The commercial baking industry, employing nearly 800,000 workers and contributing $186 billion to the U.S. economy, is projected to grow at a steady rate of 6.6% CAGR in the upcoming years. Despite these promising projections, baking manufacturers face the same challenges that have plagued the sector for years — labor shortages, stringent regulations, rising costs, and shifting consumer demands that still stand in the way of achieving sustainable, long-term growth.

In response, many forward-thinking manufacturers have capitalized on technological advancements to optimize production, enhance employee engagement, and drive profitability. Integrated, cloud-based solutions that can be deployed across the production floor and enable real-time collaboration, data-tracking, and troubleshooting are becoming more commonplace than ever. Below, we explore compelling case studies of manufacturers who’ve embraced innovative technologies like QAD Redzone’s connected workforce solution to tackle manufacturing challenges, drive engagement, and see their profits soar.

Streamlining Audits at AK Pizza Crust

Audits are a common and necessary part of manufacturing, but they can often be a cumbersome and time-consuming process to execute. That’s why when Scott Ditzman, Quality Manager at Alive and Kickin’ Pizza Crust, had to provide the paperwork for two production dates during an audit, they felt terrified and overwhelmed. Having to pull hundreds, if not thousands, of pages of data on temperatures, production checks, and quality assurance was not an inviting prospect.

Photo: ©QAD Redzone

However, the trepidation didn’t last long. Ditzman quickly realized that what used to take them hours in the past, they could now achieve within a couple of minutes using their app-based, connected workforce solution: Redzone. Since implementing the tool, the team has grown used to using it for keeping track of all of their work, so all data was digitized and available at their fingertips with a few clicks of a button. Ditzman was able to pull the requested information almost instantaneously, saving critical time and ensuring compliance.

Boosting Profit Margins at Orlando Baking

Production efficiency isn’t just about passing audits. Orlando Baking, one of the top manufacturers of consumer bread, runs a 24/7 operation where production hiccups can easily propagate across shifts if not caught and communicated early. The manufacturer implemented QAD Redzone’s frontline collaboration tool equipped with coaching and training features to both log issues and train staff and as a result, slashed downtime and hit 90% attainment targets.

Rocco Orlando, Plant Manager, explains that the tool has inspired an overall change in the facility culture since everyone could see the results of their work and the work of their colleagues. All of this has translated into a 10% increase in their profit margins in the two years since they implemented the solution. Redzone’s integration now spans production, maintenance, quality, and sanitation, fostering a culture of collaboration and accountability across the whole plant.

Going Paperless & Driving OEE at Mel-O-Cream

Another metric that can easily eat away at a manufacturer’s profits is OEE (overall equipment effectiveness), something Mel-O-Cream has been tracking meticulously. However, paperwork was still a big hurdle that prevented the business from being truly data-driven and efficient. The manufacturer used Redzone to digitize a lot of its operations and, within months, went 100% paperless.

Despite its many powerful features, though, Chad Larson, Vice President and COO, highlights the coaching capabilities that were native to the tool as playing a pivotal role in driving adoption and helping the business realize its efficiency gains. Drawing from experiences across diverse baking cultures nationwide to build best practices tailored to the facility, Mel-O-Cream enabled real-time chats across the facility and gave employees full visibility into performance metrics, enhancing employee engagement along the way.

Larson says that this wide adoption and transparency helped the bakery achieve a 20% OEE uplift and get board approval for a $13 million bakery expansion in just 45 minutes — all thanks to their data-backed credibility. With less staff than at acquisition, the bakery now produces more units, proving that efficiency, not headcount, drives growth.

Reviving Employee Retention at CraftMark Bakery

CraftMark Bakery, a wholesale producer of frozen bakery solutions, once grappled with a severe employee retention problem, with turnover rates nearing 100% just three years ago. Repeated attempts at continuous improvement (CI) had fallen flat, dragging down both morale and output.

The introduction of a QAD Redzone’s #1 connected workforce solution marked a turning point. By engaging operators across all levels, the bakery transformed its workforce dynamics, guided by expert coaching that set this effort apart from past failures. The team members were empowered with a new sense of ownership and clear career opportunities, and by late 2024, turnover at the facility had dropped to 20%.

The benefits extended beyond retention to production capacity. Two cookie dough lines, previously maxed out, gained nearly 50% more open capacity thanks to their new data-driven insights into downtime causes. This allowed the bakery to pinpoint and address inefficiencies with confidence and precision. Early adopters of the tool, dubbed super users, quickly rose through the ranks, fostering a culture of advancement and accountability. With a structured rollout plan supported by team coaching, CraftMark avoided the prolonged struggles of earlier CI attempts, achieving rapid and lasting improvements in both performance and employee satisfaction.

Photo: ©QAD Redzone

Essential Technologies for Modern Bakeries

To ensure bakeries remain competitive and can effectively address both current and future challenges, embracing technology is key. Here’s a quick guide to the essential tools that can dramatically enhance operational efficiency and profitability in the baking industry:

• Connected workforce solutions like Redzone: Foster real-time collaboration and instant problem-solving across the production floor.
• Digital compliance tools: Simplify audits with instant, detailed compliance reporting.
• Production optimization software: Enhance operational metrics like OEE with advanced analytics and real-time monitoring.
• Employee training and engagement platforms: Improve retention and adherence to standards through interactive and ongoing training.
• Paperless operation technology: Increase efficiency and sustainability by transitioning to a fully digital documentation system.

Cooking Up a Better Future

In an industry with tight margins and fierce competition, every second counts. By slashing downtime, simplifying compliance, and lifting OEE, these bakeries are securing their bottom lines for the long run. From streamlining FDA audits to doubling output with existing staff, they’re proving that empowering people with data and technology is the true formula for growth. As the baking industry evolves, specialized manufacturing technologies offer a clear recipe for success: empower your people, harness your data, and watch your profits rise.