types of kwik trip donuts

Behind the scenes of Kwik Trip’s next-generation bakery

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“Last winter, we got down to about negative 44,” said Eric Fonstad, director of operations for the bread and bun bakery at La Crosse, Wis.-based Kwik Trip. He joked, “We like it when it gets that cold because 40 below will kill off all the germs.”

Here, challenges simply carve the pathway toward success. That’s the Wisconsin mindset, and it’s ever apparent at Kwik Trip, the region’s largest convenience store operator and one of the most vertically integrated in the industry. This family-owned retailer not only operates more than 700 stores in Wisconsin, Minnesota and Iowa, but it also completely controls its own bakery, dairy, kitchens and distribution, including a 500-truck fleet.

“Every store gets a delivery every day,” Mr. Fonstad said.

Just nine years after an overhaul on its former bakery plant, Kwik Trip started up production on three new lines — one for bread and two for buns — in a brand new 200,000-square-foot facility that features state-of-the art technology, including a new continuous mixer, record-setting bread makeup and a fully automated gantry system in its warehouse, just to name a few. It’s a testament not only to overall c-store growth but also to the foresight and innovation from a half-century-old company and the can-do attitude of its workforce.

C-store’s vertical trajectory

Much of Kwik Trip’s success can be attributed to two factors: vertical integration and the rise of the c-store.

It’s no secret that consumer eating habits are changing thanks to the mobile lifestyles of young consumers raised on life hacks and instant gratification. Trends like the “snackification” of American eating habits helped evolve these outlets from gas stations to grab-and-go options to the one-stop shops they are today.

In fact, a recent article from CNN Business cited data from the National Association of Convenience Stores that indicated c-stores have increased sales by 30% in the past decade with a 28% increase of store openings since the turn of the century. The article included Kwik Trip as one of the top c-store chains in the country in part for its food service offerings such as sandwiches and take-home dinners.

Kwik Trip’s status as a c-store innovator should come as no surprise because the company has always been an early adopter: Kwik Trip began in Eau Claire, Wis., in 1965 when, according to CNN Business, there were only 5,000 ­c-stores in the entire ­country. (Today, there are more than 150,000.)

Keeping with that innovative ­attitude, Kwik Trip got into vertical integration in the early 1980s, first with its dairy operation, and then followed in 1985 with baked foods. It’s been a key factor in the company’s success ever since.

“When you talk about vertical integration, that means we make it, we ship it and we sell it,” Mr. Fonstad said. “Those are the three key ingredients, and then you have total control over the quality of products you’re sending out to the stores. We don’t pay a middleman to make it or ship it for us, but quality plays the biggest part.”

In the earlier days of its vertical integration, Kwik Trip was making cake and yeast-raised donuts along with a few other baked foods in a space it shared with the distribution center. Sales grew, and in 1988, the company built a dedicated baking facility. In 2009, it reconstructed the building, and, in addition to sweet goods, it produced bread and buns on two shifts until 2018 when that production moved into the new plant, leaving the original bakery dedicated to sweet goods production.

“We knew about two years before that we were heading for capacity, and we started planning,” Mr. Fonstad recalled. At that point, the company worked with Wieser Brothers General Contractor in La Crescent, Minn., for construction of the new building on the land Kwik Trip had reserved for growth on its roughly 120-acre campus. Construction began in 2017, and production was up and running in the fall of the following year.

“This plant was built to support four times the volume we had in 2016, and it’s positioned well to support that,” Mr. Fonstad said of the fully automated operation.

Taking baby steps

While Kwik Trip is no stranger to technology, the company knew it would have to step up its game to support the growth trajectory it’s currently on.

To meet that goal, Kwik Trip strategically planned its move. For starters, the operation would go from two shifts on a shared line — buns during the day and bread at night — to one shift with bread and buns being produced simultaneously on three new makeup lines.

Making that switch required careful overlap by first splitting the day in half and moving only bun production to the new bakery.

“We did the same thing with bread,” Mr. Fonstad said. “But we ­strategically started up the bun line first because we knew it would challenge us the most. We wanted the OEMs and our coworkers to put the most energy into that part of the start-up.”

