Case Study

Founded in 2010, Banneton Bakery specializes in freezer-to-oven (FTO) pastries. Their pastries come in 12 varieties and 80 SKUs, ranging from top-selling sandwich and cocktail croissants to Danish twists and other handheld laminated baked goods with from-scratch fillings. Their attention to quality and innovation has taken them from zero dollars, just over 12 years ago, to more than $100 million in annual revenues today.

Due to continued expansion and needing to free up floor space for a new production line, they were looking to make use of the available air space in between their proofer and freezer equipment. This additional space would allow them to relocate some of their packaging operations.

Banneton Bakery reached out to The Mezzanine Company to provide a solution. To meet their needs, the new platform would need to be designed to work around many obstacles such as building columns, conduits and piping, access panels on the proofers and freezers, and more. 

Additionally, because of active operations at the facility, across multiple shifts, that could not be interrupted, the installation schedule would need to be customized to not impact those operations.

Working closely with Banneton Bakery, we came up with a design for an irregular shaped ~6,000 square foot platform that would serve their needs. For the flooring, Resindek with a Grey Diamond Seal would be used. 

The platform was custom designed, with a specific shape and column placement, to fit perfectly around their existing proofers and freezers and the other obstructions in their facility (as you can see in the photos). It would also include one double swing gate to enable them to load and unload materials from the platform. We also provided an opening, in the mezzanine platform, for them to integrate a conveyor for their automated operations. Lastly, the platform had two IBC staircases for employee access to this new space.

Once the approval drawings were generated, our local project manager made a site visit to make the finishing design adjustments.

After the platform production was complete, we arranged for a prompt delivery and coordinated together the best installation schedule. In order to reduce interruptions to their manufacturing schedule, we installed during weekends and 3rd shift hours.

Victor Litinetsky, from Banneton Bakery, had this to say about our services “The Mezzanine Company provided very prompt service and excellent workmanship. The design and engineering team were very professional and I would use their services again”.