AIB Alumni News
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JUL - SEPT
IN THIS ISSUE
2014
Industry News
FDA Labeling Changes
Tom Lehmann Retires
Remembering Wulf Doerry
New Product Spotlight
HACCP Online Course
Environmental Monitoring Consulting Service
Baking Services
Alumni Profile—Jose Herrera
BS&T 185 Convenes
BS&T 185 Elects Class Officers
Staff Profile—Renee Boeckman
Featured Seminar
Upcoming Seminars
w w w. a i b o n l i n e . o r g
NUMBER 530
Industry News
Baking Associations Request Five Years to Comply with FDA
Labeling Changes
In their comments to the Food and Drug Administration (FDA), the American Bakers Association (ABA) and the
Retail Bakers of America (RBA) both requested five years to comply with upcoming changes to the Nutrition Facts
Panel.
The FDA’s proposed Nutrition Facts Panel changes, published March 3, 2014, recommended an effective date of
60 days after the date of the final rule’s publication in the Federal Register, with a compliance date two years after
the effective date. However, results from an ABA-sponsored packaging survey showed that bakery and packaging
companies would need significantly more time to implement changes since the sweeping proposals would affect
every packaged food product in the marketplace.
If adopted, the proposed changes would include the following:
1. Greater understanding of nutrition science
• Require information about added sugars.
• Update daily values for nutrients such as sodium, dietary fiber, and Vitamin D.
• Require manufacturers to declare the amount of potassium and Vitamin D on the label.
• While continuing to require “Total Fat,” “Saturated Fat,” and “Trans Fat” on the label, “Calories from Fat”
would be removed because research shows the type of fat is more important than the amount.
2. Updated serving size requirements and new labeling requirements
for certain package sizes
• Change the serving size requirements to reflect how people eat
and drink today, which has changed since serving sizes were first
established 20 years ago.
• Require that packaged foods, including drinks, that are typically
eaten in one sitting be labeled as a single serving and that calorie
and nutrient information be declared for the entire package.
• For certain packages that are larger and could be consumed in one
sitting or multiple sittings, manufacturers would have to provide
“dual column” labels to indicate both “per serving” and “per
package” calories and nutrient information.
3. Refreshed design
• Make calories and serving sizes more prominent to emphasize
parts of the label that are important in addressing current public
health concerns such as obesity, diabetes, and cardiovascular
disease.
• Shift the Percent Daily Value to the left of the label so it would
come first.
• Change the footnote to more clearly explain the meaning of the
Percent Daily Value.
For more details about proposed changes to the Nutrition Facts Label,
click here.
“Dough Doctor” Tom Lehmann Retires
After almost 50 years with AIB International, Tom Lehmann has
retired. Lehmann is internationally known for his expertise in pizza
production and dough troubleshooting.
“Tom’s lengthy history with AIB is unparalleled,” said Brian Strouts,
Vice President of Baking and Food Technical Services at AIB. “During
the impressive span of his career with the company, he has taken on
a number of important roles and been critical to the expansion of our
technical offerings.”
During a July 24 employee recognition ceremony held in conjunction
with AIB’s annual All-Staff Conference, Lehmann was honored by
AIB President Andre Biane as the longest standing employee in the
company’s history. A retirement reception was held on August 20. The
city of Manhattan, KS, honored Lehmann by proclaiming August 20
“Tom Lehmann Day."
Lehmann joined AIB in 1965 as a Baking Technologist and was later promoted to Director, Bakery Assistance. Shortly
after joining AIB, he was contracted to reverse engineer a popular pizza being made in Chicago and quickly became
AIB’s pizza expert and well known as a leader in the pizza industry. Lehmann started writing about pizza in 1979 and
has authored numerous publications on topics ranging from mixing and baking dough to creating different styles of
pizza. He is also a regular columnist for industry magazines such as Pizza Marketing Quarterly and Pizza Today, and
participates in online activities such as PMQ’s Think Tank and pizzamaking.com.
