Blending at its Best

Award-winning Blendex works closely with customers to solve their most challenging problems. This approach has been the company's recipe for success. By Hanna Aronovich

Within the last several months, Kentucky-based Blendex Co. has received many awards of recognition. In November, Associated Industries of KY chose Blendex as Manufacturing Company of the Year. The local business newspaper, Business First picked them as one of the three finalists for Small Business of the Year to be presented in December. In July, the Jeffersontown Chamber of Commerce recognized Blendex as the Member Business of the Year. The Greater Louisville Chamber awarded them the INC. credible Award as well as being picked to be a member of the Mayor's High Impact Program in May of this year.

In January, Blendex received the KMAC Quality Award at the Greater Louisville Manufacturing Awards of Excellence ceremony. The company also received, for the second year in a row, Louisville Business First's "Fast Fifty" Award as one of the top-50 fastest growing, privately held companies in greater Louisville.

"We attribute our growth over the last few years to our ability to exceed our customers' expectations for quality products, delivery of goods and customer service," CEO Ron Pottinger says.

Despite the company's success, there are certain limitations on its capabilities.  “We don’t repair blenders,” 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. "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's perfect, Pottinger says.

Blendex is able to work 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.

Pottinger says the company is able to solve almost any problem.  “One company that we were working with was trying to develop guacamole seasoning for the snack chips”, he recounts.  “They couldn’t get the green color right, so they took 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 its focus on breads and seasonings.  He says currently, whole grain products are the latest nutrition and health push.

“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 bars 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 in similar ways as most other industries.  However, the work force issues Blendex faces are more unique.

Being in Kentucky, the state has 5.7 percent unemployment,” Pottinger says.  We have large manufacturers here, like Ford, that really draws a large amount of potential 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 only four days a week.  However, this schedule allows the company to meet its customers’ emergency orders, as well as operate more productively.

Blendex’s many ribbon blenders can blend up to 4,000 pounds at one time.  The production line is separated based on the type of mix – a white powder line, seasonings, and oleoresins.  The segregation is required, Pottinger says, to avoid mixing ingredients with high allergens and to facilitate a smoother clean-up process.

“On certain days, we can only run certain products,” he explains.  “When we use peanut flour, because of the allergies associated with it, we dedicate a blending room just for the one mix.”

After an allergen product is run, the entire room must be sanitized.  Oil-based mixes require even more effort.  “It’s like watching an Indy pit crew take over when it’s time to switch products,” Pottinger jokes.  “Everyone has a job to do.  It’s like magic in motion.”

Packaging is another critical component to product development, and Blendex offers a variety of options.  From small pillow bags to tankers carrying 44,000 pounds of flour, Blendex is able to deliver the amount of product its clients need.

Because of the transportation costs, many companies prefer to receive large shipments.  However, companies requesting chicken breading products prefer smaller packages, but a variety of flavors.

Milestone Mixes

Founded in 1975, the company was led by Eugene A. Pottinger, Ron Pottinger’s father.  Throughout the years, Blendex has not only expanded it 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 and trade shows to expand it 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 it developments.  “You get what you pay for,” Pottinger stresses.  “When customers come to us, they get great products.  We don’t want to get rich overnight; we want to provide solutions for the industry and maintain our commitment to excellence.”

Food and Drink Magazine

Nov/Dec 2005 Issue