July 2009

Vol. 20, No. 7

2009
NORTH AMERICAN
REFRIGERATED
WAREHOUSE GUIDE
EASY PULL-OUT

Private Label GROWTH

It’s in the bag.
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 &
4 A LETTER TO OUR READERS

6 REFRIGERATED FOODS REPORT

Avoid the headlines
Here are three ways to prevent foreign objects
from reaching your food.

8 COVER FEATURE Private Label

Growth
Private label growth.
It’s in the bag.
Private label frozen food processors are
stepping up to meeting growing consumer

8
interest, customer demand. Includes profiles
of Food Source LP, Victory’s Kitchen and
It’s in the bag.
Frozen Specialties Inc.

16 INSIDE THE PLANT

Pour it on
Frozen Specialties’ Archbold, Ohio, plant
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20 PACKAGING SOLUTIONS
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Microwave technologies are improving and
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26 PARTNERS IN PROGRESS

16
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FROMTHEEDITOR
BY BOB GARRISON • garrisonr@bnpmedia.com
A letter to our readers...
I
n response to the unprecedented
economic impact on most business
segments served by Refrigerated &
Frozen Foods; the magazine has made
some adjustments to maintain a strong
and viable presence in the marketplace.
Beginning with the August/Septem-
ber issue, Refrigerated & Frozen Foods
will begin to publish on a bi-monthly
basis through 2009.
An August/September issue (mailed
in September) will be followed with an
October/November issue (mailed in No-
vember) and then a December/January
issue (mailed in January of 2010).
The editorial calendar has been
enhanced for the remaining issues
in 2009, ensuring that we continue
to deliver strong, meaningful
content that you rely on to
stay on top of the latest
trends and developments
and enhance your job
performance.
Here’s a look at what’s
coming:
• The August/September
issue will feature R&FF’s
2008-09 “Processor of the
Year.”
• Our October/November issue
will include the 2010 Buyers
Guide, plus R&FF’s popular
“Ones to Watch” profiles of
GO GREEN
SWITCH TO THE
DIGITAL
FOR COMPLETE, DIGITAL ISSUES,
EDITION DS.COM
NEW PRODUCTS, INDUSTRY NEWS
ENFOO
WWW.REFRIGERATEDFROZ
4 REFRIGERATED&FROZEN FOODS July 2009
&
dynamic, up-and-coming companies
in each of six temperature-controlled
product categories.
• The December/January issue will
profile of a leading temperature-con-
trolled food processing company.
Along with these changes we will
continue to bring our regular features,
containing superior information, inside
every issue of Refrigerated & Frozen
Foods.
We’re strengthening our Web pres-
ence – at www.refrigeratedfrozenfood.
com – with breaking industry news
updates, blogs, new product
coverage and more. Starting
this month, as well, we’ll begin
posting complete digital,
page-by-page copies of the
magazine.
The editorial and
publishing staff of
Refrigerated & Frozen
Foods would like to
thank advertisers for
their continued support.
It is because of these
companies that we are
able to continue to bring
our readers the best tech-
nical articles, industry news
and product information.
Please do not hesitate to
contact me with any ques-
tions or concerns. RFF
VISIT
REFRIGERATEDFROZENFOOD.COM
AND MUCH MORE.
VOL. 20, NO. 7
BNP MEDIA
Publisher JEFF PLASTER
EDITORIAL
Editor-In-Chief BOB GARRISON
garrisonr@bnpmedia.com
Art Director MaTT BRITCHER
ADVERTISING
National Sales
JEFF PLASTER
plasterj@bnpmedia.com
International Sales
ERHARDT EISENACHER
info@eisenacher-medien.de
Reprints
DEB SOLTESZ
solteszd@bnpmedia.com
Classified Sales
SHARON WARD
wards@bnpmedia.com
AUDIENCE DEVELOPMENT
Corporate Audience Development Director
Christine A. Baloga
Audience Development Coordinator
Meghan Pratt
Multimedia Coordinator
Katie Jabour
Audience Audit Coordinator
Carolyn M. Alexander
List Rental
Postal Contact: Rob Liska at 800-223-2194 x.726
robert.liska@edithroman.com.
Email Contact: Shawn Kingston at 800-409-4443 x.828
or shawn.kingston@epostdirect.com.
For subscription information or service,
please contact Customer Service at:
Tel. (847) 763-9534 or Fax (847) 763-9538 or
e-mail: RFF@halldata.com
www.refrigeratedfrozenfoods.com
BNP CORPORATE DIRECTORS
Publishing TIMOTHY A. FAUSCH
Publishing JOHN R. SCHREI
Audience Development CHRISTINE A. BALOGA
Custom Media STEVE M. BEYER
Online Business Director DAVID P. BROWN
Information Technology SCOTT KESSLER
Finance LISA L. PAULUS
Human Resources MARLENE J. WITTHOFT
Conferences & Events SCOTT A. WOLTERS
Production VINCENT M. MICONI
Directories NIKKI SMITH
Creative MICHAEL T. POWELL
Marketing MICHELE WESTON-ROWE
Clear Seas Research SARAH CORP
Corporate Strategy Director RITA M. FOUMIA
REFRIGERATED & FROZEN FOODS (ISSN 1061-6152) is published
9 times annually, Jan,Feb,Mar,Apr,May,Jun,Jul,Aug/Sep and Oct/Nov,
by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI
48084-3333.
Telephone: (248) 362-3700, Fax: (248) 362-0317.
No charge for subscriptions to qualified individuals. Annual rate for
subscriptions to nonqualified individuals in the U.S.A.: $161.00 USD.
Annual rate for subscriptions to nonqualified individuals in Canada:
$198.00 USD (includes GST & postage); all other countries: $211.00
(int’l mail) payable in U.S. funds.
Printed in the U.S.A. Copyright 2009, by BNP Media II, L.L.C. All
rights reserved. The contents of this publication may not be reproduced in
whole or in part without the consent of the publisher. The publisher is not
responsible for product claims and representations.
Periodicals Postage Paid at Troy, MI and at additional mailing offices.
POSTMASTER: Send address changes to: REFRIGERATED &
FROZEN FOODS, P.O. Box 1080, Skokie, IL 60076.
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Change of address: Send old address label along with new address to
REFRIGERATED & FROZEN FOODS, P.O. Box 1080, Skokie, IL
60076.
For single copies or back issues: contact Gisele Manelli at (847) 405-4061
or manellig@bnpmedia.com.
www.refrigeratedfrozenfood.com
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Refrigerated Foods Report:
Food Safety Update
Avoid the headlines
Here are three ways to prevent
foreign objects from reaching your food.
By Bryan Westerby
W
e’ve all the seen newspaper headlines: “Man
finds XXX in his hamburger” or perhaps it’s
“Woman bites into XXX.”
Of course most of these outlandish cases either involve
an explainable rare occurrence or a contrived incident
(designed to get cash compensation). Regardless, the
resulting process often involves a lawsuit and damage to a
company’s image as well as its customer reputation.
In any event, foreign object control is a very real con-
cern for food manufacturers and we have a responsibility
to eliminate items that don’t belong in the formula.
Although detection equipment provides a safety net,
the most effective way to eliminate foreign objects involves
total prevention. A holistic approach includes your suppli-
ers, employees and supporting management systems. Here,
we’ll briefly look at all three areas.
Suppliers: It’s important to partner with your suppli-
ers. Have you audited or visited them? Where are potential
areas for objects to enter their system?
You should examine their systems to learn how they are
preventing foreign objects from contaminating their food
ingredient or raw material. Tell vendors about any objects
you find in shipments to your facility. Develop and intro-
duce an effective tracking system (scorecard) to measure
the performance of your suppliers in relation to foreign
objects. This would help them improve.
Employees: Employees are one of your plant’s best
defenses. Train employees to look for anything not in the
recipe. Recognize them for finding any object and thereby
preventing a customer complaint. You also should conduct
a full investigation of employee findings. Keep employees
informed of the items found and actions taken. Set reduc-
tion goals and publish them to everyone.
6 REFRIGERATED&FROZEN FOODS July 2009
Photo courtesy of The Suter Company
The bottom line is to treat each event as if it were a
complaint from your best customer. If you can put mea-
sures in place to prevent an internal problem from ever
repeating itself, you have avoided a potential complaint.
System process: A systematic approach such as FMEA
(Failure Mode Effect Analysis) can prevent foreign objects.
This involves trained, knowledgeable employees who
develop a very detailed process flow and who audit each
step for potential foreign object hazards. All potential
hazards are listed and ranked based on (1) how likely they
are to occur, (2) what the severity would be, and (3) the
probability of having this potential event. Then you should
prioritize the highest rated items and conduct follow-up
auditing to ensure your resolutions are effective.
Another key management approach is a successful pre-
ventive maintenance program — or better yet — a “predic-
tive” maintenance program. The goal is to replace wear
part or conduct inspections of equipment before failure.
In addition to these prevention measures, most opera-
tions have some foreign object detection systems. Although
these are necessary, they are not foolproof. Make it a goal
to drive down the number of events from your detection
system and react to each event as a failure followed by a
complete investigation. RFF
Bryan C. Westerby, Ph.D., is vice president quality and
food safety at The Suter Company Inc., a Sycamore, Ill.,
prepared foods processor. Westerby also is a member of
the Refrigerated Foods Association’s technical committee.
www.refrigeratedfrozenfood.com
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 COVER FEATURE

Private Label GROWTH

It’s in the bag.
Private label frozen food
processors are stepping up to
meeting growing consumer
interest, customer demand.

