Shearer's Foods Explained

Shearer's Foods, LLC
Type:Private company
Location City:Massillon, Ohio
Location Country:United States
Area Served:United States
Canada
minimal global distribution
Key People:Bill Nictakis CEO
Industry:Snack food
Products:List of products

Shearer's Foods, LLC is a U.S. manufacturer and distributor of snack foods. Founded in 1974 as Shearer's Snacks, it is headquartered in Brewster, Ohio.

With more than 5,000[1] employees across eight facilities, the company manufactures, warehouses, and distributes branded snacks such as Sheerer's Potato Chips as well as private label products for snack food companies and retailers.

Shearer's now has factories in Ohio, Texas, Arkansas, Oregon, Virginia, Iowa, Minnesota and Ontario, with worldwide distribution. Its plant in Massillon is the first food manufacturing plant in the world to achieve LEED platinum certification.[2]

In December 2023, Clayton Dubilier & Rice completed the acquisition of the company.[3]

History

In the early 1900s, the Shearer family opened Shearer's Market in Canton, Ohio. The third generation, Jack Shearer and his wife, Rosemary, operated the family grocery store from the 1950s until 1976, and in 1974 bought a snack food distributorship and named it Brookside Distributing. In 1979, they began manufacturing "hand-cooked" potato chips until discovering that a kettle cooked chip provided more of a crunch and a standardized method of preparation. The Shearers hand-cooked potato chips from the kettle, packaged them in one-pound poly bags with a twist tie, delivered them from a warehouse and first sold them under the Kettle-Cook'd label.[4]

Growth and transition

In 1982, Shearer's purchased a 20,000 square foot facility on ten acres in Brewster, Ohio. Soon after, six hand-kettles and a peanut roaster were in operation. The Grandma Shearer's logo appeared on shelves in 1983, and 3,700 pounds of potatoes were processed daily. Shearer's installed its first continuous fryer to produce up to 1,000 pounds of potato chips every hour and expanded its warehouse and maintenance space by 9,000 square feet in 1986.

In 1988, the company increased its plant size again. This growth continued through the 1990s and included the addition of a second continuous fryer, two hand-kettle fryers that featured automatic stirring systems (among the first manufactured in all of the United States), computerized combination weighers, state-of-the-snack equipment for tortilla chips and cheese curls, and an additional 100,000 square feet of space.[5]

In the early 2000s, six hand-kettle cookers, a new potato peeling system, distribution and transfer conveyors, and a new seasoning system were installed. Thirty-three acres adjacent to the current location were purchased to combine for 77 acres in total, while a portion of the storage operation was relocated nine miles from the headquarters to Massillon.The company was named "Snack Manufacturer of the Year" by Snack Food & Wholesale Bakery magazine in 2002[6] and again in 2011.

Shearer's developed a new logo, revamped packaging, and expanded its factory outlet store in 2004. A $2.6 million wastewater treatment plant was completed in the spring, and six additional hand-kettle cookers were installed along with a new packaging area, making Shearer's one of the largest manufacturers of kettle-cooked potato chips in the nation.[5]

Recent history

An increasing trend of whole grains and better-for-you snacks resulted in three new whole grain tortilla chip products with 100% whole grain yellow corn in 2006.[7]

Environmental sustainability

The company has expressed a commitment to sustainability and energy performance, joining Energy Star in 2006 and working to improve energy performance in its offices, manufacturing facilities and distribution centers.[10] The company received recognition by way of a Crain's Cleveland Business Emerald Award for its efforts.[11]

Their energy management program includes:[12]

The company broke ground on its LEED Platinum Certified snack food manufacturing plant in 2009. The plant in Massillon, Ohio was the first manufacturing plant in the world to achieve the highest sustainability award for environmental responsibility.[2]

Manufacturing

Manufacturing capabilities

Shearer's various products are made from potatoes, yellow, white, blue, and organic corn, and for tortilla chips, company-produced masa. Seasonings and flavors are developed by an in-house R&D group and also in conjunction with external partners. Production capabilities include:

Products include sliced, rippled, and wavy potato chips, kettle-cooked potato chips, tortilla and whole grain extruded chips, and other extruded products such as cheese curls and puff corn (also known as hulless popcorn).

The company maintains six distribution centers in Ohio and Pennsylvania, and operates its own distribution routes, while also relying on a network of select distributors throughout the midwestern United States, New England, and parts of Canada.

Plants

Products

Shearer's Branded Snacks

Other Shearer's brands include riceworks, Granny Goose, Thin & Crispy, Brent & Sam's, Delicious Bakery, and Vista.

References

[15] [16]

Notes and References

  1. https://www.indeonline.com/story/news/local/2022/09/01/original-shearers-brewster-plant-40th-birthday-celebration/65458858007/
  2. News: Staley . Doug . March 14, 2011 . Shearer's, Fresh Mark, Drummond are success stories . The Independent, Massillon . live . 16 June 2011 . https://web.archive.org/web/20110425113145/http://www.indeonline.com/progressbusiness/x698047252/Shearer-s-Fresh-Mark-Drummond-are-success-stories . 2011-04-25.
  3. Web site: CD&R completes acquisition of Shearer’s Foods from Ontario Teachers’. Benefits and Pensions Monitor. 2024-01-05. en-US.
  4. Web site: Schultz. Martin. True grit: How Shearer's Foods started out as a corner store and became one of the U.S.'s fastest-growing snack food manufacturers and most progressive companies. (2002 Snack Manufacturer of the Year). https://web.archive.org/web/20140610060108/http://www.highbeam.com/doc/1G1-84721953.html. dead. 10 June 2014. Snack Food & Wholesale Bakery. 21 June 2011.
  5. Web site: Shearer's Foods, Inc.. FundingUniverse. 21 June 2011.
  6. News: True grit: How Shearer's Foods started out as a corner store and became one of the U.S.'s fastest-growing snack food manufacturers and most progressive companies.. 2010-02-25 . Snack Food & Wholesale Bakery . 2002-03-01.
  7. Web site: Snack Food Association Endorses Alliance for a Healthier Generation Snack Food Guidelines. Alliance for a Healthier Generation. 21 June 2011.
  8. Web site: Shearer's Foods Inc. Acquires Snack Alliance, Inc.. Manufacturer's Group. Manufacturers Group, Inc.. 21 June 2011.
  9. Web site: Shearer's Foods sold to Chicago Company. IndeOnline.com. The Independent. 12 November 2012.
  10. Web site: Saving green . 2009-01-27 . 2021-02-19 . SBN Online Cleveland . Smart Business Network.
  11. Web site: Champions of sustainability honored. 16 September 2009 . 2009-09-21 . Crain's Cleveland Business.
  12. Web site: Gueverra. Leslie. Shearer's Cuts the Ribbon on America's Greenest Snack Factory. Green Buildings. Green Biz Group. 21 June 2011.
  13. Web site: Higgins. Kevin. Plant of the Year: Shearer's Foods Rethinks the Food Plant. Food Engineering Magazine. 21 June 2011.
  14. Web site: Making an effort. Akron/Canton Smart Business. Smart Business Network. 21 June 2011.
  15. Web site: Shearer's Foods stops making its branded chips to focus on private label business .
  16. Web site: You won't be seeing Shearer's brand chips on shelves anymore — here's why . 19 February 2022 .

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