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Past, present, future: New Horizons Baking Co.’s growth path

Past, present, future: New Horizons Baking Co.’s growth path
PHOTO COURTESY OF AVANT FOOD MEDIA; TRINA BEDIAKO (LEFT) STANDS WITH MIKE PORTER IN THE BAKERY
BY: Lily Cota

Lily Cota

KANSAS CITY, MO — Seven simple words. Strung together and punctuated, they form a question that comes with a myriad of answers, a lifetime of achievement and turning points on a path with unlimited potential.

“How big do you want to be?” That’s what Tilmon “Tim” Brown, founder and chairman of Norwalk, OH-based New Horizons Baking Co., asked his daughter Trina Bediako before she took the helm as the company’s CEO in 2020.

New Horizons was a small bun operation for McDonald’s when the Brown family purchased the business (formerly known as West Baking Co.) in 1995. Today, the company is home to more than 700 employees in four baking facilities that produce buns, English muffins, and, soon, pancakes for a variety of retail and foodservice custom­ers throughout the US, as well as an ingredient blending operation, known as New Horizons Food Solutions.

“I asked that question 25 years ago,” Brown said. “I asked the question to keep people encouraged about our growth. To tell them that we could grow if we had the right vision within us.”

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High risk, high reward

While the direction and speed of growth might be executed differently from how Brown did it in his day, Bediako’s vision and the operational expertise of Mike Porter, president and COO, are ushering in a new era for New Horizons. The latest milestone is a 155,000-square-foot bakery in Columbus, OH, which houses a high-speed bun line and a new pancake line set for startup in early Septem­ber, as well as a 120,000-square-foot production facility, also in Columbus, dedicated to the ingredient operation.

“Trina’s doing things that make sense for the company,” Brown said. “I was more risk-averse and didn’t move the company as fast or as far as she has. It served me well at that time, but I applaud what she’s doing now. This team has come a long way, not only with the plant and equip­ment but also in their thinking about acquisitions and how big they truly want to be. In my mind, it’s picture perfect.”

Between strategic vision and operational execution, New Horizons has figured out how to take fundamentals into the future by turning traditional bun production into all-new possibilities. That began with getting the basics right.

“This team has come a long way, not only with the plant and equipment but also in their thinking about acquisitions and how big they truly want to be. In my mind, it’s picture perfect.” — Tim Brown | founder and chairman | New Horizons Baking Co.

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Known as “the baker’s baker,” New Horizons spun off the Genesis Baking subsidiary in 2008 to handle contract manufacturing for all non-McDonald’s production, including the new pancake line. By strategically entering new markets through Genesis, New Horizons has diversified its business while main­taining McDonald’s as a longstanding, valued partner.

The past five years brought a surge of growth when the company transformed its Toledo, OH, distribution center into a bakery with a new English muffin line that launched in 2021. Then later that year, New Horizons acquired Coalescence, a manufacturer of dry ingredient blends, followed by the 2024 acquisition of Graffiti Foods, which produces liquid blends for the foodservice market.

Bolstering the business

While the ingredient side was coming together, Bediako envisioned the next chapter of growth.

“When we thought about that idea of, ‘How big do you want to be,’ we put together a plan for three to five years,” Bediako said. “We recognized there’s a lot of change in the industry. There are fewer family businesses, more private equity groups coming in, and we wanted to be sure our place in the industry was as strong as it could be.”

Oftentimes, opportunity spurs action. But sometimes, the action has to come first, and that can be risky. Intuition must be sharp and in tune. For Bediako, the iron was heating up, and it was time to strike.

In 2024, a building became available in Columbus, originally designed for food manufacturing and equipped with an existing internal freezer, space for a high-speed bun line and capacity for additional lines. The vision was coming into focus.

“We realized we couldn’t wait for all the business to be booked before we built this next phase,” Bediako said. “If we did, we’d end up missing the opportunities when they came. So, we strategized. We assessed. We planned. We looked at where we wanted to be and what our customers’ needs were, and we decided we were ready to take some degree of risk.”

They sat with a team of 10 bankers to share the New Horizons vision and strategy for the future, and the result was the capital needed to bring both Columbus facilities to fruition. A year later, Coalescence and Graffiti merged into one operation to become New Horizons Food Solutions. With full blending capabilities, the opportunities increased exponentially, whether blending for its own bakeries or supporting customers, ingredient suppliers or even other bakers. And with the ingredient operation streamlined, the Columbus bakery is now running one of the fastest bun lines in the McDonald’s network.

“The business we’ve created from these investments has put us in an enviable financial position,” said Kurt Loeffler, New Horizons’ CFO. “The work has just begun, but the possibilities of where we go from here are endless.”

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Beyond the buns

Not only will the new bakery allow New Horizons to increase its bun capacity by about 55 million dozen per year, but it will also allow the company to serve a customer base in a 250-mile radius, reaching almost as far as Washington, DC.

But the Columbus operations aren’t limited to buns and ingredient blends. The team originally planned to install an English muffin line after the bun line, but opportunity knocked from a non-McDonald’s English muffin customer on the Genesis side of the business.

“Opportunities have a way of presenting themselves,” Porter said. “We had the privilege to sit down with one of our largest customers, and we were awarded pancake business, not because of what we could do for them, but because of what we have done for the past 19 years.”

These types of opportunities come from a commitment to quality that often begins with New Horizons’ R&D team, led by Matt Bowers, direc­tor of R&D, who has been with the company for more than 34 years.

“We pride ourselves on the fact that we don’t bake in a lab,” Bowers said. “Our R&D team is beyond brilliant, and they focus on doing samples on the line, especially when it comes to clean-label and high-protein products. With this strategy, we can demonstrate how we make these products day in and day out.”

With the pancake line starting up this fall, the Food Solutions facility will feed that business by blending its pancake mix, allowing New Horizons to leverage buying power for sugar and other ingredients.

What’s more, the vertical integration makes growth more tangible than ever, especially when the pancake line alone will have the capacity to produce 30,000 full-size pancakes or 72,000 minis an hour. It also provides opportunities for further expansion, should the business call for it.

“We’ve taken risks, but when we get new business opportunities, that’s how we can pay for it,” Porter said. “That’s why the pancake line and the business it created have been such a blessing for us. Trina’s taking the question of, ‘How big do you want to be’ even deeper. We’re thinking inward and reminding ourselves that we have to be better than we were yesterday. When we are, the sky’s the limit.”

With new infrastructure in place, dreams are becoming reality in nearly every aspect of the business.

“Mike and I did a lot of ‘blue sky’ thinking,” Bediako said. “Now that the ingredient business is underway, we’re bringing the vision to fruition with the bun and pancake lines. It’s a beautiful thing.”

This story has been adapted from the August | Q3 2025 issue of Commercial Baking. Read the full story in the digital edition here.

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