By Bob Garrison

I
t could the home fireplace or – given the
summertime season – the backyard fire pit. In
either place, the most enjoyable fires have the
right mix of fuel and air for embers that generate a
long, slow burn.
Similarly, the private label market is poised to
generate some considerable heat. Although the basic
fuel or business has been around for quite some time —
the right mix of elements (a recession, increased product
quality) is creating the base for sustained growth.
GfK Custom Research North America, New York,
N.Y., recently surveyed nearly 800 primary household
grocery shoppers and found that 91 percent plan to keep
buying own label products after the recession. Shoppers
say they have been impressed with private label quality and
90 percent agree that product quality is as good as or better
than national brands. About half of those surveyed also said
they would want their supermarket to carry an even broader
array of private label items. label
Perhaps most interesting, GfK found 35 percent of refrig-
shoppers are still trying private label products in catego- erated/fro-
ries where they had previously only purchased national zen meal solu-
brand items. tions; as well as
This point goes straight to the heart of the matter — or natural and organic
the center of the plate, as it were. Before now, private label foods and beverages.
hasn’t competed significantly with retail packaged frozen This portends to be es-
entrees. However, as readers will find in this month’s cover pecially interesting era of retail
feature, private label frozen prepared food companies liter- packaged food competition. We
ally are stepping up to match growing demand. say that because major branded processors in frozen entrees,
And there is increased demand in the refrigerated and pizza and snacks are themselves healthy and quite focused
frozen food categories. Clear Seas Research, Troy, Mich., on product innovation.
interviewed more than 100 retailers this May and found that No matter what, consumers will win and refrigerated and
they see large, short-term growth opportunities in private frozen food department sales should grow.

8 REFRIGERATED&FROZEN FOODS July 2009 www.refrigeratedfrozenfood.com

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COVER FEATURE
Made to order
Product quality, packaging versatility make Victory’s Kitchen a win-win proposition for retailers.
Sauce expertise fuels
growing entrée line.
AT A GLANCE:
Victory’s Kitchen Ltd.
Name: Victory's Kitchen Ltd.
Location: Toronto, Ont., Canada
Top executive: President & CEO
Allan Kliger
Products: Refrigerated and frozen
soups, entrees, sauces, salsa, chili,
dips and marinades, pizza sauces,
dressings and rice puddings
Website: www.victoryskitchen.com
10
A
dmittedly, Allan Kliger’s entre-
preneurial career didn’t start
with a dream. Rather, the story
of Kliger’s business, Victory’s Kitchen
Ltd., Toronto, begins with a challenge.
After graduating from law school in
1982, the one thing Kliger knew was
that he did not want to practice law. So
he took time to travel and think about
his next move. It was when he returned
home that Kliger found himself inspired
by the canned soups in his pantry – or
rather, by the thought that he could do
better.
“My sister once remarked, ‘As long
as you decide – whatever you do – to
be the best at it, you’ll be successful,’”
he recalls.
“I knew nothing about food. But
I started to think, ‘These [shelf stable
soups] are not as good as what there
could be and I began to take that as a
challenge.”
It was in 1985 that Kliger started to
attack that challenge. In quick order, he
went from borrowing a food proces-
sor, pots and pans to make fresh soup
in his own kitchen; to renting part of a
REFRIGERATED&FROZEN FOODS July 2009
larger commercial kitchen; to renting
commercial processing space inside a
120,000-square-foot building.
Nearly 25 years later, Kliger now
owns the same building.
“It’s amazing to think about how
we arrived here but it was just one foot
in front of the other, one customer at
a time,” he notes. “We went from a
20-gallon, tilting skillet to a 600-gallon
cook-chill steam kettle.”
Actually, Victory’s Kitchen is now
one of North America’s most diverse
and flexible private label processors of
refrigerated and frozen “spoonable”
foods including soups, sauces, salsa,
chili, dips and marinades, pizza sauces,
dressings and rice puddings. The com-
pany also has moved on to add frozen
entrees and even specialty desserts.
Meanwhile, Kliger isn’t concerned
about being the “biggest” at anything.
“While our company has grown by
leaps and bounds, our core philosophy
hasn’t changed one bit,” he says. “From
the start, the only way to get business
was to do what customers wanted us to
do, with no shortcuts. That’s still our
niche today – often the smaller, more
value-added runs that other manufac-
turers either can’t or wont do.
“There are very few companies that
are as focused or that have the produc-
tion and packaging capabilities we do,”
he continues. “Most do private label
for [production line] efficiency and try
to compromise the finished product
by simply working with ingredients or
packaging they already have.
“We’re the opposite. For us, it’s all
about doing it right the first time, and
then being consistent and uncompro-
mising day after day. Being a specialist
in this field, we’re also very quick to
turn projects around. From our experi-
ence, it shouldn’t take more than three
weeks and three tries to nail a product
perfectly. We won’t compromise on
delivering exactly the right product, 4
www.refrigeratedfrozenfood.com