By doing this, the bakery never missed a beat in production, and every store received its order on time, every day. It’s another testament to the company’s vertical integration. After all, coworkers are not just in the Kwik Trip bakery. They’re also the folks working in each of those 700 stores, and the bakery has a responsibility to provide them with the product they need.

“We had to plan inventory, so we never stopped producing,” said Dan Walters, bakery R.&D. manager. “We never shorted one package of buns to stores.”

Mr. Fonstad credits the relationship with vendors and the commitment from coworkers for that success.

“Without our OEMs, this process would have been a lot harder,” he said. “But the equipment vendors did a great job helping us get this plant started. A lot of credit goes to them, but also a lot of credit goes to the coworkers on the floor. They paid attention and learned from the OEMs how to run the new equipment.”

Bigger, better, faster

Once the new plant was fully operational, automation was only the beginning. New and upgraded technology enabled the bakery to crank out more product at higher quality than it had experienced before, and that’s the key to sustaining growth.

“Uptime was critical for us,” Mr. Fonstad said. “We asked all our OEMs, ‘What’s your uptime?’ And we checked references. If someone was using AMF or Reading or Zeppelin, we wanted to hear from them.”

For example, raw ingredients are now managed through a Zeppelin Systems USA PRISMA ingredient handling ­system that automates everything from a sprinkle or dash of minor ingredients in the bakery’s J-Bin ingredient ­storage room to bulk items such as flour housed in one of two 224,000-lb silos or sugar from the 80,000-lb silo, all from Zeppelin.

Eric Reimer, bread line supervisor, said the automated ingredient handling not only streamlines the operation but also mitigates the potential for human error. Through the PRISMA system, Mr. Reimer can view the status of all raw ingredients on one of two laptops.

“We want to make sure our products are moving through the pipe,” Mr. Reimer said. “You can’t see a lot, so you need to be able to trust the system.”

With four main common hoppers and 16 individual 800-lb hoppers, along with a weight-loss system that has two load cells that talk to each other, this automation ensures that all ingredients stay on spec.

“If we’re requesting 120 lbs of something, we want exactly 120 lbs,” Mr. Reimer said. “We don’t want anything over or under a parameter because it will hinder the quality of the product. That was the biggest thing we needed here. We needed to eliminate any chance of human error, and we did that with this level of automation. We set parameters, and we can’t move on to execute the product until those parameters are met.”

From there, ingredients are sent to either the “bun side” or “bread side” of the bakery.

“This plant was built to support four times the volume we had in 2016, and it’s positioned well to support that.” Eric Fonstad, Kwik Trip

On the bread side, three 2,000-lb AMF vertical mixers feed one AMF makeup line that produces a variety of bread loaves at an astonishing rate for 1-lb loaves: 225 per minute.

“We broke the record for AMF,” Mr. Reimer proclaimed. “Their old record was around 209, and I said, ‘We can go faster than that.’”

The three-pocket divider cuts 75 per minute per pocket, and dough balls are weighed by a BSI system that rejects any that are out of spec and reintroduces the dough back into the process. In all, the operation produces around 18,000 lbs of bread per hour.

“It’s pretty impressive when all of a sudden you see how many loaves of bread we made,” Mr. Reimer said.

Meanwhile, on the bun side, Zeppelin dosing systems feed an Exact Mixing from Reading Bakery Systems continuous mixer, a technology first for Kwik Trip. Flour and minor ingredients come together in a Brabender premixer at a constant rate before feeding into the mixer.

“One big advantage of the continuous mixer is the shorter mix time,” Mr. Fonstad said. “It’s meant for long runs, and we probably only changeover three or four times based on demand. The other advantage is the consistency. We get the same, consistent dough coming out all the time. You maintain efficiency and quality with a continuous mix.”

The new technology was not without its learning curve, but thanks to a good relationship with Reading, it was a short one.