During his tenure with AIB, Lehmann coordinated the move of the Research Department from Chicago to Manhattan,
developed the company’s first Technical Assistant, Individualized Training and Technical Assistance programs, taught
many classes and seminars (as well as in the Baking Science and Technology course), and consulted for numerous
clients.
“Tom has been a terrific asset in the classroom. His experience in and
knowledge of the baking industry made him an invaluable resource for seminar
participants,” Strouts said.
Popularly known as “The Dough Doctor,” Lehmann has contributed hundreds
of articles on dough troubleshooting and pizza production, hosted a series of
radio shows, and has
a series of videos
available on YouTube.
Courtesy of The Manhattan Mercury
Making New York style pizza dough
In Memory of Wulf Doerry
Wulf Thedel Albrecht Doerry,
85, Manhattan, KS, passed away
August 2, 2014.
Mr. Doerry was born on
December 29, 1928, in
Marienburg, Germany (now
Malbork, Poland). He served
in the military and worked
on farms until he immigrated
to the United States in 1951.
In the US, he farmed in Iowa
before taking on an entry level position at Peterson Baking
Company in Omaha, NE. In 1953 he was drafted into the
US Army.
Wulf married Edith Penner on August 27, 1955, in Omaha,
NE. In 1956, the Doerrys moved to Chicago where Wulf
completed a 20-week course at the American Institute
of Baking (AIB), funded by the GI Bill. Following
graduation, Doerry started his career in baking research
and development as a technician for the research bakery
of Swift and Company in Chicago. His research baking
career would take him to Awrey Bakeries and Polly
Anna Pastry Kitchen in Michigan, Interstate Brands
Corporation in Kansas City, MO, and finally back to AIB,
in Manhattan, KS.
Doerry’s career culminated as the Director of the Cereal
Technology Research Group at AIB, from which he retired
in 1999. While with AIB, Doerry authored three books on
baking technology, travelled worldwide, and received the
Louis Gardner Award, which recognizes outstanding AIB
employees each year. He was a dedicated member of the
American Society of Bakery Engineers (now American
Society of Baking).
In lieu of flowers, memorial contributions may be
made to the American Institute of Baking for the BS&T
Scholarship fund or to The Nature Conservancy—
Kansas Chapter. Contributions may be sent in care of the
Yorgensen-Meloan-Londeen Funeral Home, 1616 Poyntz
Avenue, Manhattan, Kansas 66502.
New Product Spotlight
HACCP Online Course
AIB International is pleased to announce the rollout
of their anticipated HACCP Online course. The
course is designed to provide practical, relevant
instruction in an accessible, self-paced, online
format.
This new course includes timely examples, online
delivery, and allows participants to pace themselves
and return to content as needed. While deeply
technical, the course is also easy to understand.
Assessment and evaluation takes place throughout
the course.
The
streamlined,
online course
covers the
history and
background of
HACCP and
provides an
understanding
of HACCP
plan development including the seven principles
of HACCP, prerequisite programs, and forms and
reports used.
Graduates will be prepared to participate on a
HACCP team and meet the training requirements
for audits. Course participants have 60 days to
complete the course at their own pace. Certificates
of completion and Continuing Education Units are
provided following successful completion of the
course.
Topics covered include:
• History of HACCP
• Overview of HACCP
• Prerequisite programs
• Biological, chemical, and physical hazards
• The seven principles of HACCP
• HACCP plan development
• Deviation reports
• Validation
Learn more here.
Environmental Monitoring
Consulting Service
AIB’s new Environmental Monitoring Consulting
Service equips our clients with the skills needed to
comply with the FDA’s Food Safety Modernization Act
(FSMA). This consulting service helps food facilities
develop and improve their environmental monitoring
programs to reduce the risk of food safety events such
as recalls and outbreaks.
Though environmental monitoring has been an
industry standard for a while, FSMA now requires it.
AIB’s technical and production experts are able to
offer a holistic, all-inclusive view of the entire food
production process without unnecessary lab services.