and, when you know what you’re doing
it doesn’t take long.”
Kliger’s uncompromising approach is
evident in every facet of . . .
… sourcing. With its dedicated farms
in Ontario, Victory’s Kitchen is perhaps
the only private label processor to grow
and source many of its own vegetables.
To ensure consistent product quality
and taste, the company cooks its beans
from scratch, makes its own soup stocks
and blends all spices and seasonings. All
other incoming ingredients are quaran-
tined until they pass rigorous internal
QA/QC tests.
… processing. Victory’s versatile
processing equipment accommodates
products in all temperature states (shelf-
stable, refrigerated or frozen) and in all
volumes from 20 gallons to 600 gallons.
www.refrigeratedfrozenfood.com
RFF04094POWE.indd 1
July 2009 REFRIGERATED&FROZEN FOODS
… quality assurance. Kliger says
Victory’s Kitchen is ranked by NSF
Cook & Thurber in the top 10 percent
of processors worldwide for its quality
assurance programs.
… packaging. To give customers
exactly they want, Victory’s Kitchen
invests in the equipment and packag-
ing for everything from portion packs
to totes (foodservice to retail) in all
materials including plastic, glass and
paperboard.
Not surprisingly, Kliger chooses to
view today’s challenging market as op-
portunity.
“It’s been a very interesting year,”
he notes. “Tremendous inflation in raw
materials and packaging materials has
applied pressure throughout the indus-
try. Meanwhile, consumers are watch-
COVER FEATURE
ing their spending. We’ve always been
great at separating ourselves from the
pack and coming up with new ideas to
become an even more valuable business
partner for our customers, and, in to-
day’s challenging business environment,
this has become even more important
than ever.”
Of course it’s that attitude that took
Kliger quickly through 25 years at Vic-
tory’s Kitchen. Although the business
did not come as a dream ambition, it
likely will leave a lasting mark on the
Toronto native.
“It will be satisfying to look back
from a rocking chair some day and
think that we built these company one
step at a time from just the spark of an
idea, ” Kliger says. “That’s very appeal-
ing to me.” RFF
11
3/23/09 1:23:08 PM
COVER FEATURE
Fresh, homemade
pasta, sauces
reflect Food Source
approach.
That's amore
Food Source celebrates 25
years of a love and passion
for cooking, customer service.
AT A GLANCE:
Food Source LP
Name: Food Source LP
Location: McKinney, Texas
Top executives: (L-R) CEO Gaetano
Riccardi, President Richard Riccardi
Products: Frozen single and multi-
serve entrees, pastas, soups, stews,
sauces
Website: www.foodsourcelp.com
12
Q
uick. Name a long-standing
Dallas organization identified,
in part, with the color, silver?
Never mind the city’s pro football
team. The answer is Food Source LP, a
McKinney, Texas, private label frozen
entrée processor celebrating its 25th
silver anniversary.
Founded in 1984 by Italian immi-
grant and life-long chef Gaetano Ric-
cardi, the business began as a co-pack-
er and supplier of in-flight entrees. By
1995, it had doubled operations and
expanded into foodservice sales. Food
Source then became a private label
supplier in 1998, added 50 percent
more production in 2000 and pur-
chased a second facility — including
a state-of-the-art, European-designed
plant — in 2002.
“‘Thats amore,’ is the best way to
describe our company history,” says son
Richard Riccardi, a former attorney and
certified public accountant who joined
the company as president in 1991.
“Food Source got its start from my
father — out of his love and passion for
cooking delicious food.
“This year, we’re celebrating our
25th anniversary. We attribute this suc-
REFRIGERATED&FROZEN FOODS July 2009
cess to three factors: our loyal custom-
ers, dedicated team members and an
effective supplier base. We are passion-
ate about serving our customers and
our team members and suppliers allow
us to achieve those goals. Our custom-
ers have fueled our success by faithfully
allowing us the opportunity to prepare
their products. We respect the trust they
place in Food Source.”
For the record, Food Source has two
McKinney plants with about 150 team
members. The company processes and
nationally ships more than 75 SKUs
including multi- and single-serve ethnic
and homestyle entrees as well as a range
of stuffed pastas, soups, side dishes and
dips. Gaetano still leads the business
as chief executive officer and head of
culinary R&D.
“We are a very hands-on operation,”
Richard notes. “Our food preparation
area is designed to cook and prepare
components ‘restaurant-style.’ By sauté-
ing ingredients in a kettle and adding
spice and meats at just the right time,
we continue to achieve that ‘white table
cloth taste’ that keeps consumers com-
ing back.”
Food Source effectively prepares all 4
www.refrigeratedfrozenfood.com

products from scratch. Riccardi says
both plants cook fresh meats; make
fresh sauces; and prep and blend every-
thing else from fresh vegetables to real
cheese. Not surprisingly, the business
follows its own pasta recipes starting
with semolina durum flour and eggs.
Meanwhile, the company’s recipe
for success with retail private label
customers is just as basic: give them
what they want.
Richard reports on talks at the Pri-
vate Label Manufacturers Association’s
annual convention last fall.
“Let’s face it. Every penny counts
more today than ever. I believe that our
economic times have caused consumers
to switch to private label but they have
become repeat customers because of
the quality along with value,” he says.
www.refrigeratedfrozenfood.com
Rff709grote.indd 1
“What we heard from most customers
was an emphasis on growing private
label business because of consumer
interest in high quality entrees at a bet-
ter value. Retailers also talked about
lowering costs and collaborating with
suppliers to gain efficiencies.”
Food Source indeed is working
more closer to its customers. Besides
its work through branded companies,
Food Source recently established direct
private label supplier relationships with
three of the nation’s top 10 retail chains.
Behind the scenes, Riccardi says
Food Source stepped up its measured
performance in food quality and food
safety. Already reviewed by several
external audit firms, he notes that com-
pany operations successfully passed a
more robust SQF Institute audit on the
www.grotecompany.com • sales@grotecompany.com
July 2009 REFRIGERATED&FROZEN FOODS
COVER FEATURE
first attempt.
Likewise, Food Source’s R&D pro-
gram has added staff (food scientist,
certified chef) and has worked more
closely with customers on new prod-
ucts, packaging and healthier items
that meet strict nutritional values
with clean labels.
“From all indications, we are on
track to launch more products with cur-
rent [private label] customers and add
new customers,” Richard concludes.
“Meanwhile, our team is achieving
higher food safety and quality goals and
increasing our per-shift throughput.
“Wherever I travel, I visit the local
grocery stores to see what is going on.
It is very humbling and rewarding to
see our products in every part of the
United States.” RFF
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7/1/09 10:29:2013
AM
COVER FEATURE

No compromise
At a time when consumers want more, Frozen Specialties
returns to its core in frozen pizza and pizza bites.

this everyday by the value, the consis-

tency, the convenience and the quality
of the products we market.”
Purchased in 2002 by Swander
Pace Capital, Frozen Specialties has
been in the private label channel
for nearly a half a century. Over the
years, the company has been a part of
a market that’s evolved from produc-
ing alternatives of the most popular
products to creating innovative items
for store brands that actually com-
pete with the national brand equiva-
lents.
Photo by Vito Palmisano

To better focus on its best-sellers,

Frozen Specialties closed a Connecti-
cut pizza bite plant last October and
relocated operations to its Archbold,
Ohio, facility. This has helped Alva-
rez and his team better evaluate the
company’s product line and stream-
Specialist can handle
all shapes, sizes and by Marina Mayer line its portfolio.
flavor profiles. “We used to have a lot of other

AT A GLANCE:
Frozen Specialties Inc.
Name: Frozen Specialties Inc.
Location: Holland, Ohio
Top executive: President & CEO
Ricardo “Ric” Alvarez
Products: Frozen pizza, pizza bites
Website: www.frozenspecialties.com
I
n good times, consumers can be
loyal to a fault. That’s especially
true in the highly competitive
frozen pizza and snacks categories.
Here, the major players spend mil-
lions of dollars annually building
trust in their brands to ensure that
shoppers keep on coming back for
more.
With the economy as cold as a
supermarket freezercase, however,
many Americans are reassessing
their grocery purchases. Now, they
don’t have to compromise because
of companies like Frozen Specialties,
Inc., a private label producer of value
pizza and pizza bites. With its line of
products, the Holland, Ohio-based
company helps shoppers trade in
their national brand choices without
feeling that they have sacrificed qual-
ity and taste.
“Our mission is to be the con-
sumer’s choice in value pizza and
pizza bites,” says President and CEO
Ricardo “Ric” Alvarez. “We show
product categories,” Alvarez says,
“[but] we shed them, disposed them,
sold some of them, and now we’re a
really focused business on value pizza
and pizza bites.”
Officials say Frozen Special-
ties produces between 150 and 200
million pizzas per year and enough
frozen pizza bites to stretch from
New York City to San Francisco. In
terms of sheer volume, the traditional
varieties such as cheese and peppero-
ni still outpace unconventional ones,
notes Patrick Koralewski, director of
marketing.
However, the increased acceptance
of higher quality private label pizzas
has enabled Frozen Specialties to
introduce more avant-garde choices
such as barbeque chicken, garlic
chicken, bistro-style Italian margarita
and even some Mexican-style, taco
pizzas.
Loyal consumers, it seems, are ex-
panding their horizons in more ways
than one. 4

14 REFRIGERATED&FROZEN FOODS July 2009 www.refrigeratedfrozenfood.com

 COVER FEATURE

“A lot of studies recently have consumer. “I think our secret is that we

shown that consumers are much more
confident with private label. They see
it actually as a brand,” Koralewski
adds. “Consumers overall across a
lot of economic situations are finding
private label as a quality convenient,
value alternative to national brands.”
In addition to providing alterna-
tives to the national brands, Alvarez
says consumers now recognize that
many of its private labels actually
provide a better option than some
national brands.
“They realize that [private label
products] offer all the benefits that
they look for and what they want for
their family,” he notes, “and [private
label items] offer the quality, value
and convenience at an affordable
price in today’s economical environ-
ment.”
“We’re trying to marry [health and
wellness] together and understand
that people are on the move a lot,”
Alvarez says. “So there’s that single-
serve need and there’s also the health/
wellness need and some fun flavors
beyond the basic cheese and pep-
peroni.”
Once the trend changes have been
identified, Frozen Specialties partners
with its retail customers via their
R&D teams.
“We want to make sure that we’re
satisfying the needs of our retail part-
ner and are meeting the needs of their
customers,” Koralewski says.
It’s no surprise that gaining con-
sumer acceptance is a big part of the
plan.
have created a trust, a bond with
our customers because we provide
them a consistent, high-quality, value
product that is convenient at a value
price, in so many different flavors
and formats that satisfies the needs of
our valued customers,” Alvarez adds.
Consumers can rest at ease when
reexamining their grocery lists.
Companies like Frozen Specialties are
upping the ante on quality, value and
taste without it costing an arm and a
leg. RFF
Editor’s note: This article excerpted
from the May 2009 issue of Snack
Food & Wholesale Bakery, a sister
publication to Refrigerated & Frozen
Foods.

