Shearer's Foods

Shearer's Foods, LLC
Private company
Industry Snack food
Founded 1974
Headquarters Massillon, Ohio, United States
Area served
 United States
Canada
minimal global distribution
Key people
 CJ Fraleigh CEO
Fritz Kohmann CFO
Monty Pooley CCO
Scott Heldreth SVP & CIO
Walt Fink VP HR
Products See products section
Owner Ontario Teachers' Pension Plan
Website www.shearers.com

Shearer's Foods is a manufacturer of snack products including potato chips, tortillas, whole grain chips, cheese curls/puffs (and other extruded snacks), popcorn, pork rinds, rice crisps, wafers, cookies, and both sweet and savory biscuits. Shearer's Snacks was founded in 1974 as a snack food distributor in Brewster, Ohio, and has now factories in Ohio, Texas, Arkansas, Oregon, Virginia, Iowa, and Ontario, with worldwide distribution.

Shearer's manufactures, warehouses, and distributes branded snacks and contract and private label products for snack food companies and retailers. Its branded products include Shearer's Potato Chips, including home-style, savory and kettle-cooked options, tortilla chips, pretzels, pork rinds, corn puffs and curls. Its newest plant in Massillon, OH is the first food manufacturing plant in the world to achieve the highest sustainability award for environmental responsibility.[1]

Shearer's employs more than 3,400 people in eight facilities. Its headquarters is located in Massillon, Ohio.

History

In the early 1900s, the Shearer family opened Shearer's Market in Canton, Ohio. The third generation, Jack Shearer and his wife, Rosemary, operated the family grocery store from the 1950s until 1976, and in 1974 bought a snack food distributorship and named it Brookside Distributing. In 1979, they began manufacturing "hand-cooked" potato chips until discovering that a kettle cooked chip provided more of a crunch and a standardized method of preparation. The Shearers hand-cooked potato chips from the kettle, packaged them in one-pound poly bags with a twist tie, delivered them from a warehouse and first sold them under the Kettle-Cook'd label.[2]

Growth and transition

In 1982, Shearer's purchased a 20,000 square foot facility on ten acres in Brewster, Ohio. Soon after, six hand-kettles and a peanut roaster were in operation. The Grandma Shearer's logo appeared on shelves in 1983, and 3,700 pounds of potatoes were processed daily. Shearer's installed its first continuous fryer to produce up to 1,000 pounds of potato chips every hour and expanded its warehouse and maintenance space by 9,000 square feet in 1986.[3]

In 1988, the company increased its plant size again. This growth continued through the 1990s and included the addition of a second continuous fryer, two hand-kettle fryers that featured automatic stirring systems (among the very first manufactured in all of the United States), computerized combination weighers, state-of-the-snack equipment for tortilla chips and cheese curls, and an additional 100,000 square feet of space.[4]

In the early 2000s, six hand-kettle cookers, a new potato peeling system, distribution and transfer conveyors, and a new seasoning system were installed. Thirty-three acres adjacent to the current location were purchased to combine for 77 acres in total, while a portion of the storage operation was relocated nine miles from the headquarters to Massillon. The company was named "Snack Manufacturer of the Year" by Snack Food & Wholesale Bakery magazine in 2002[5] and again in 2011.

Shearer's developed a new logo, revamped packaging, and expanded its factory outlet store in 2004. A $2.6 million wastewater treatment plant was completed in the spring, and six additional hand-kettle cookers were installed along with a new packaging area, making Shearer's one of the largest manufacturers of kettle-cooked potato chips in the nation.[4]

Recent history

An increasing trend of whole grains and better-for-you snacks resulted in three new whole grain tortilla chip products with 100% yellow corn whole grain in 2006.[6]

In 2008, Shearer's Foods unveiled plans to build the first manufacturing plant in the world to achieve the highest sustainability award for environmental responsibility.[1]

In 2009, Shearer's introduced two multi-SKU brands to retail, Tangos™ Tortilla Chips and Shapers™ Whole Grain Chips.

In 2010, Shearer’s acquired Snack Alliance, Inc. and its Canadian affiliate (collectively, “Snack Alliance”), a branded, contract pack and private label snack producer in North America. Founded in 2000, Snack Alliance employed over 400 associates across the United States and Canada. Snack Alliance had manufacturing operations located in Hermiston, Oregon and Bristol, Virginia that produced potato chips, tortilla chips, extruded products, popcorn, and their Riceworks brand of whole grain rice snacks.[7]

In May 2011, Shearer's extended their line of potato chips to include zero trans fat chips, cooked in 100% canola oil.

