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Mr. Lee’s: Noodles that Consumers Will Pay for

By Lorrie Baumann

Like many others, Damien Lee used to buy instant noodle soups because they were convenient and tasted okay, not because he thought they were particularly good for him in any other way. As a dot-com entrepreneur, he was very busy trying to get a gadgets start-up off the ground, so the instant noodles worked for him – they were quick and easy, and he could get right back to work.

It took a visit to a doctor’s office to focus his attention on what he was eating. “I thought, I’ve got to step up to the plate,” he said. “I instantly changed my life.”

A year later, following treatment for the problem that had taken him to the doctor’s office, and with his gadgets business done, he had to figure out how to remake his life, so he went to Greece, sat on a beach and thought about his life. Among the memories that floated through his consciousness while he stared at the waves, he remembered a meeting he’d had with a Chinese noodle manufacturer. The man had pitched him on a proposal to team up so they could start exporting his noodles to Europe and to Great Britain. “I told them I knew nothing about either retail or noodles,” Lee said. “Thanks, but no thanks.” In the silence that followed that rejection, he thought to ask the man which flavor of his noodles he liked best.

The man told him, “We don’t eat our own noodles.”

He’d gone back to his home in the U.K. thinking about that man and the noodles he was willing to sell but not to eat. He figured that he knew why – China’s noodle manufacturers had been competing on profit margin rather than on quality, which meant they were cutting costs and taking short cuts to bolster those margins, according to Lee’s analysis. “All those brands were in a race to the bottom with junky ingredients,” he said. “That was my light-bulb moment.”

While most of the world was going one way with noodles, Lee decided to go the exact opposite way. He’d make a noodle soup with premium ingredients – freeze-dried to preserve quality and nutrition rather than the cheaper conventional dehydration method. “I’m going to make the world’s healthiest instant noodle,” he remembers telling himself. “I wanted to make a proper instant noodle that I could eat.”
He consulted Andy Chu, a well-known executive chef in U.K. restaurants who lived in Bournemouth, where Lee had his home. “He’s originally from Macau,” Lee said. “I needed a chef to help develop the product range…. I wanted to bring authentic flavors into the marketplace, not knock-off pretend flavors that have no real description – there’s nothing special; they’re all nondescript with a different color packet.”
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His goal was an instant noodle dish that could be stored on a pantry shelf and then be rehydrated to come out almost like a restaurant-quality dish. With that mandate, Chu went to work. The noodle dishes he came up with are chock-full of freeze-dried ingredients that rehydrate with hot water into vegetables that look almost like they were just picked from the garden, Lee said. “We don’t use MSG, palm oils, no plastic packets inside the package. All the seasonings and components are open inside the cup. Pour in hot water, stir, wait three minutes.”

All of the Mr. Lee’s recipes are authentic and gluten free. In the U.K., where Mr. Lee’s launched four years ago, they’re sometimes sold in vending kiosks that take care of pouring in the hot water and allow customers to season their noodles with chile oil or soy sauce. “The consumer helps themselves. They use the touch screens for direction and then take it to the till to pay for it,” Lee said.

Mr. Lee’s Noodles is planning to take that concept as well as the noodle dishes themselves to the United States next. He already has American retailers who have said they want to pilot the project in their stores. “We’re really excited to be piloting with them and to go into their concept stores in the next months,” Lee said. “We’re launching into America with both the tech and with the food.”

Mr. Lee’s will be launching in the U.S. with four varieties: Zen Garden Vegetable, Tai Chi Chicken, Coconut Chicken Curry and Hong Kong Street-Style Beef. Each single-serving cup retails for $4.

Another two noodle varieties are coming along soon, and then Mr. Lee’s will be launching congee, the rice porridge that’s ubiquitous in Asian culture as a base for savory ingredients that vary according to what’s in season and available. “Every Asian knows congee,” Lee said. “It’s not just for breakfast – it’s comfort food…. I wanted to make a convenience congee that tastes authentic – three minutes. Add hot water; hey presto.”

The Mr. Lee’s brand will be launching in the U.S. In the second quarter of this year with Whole Foods as a launch partner. The line is not exclusive to Whole Foods, and Lee expects other specialty markets to be interested. Distribution is through UNFI.

For more information, visit www.mrleesnoodles.com.