Has your facility design

Along with value, consumers
– especially those in smaller-sized
households – search for such healthy

lost its pluck?

products as pizzas that offer portion
control.
“Frozen specialties has a core
focus around our single-serve frozen If you want to stay abreast of the latest and greatest
pizza and pizza bites,” Koralewski in total facility design services, consider the
says. “There are few manufacturers international firm selected by some of the
biggest food processors in the world.
who have invested in producing piz-
zas as quickly and efficiently as Fro- Jacobs is ahead of the flock in the
zen Specialties. And this is especially field of food processing.
true on the private label side. We’ve
Go to www.jacobs.com/chicken
done a really nice job of focusing to download our exclusive
around that value, convenience and white paper.
quality and try to do it operationally
and with the products we bring to
market as well.” engineering
For instance, the megatrends of architecture
convenience, health and wellness are process integration
on the rise. Frozen Specialties has refrigeration system design
& engineering
responded to this well-established
LEED & sustainable design
movement by introducing its lean
sanitary design
and microwavable pizzas that can be
design-build
eaten for lunch while at work, on the EPCM project delivery 800.570.1985
weekends or as a dinner replacement
for the fast-paced, always-on-the-go
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www.refrigeratedfrozenfood.com July 2009 REFRIGERATED&FROZEN FOODS 15

Rff709jacobs.indd 1 6/30/09 8:41:38 AM

COVER FEATURE - INSIDE THE PLANT
AT A GLANCE:
Frozen Specialties Inc.
Name: Frozen Specialties Inc.
Location: Archbold, Ohio
Sr. Director of Operations:
Brian Replogle
Products: As many as 450 SKU's of
complete and single-serve pizzas,
pizza bites
Plant size: 150,000 square feet
Production lines:
Pizza - 3, Pizza bites - 1
Employees: Approximately 190
16
Pour it on
Frozen Specialties’ Archbold, Ohio, plant keeps pace with
increasing demand for frozen private label pizza and pizza bites.
by Marina Mayer
N
estled in a tranquil town made
up of old-fashioned diners and
1950s-style street lamps stands
Frozen Specialties Inc., a producer of
private label pizzas and pizza bites.
Aside from the few pedestrians casu-
ally strolling up and down the brick-
paved streets on a brisk March morn-
ing, there wasn’t much outdoor activity
in Archbold, Ohio. It was as if time
stood still, in more ways than one.
However it was anything but
quiet inside Frozen Specialties’
REFRIGERATED&FROZEN FOODS July 2009
Photos by Vito Palmisano
150,000-square-foot facility. Behind
closed doors, nearly 190 employees
hustled and bustled about the two-story
plant to stay on schedule and to meet
yet-another deadline for delivery of
frozen pizza and pizza bites.
“We are pretty much a make-to-
order company today,” says President
and CEO Ricardo “Ric” Alvarez. “We
receive packaging and many of our in-
gredients just in time, and we manufac-
ture to the orders that we receive from
our customers.”
As a private label manufacturer, this
Holland, Ohio-based company needs 4
www.refrigeratedfrozenfood.com
 INSIDE THE PLANT - COVER FEATURE

Frozen Specialties has its own Mr.

P's and Fox de Luxe brands for some
pizza bite and pizza sales.

to be just in time to stay abreast of and

react to today’s constantly changing
trends. In fact, the operation cranks out
more than 450 SKUs – primarily for
the private label accounts, as well as its
own Mr. P’s and Fox de Luxe brands.

Recipes for success

Frozen Specialties’ Archbold plant
has three pizza lines and one snack line.
The plant’s first floor production area
houses two steel bins that each hold
more than 100,000 pounds of flour for
the plant. Flour destined for pizza bite
production is stored in two collapsible
bins, which hold nearly 25,000 pounds
each.
Once flour is mixed into pizza
dough, Frozen Specialties will sheet and
cut it into various sizes (5 inches to 11
inches in diameter) and shapes (tradi-
tional round to rectangular). The pizza
lines even can produce non-traditional
pizza crust shapes, such as the outline
of Mickey Mouse (for work with Walt
Disney products).
Pizza dough crusts enter an impinge-
ment oven with six baking chambers.
There, they’ll bake for less than two
minutes at 400°F to 600°F. Afterward, pallet positions of product. a radio frequency identification (RFID)
baked crusts travel to one of three pizza bar coding system to organize every-
topping lines, where pizza sauce is ap- Ensuring quality thing from ingredient shipments to fin-
plied by a waterfall system. Behind the scenes, Frozen Special- ished product inventories in a real-time
Frozen Specialties will shred blocks ties has its ingredients and packag- format. For instance, every case has its
of cheese – including real mozzarella, ing materials arrive on a just-in-time own label (or “license plate”), which
real cheddar and Monterey Jack – be- basis (keeping on-site inventories low). includes such information as the SKU
fore it is sprinkled on top of the sauce. Meanwhile, the company also engages number as well as data about where
Other toppings, such as real pepperoni suppliers in a rigorous approval process, it came from, where it’s going, pallet
or ham, also are applied at this time. notes Alvarez. number and measurement size.
Topped pizzas then enter one of “It’s all about uniformity,” he says. FSI receives most orders electroni-
three spiral freezers. Inside, they’ll travel “That’s why we measure, measure, cally and it stores them (in real time) in
at a cool -20°F for about 22 minutes. measure. Our customers entrust us with a database connected to work stations
Afterward, they’ll travel on to an auto- their products.” on the plant floor. Frozen Specialties’
mated packaging area. To monitor quality and value, Frozen in-house system provides data entry
After packaging and casepacking, Specialties requires pre-sample verifica- points and monitoring graphs so that
both pizzas and pizza bites are taken to tions, continuous testing and measur- quality assurance personnel can enter –
Frozen Specialties’ 55,000-square-foot ing, certificates of analysis and ongoing and monitor – proper weights, sizes and
freezer, which is maintained at -10ºF quality tracking of shipments. other variables.
and holds up to 320,000 cases or 4,800 Interestingly, Frozen Specialties uses All information – from ingredient 4

www.refrigeratedfrozenfood.com July 2009 REFRIGERATED&FROZEN FOODS 17

COVER FEATURE - INSIDE THE PLANT

Employees inspect and weigh

product samples at one of six
quality control stations.
handling to final product inventory – then
is linked for quality control use, notes
Brian Replogle, senior director of opera-
tions.
“Everything in this facility is inter-
twined and put into our IT system, and
the information and the data are available
to all departments and evaluated daily to
make sure that we stay as efficient as we
say we are,” he says. “That’s one of our
top priorities.”
Because Frozen Specialties is a private
label manufacturer, many of its customers
bring their own auditing teams. However,
the facility recently received a superior
rating through American Institute of Bak-
ing and underwent an intensive four-week
U.S. Department of Agriculture food safety
evaluation. Additionally, the operation is
in the approval process for the new Global
Food Safety Initiative. The company ex-
pects that process to be completed by the
end of the year. RFF

Editor’s note: This article excerpted from

the May 2009 issue of Snack Food &
Wholesale Bakery, a sister publication to
Refrigerated & Frozen Foods.

