Efficiency and demand find harmony in bread category

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Efficiency and demand find harmony in bread category

17 Apr 2026

KANSAS CITY, MO — Bread, buns and rolls are grocery staples used to make a variety of simple, affordable meals that can be eaten at home or on the go.

Here’s how bakers are evaluating their operations to solve industry challenges, meet evolving needs, and improve efficiency and output.

New-age bread making

For 130 years, Hebron, KY-based Klosterman Baking Co. has produced bread, buns, rolls and other products for generations of consumers. With decades of experience, the company fundamentally understands the precise chemistry of baking and the coordinated operations and teamwork necessary to effectively manufacture each product.

“Since coming to Klosterman, I have learned that baking is a science, so variables make a difference in the outcome,” said Dale Easdon, CEO of Klosterman Baking. “For example, any variation in a major ingredient like yeast or wheat can impact the finished product. To ensure consistent quality, the team must make appropriate adjustments, whether to the dough itself or the baking conditions. Our amazing team of master bakers helps guarantee every product is something our customers will love.”

Klosterman uses the straight dough and sponge-and-dough fermentation methods. It continually invests in upgrading and replacing equipment across the enterprise. Bakery technology has evolved, but lead times to acquire new machinery can be extremely long, as much as 18 months, according to Easdon. To manage these cycles, Klosterman structured a five-year capital investment plan that includes critical investments in modern technology.

High-speed innovation

“We have incorporated new technology for growth with a 50/50 mix on replacement just by age of assets, so investing in our operations has been an integral part of our growth,” Easdon said. “We are purchasing equipment that can handle our volume for the next five years.”

“Any variation in a major ingredient like yeast or wheat can impact the finished product. To ensure consistent quality, the team must make appropriate adjustments, whether to the dough itself or the baking conditions.” — Dale Easdon | CEO | Klosterman Baking Co.

All Klosterman bakeries are undergoing significant capital investment projects. Its oldest bakery had a full oven upgrade, and a new conveyor system was installed. New proofers, a tracking cooling system, faster packaging lines and a new divider for a high-speed bun line were also purchased for other bakeries.

“I am especially excited about the new mixing equipment, which accommodates larger batches,” Easdon said. “We installed a new mixer that is larger than my office, so now one new mixer replaces two, which increases production capacity.”

Klosterman’s newest bakery in Hebron houses three production streams, including a bun, bread and donut line, as well as its new flagship headquarters, which was moved from the original location in Cincinnati.

Operationally, the biggest challenge for Minneapolis-based Rise Baking Co. is balancing efficiency with innovation. Its R&D and insights teams partner closely to stay ahead of emerging trends, anticipate market shifts and develop new products that resonate with customers.

Listening to the masses

“There is an ever-increasing desire for products that are both convenient and high-quality, so we are always working to balance our novel ideas with efficient operations,” said Michael Docherty, EVP of marketing, R&D and innovation at Rise Baking. “We are committed to working with our customers so we can develop products that meet market demands and also perform well in operational environments.”

Rise is dedicated to maintaining the consistency and quality its customers depend on, while also investing in the right technologies and processes to stay agile. Docherty emphasized that the company’s ultimate goal is to make life easier for customers.

More consumers are demanding bread products that are high in protein and made with clean ingredients, and aligning those needs with R&D and operations capabilities ensures more efficient production. To serve that demand, the Klosterman team works directly with its customers, hosting weekly tastings and quality inspections.

“One of our largest customers is close to launching a new high-protein bread,” Easdon explained. “The formulation is being developed by a cross-functional team, including the testing phase, packaging and labeling. It is high protein, but not carb-free, which helps retain a strong flavor and texture profile. Our customer will launch the bread variety while we work with them on formulating a similar bun product.”

High-protein bread formulations can challenge operations, requiring adjustments to mixers and equipment. As a result, the price point for this new product is about two and a half to three times higher than a standard loaf, but it meets the demand of those who are seeking more protein.

“We are also seeing requests for artisan bread, so we partnered with Sixteen Bricks Bakery, owned by Cincinnati baker Ryan Morgan, to produce an artisan bread line for us,” Easdon said. “Between production of our high-protein products and our artisan bread line, we’re meeting all our customers’ creative needs.”

The artisan bread line is distributed to some of Klosterman’s fresh markets. For larger-volume orders, frozen product is shipped nationwide for distribution through the company’s network. For example, Klosterman partners with DOT Foods to ship smaller quantities more affordably to customers with limited storage.

“Our frozen business stream is growing at an extremely fast rate, nearly catching up to our fresh volume, as many customers prefer frozen product due to extended shelf life,” Easdon said. “Frozen products are also more affordable because operations can run large batches, which reduces price points.”

This story has been adapted from the February | Q1 2026 issue of Commercial Baking. Read the full story in the digital edition here.

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