AIB’s Environmental Monitoring Program is led
by Lakshmikantha Channaiah, PhD, director of
microbiology. “I am excited to be part of this new
venture with AIB,” Channaiah said. “Our program
was created around strong science and real-world
application, and will eventually grow to include a full
line of microbiology support services such as kill step
validation and product testing conduit.”
Program benefits include:
• An application-oriented consultation in which our
experts work with you in detail
• A confidential report within 10 days of your
consultation
• Flexibility - schedule at your convenience
Learn more here.
Baking Services
Alumni Profile
Jose Herrera • BS&T Class 175
Production Line Supervisor, New Hostess LLC, Schiller Park, IL
Jose Herrera can honestly say that baking is in his blood. “I come from a baking business family,”
Herrera said. “My father was an old school baker all his life. I first started baking as a part-timer
when I was a junior high school student near Chicago.”
To enhance his skill set and boost his career opportunities, Herrera attended BS&T Class 175.
“My class had so many great students from all over the world, which made it so interesting,” he
said. “I learned so much about different cultures, and every day in class was exciting. It was such
a good atmosphere, with all of the instructors and participants helping each other out. Every day I
was there was just great.”
After completing the BS&T, Herrera was promoted to Assistant Production Manager. “When I
returned to work from the course, I was able to share with my co-workers all the knowledge and
experience I gained at AIB,” Herrera said.
Herrera is currently a Production Supervisor for New Hostess LLC (formerly IBC Hostess) in Schiller Park, IL, where he
oversees the HoHo line. He also assists with other lines including Twinkies, Cupcakes, Sno Balls, and other popular New
Hostess products.
“I would highly recommend to anyone going to the BS&T to go in with an open mind and learn everything that is made
available to you,” Herrera said. “No matter how much you think you know about baking, or how many years you have
been in baking, the science and function of ingredients is the most important. I never thought about that until I learned
it at the BS&T. You learn all about the ways you can replace or substitute ingredients, how to do tests on ingredients
and doughs—endless situations. That part of the course has truly helped me at my workplace and allows me to help my
coworkers when there are problems.”
Having benefitted personally and professionally from attending the BS&T, Herrera encourages others to pursue the
opportunity to attend. “The course not only gave me more knowledge, it provides you with more career opportunities in
your current workplace or for future jobs,” he said. “Don't be afraid to ask. The teachers are great, and they always take the
time to help one on one. Just enjoy and learn.”
BS&T Class 185 Convenes
On August 20, 27 participants attended the first day of BS&T Class 185. Participants from Japan, Mexico, Nigeria,
Saudi Arabia, Spain, United Arab Emirates, and the United States are enrolled.
Class 185 Officers Elected
Class officers for BS&T 185 were selected on September 10.
Chosen by their fellow participants were:
President: Luis Palau, Bimbo Iberia
Vice President: Matt Murray, Bimbo Bakeries USA
Treasurer: Nick Byrd, Flowers Foods
Staff Profile
Renee Boeckman • Manager, Experimental Baking
Renee Boeckman's first job after graduating from college with a degree in food and nutrition
science was working as laboratory technician in a hybrid wheat research facility. Ten months
later, her resume still on file for an internship for which she had earlier applied, she received
a call from AIB International asking if she would be interested in interviewing for a position
in the Experimental Bakery. “I was really excited after I learned what they did in the labs
here,” Boeckman said. “During my coursework at Kansas State University, I discovered that
my interest was more in science than nutrition. The idea of working with ingredients and
conducting controlled bake tests to see what happens really appealed to me.”
Twenty four years later, Boeckman is still excited about her work. “I think the most enjoyable
aspect of my job is that the work we do is always changing,” she said. “We are not just
conducting routine flour tests in bread—we make a a variety of products and change ingredients in those formulations."
In the past couple of months the lab has worked on tortillas, crackers, frozen pizza, yeast raised doughnuts, and white pan
bread. This month they are making pan pizza, bread, and pet food.
The variety of products produced and tested in experimental baking differ from those being prepared for commercial
sales. “One thing that some people may not understand about experimental baking is that our formulas tend to be very
lean, containing minimal ingredients,” Boeckman said. “We just need to be able to detect changes that may occur when
ingredients or processes are changed. Commercial formulas are developed to tolerate changes, but in research we want
to be able to observe and measure differences when we swap out ingredients.”