18
RFF04094FRIC.indd 1
REFRIGERATED&FROZEN FOODS July 2009 www.refrigeratedfrozenfood.com
3/24/09 3:20:20 PM
packaging
SOLUTIONS
Just heating up
Microwave technologies are improving and
growing prepared food sales.
Editor’s note: For an industry insider’s
look at microwave technology trends,
Refrigerated & Frozen Foods turned
to Timothy Bohrer, founder of Pac
Advantage Consulting, LLC, Chicago.
A 30-year-plus industry veteran, Bohrer
was a featured speaker at the Inter-
national Microwave Power Institute’s
43rd annual microwave power sym-
posium this July in Washington, D.C.
He addressed the topic, “Microwave
Packaging: Past, Present & Projected.”
Refrigerated & Frozen Foods: What
trends and technologies do you
see in refrigerated and frozen food
categories?
Timothy Bohrer: Several trends here are
encouraging and exciting. Continued
growth in foods designed to only be
heated in the microwave, tells me that
the question of whether microwave-
New ConAgra offering uses popular
Healthy Choice Cafe Steamers
technology.
20
“We’re seeing an increase in the value
of products packaged for microwaving
and accordingly, we’re seeing more
complicated and sophisticated structures.”
– Timothy Bohrer,
Pac Advantage Consulting
only foods can succeed has been
answered emphatically in the positive.
That’s really important. It opens up the
door to more innovation and we don’t
have to settle for sub-optimized perfor-
mance while balancing conventional
and microwave performance.
We’ve seen an expansion of conve-
nient hand-held food products that use
active packaging – meaning susceptors,
shielding or both. Plus, there’s been the
proliferation of what people are calling
“steaming” packages, which are really
packs with limited, but controlled vent-
ing of air pressure and steam in the
heating cycle. Processors have extended
their offerings from relatively simple
products like one or more servings of
frozen vegetables to more complex side
dishes and entrées. Venting pouches
and lidding solutions for rigid tray
packages undergird this rapid growth.
Cooking products – for which
browning or crisping are not needed –
are especially suited to these approach-
es. These microwave steam products not
only benefit from moisture retention,
but also from faster cooking – because
the bulk of the energy used to vaporize
moisture is contained in the package
and can be used to heat the food.
REFRIGERATED&FROZEN FOODS July 2009
Timothy Bohrer
R&FF: So it’s a case of right place,
right time for these new offerings?
Bohrer: There are probably several
reasons why the time is right for
these products. Consumers are be-
ing told to eat more vegetables but
are also being advised not to drown
them in boiling water. It’s ideal to
steam or microwave them, as this
enhances nutrient retention and can
improve texture.
Convenient self-venting packages
have made it easy to just put a pouch
in the microwave oven for a few
minutes with no additional attention
needed, which plays to consumer in-
terest in convenience and time saving.
Finally, there is growing realization
that microwave cooking can save en-
ergy compared to many conventional
food preparation techniques.
R&FF: Processors have extended
the flexible bag microwave steam-
ing application to refrigerated pro-
duce as well as a range of frozen
items including pasta, seafood
and mashed potatoes. What do
you notice about the technologies
involved? 
www.refrigeratedfrozenfood.com
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Rff709alcan.indd 1 6/11/09 11:24:19 AM

packaging
SOLUTIONS
Honors for Southern Specialties,
Heinz microwave packages
New microwave products from Southern Specialties Inc.,
Pompano Beach, Fla., and H.J. Heinz Co., Pittsburgh, were
among those honored during the Flexible Packaging Associa-
tion’s (FPA) 53rd annual Flexible Packaging Achievement
Awards Competition this spring. FPA’s 2009 award winners
included:
Product: Southern Selects asparagus
Award(s): Highest Achievement and Gold awards for
packaging excellence
Description: “This package improves the way fresh
asparagus is sold in retail stores and the way it is prepped
and cooked by the consumer. Clean asparagus is vacuum
skinned, which improves shelf life more than traditional
packaging methods, and enables consumers to quickly steam
the asparagus in the microwave. This package also provides
consumers with a more energy efficient alternative to boiling
water.”
Supplier: Sealed Air Corp., Cryovac Food Packaging Div.
Product: Ore-Ida Steam n’ Mash mashed potatoes
Award(s): Silver award for packaging excellence
Description: “Package combines a high performance sealant
and self-venting technology for a solution that goes directly
from freezer to microwave and cooks the product without
any additional steps.This package meets the demands of
frozen food distribution, holds up to the extended cook-cycle
and safely vents excess steam to provide perfectly steamed
potatoes right out of the microwave.”
Supplier: Alcan Packaging Food Americas
22 REFRIGERATED&FROZEN FOODS July 2009
Bohrer: In the end, there are a limited number of basic ways
to create self-venting features in pouches or sealed trays.
Fully sealed packages generally depend on an area of the
pouch or lidstock with a feature that releases at some pre-
determined combination of temperature and pressure. This
prevents excessive pressure from developing, which would
result in uncontrolled package rupture or seal failure.
Solutions can be as simple as deliberately weakened seals,
peelable sealant formulations that soften at expected cook
temperatures or perforations covered by removable tapes.
There are more complex variations as well, even to the point
of one-way valves that close when temperature and pressure
is reduced.
R&FF: When it comes to the flexible bag market, are
you still seeing new technologies continuing to enter
the market or are we seeing the same technologies –
now simply being applied to new product categories?
Bohrer: We’re seeing an increase in the value of products
packaged for microwaving and accordingly, we’re seeing
more complicated and sophisticated structures. For example,
there are more packages with reverse printing and upscale
graphics to portray a premium positioning.
I think there will be more “hybrid” technology entries.
Perhaps these will offer combinations of several technologies
– especially as content weights increase and you have more
challenges to balance cooking between components such as
vegetables and proteins.
R&FF: We’re seeing microwave packaging technologies
from North America, Europe and Asia. Any thoughts on
such global market competition?
Bohrer: What stands out to me is the seemingly simultaneous
global nature in the growth of the “steamer” packages. Sure,
there were pockets of activity before, with the United King-
dom’s refrigerated ready meal market probably leading the
way. However, it’s been interesting to watch suppliers and
processors extend the technology into frozen and even some
shelf-stable formats.
Meanwhile, there’s been a sort of “rediscovery” that
steaming some foods is a very good way to prepare them.
It’s terrific for our industry that packaging can simplify what
is otherwise a somewhat cumbersome preparation method
using conventional appliances and cookware.
To your point about the various global markets, there are
ample [packaging] solutions to choose from in all geographic 
www.refrigeratedfrozenfood.com

