000 sq ft building.
Fowler’s Chocolate Co. Buffalo, New York
Tomric Systems Buffalo, New York
A Fowler’s employee fed the enrobing machine with sponge candy,
observed by Kathy Bomboy-Casteel (Bomboy’s Home Made Candies).
Sponge candy is the main product, year-round, at
Fowler’s. Half their business is retail, with the remainder
wholesale and corporate business. The candymakers flavor the sponge candy inside with raspberry, orange, cinnamon, peppermint, PB&J, pumpkin, etc. Some of their
other featured products include Buffalo Wing Candy
Pizza and other moulded items.
Founded as Tomric Plastics in 1962 with the intent to provide plastic chocolate moulds for confections, the company
now manufactures its own designs, and is also a distributor of
moulds from other manufacturers. It addition, Tomric
designs and manufactures stock and custom plastic tray packaging for the confectionery, bakery and biscuit industries.
Featured during the tour of the company was its mould-making creative process, including time with the artists who begin
with sculptures in clay. As details are improved along the way
from prototype to final mould, many steps and materials
(clay, silicon, epoxy, plaster) are involved.
INTRODUCING
SAVAGE Re-Engineered
WC SMITH ENROBING LINE
Updated to today’s PLC Touch-Screen control technology and current
manufacturing methods, Savage re-introduces the 16”/400mm and
24”/600mm chocolate coating lines. The lines are uniquely designed with
‘plug-n-play’ modules for easy and flexible future expansion. Modules
include Pre-Bottomer with Cold Plate, Enrober, self-contained Cooling
Tunnel sections with two or three cooling zones, and in-feed and packout tables. Space for hand decorating or automatic stringer is included.
The line features a single PLC control for belt speed with tracker and all
functions.
1125 Lunt Avenue, Elk Grove Village, IL 60007 USA
www.SavageBros.com
[email protected]
847-981-3000
The Manufacturing Confectioner • November 2013 23
RCI fall regional
Kettle Talks
Brian Donaghy demonstrated some of the Selmi equipment at Tomric
The 12,000 sq ft warehouse allows for storage of items
coded by lot numbers for each customer.
Tomric is the North American distributor for Selmi
Chocolate Machinery.
ModPac Buffalo, New York
As a manufacturer of custom folding cartons and stock
packaging, ModPac also personalizes print products including invitations, napkins, matches, glassware and gift bags
and more. Representatives from the company showed RCI
visitors their process from sheeting to shipping throughout
the company’s 500,000 sq. ft of production area.
Global Source Directory of Ingredients, Equipment and Packaging
JJUL
JULY
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2013
V ol. 9
93,
3 , No.
No. 7
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CONFECTIONER
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INGREDIENTS
This session, an opportunity to ask a panel of experts and
others in attendance about confectionery production questions, featured David Jones Hansel & Gretel Candy Kitchen,
Jim Bourne Hilliard’s Chocolate Systems and Tim Burke
Burke Candy & Ingredient Co. Several questions were
fielded for discussion by the panel and the RCI audience.
Examples of topics included problems with prebottoming
truffles before enrobing (perhaps a belt needs to be
changed); labeling products with alcohol (each state regulations vary) and inspections by state and federal agencies
(be prepared with traceability and allergen records).
Upcoming Events
RCI will not hold a spring regional event in 2014 because of
Easter’s late date. However, space still remains at this time
for the Winter Getaway in Barbados January 20 – 24. The
annual convention and industry exposition will be held in
St. Louis June 16 – 20, 2014, and the fall regional will be
n
held in Las Vegas (date to be announced shortly).
Choice Confections
By Walter Richmond
The most complete list of supplies and suppliers to the
candy, chocolate, chewing
gum and bar line industry.
ritten primarily for
the manufacturing
retailer. The 365 formulas are given in two
batch sizes, one for
hand work and one for
machine work. There
are separate instructions for working each
batch size with suggestions for coloring and
flavoring methods. A
glossary is included of
candy and chemical
terms. 544 pages.
W
EQUIPMENT
Ingredients: company index,
ingredient index, listed
ingredients.
Equipment: company index, equipment index,
listed equipment, machinery agents.
PACKAGING
G
G
AAC
AACT
CT
T TECHNIC
ECHNICAL
ECHNICAL
AL SEMINAR
EMINAR
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ONFECTIONERY
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TIONERY SA
ALES
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Packaging: company index, packaging index,
listed packaging material and services.
Price is $50.00 per copy, please remit with order.
Shipping charges: U.S.: add $8; Canada & Mexico: add US$15
All other countries: add US$28
MC Publishing Company, Inc.
711 W Water St, PO Box 266, Princeton, WI 54968 USA
Tel: +1 (920) 295 6969 • Fax: +1 (920) 295 6843
Email: [email protected]
24 November 2013 • The Manufacturing Confectioner
$75.00
per copy, please remit with order.
Postage charges: U.S.: $8 • Canada & Mexico: US$15
All other countries: US$28
MC Publishing Company, Inc.
711 W Water St, PO Box 266, Princeton, WI 54968 USA
Tel: +1 (920) 295 6969 • Fax: +1 (920) 295 6843