Whats ironic or coincidental is that we had this SAME Discussion EXACTLY a year ago.http://www.getbig.com/boards/index.php?topic=351776.150http://www.ocregister.com/articles/mcdonald-100289-plant-buns.htmlFresh buns: How does McDonald's get them?By NANCY LUNA
The Orange County Register
Brea-based Fresh Start Bakeries, a key supplier to McDonald's, gives the Register a rare glimpse of its new $22 million plant.
The first of a two-part look at McDonald's suppliers
ONTARIO — As I walked into the lobby of Fresh Start Bakeries' multimillion dollar plant the other day, I could feel my nostrils flare as the powerful and pleasing smell of yeast overtook me.
MUFFIN MAKING: This machine is cutting muffin dough. Fresh Start's Ontario plant cranks out 1,400-dozen English Muffins an hour. The muffins are used for Egg McMuffins, one of McDonald's most popular meals.
McDonald's ketchup kingdom: a tour of Golden State Food
Behind the Scenes at In-N-Out Burger Fresh Start Bakeries
Headquarters: Brea
History: The small bakery, founded in Los Angeles in the early 1960s, got its first break in 1964 when it began baking buns for McDonald's. Through expansion and various acquisitions, the company has grown into a global baking giant with 25 plants operating in the U.S., Europe, South America, Central America and Australia. Last year, Fresh Start bought Santa Ana-based Sweet Life, a cookie supplier for McDonald's.
Customers: 17 plants, including the one in Ontario, are dedicated to making buns and muffins for McDonald's. The company also supplies other fast-food chains and grocery stores such as Costco, Smart & Final and Stater Bros.
Finances: Annual sales at the private firm exceed more than $500 million. McDonald's accounts for about 50 percent of Fresh Start's global revenue, down from 90 percent five years ago.
Source: Fresh Start Bakeries
Food facts and milestones
McDonald's beef is 100% USDA-inspected beef with no fillers, additives or extenders
In 1987, McDonald's introduced fresh-tossed salads.
In 2003, the chain started using �all-white� chicken for Chicken McNuggets. Previously the meat was �blended� or a grounded mix of dark and white meats.
In 2006, McDonald's became an industry leader when it added nutrition information on packaging.
McDonald's food comes from certified suppliers who are audited and inspected on a regular basis. Besides Fresh Start Bakeries in Brea, key McDonald's suppliers in the U.S. include Dannon, Kraft, Nestl�, Tyson, Newman's Own and Irvine-based Golden State Foods.
Food served in restaurants goes through more than 2,000 safety, quality and inspection checks. Bakeries, for example, must run bread products through a metal detector.
For its Fruit & Walnut Salad and Apple Dippers, McDonald's uses four kinds of apples that are available year-round and that meet quality standards: Granny Smith, Gala, Jonagold and Empire apples.
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•McDonald's McRib to get national spotlightI felt like I'd entered grandma's house as she pulled a hot loaf of bread from the oven.
Later, as I witnessed hundreds of Big Mac buns whizzing past me on a conveyor belt, it was clear that I was visiting someplace much more complicated — and more fascinating — than granny's kitchen.
The plant, run by Brea-based Fresh Start Bakeries, cranks out 14.4 million buns per week for fast-food chains and supermarkets in Southern California.
Its most important client: McDonald's.
The companies have been partners since 1964 — a time when Ray Kroc made handshake deals with suppliers as he vigorously pursued building a burger empire. Today, Fresh Start has 17 bakeries across the globe dedicated to making buns for the world's most famous burger brand.
McDonald's invited me and a couple of nutritionists to tour Fresh Start's $22 million, state-of-the-art plant in Ontario recently as part of a special "quality assurance" program.
The idea: by viewing how its suppliers operate, McDonald's can send a message that the chain is serious about food safety and quality.
"Quality is certainly a top priority at McDonald's," said Todd Bacon, head of the chain's U.S. Supply Chain Management.
Bacon, who holds a doctorate in "meat science," discussed the strict controls and guidelines McDonald's places on vendors and suppliers. Rules apply for just about any kind of scenario along the food chain — from how to treat a sick broiler chicken to requiring hot buns to pass through metal detectors.
Any supplier that goofs is out.
That's it. No second chances.
"There's too much at stake for us not to do everything we can," Bacon said of McDonald's pursuit of food safety and quality.
I was not allowed to bring a staff photographer to document the tour. The reason? Something about revealing "trade or proprietary" secrets. However, I did manage to get approval to snap a few photos with my point-and-shoot camera during the hour-long tour, led by veteran plant manager Bob Mitchell.
"Baker Bob," as he's affectionately called, put on a great show for us.
We saw giant blobs of dough whirling through stainless steel kneading machines. We held delicate dough balls drizzled with corn meal that would eventually become steaming hot English muffins. And we got a peek at how the basic dough is made for any McDonald's bun. (Sorry, exact recipes were not revealed.)
The most stunning detail of the plant: very little human handling of product. I saw only a handful of workers in the entire 150,000-square-foot bakery, which also makes buns for Costco, Smart & Finaland Stater Bros.
When Fresh Start moved the facility to Ontario from the City of Industry in 2007, the company added state-of-the-art computer equipment to automate nearly every part of the baking process.
Overall, it was an eye-opening experience. I learned some fun factoids, including the answer to this question: How many seeds are on top of a sesame-seed bun?
To get the answer, take a look at the slide show.
Part 2: The lettuce fields of Salinas
Contact the writer: nluna@ocregister.com or 714-796-6756. Checkout my fast food blog at ocregister.com/fastfood