regions, which also is
positive for food companies
interested in entering the
sector with new products.
R&FF: We’re seeing more
microwaveable products
involved uncooked foods.
What are your thoughts
about this growing market?
Bohrer: I’m not surprised. Some foods
don’t freeze well after cooking and
their texture and flavor take a real
beating in subsequent reheating. How-
ever, because we are now dealing with
primary cooking – rather than heating
– processors must be more careful
when it comes to food component han-
dling and packaging operations. Most
important, though, is to ensure that
the product reaches proper tempera-
tures when consumers cook it.
You need robust technologies to
work in different ovens with varying
power levels and [power] distributions.
Moreover, processors must ensure that
directions are prominent and clear so
consumers can and will reasonably
follow them.
These products may well benefit
from hybrid packages, where supple-
mentary or redirected heating from
susceptors or field modification ele-
ments can help ensure the most critical
components are properly cooked.
R&FF: We’ve now seen ConAgra
apply the steam-cooking concept
to frozen entrees in rigid plastic
tray. What interests you about this
approach?
Bohrer: The technology is somewhat
similar to the flexible approach in that
(1) both take advantage of containing
the thermal energy in the vaporized
water in the package and (2) they
aren’t aimed at foods that have to
brown or crisp.
www.refrigeratedfrozenfood.com
Steaming technologies
spreading to more
value-added frozen
side dishes.
That said,
ConAgra’s rigid
approach is dif-
ferent in several
important ways.
First, it is really
much more like
steaming, where
the food is held over a
hot liquid and then vapor condens-
es on the food to supplement direct
microwave heating. And when heating
is done, the consumer is responsible
for applying the resulting hot sauce.
The relatively simple manipulations
may make the consumer feel like they
are really cooking, which can be ad-
vantageous. This approach also offers
the option of using all or part of the
sauce as desired. By comparison, com-
petitive offerings – where you have all
the ingredients in a pouch – are hard
pressed to easily offer this option. In
some cases, the pouch approach also
can result in texture degradation.
The success of this rigid package
also is interesting in that it has the ap-
pearance of being a lot more packag-
ing intensive than other offerings. But
its success proves once again that con-
sumers will pay for and use solutions
that they perceive to offer convenience,
quality and control.
R&FF: Consumer interest in on-the-
go foods and convenience means
new product developers are quite
active with sandwiches, pizzas and
other specialty bread-based prod-
ucts. Do these packages use sus-
ceptor technology? What advances
have you noticed in the field?
Bohrer: Companies are working hard
to expand the numbers and types of
foods that work well in a microwave.
Where dough is involved, susceptor
technology almost always has a help-
ful role to play. A lot of patent and
commercial activity involves insula-
July 2009 REFRIGERATED&FROZEN FOODS
packaging
solutions
tion approaches, integrated venting to
ensure crispness and improved opening
features to increase convenience.
It’s no secret that consumers are
looking for the toasted style sand-
wiches popularized in quick-service
restaurants and other restaurant
settings. Retail packaged food com-
panies believe there is an opportunity
to give consumers the same sandwich
options anywhere they have access to
a microwave. Indeed, that’s why you
see more microwaveable sandwich
products including hot dogs, Panini-
style sandwiches, subs and even grilled
cheese sandwiches.
R&FF: What do you think of the
microwave pizza market?
Bohrer: I think there always will be a
search for a larger microwave pizza –
at least up to a size that would fit in
most medium and large ovens. This
has been something of an elusive goal.
Moreover, to get there means proces-
sors and packaging suppliers will need
to combine food formulation with a
clever use of susceptors. In some cases,
too, it could require patterned thick
foil elements.
The combinations of shielding and
browning are intriguing, as they offer
more degrees of freedom in treat-
ing different parts of complex foods
differently. They also can create more
uniform results in the huge range of
consumer ovens.
R&FF: Where can microwave steam
cook technologies improve during
the next three to five years?
Bohrer: I think there are several areas
that make sense to pursue. Just con-
sider that handling these hot pouches
requires some care. I see room for
improvements related to convenient
holding, opening and pouring. 4
Moving towards more complex
23
 packaging
solutions
foods, where some of the components
benefit from high moisture environ-
ments and others need dehydration for
proper texture and flavor development
24
Rff709hinds.indd 1
will require hybrid packages. There are
a few published patent applications
considering solutions to this, but there
seems to be plenty of room for new
REFRIGERATED&FROZEN FOODS July 2009
6/16/09 9:09:21 AM
thoughts and approaches.
R&FF: Has microwave susceptor
technology reached its full maturity
level or is there room for growth?
Bohrer: I was involved in commercial-
izing the first disposable susceptor
package and – just about when people
start thinking the market has plateaued
– another clever introduction occurs
to push it even further. There still
are many foods that have yet to take
advantage of the speed and quality ad-
vantages offered by susceptor, shielding
or combination packaging.
More control over heating levels
has always been a goal, and there are
plenty of patents pursuing that control.
That is probably a key improvement
area that would unlock another large
increment of growth.
R&FF: What did you tell microwave
convention attendees about future
microwave packaging applications?
Bohrer: I suggested that combining quite
different foods into a single “complete
meal” package represents significant
hurdles. However that type of ap-
proach would be welcomed by consum-
ers because it would alleviate the need
to juggle multiple packages in and out
of the microwave with different cook
times and potentially different power
levels.
Many applications will require dif-
ferent packaging, in both passive and
active formats. Some would combine
steaming with browning and crisping –
in the same package – to deliver more
complex meal solutions.
R&FF: You mentioned browning and
crisping. What’s been happening
there?
Bohrer: High moisture breaded products 4
have presented difficulties for quite
www.refrigeratedfrozenfood.com

some time. However, I am confident
that more latitude in susceptor control
– coupled with innovative breading
and coating technology – can signifi-
cantly advance the performance here.
Although these are isolated cases,
we’ve seen several successful large mi-
crowaveable raw dough pies, involving
both sweet and savory varieties.
R&FF: How do you see the broader
market evolving? What are the big-
gest challenges ahead?
Bohrer: Food companies will continue
to expand their understanding of how
foods interact with microwave radia-
tion and innovate around ingredients
and food fabrication methods. To the
extent they develop close partnerships
www.refrigeratedfrozenfood.com
NP03094TGW.indd 1
with highly capable microwave pack-
aging providers, new product/package
combinations will result that enable
entirely new categories to benefit from
the speed, convenience and energy sav-
ings of microwave cooking, and with
high quality.
My challenge to the food compa-
nies in the audience at IMPI was to
think about the foods or food com-
binations that they don’t think will
work in the microwave. Sit down with
a microwave packaging supplier and
ask them “why not?” I also think pro-
cessors should be prepared to bring
their best food innovators along and
see what can be done together. There
is an opportunity to not only compete
with conventional oven cooking, but
also with the other channels in which
July 2009 REFRIGERATED&FROZEN FOODS
packaging
solutions
consumers purchase foods. Prepared
foods offering restaurant quality at a
lower price and with greater conve-
nience can contribute in important
ways to revenue and profit growth for
the prepared food retail value chain.
Microwave packaging coupled with
food innovation has delivered on this
promise before and is fully capable of
continuing to do so. I am very bullish
on these opportunities. RFF
Timothy Bohrer, Pac Advantage
Consulting LLC, works with both
flexible and rigid structures in plastic,
paper and composite packaging and
the materials that form the foundation
of these package types. Readers may
contact him at (773) 268-2232 or by
e-mail at tim@pacadv.com
25
2/17/09 2:42:53 PM
partners
IN PROGRESS
Tough enough
United States Cold Storage
relies on highly ruggedized
mobile devices to track and
maintain inventory in extreme
freezer environments.
Y
ou could say that United States
Cold Storage (USCS) literally goes
to extremes for its customers.
Based in Voorhees, N.J., this public
refrigerated warehouse company
handles much of the nation’s refrigerat-
ed and frozen food distribution to both
retail and foodservice channels. In doing
so, the company’s 30-plus warehouses
provide everything from basic primary
storage to fully integrated third-party
logistics solutions — all while maintain-
ing temperatures from +50˚F and below.
Regardless of whether the account
is large or small, USCS has to handle its
customers’ perishable products with care.
That’s why it has selected Psion Teklogix,
Cincinnati, as a key technology partner.
Since 1997, USCS has used Psion
Teklogix’ highly ruggedized mobile
devices to track and maintain inventory.
The company’s partnership began with
Psion Teklogix radio frequency equip-
ment. Although officials say these de-
vices still work well, USCS has needed a
technology upgrade.
“Psion Teklogix devices are built like
tanks,” notes Terry Groff, an IT/RF tech
specialist at USCS. “Many of the units
initially deployed in the 1990s are still
working extremely well today.
“As we phase out the older narrow-
band units and convert to the 802.11
technology standard — with Psion Tek-
logix’ 7530 G2 flexible, rugged hand-
held and the 8525 G2 wireless vehicle
26
Psion Teklogix’ 7530 G2 is a rugged handheld device design for harsh cold chain
environments.
mount computer — we look forward
to getting the same type of exceptional
results and reliability delivered by the
older models.”
Groff says USCS needs new mobile
units that (1) are easy to use, (2) func-
tion completely in temperatures from
–5˚F to –15˚F, (3) carry a sustainable
battery life throughout the work day,
(4) deliver real-time data, (5) integrate
easily with a remote software mainte-
nance and distribution system, and (6)
are easy to read (with brighter touch
screens) in freezer environments.
USCS chose to purchase and deploy
more than 1,000 new mobile devices
including Psion Teklogix’ 8525 G2
rugged vehicle mount terminals (VMT)
and Psion Teklogix’ 7530 G2, a rugged
handheld built for harsh cold chain
environments. The devices are every-
where — from receiving to picking and
stacking to shipping — and are tasked
with managing inventory and orders
wirelessly in real-time.
In addition to new ruggedized
devices, USCS needed software to
maintain its mobile devices. As a result,
it has begun rolling out Psion Teklogix’
Mobile Control Center (MCC) software
on all devices in each of its 30 sites.
July 2009 REFRIGERATED&FROZEN FOODS
This software helps remotely monitor,
manage, troubleshoot and support these
devices in real-time. Other MCC fea-
tures include seamless software distribu-
tion and remote control and configura-
tion. Because USCS has numerous sites
and deploys more than a thousand
mobile devices, the ability to control
each device regardless of location, not
only saves time and money but makes
them more efficient.
With the new Psion Teklogix devices,
USCS is able to keep the supply chain
moving while it improves warehouse
productivity. Meanwhile, Psion Teklogix
devices meet the demand goals. They
are rugged, maintain all functionalities
in extreme conditions and have the bat-
tery life to last an entire workday.
“For companies like us who have
numerous sites with thousands of units,
the ability to control each device regard-
less of location, not only saves time and
money but makes us more efficient as a
company,” says Groff. “Psion Teklogix’s
MCC software provides our employees
with user-friendly, powerful and reliable
software that stands heads and shoul-
ders above competitive offerings.”
– Psion Teklogix
(800) 322-3437 / www.psionteklogix.com
www.refrigeratedfrozenfood.com
 Suppliers
Marketplace

