A Sweet Success: Innovating Production for a Top Confectionery Brand’s Sandwich Cookie Line Expansion

Consumer disappointment arises in the baked goods industry when favorite products are missing from store shelves. To keep pace with demand, confectionery companies must balance high production costs, narrow profit margins and the urgency of speed-to-market. A leading Southeastern confectionery client turned to Haskell to expand production with a unique sandwich cookie line—one they had never attempted before—while also managing tight budget and scheduling constraints.

Haskell master planned and designed a bakery expansion to deliver value and innovation.

Haskell master planned and designed a bakery expansion that included three standard cookie lines and one complex new line for cream-filled sandwich cookies. When budget realities required scaling back, Haskell and the client prioritized the new sandwich line, which would diversify offerings and create greater consumer value.

A major challenge was ensuring product integrity across a 400-foot assembly process. No existing equipment met the client’s needs, so Haskell innovatively adapted a cooling tunnel originally designed for hard candies, upgrading oven discharge belts to control temperature and moisture. This safeguarded the cream filling and improved product quality.

Throughout the process, Haskell emphasized safety and hygiene by implementing Cleaning-in-Place (CIP) systems, guarding moving parts, and jacketing hot surfaces. The project team also accelerated delivery by coordinating transcontinental equipment design and shifting overseas shipments to air transport, saving valuable time. Repurposing existing machinery further reduced costs and sped implementation.

A smart, safe and successful line was launched to meet demand.

The project enabled the candy client to successfully launch a new sandwich cookie line that met rising consumer demand while maintaining safety, efficiency, and budget discipline. Haskell’s collaborative and innovative approach delivered not just an expansion, but a tailored solution that balanced cost, efficiency, and innovation—reinforcing Haskell’s role as a trusted partner in advancing food production.