Whether aligning innovation with current capabilities or scaling operations, cookie manufacturers must be strategic to stay ahead of unforeseen production challenges, such as supply chain disruptions, that can derail daily operations.
“It’s no secret that commodity volatility impacts the entire food industry, from cocoa to eggs,” Utz observed. “We are managing our supply chain and mitigating potential disruption to our customers by leveraging strong relationships, dual and triple sourcing essential commodities, and partnering with customers to create customized solutions.”
Overall, Duggan believes the state of the cookie industry is positive. From a labor standpoint, she noted jobs have been easier to fill over the past several months, and the average tenure of a line employee is more than three years.
“I think the key to minimizing turnover is to hire effective, communicative and extremely likable management and make sure that employees know their voices matter,” she explained.
Fancypants recently invested in new packaging equipment that will double the speed of the current line and expand packaging capabilities.
“We are replacing our current 10-head vertical scaling system line with two 20-head scales and a duplicate rotary bagger,” Duggan explained. “We are also adding two twin-tube pillow baggers capable of filling one- to three-ounce bags at a rate of 200 per minute.”
The addition means the company will be able to offer single-serve pillow bags.
The company sourced the equipment and made additional supplier contacts during a visit to the International Baking Industry Exposition in 2022.
“We learn so much by attending and networking at the show,” Duggan said.
3Bros Cookies continues scaling production and increasing automated processes, while maintaining product integrity and authentic taste.
“We are always planning for the next product innovation, customer and capability,” Vliegen said. “While automation can streamline processes, it also requires supervision. We work as a team to align automation with labor capabilities to increase production.”
Offering cookies made with real ingredients in a variety of flavors, styles and better-for-you options will help meet customer needs and satisfy consumer preferences. Focusing on production efforts on innovation that improves freshness, quality and shelf life, while promoting sustainable practices, is a winning strategy.
This story has been adapted from the August | Q3 2025 issue of Commercial Baking. Read the full story in the digital edition here.