Cartoner meets real needs

Normally, food processors are the ones hosting consumer focus groups for
new product insights. In this case, Kliklok-Woodman, Decatur, Ga., says its
latest new product is based on feedback from food processors themselves. Standard belt,
“They talked and we listened,” notes Brett Duernberger, director of sales. heavy duty work
“Food processors said that when it came to cartoners, they wanted a superior, Ashworth’s new Omni-Pro®075 can
dependable design. So we developed our new Celox accordingly. withstand 150 pounds of tension
“It features an improved rotary feeder with servo profiling, a robust hybrid for 100,000 cycles (competition
frame that provides outstanding access and sanitation, an ancillary device tests for 50,000 cycles), a rating
rail-mount system, reliable controls and superior-quality components.” that only heavy duty belts could
Duernberger says food processors also have voiced interest in equipment that deliver – until now. The strength
quickly and easily adjusts for changing products and workforces. In response, rating of the Omni-Pro®075 is
Kliklok-Wood gave the Celox a modular design for quick assembly and cus- the highest among all standard
tom configuration as well as advanced motion control for quick size change- weight spiral/turn-curve belts. The
overs. The machine also features an easy-to-use, icon-based Insight® color Omni-Pro®075 retains the same
touch screen operator interface, which eliminates language barriers. design features that allow the belt
The Celox features an Allen-Bradley ControlLogix control system, housed in to minimize cage bar wear, main-
the unit’s heavy-duty fully welded stainless steel frame. Other components in- tenance costs and downtime in the
clude a powered carton hopper, a patented, servo-driven rotary carton feeder most demanding high-tension spiral
and a barrel-cam product inserter. applications. The shorter pitch of
– Kliklok-Woodman the Omni-Pro®075 is ideal for small
(770) 981-5200 / www.kliklok.com products and closer transfers.
– Ashworth Bros., Inc.
(800) 682-4594 / www.ashworth.com
Better way to “sea food”
Alcan offers seafood processors innovative
alternatives to carton packaging. Providing sig- Web site offers more
nificant consumer convenience benefits, includ- Henningsen Cold Storage introduced
ing steam-in-bag capabilities, stand-up pouches a new Web site (www.henningsen.
(SUPs) from Alcan Packaging are moving frozen com) with improved navigation,
seafood brands out of cartons and into an im- downloads, information and maps to
proved competitive position in the marketplace. each of its 10 warehouse and distri-
SUPs save space in home freezers, while resealability bution facilities nationwide. Hen-
inhibits freezer burn and ensures fresher, longer-lasting product. Alcan also ningsen is a full-service, multi-temp
offers hermetically sealed SteamRight pouches for steam-in-bag applications. logistics company with more than 42
Consumer demand for reduced meal preparation and easy clean up has cre- million cubic feet of refrigerated and
ated strong demand in the microwave steam cooking category. SteamRight frozen storage at sites in Oregon,
pouches deliver precision steam venting and safe, easy opening, as well as Washington, Idaho, North Dakota,
exceptional durability at every stage of frozen food distribution. Oklahoma and Pennsylvania.
– Alcan Packaging Food Americas – Henningsen Cold Storage Co.
(773) 399-8037 / www.alcanpackagingfood.com (800) 791-2653 / www.henningsen.com 4

www.refrigeratedfrozenfood.com July 2009 REFRIGERATED&FROZEN FOODS 27

 SUPPLIERS
MARKETPLACE
Juicier,
tender product
Advanced Food Sys-
tems’ new TenderBite™
marinades use a unique
binding matrix to entrap
moisture and natural
juices inside meats and
seafood. This produces
a more juicy and tender
product with greater
yields when frozen,
thawed, and cooked –
especially in microwave
applications. TenderBite
products are dry blends
that are hydrated and applied as marinades, and do not
increase cold viscosity of marinades. They have a neutral
flavor, and can be combined with seasonings if desired.
Phosphate-free versions are available.
– Advanced Food Systems Inc.
(800) 787-3067 / www.afsnj.com
Teamwork, dedication, integrity and respect are
key ingredients in our success. Request Foods
has grown to become a leading co-packer of frozen
p
prepared entrées, and as our national foodservice and
rretail customers know, We Make Your Brand ... Better.
Delkor a Rockwell partner
Automated end-of-line packaging machinery supplier
Delkor Systems has qualified as a Machine Builder
partner in the Rockwell Automation PartnerNet-
work program. Officials say Delkor now can access
additional innovative technologies, ongoing techni-
cal support and much more – all to make Delkor
equipment easier to install, operate and maintain.
Delkor uses Rockwell’s Allen-Bradley products
including ControlLogix and CompactLogix control
systems.
– Delkor Systems
(763) 783-0855 / www.delkorsystems.com
Belt improves food safety
Intralox LLC’s new ThermoDrive is a patented,
positive-drive, low-tension conveyor belt with an
easy-to-clean, 100-percent closed surface. Like Intralox
SeamFree belting, ThermoDrive is especially suited for
hygiene-critical applications. It dramatically improves
food safety and lower operating costs related to water
and chemicals as well as cleaning labor and time.
Come see Intralox and ThermoDrive at the American
Meat Institute’s AMI 2009 convention this October in
Chicago.
– Intralox LLC USA
(504) 733-0463 / www.intralox.com
New branding for Dorner
To better reflect its commitment to offering custom-
ers unmatched speed, intelligence and flexibility,
conveyor equipment supplier Dorner Manufacturing
introduced an updated corporate logo with the new
tagline: “Move Fast. Move Smart.” The “move fast”
reference reflects Dorner’s high-speed systems as well
as the company’s ability to quickly ship orders and
service customers. “Move smart” refers to the fact
that Dorner equipment is automation enabled for
fast system set-up and integration. The equipment
also offers maximum flexibility and can be reconfig-
ured quickly.
Î{ÈäÊœ…˜Ê°Êœ˜˜iÞÊÀ°ÊÊÊUÊÊÊœ>˜`]ÊÊ{™{Ó{ – Dorner Manufacturing Corp.
ȣȰÇnÈ°ä™ääÊÊÊÊUÊÊÊÊÀiµÕiÃÌvœœ`ðVœ“ (800) 397-8664 / www.dorner.com RFF

28 REFRIGERATED&FROZEN FOODS July 2009 www.refrigeratedfrozenfood.com

RFF03094Requ.indd 1 2/13/09 10:28:10 AM

 Custom Freezing Services
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To place your classified
• New Installation - Opening Mayad 2009in
Refrigerated & Frozen
• Frozen and Cold Foods
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• Flexible Scheduling
call Sharon Ward at
847-405-4078
South Mill Mushroom Sales, Inc - Kennett Square, PA
Fax:Contact: Mark Moran - 610-444-4800 ext. 217
847-405-4100
mmoran@southmill.com
E-mail: wards@bnpmedia.com

musHrooms equipment for sale

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610-444-4800 ext. 269 • vversagli@southmill.com
• Brokers Inquiries Welcome
equipment for sale
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REFRIGERATION SYSTEMS – EQUIPMENT
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www.refrigeratedfrozenfood.com July 2009 REFRIGERATED&FROZEN FOODS 29

RFF_July_2009.indd 29 7/1/09 1:49:31 PM

 To place your classified ad in
Refrigerated & Frozen Foods
call Sharon Ward at
847-405-4078
Fax: 847-405-4100
E-mail: wards@bnpmedia.com

equipment for sale equipment for sale equipment for sale

Terlotherm
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• Faster cooling of hot food
products using ambient air.
Heat
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in continuous freezers. Typical applications
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Heating • Cooling
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www.terlotherm.com

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30 REFRIGERATED&FROZEN FOODS July 2009 www.refrigeratedfrozenfood.com

RFF_July_2009.indd 30 7/1/09 1:45:56 PM RFF

 To place your classified ad in
Refrigerated & Frozen Foods
call Sharon Ward at
847-405-4078
Fax: 847-405-4100
E-mail: wards@bnpmedia.com