Given the highly technical, research-oriented nature of the work, experimental baking requires precision and great
attention to detail. “We go to great lengths to conduct controlled bake tests. From the way we set up scale sheets, to
scaling ingredients, to the actual mixing and processing and all the follow up work, attention to detail is critical to good
research. Our group takes a lot of pride in being detail oriented.”
Industry demand dictates the types of products produced, tested, and scored by the experimental baking staff. “For
example, if companies are trying to reduce sodium or extend the shelf-life of their baked goods, our projects will reflect
those changes and trends,” Boeckman said. A typical week in the experimental baking lab might start with creating scale
sheets and weighing the proper ingredients, then conducting the test bake, scoring the baking products, and digitally
photographing and collecting data on the products so tables and charts can be created.
Experimental baking requires photographic
records, and the photography aspect of her work
is particularly appealing to Boeckman.
“I have a passion for photography and I
incorporate it into most of our research projects.
I take pictures of production lines when we are
running doughs, equipment, finished baked goods,
BS&T students working in the labs, and AIB
activities.”
Experimental baking serves clients from industry
by conducting outreach and testing products.
The group also assists BS&T participants and
demonstrates equipment to seminar attendees.
>> Enroll
Today!
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Featured Seminar
Hamburger Bun Solutions
December 2-5
Manhattan, KS
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The Hamburger Bun Solutions seminar shows participants how to achieve consistent quality by using a
combination of proper ingredient selection and processing conditions. The seminar provides specific information
useful to production supervisors about ingredients and processes used to make quality hamburger buns.
Participants will split their time between instructor-led classes and hands-on labs that encourage interaction
between instructors and seminar participants.
Participants will learn:
• To relate how mixing and fermentation affect dough development
• To recognize the main ingredients in a hamburger bun formula and what they do to the dough
• To identify common additives to a bun dough and why they are added
• To recognize how flour selection and specifications impact product quality
The seminar includes three afternoon lab sections. Participants will learn how ingredient variations affect bun
strength and volume in the first lab. The following two labs cover processing and fermentation variations.
For more information or to register
Upcoming
Seminars
September 2014
23-24 Food Plant GMP/Sanitation Workshop, Chicago, IL
24-25 Labeling of FDA Regulated Food Products, Chicago, IL
25-26 HACCP Workshop, Chicago, IL
30-01 GMP Workshop for Packaging Manufacturing Facilities, Louisville, KY
October 2014
2-3
HACCP Workshop for Packaging Manufacturing Facilities, Louisville, KY
7-9
Food Defense Coordinator, San Jose (Milpitas), CA
7-8
Supply Chain Essentials, Chicago (Rosemont), IL
14-15 HACCP Assessments, Nashville, TN
21-22 Food Plant GMP/Sanitation Workshop, College Park (Atlanta), GA
23-24 HACCP Workshop, College Park (Atlanta), GA
27-31 Practical Pizza Production Technology and Innovation, Manhattan, KS
28-29 FSMA: The Implementation Phase, Portland, OR
28-30 Food Defense Coordinator-Level 2, College Park (Atlanta), GA
28-30 Grain Milling HACCP Workshop, Manhattan, KS
November 2014
11-12 Principles of Inspecting Food Plants, Ontario, CA
13-14 Principles of Internal Auditing, Ontario, CA
18-19 Food Plant GMP/Sanitation Workshop, San Jose (Milpitas), CA
18-20 Food Defense Coordinator, Chicago, IL
20-21 HACCP Workshop, San Jose (Milpitas), CA
December 2014
2-5
Hamburger Bun Solutions, Manhattan, KS
Upcoming International Seminars
For a complete list of seminars click here
AIB
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AIB? Visit our Career Center.
https://www.aibonline.org/about/GetMail.html
The Dough Chute is published quarterly by:
AIB International Alumni Association
1213 Bakers Way • Manhattan, KS 66502
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