In June 2012, Shearer's moved its headquarters into the four story Grand Mill Centre building in downtown Massillon, Ohio.

In October 2012, Shearer's sold to Chicago based Wind Point Partners.[8]

In January 2015, Ontario Teacher's Pension Plan acquired majority stake in Shearer's Snacks through the purchase of additional equity stake. The private equity group had initially acquired stake in the company in 2012 alongside Wind Point Partners and in partnership with CJ Fralaigh. Since the sale in 2012, Shearer's completed acquisitions of Lance Private Brands and Medallion Foods. These acquisitions doubled the size of the business and significantly expanded private label and contract manufacturing offerings.

Environmental sustainability

The company has expressed a commitment to sustainability and energy performance, joining Energy Star in 2006 and working to improve energy performance in its offices, manufacturing facilities and distribution centers.[9] The company received recognition by way of a Crain's Cleveland Business Emerald Award for its efforts.[10]

Their energy management program includes:[11]

The company broke ground on its LEED Platinum Certified snack food manufacturing plant in 2009. The plant in Massillon, Ohio was the first manufacturing plant in the world to achieve the highest sustainability award for environmental responsibility.[1]

Manufacturing

Manufacturing capabilities

Products range from standard sliced and rippled potato chips, kettle cooked potato chips, tortilla and whole grain extruded chips, and other extruded product such as cheese curls and puff corn (also known as hulless popcorn).

Products range from standard sliced and rippled potato chips, kettle cooked potato chips, tortilla and whole grain extruded chips, and other extruded product such as cheese curls and puff corn (also known as hulless popcorn). The company is conversant over a variety of base ingredients, including potatoes, yellow, white, blue, and organic corn, and seasonings and flavors developed both by both an in-house R&D group and external partners. Tortilla chips are produced using company produced masa. Production capabilities include:

Plants

The Products

Shearer’s Branded Snacks

Other Shearer’s brands include riceworks, Granny Goose, Thin & Crispy, Brent & Sam’s, Delicious Bakery, and Vista, in addition to miscellaneous items such as Jenny’s Popcorn varieties.

References

  1. 1 2 3 Staley, Doug (March 14, 2011). "Shearer's, Fresh Mark, Drummond are success stories". The Independent, Massillon. Archived from the original on 2011-04-25. Retrieved 16 June 2011.
  2. ↑ Schultz, Martin. "True grit: How Shearer's Foods started out as a corner store and became one of the U.S.'s fastest-growing snack food manufacturers and most progressive companies. (2002 Snack Manufacturer of the Year)". HighBeam Research. Snack Food & Wholesale Bakery. Retrieved 21 June 2011.
  3. ↑ "Shearer's Foods,Inc.". FundingUniverse. Retrieved 21 June 2011.
  4. 1 2 "Shearer's Foods, Inc.". FundingUniverse. Retrieved 21 June 2011.
  5. ↑ "True grit: How Shearer's Foods started out as a corner store and became one of the U.S.'s fastest-growing snack food manufacturers and most progressive companies.". Snack Food & Wholesale Bakery. 2002-03-01. Retrieved 2010-02-25.
  6. ↑ "Snack Food Association Endorses Alliance for a Healthier Generation Snack Food Guidelines" (PDF). Alliance for a Healthier Generation. Retrieved 21 June 2011.
  7. ↑ "Shearer's Foods Inc. Acquires Snack Alliance, Inc.". Manufacturer's Group. Manufacturers Group, Inc. Retrieved 21 June 2011.
  8. ↑ "Shearer's Foods sold to Chicago Company". IndeOnline.com. The Independent. Retrieved 12 November 2012.
  9. ↑ "How Shearer's Foods improved the bottom line by focusing on sustainability". Smart Business Cleveland. Retrieved 2009-02-04.
  10. ↑ "Champions of sustainability honored". Crain's Cleveland Business. Retrieved 2009-09-21.
  11. ↑ Gueverra, Leslie. "Shearer's Cuts the Ribbon on America's Greenest Snack Factory". Green Buildings. Green Biz Group. Retrieved 21 June 2011.
  12. 1 2 Higgins, Kevin. "Plant of the Year: Shearer's Foods Rethinks the Food Plant". Food Engineering Magazine. Retrieved 21 June 2011.
  13. ↑ "Making an effort". Akron/Canton Smart Business. Smart Business Network. Retrieved 21 June 2011.
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