“We were accustomed to barrel mixing, so when we were first introduced to continuous, we needed some education,” Mr. Fonstad said. “We spent a lot of time learning how to run it. They had a lot of in-house supervision for us and trained us on how to use the mixer as far as moisture content and mix time. We developed all our ­recipes with Reading, and they did a great job with us.”

The mixer feeds two AMF Accupan bun systems that produce 1,600 buns a minute. Each divider makes and deposits them into a Bundy Baking Solutions pan. The pans are fed into the makeup area by a Workhorse Automation system.

“We run all our bun products at full rate,” Mr. Fonstad said. “None of them are at half or even three-quarter rate. We’re running them at the full rate the system was designed to run.”

With the three new lines and the efficiency of the continuous mixer, Kwik Trip makes more bread and buns in one shift per day — instead of two at the old plant — and creates a better work-life balance for coworkers.

“Now, they work four 10-hour shifts,” Mr. Fonstad said. “We ­eliminated overtime, which is a big benefit.”

Going bigger, better and faster is all about doing more with less.

This article is an excerpt from the February 2020 issue of  Baking & Snack . To read the entire feature on Kwik Trip, click here .

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Kwik trip faqs, 1) does kwik trip deliver to my location, 2) how much do popular kwik trip menu items cost, 3) can i get $0 delivery for kwik trip, 4) what if my nearest kwik trip location isn't on grubhub.

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Cake Donut with Sprinkles

Traditional cake donut hand dipped with chocolate icing and topped with seasonal sprinkles.

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Kwik Trip's Blueberry Donut Flavored Chips Is A Must Try!

K wik Trip, one of the major snack bar in the world, has recently brought in a new snack sensation – Blueberry Dunker Donut Flavored Chips. Spotted in several Kwik Trip stores, these unique chips have generated a lot of talk. Some snack lovers are excited about this novelty in taste, but others are most likely intrigued and thinking if it’s actually good with its unique taste. The community has already started discussing and sharing this news.

A Bit Of Kwik Trip History

In 1965, Kwik Trip , a popular brand in the convenience store business, embarked on their journey. They opened the initial shop at Eau Claire, Wisconsin by the founders, John Hansen and his sons, Don and Rick, with a simple goal of offering a quick and easy mode of high-quality fresh food delivery.

For a long time now, Kwik Trip has been growing very fast. They have more than 700 stores in Wisconsin, Minnesota, and Iowa today. What makes Kwik Trip different is its vertical integration. They own dairy, bakery, and commissary units thereby guaranteeing that their products are fresh and of good quality throughout.

In the 1980s, people saw the inception of healthy dining options in Kwik Trip, which was a pioneer in this line of thought among convenience stores. They were visionary in realizing that customers didn't want only quick options but also those which are nutritious.

By continuously innovating and listening to their customers, Kwik Trip has earned a loyal following and become a staple in the communities they serve.

RELATED : Top 20 Best Snacks From The 90s

Diving Deeper into Kwik Trip's Blueberry Donut Chips

The release of Blueberry Dunker Donut Flavored Chips has definitely gotten a lot of people curious. This distinct product brings together the sugary flavor of blueberries and the crispy quality of chips in such an interesting way, that makes it an advisable snack item.

Why did Kwik Trip choose this flavor? In the opinion of experts from the food industry, an unexpected taste is a new trend. There is a tendency for people to accept strange things, maybe? This has also happened with other products such as Lay's that has had crazy competitions with flavors.

Despite Blueberry Donut Chips, Kwik Trip is known for its tendency to venture into unknown tastes. Not only are they always trying out new drink combinations, but they also have some pretty unique flavors that they’ve created in their shops. Such daring moves work out well a lot of times because they increase the profile of the business as well as attracting fresh faces.

If you want to have a taste of these chips then make sure that you pay close attention to the nearest Kwik Trip store near you or visit its website for more information. At times these offers which are only available for a limited period of time tend to go out of stock thus it is important not to let an opportunity escape from your hands to experience something extremely special.

Kwik Trip never ceases to amaze its customers with groundbreaking merchandise. The company has always been on top since its time memorial, even while it still prides itself on offering top shelf snacks peculiar to only them, it is still strides ahead on trends over passing years of operation when compared to other players in the same field. More is still coming!

