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To achieve the high volume of par-baked products that its business forecasts predicted, the company adopted automated systems that maintained the characteristics of its manual methods.īrian Sisson, ACE’s vice-president of operations, and company engineers thoroughly studied mixing, makeup, proofing, baking and freezing options. Less than 20 km (about 12½ miles) from ACE’s fresh facility in Toronto, the Vaughan bakery created a new paradigm for the company. The company became part of Weston in 2010. In 2009, ACE opened an automated facility at Vaughan to produce par-baked breads. Demand rose even higher as the company entered foodservice channels. Two years later, par-baked baguettes joined the roster to meet the needs of in-store bakery clients. It moved into a larger facility in North York, ON, during 1997. That passion prompted the husband-and-wife team to open to the public in 1993, establishing ACE Bakery in Toronto. Over the next several years, they visited artisan bakeries throughout North America and Europe, researching methods and experimenting extensively. They launched their quest in 1982 by building a tiny backyard bakehouse at Caledon, ON. But unlike those other bakery entrepreneurs, they sought a different archetype: not a soft farmhouse-style loaf of white bread but an authentic French baguette. Like many of the big names in the baking industry, ACE Bakery started in a family kitchen, that of Martin Connell and his wife, Linda Haynes. “That’s a sweet spot for us with our customers.” Today, almost two-thirds of the company’s business is with in-store bakery and foodservice customers.
What began as a passionate hobby evolved into a world-class bakery, a leader in the fresh-baked artisan category and an emerging powerhouse in frozen par-baked breads.
Toronto has been home to ACE Bakery since its founding 20 years ago. During a May 7 analysts’ briefing, company president Pavi Binning cited the new Gaffney bakery as an example of this commitment. In a related move, two weeks after celebrating Gaffney’s grand opening, ACE Bakery’s parent company, George Weston Ltd., Toronto, indicated a new focus favoring the US for its capital investment program over the next few years. “But it was challenging to supply bread to California,” he observed, “however, we knew we could ship from a Mid-Atlantic location throughout the US.” The Vaughan, ON, bakery handles the Northeast, explained Philippe Gaudet, director of marketing. Selection of Gaffney gives the company access clear down to Florida and points west. “This bakery will take us up to 100 million loaves annually systemwide,” Mr.
As currently configured, the new bakery produces par-baked breads, including ACE’s classic baguettes and rustic ovals, and it will eventually bake breads 24 hours a day, seven days a week, 365 days a year.
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At full capacity, ACE Bakery’s newest location can output 32 million frozen par-baked baguettes a year - enough to stretch across the Atlantic from Gaffney to Paris and back again.
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