PERFECT BLEND

 Close collaboration with customers and an intense drive to solve challenging problems have been Blendex's ingredients for success.

Although Blendex Co. is willing to do almost anything for its customers, some requests aren't honored.  "We don't repair blenders," CEO Ron Pottinger jokes.  "We get a lot of calls asking for that because our name can be misleading."

However, when it comes to creating customized blended mixes, ingredients and batters, Blendex can meet any expectation, he says.  "Customers will come to us with an idea in mind of the type of product they would like developed," Pottinger explains.  "One company, for example, had a new slushy machine, and they wanted a powdered drink mix instead of the standard liquid mix."

Blendex worked with the customer, gathering information about the desired properties and taste profile of the product.  Often, Blendex R&D experts will visit the customer's production facility to better understand the requirements.

With about 5,000 base formulas on file, Blendex begins with a standard framework for the formula, but customizes it until the customer says it is perfect, Pottinger says.

Blendex also works in strict confidence to develop "secret" formulas.  The raw materials used in production are specifically designed for blending and mix smoothly and reliably.  The company offers custom blending and private-label products.

Currently, Pottinger says, the industry is on a "health kick."  Low-carb formulas, such as pizza dough, are some of the most frequent requests lately.  "The jury is still out on the low-carb craze," he says.  "Some say it is here to stay, others say it won't last.  Either way, there's never a dull day around here."

Low-carb mixes are just a fraction of Blendex's capabilities.  Pottinger says the company is able to solve almost any problem.  "One company that we were working with was trying to develop seasonings for their snack chips," he recounts.  "They needed a certain profile, so they presented the problem to us."

Several years back, Blendex developed mixes for fried foods.  But because the term "fried" has taken on a negative connotation, Blendex has shifted some of its focus to breads, seasonings and spice mixes.

"But we've developed everything from tea blends to beverage blends to colored salts and sugars,"  Pottinger notes.  "We've even had nutriceutical companies ask us to develop health bar mixes that taste good, have vitamins, nutrients, protein and are low in calories."

Production Process

In addition to facing the challenge of developing highly specific ingredient blends, Blendex must also address industry challenges.  Food safety, Pottinger points out, has been a critical issue in recent years.

"To make sure we are upholding our safety standards, the quality control department now checks the products more thoroughly than before," he says.  "We always had strict safety controls, but now it's even more so.  Food safety is on everyone's mind."

Tighter profit margins and the rising costs of insurance, raw materials and transportation have impacted Blendex similarly to most other industries.  However, the work force issues Blendex faces are more unique.

"Being in Kentucky, the state has less than 5 percent unemployement," Pottinger says.  "We have large manufacturers here, like Ford, that really draw a lot of employees."

Therefore, attracting strong employees is a continual initiative.  Blendex runs two shifts, and staffing its facility with people willing to work in a creative and challenging environment is not easy.  "Our employees aren't putting on the same lug nut every day," Pottinger explains.  "We are trying to automate more aspects of our facility, but with all the product changes we have each day, a lot of manual labor goes into the job."

Running two 10-hour shifts, Blendex employees work four days a week.  However, this schedule allows it to meet customers' emergencies, as well as operate more productively.

"On certain shifts, we can only run certain products," Pottinger explains.  "When we use peanut flour, because of the allergies associated with it, we use a whole blending room just for the one mix."

Milestone Mixes

Eugene A. Pottinger, Ron Pottinger's father, founded the company in 1975.  Throughout the years, Blendex has not only expanded its capabilities, but its presence in the industry.  Before a large pizza chain gained nationwide recognition, it turned to Blendex to develop high-quality pizza dough.  This led to other pizza-making-related products, and Blendex's reputation gained momentum.

Today the company participates in several industry events to expand its customer base and showcase its innovation.  "We consider ourselves an industry leader - the Cadillac of the food industry," Pottinger says.  "We don't want to be complacent.  We don't want to be good.  We want to be great.

Blendex never devalues its products or cuts corners on its developments.  "You get what you pay for," Pottinger stresses.  "When customers come to us, they get great productions.  We don't want to get rich overnight; we want to provide solutions for the industry."