From The Club

Blueberry-flavored snack? In donut-flavored chips? I’m pretty sure I’m not the only one thinking, ‘How’s the taste?’ But yes, this is actually spotted in few of the Kwik Trip stores and I must admit, I badly wanted to try this weird yet interesting snack! I mean, it’s not that food manufacturers are releasing unique snacks. It’s a great way for them to become the talk on the food industry, and if it tastes good, then better. If you’re curious about it as well, you might want to check if it’s available in the nearest Kwik Trip store, and if not, just check the availability in the stores’ mobile app.

Image and tip courtesy of @markie_devo

This article may contain affiliate links that Microsoft and/or the publisher may receive a commission from if you buy a product or service through those links.

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Would you try a blueberry doughnut-flavored potato chip? You can find them at Kwik Trip.

The new potato chips, inspired by the popular blueberry dunker donuts, will hit shelves starting may 18 at kwik trip..

Kwik Trip shoppers can now find Blueberry Dunker-flavored potato chips for a limited time.

The convenience store announced on social media Monday the reveal of its new Blueberry Dunker-flavored URGE potato chips. The new product will hit shelves this weekend, starting May 18. The new flavored snack is a nod at Kwik Trip’s popular Blueberry Dunker Donuts, which debuted in 2013. Last year, the company made more than 9 million Blueberry Dunkers.

Will Churchill, Kwik Trip’s director of category management, said the company wanted to create a new product based on one of its popular products. After testing various options, the Blueberry Dunker chips were the winner, combining sweet and salty flavors.

Kwik Trip has been telling its followers it had an announcement to share for the last few weeks , teasing something big was coming via its social media pages.

“The launch of this new product has been a fun one for our team to tease on social media these past few weeks,” said Paige Geary, Kwik Trip’s social media supervisor.

The company shipped the new chips to all of its influencers early, giving them the opportunity to taste test the products and share their thoughts on their social media platforms before everyone else can find them in stores.

This is the second time Kwik Trip has been inspired by a doughnut while creating a limited-time snack. In 2019, the brand launched Glazers-flavored chips . The idea for that chip started from an April Fool’s Day joke three years prior. Employees and customers loved the idea, and Kwik Trip worked to make it a reality.

Kwik Trip started out as a neighborhood grocery store, opening its first location in Eau Claire in 1965. The second store opened in 1971 in its now home-base, La Crosse. In the last 59 years, the convenience store and gas station has continued to grow, both in physical locations and in popularity, largely because of its social media presence that interacts with its followers on a whole new level.

USA TODAY NETWORK-Wisconsin talked with the company about its social media presence and growing popularity in 2022 . Kwik Trip team members shared how the business shifted its entire digital marketing strategy from focusing on products to focusing on people and developing a brand voice to humanize the company and its content. It's the type of social interaction that can take an April Fool's Day joke and develop new products for its guests.

More trending stories: Have you seen this Wisconsin Rapids native on TikTok? Howie Mandel and Doja Cat have.

More trending stories: Did Farmer Brandon pick Wisconsin sweetheart Grace Girard on the 'Farmer Wants a Wife' season finale?

Contact Caitlin at  [email protected]  or follow her on Twitter  @CaitlinShuda .

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• Latitude: 55.79. Longitude: 38.46
• Population: 144,000

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Ratings and reviews

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Hotel Djaz is an excellent choice for travellers visiting Elektrostal, offering many helpful amenities designed to enhance your stay.

24 hour front desk is one of the conveniences offered at this small hotel. In addition, Hotel Djaz offers a lounge, which will help make your Elektrostal trip additionally gratifying. If you are driving to Hotel Djaz, free parking is available.

While staying at Hotel Djaz, visitors can check out Statue of Lenin (1.3 mi), which is a popular Elektrostal attraction.

Travellers looking for cafes can head to Ermitazh, 400 Krolikov, or Fabrika Obedov.

Should time allow, Electrostal History and Art Museum is a popular history museum that is relatively easy to get to.

Enjoy your stay in Elektrostal!

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