Ingredient Silos

Ingredient Silos

Voortman's state-of-the-art silos hold important ingredients in a clean, safe environment until they're needed. The silos are computer controlled, feeding their contents to the Reimelt Bulk System on demand.

Ingredient Silos

The Reimelt Bulk System

The Reimelt Bulk System

The Reimelt Bulk System is a computer controlled system for weighing and transporting the ingredients as they are needed for each specific recipe. Here we see a partial view of the main system.

The Reimelt Bulk System

Dough Mixers

Dough Mixers

The ingredients are then brought to one of our giant “Dough Mixers”.

Dough Mixers

Mixing Complete

Mixing Complete

With the mixing process complete the operator starts to fill the waiting bucket.

Mixing Complete

One Giant Cookie Bin

One Giant Cookie Bin

With approximately 1,500lbs. of cookie dough resting inside, this bucket will now be lifted by a powerful overhead hoist that will easily bring it into position for unloading. To the right, you can see a couple of these buckets ready to be loaded into the cookie forming machines.

One Giant Cookie Bin

Ready For Cookies

Ready For Cookies

This freshly mixed dough is now ready for transport to a rotary cookie forming machine.

Ready For Cookies

Cookie Forming Begins

Cookie Forming Begins

Bronze rotary dies are used to form the fresh dough into custom-shaped cookies.

Cookie Forming Begins

Time to Add Some Flavour

Time to Add Some Flavour

A rotary brush applies a thin coating to the top of the top of the cookies. Then, delicious almond slices are sprinkled from above.

Time to Add Some Flavour

Deposit Die

Deposit Die

Here we see a different type of cookie being made using a “Deposit Die” with rotating nozzles. This gives these delicious cookies a lovely and very unique shape!

Deposit Die

Oven Hall

Oven Hall

Here we see a view of the "Oven Hall". With up to 10 manufacturing lines running simultaneously, over 20 million cookies can easily be produced in just one day! Cookies travel an average of 10 minutes through the huge conveying ovens. As you can imagine, this room becomes extremely warm.

Oven Hall

Wafer Oven Cooling Arch

Wafer Oven Cooling Arch

After leaving the "Wafer Oven”, these wafer sheets must enter the "cooling arch" before the cream can be added. On the right, you see an overhead view of the wafer sheets as they proceed through the cooling arch.

Wafer Oven Cooling Arch

Wafer Cutting

Wafer Cutting

Here the "Wafer Books" are cut by a high-tension wire into individual cookies.

Wafer Cutting

Wafer Packaging

Wafer Packaging

Here the wafer freshness is sealed in as stacks of wafers pass through an automated wrapping system. Mmmm, so fresh!

Wafer Packaging

Wafer Boxing

Wafer Boxing

Next, the wafer cookies are carefully and expertly boxed for shipping.

Wafer Boxing

Chocolate Chip Classics

Chocolate Chip Classics

Mmmm, just out of the oven, these chocolate chip cookies smell so good, but they're still really hot!

Chocolate Chip Classics

Cookie Cooling

Cookie Cooling

These large fans will cool the chocolate chip cookies so they're just right for packaging.

Cookie Cooling

Cooling and Packaging

Cooling and Packaging

The chocolate chip cookies continue to cool as they are gently directed into rows for packaging.

Cooling and Packaging

Automatic Robotic Packaging

Automatic Robotic Packaging

Here we see the cooled Almond Krunch cookies as they're about to enter the automated robotic packaging system.

Automatic Robotic Packaging

Tray Loading System

Tray Loading System

Depending on the final package type required, different packaging methods are used. This line of Chocolate Chip cookies is about to enter a fully robotic tray loading system.

Tray Loading System

Tray Packaging

Tray Packaging

Using a vacuum system, these robotic arms gently select each cookie and then deposit them into a tray. When each tray is full, another arm quickly moves the tray to a conveyor belt and off it goes.

Tray Packaging

Cookie Tray Journey

Cookie Tray Journey

The cookie trays that were loaded by the robotic arms now proceed down the line.

Cookie Tray Journey

Packaged with Care

Packaged with Care

The trays are carefully monitored to ensure that they proceed smoothly to the automated packaging area.

Packaged with Care

Bulk Cookie Packaging

Bulk Cookie Packaging

The trays of bulk Chocolate Chip cookies that have just come from the automated robot arms are now expertly loaded into shipping boxes. Packaging bulk trays this way requires extra care.

Bulk Cookie Packaging

Almonette Cookie Shipping

Almonette Cookie Shipping

The Almonette cookies that we followed earlier have been collected into trays by the robotic arms, packaged automatically, and are now placed into shipping boxes.

Almonette Cookie Shipping

Shipping Begins...

Shipping Begins...

Once boxed, the packages travel by conveyor directly to the shipping area of the plant.

Shipping Begins...

Shipping Warehouse

Shipping Warehouse

The arriving shipping boxes are now picked up by extremely efficient forklifts that are in constant motion. Orders from all over North America, as well as more than 50 countries from around the world, are loaded directly onto waiting transport trailers and shipping containers.

Shipping Warehouse