REFRIGERATED AND FROZEN FACILITIES

AVAILABLE REFRIGERATED AND FROZEN FACILITIES

Presented by
Jeffrey J. Counsell, Senior Vice President
CB Richard Ellis/ Food Facilities Group
Location Size Description
Chicago, IL 267,043 SF High velocity bakery with 700' linear production lines (7), 30' clear freezer, 24' clear warehouse, air-conditioned packaging,
AIB Excellent
Plant City, FL 265,000 SF 220,000 SF refrigerated further meat processing space, with 95,000 lb ammonia system, 1200 hp process steam capacity,
300,000 gpd permitted DAF waste-pretreatment, unparalleled food production infrastructure, USDA regulated
Great Bend, KS 180,500 SF 150,000 SF refrigerated further meat processing space, with 160,000 lb smokehouse capacity, 80,000 lb brine chill, on-site
well and Class 1 waste pretreatment and disposal facility, USDA regulated
Elon, NC 154,000 SF 120,000 SF refrigerated dry cure space, with fifteen (15) time, temperature, and humidity-
controlled Travaglini rooms with 100-day programmable controls, double-tee concrete roof deck,
USDA regulated
Martin, TN 147,600 SF Tri-temp warehouse with 30' clear, 41,250 SF freezer, 16,193 SF cooler, 85,652 SF ambient, expandable, on 39.00 acres
Chicago, IL 123,316 SF Impeccable rail-served frozen bakery with ammonia refrigeration; one (1) spiral freezer, wet/dry mixing bulk storage and mixing,
Union Pacific rail, DAF waste pretreatment, AIB Superior
Columbia, SC 102,486 SF Immaculate frozen meat processing facility, with 36,000 SF production, 11,322 SF 25' clear freezer, two (2) spirals, waste
pre-treatment, USDA regulated
Bristol, VA 90,855 SF High-velocity dairy plant with 34,844 SF processing, 18,932 SF cooler, 13,500 SF freezer, 45,000 gal bulk milk receiving,
extensive and secure external staging and storage, USDA regulated
New Riegel, OH 88,000 SF 45,000 SF refrigerated meat processing space, with contiguous coolers, blast cells, freezer, raw / RTE configuration,
50,000 gpd sequence-batch-reactor waste pre-treatment, USDA regulated
Portland, OR 82,862 SF Former vegetable processing facility with 30,000 SF production, 2,400 SF cooler, waste pre-treatment, extensive
exterior staging, Port of Portland location, AIB Superior
Fife, WA 82,363 SF Ammonia chilled frozen seafood plant, with 59,587 SF production, one (1) spiral freezer, 6,671 SF freezer, Port of Tacoma
location, USDC regulated
Atlanta, GA 82,000 SF Partially equipped (debone / par fry) further poultry processing facility, with ammonia chilling, 7,000 SF freezer, waste
pre-treatment, USDA regulated
Des Moines, IA 63,400 SF Modern pork processing facility with ammonia refrigeration, freezers, coolers, two (2) steam cabinets, process boilers,
USDA regulated
Gibbon, NE 105,000 SF Turn-key / fully equipped turkey processing facility capable of 15,000 daily kill and freeze capacity, with a 1,250 ton ammonia
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For Information, Contact Jeff Counsell

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WORk pOSITIONER CUSTOM pACkAGING

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Contact: Mark Moran - 610-444-4800 ext. 217
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www.refrigeratedfrozenfood.com July 2009 REFRIGERATED&FROZEN FOODS 31

M Mushrooms M
56 PM RFF_July_2009.indd 31IQF • Fresh • Blanched 7/1/09 1:46:06 PM
 TOUGH ON
INEFFICIENCY.

It takes a rugged mobile computer to beat inefficiency in the work-

place. Toughness and reliability win user trust and enable you to
attain peak efficiency in your cold chain operation. Count on the
unsurpassed toughness of Psion Teklogix’ Mobile and Vehicle Mounted computers. © 2009 Psion Teklogix, Inc. The Psion Teklogix and

We’re changing the way industries like yours mobilize their workforce.
NEO logos are registered trademarks of Psion Teklogix,
Inc. Windows and the Windows logo are trademarks
or registered trademarks of Microsoft Corporation in
the United States and/or other countries.

Contact us today to find out more! Call 800.322.3437 or e-mail americas@psionteklogix.com.

800.322.3437
americas@psionteklogix.com

Rff709psion.indd 1 7/9/09 9:00:17 AM

 ADINDEX
Advertiser Page E-mail/Website

Alcan Packaging Inc. 21 www.alcanpackagingfood.com

Bemis Flexible Packaging-Milprint Div Inside Front Cover www.milprint.com
Deville Technologies 9 www.devilletechnologies.com
The Fricks Company 18 www.TheFrickscompany.com
Grote 13 www.grotecompany.com
Hind-Bock Corporation 24 www.hinds-bock.com
Hixson Inside Back Cover www.hixson-inc.com
International Institute Ammonia Refrigeration 7 www.iiar.org
Intralox 19 www.intralox.com
Jacobs Carter Burgess 15 www.jacobs.com
Powerit Solutions 11 www.poweritsolutions.com
PMMI/FPSA 1 www.packexpo.com
Raque Food Systems, Inc 3 www.raque.com
Reiser 5 www.reiser.com
Request Foods, Inc. 28 www.requestfoods.com
TGW International 25 www.tgwint.com
United States Cold Storage, Inc. Back Cover Issue www.uscold.com

WAREHOUSEADINDEX
Advertiser Page E-mail/Website

Americold Logistics IFC Warehouse Guide www.americoldrealty.com

H&M Bay, Inc. Warehouse Guide 16 www.hmbayinc.com/RFF
Henningsen Cold Storage Warehouse Guide 25 www.henningsen.com
Metl Span Corporation Warehouse Guide 23 www.metlspan.com
Millard Refrigerated Services, Inc. Warehouse Guide 7 www.millardref.com
Nelson Jameson Warehouse Guide 13 www.nelsonjameson.com
Psion Teklogix Warehouse Guide IBC www.psionteklogix.com
Richmond Cold Storage Warehouse Guide 27 www.richmondcold.com
Tippman Group/Interstate Warehousing Warehouse Guide 15 www.tippmanngroup.com
Trademark Transportation Warehouse Guide 21 www.trademarktransportation.com
United States Cold Storage, Inc. Warehouse Guide Back Cover www.uscold.com
Zero Mountain, Inc. Warehouse Guide 5 www.zeromtn.com
VRTX Warehouse Guide 13 www.vrtx.com

Also publishers of Beverage Industry,

Reader & Marketing Services
BrandPackaging, Candy Industry,
LETTERS Reprints PRINT & Internet
Bob Garrison Deb Soltesz AdvertIsing SOLUTIONS FOR VALUE-ADDED PROCESSORS
Dairy Foods, Flexible Packaging,
Mail: RFF E-mail: solteszd Jeff Plaster Food & Beverage Packaging,
155 Pfingsten Road @bnpmedia.com E-mail: plasterj BNP Media
Suite 205 Call: (248) 786-1596 @bnpmedia.com Food Engineering, Independent
Deerfield, IL 60015 Call: (847) 405-4042 155 Pfingsten Road, Suite 205 Provisioner, Industria Alimenticia,
E-mail: garrisonr Custom Deerfield, Illinois 60015
@bnpmedia.com Publishing CLASSIFIED Meat & Deli Retailer, The National
(847) 405-4000
Steve Beyer ADVERTISING
Fax: (847) 405-4100 Provisioner, Prepared Foods, Private
BACK ISSUES E-mail: beyers@ Sharon Ward
Giselle Manelli bnpmedia.com E-mail: wards Label Buyer, Refrigerated & Frozen
E-mail: manellig Call: (847) 516-1977 @bnpmedia.com Reaching a total Foods, Refrigerated & Frozen
@bnpmedia.com Call: (847) 405-4100 qualified circulation of
Call: (847) 405-4061 20,500 copies. Source, Foods Retailer and Snack Food &
December 2008 BPA Publisher’s Statement Wholesale Bakery.
 FREE
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Rff709hixson.indd 1 6/24/09 11:56:37 AM

RFF0109USCS1.indd 1 12/17/08 10:41:28 AM