While the plant is highly automated, all
the dough is hand-woven for perfection.
Each ball is then manually rolled, dipped
and sewed in with the various seeds and
grains. Many of the organic ingredients
make it tough to run through the auto-
mated equipment, so Dave's Killer Bread
has found a happy marriage of people and
machinery. “We couldn't do it without the
people,” Letchinger says. “Symbolically,
but also like literally from a formulation
standpoint, we need that.”
Every three hours or so, the production
cycle changes to include a different prod-
uct — meaning a new variety of wheat.
With each wheat change, the protein levels
fluctuate, keeping the mixers hard at work.
Without the luxury of added chemicals to
help the dough run through the machines,
the DKB team is constantly performing
mix tests. “There's a very tactile way of
making this bread. There's a lot of feel
involved. Our mixers always have to be
on top of their game because the margin
for errors is very small with these seeded
breads,” Letchinger says.
Dave’s Killer Bread is currently the
number one organic bread brand in the
U.S. and the number 20 bread brand overall. The breads can be found in thousands
of retailers nationwide, as the company
officially announced its expansion into all
50 states in May. DKB products can now
be found in stores like Kroger, Safeway,
Costco, Sam’s Club, Whole Foods, Fred
Meyer and a handful of independent and
DKB is notorious for keeping tabs on
consumer trends when developing new
products, and Letchinger said grains and
seeds are a great way to bring their nutrition story to the forefront. “There’s still
quite a bit of momentum for a clean label
and we feel comfortable on delivering on
that promise with these breads. That kind
of guides whatever we do when it comes
to innovation. All the consumer and retail
trends are pointing in that direction, so it’s
very important for us to not lose sight of
that. We’re a transparent brand, we make
clean-label products. That’s not going to
change any time soon.” Newark, NJ 07105 / Toledo, OH 43605 / 800-733-4755
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