Brightening its Beacon
8/2/2009
Source: BSImagazine.com
http://www.bsimagazine.com/Feature_Stories.asp?ArticleID=105008

BSImagazine.com
by Steve Berne

Since my last visit to Lanterna Alimentari Genova, Genoa, Italy, three years ago, (See Fervent for Focaccia) the company has made considerable changes to its formulas and expanded its production operations as well as its product distribution.

Literally translated as Genoa Lighthouse Foodstuffs, the company is situated up the hill from the lighthouse that symbolizes the regional capital of Liguria. With its mandate to produce focaccia with the quality and flavor of the original artisan product but at a production level sufficient to offer it not only to the people of the city and region but also to the rest of the world, the company is fulfilling its destiny.

Although most of the processes were easily automated using modern technology, manual work was still a critical step to producing an authentic looking product, until now. Now, both employees and new, portable robots with specially designed end effectors go through extensive training or programming to mimic the technique of randomly pressing the proofed sheeted dough prior to baking in the manner it has been done since the 15th century when focaccia was extensively used in ceremonial events. It is said that focaccia was part of Christopher Columbus’ food provisions during his voyages to the New World.

The plant was built in 2002 and is more than 6,000 sq m (64,600 sq ft). Total employment is more than 70, with each line requiring between seven and 11 people per shift, depending on production. Annual output volume at Genova is approximately 9 million kg equaling €28 million in sales. About 15% of production is currently being exported.

Last year, business success demanded greater production. No building construction was required for the added production line, but output capacity more than doubled. The high-volume line, commissioned in March, includes next-generation processing systems with added automation and process control.

"This plant was designed with sufficient room for a second line," said Rita Preziotti, export manager for Lanterna. "Product popularity has grown to the point of international distribution. We were fortunate that our directors had foresight and designed the facility also to have freezing capabilities to allow far-reaching distribution."

"In addition to distributing our products throughout Italy and France, current export markets include Germany, Austria, Benelux, UK, Scandinavia, Russia and Spain," added Marialetizia Mele, marketing consultant.

In June, the company displayed its products at the International Dairy•Deli•Bakery Association Expo at Atlanta, Georgia, USA. Working with a distributor in the US, Lanterna hopes to bring its products to the vast North American market.

Its products are either par-baked or fully baked, and its customers are food service and large catering companies as well as supermarkets. With par-baked items, customers finish the baking process so products can be marketed as fresh and have the aroma needed to draw business.

Lanterna produces traditional focaccia in sheets and has four pan sizes: 40 by 60 cm, 15 by 20 cm, 20 by 30 cm and 40 by 30 cm. It also makes focaccini, which are round pieces of approximately 12.5 cm in diameter. Focaccini are also a little taller and with a softer texture and are used for sandwiches.

While capacity is calculated based on full-size pans, smaller square and rectangular focaccia are produced by inserting dividers providing options of two, four or eight equal portions per sheet.

KEYS TO QUALITY. Producing a quality traditional product on an industrial scale requires four things: people, ingredients, equipment and a strict adherence to process parameters, according to Annamaria Dellachà, quality manager. "Our ingredient list is small because the base formulas are very similar," she said. "We use no preservatives or artificial ingredients, and all toppings received, except spices, are pre-frozen to eliminate potential