Family Tradition Drives Toufayan Bakeries Through Pandemic

By Lorrie Baumann

In 1926, Karen Toufayan’s grandfather Haroutoun was a baker living amidst an Armenian community in Egypt. As soon as he could after he emigrated to the United States in the mid-1960s, he set out to make a living in his new country doing what he knew best – making the pita bread that had its origins in the prehistory of the Middle East. In the fall of 2018, Toufayan Bakeries celebrated 50 years of doing business in the U.S.

Haroutoun and his son Harry set up their bakery near the New York-New Jersey border with a small retail store in front and the bakery in the back. “They would bake the bread and sell it in their store and load it up in a station wagon and go out and sell it to restaurants and other retail stores,” Karen said.

Toufayan’s business as a wholesale bakery really started when Harry persuaded a local delicatessen that his front counter would be a great place to merchandise bread to go along with the sliced meats that the store was selling to customers who were buying them for sandwiches they’d make at home. Once that first delicatessen owner was successfully ringing up sales of Harry’s pita breads, he started knocking on other doors, Karen said. “As he got bigger orders, he automated and moved the business to North Bergen, New Jersey, and expanded his retail customers to include pretty much everybody up and down the East Coast.”

From there, the business just continued to grow, and in the early 1980s, Toufayan Bakeries expanded again through the purchase of a bakery in Orlando, Florida. Harry added breadsticks that had been the Florida bakery’s specialty to his product line and began including flatbreads and other pita breads. In 2000, the company moved out of its North Bergen bakery and into a larger facility in Ridgefield, New Jersey, where the company is now headquartered. “We operate out of 180,000 square feet,” Karen said. “The Orlando bakery has expanded many times over the years and is now a little over 200,000 square feet.” The company’s latest expansion is already under way and will enlarge the Ridgefield plant yet again. It is scheduled for completion this fall.

The company has also acquired a cookie bakery in Plant City, Florida, where Toufayan makes cookies, gluten free cookies and its gluten-free Pita Chips as well as hamburger and hot dog rolls.
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Toufayan Bakeries was the first company to introduce a Gluten-Free Wrap to the market, and its Smart Pocket is a modern take on its traditional pita breads – it’s got a pocket like a pita, so it’s easy to stuff, but it’s square, so it’ll fit into a sandwich bag. Toufayan also makes bagels as well as flatbreads that predate even pita in the history of Middle Eastern yeast-risen wheat breads. Toufayan Naan breads are offered in Garlic and Plain flavors, and the company also offers a traditional Tandoori bread. “We’ve certainly mastered it when it comes to the different flatbreads,” Karen said. And, of course, the company still makes lots of different pita breads so essential to the cuisine of the homeland that Harry embraced, and the company’s wide range of products are distributed and merchandised in bakery and deli departments of supermarkets across the U.S. “We’ve always been classified as specialty,” Karen said. “We’re not sliced white bread – we’re pita bread.”

These days, the company is being run from day-to-day by the third generation of the family, which includes Karen, the company’s Vice President of Sales and Marketing; her brother Greg, who oversees the factories and day-to-day operations; and her sister Kristine, who manages the company’s business affairs. “I’m lucky enough to be third-generation, and I’m even luckier to be working alongside my brother and sister,” Karen said. “Having our own roles is what makes us successful in working together, My mother and father were very strict, and they made sure that we all just got along.”

Karen’s father, Harry, is still very involved in the business, although he’s had to stay away from the bakery during the COVID-19 crisis. “We’ve been missing him terribly,” Karen said. “Thankfully, he’s safe and he’s healthy, so that’s what’s most important.”

The company has continued to operate through the COVID-19 pandemic by incentivizing the employees of all three bakeries with a bonus and has matched that bonus with large donations to food banks in the communities where the bakeries are located. “It’s a way to thank the communities where our factories are. We thought it was the right thing to do,” Karen said. “We consider all of our team, all the people who work for us, our extended family.”

“It was really important for us to stay open so that we could continue to supply our customers. This was very important to my brother,” she continued. “It was not easy, by any means. We had a lot of people who were afraid to come to work, but we instituted specific distancing procedures to ensure the safety of all our employees. I think we made certain that everyone felt comfortable coming to work. After all we can’t continue to do our jobs, if our own people don’t feel we’re focused on protecting them.”

A New Life for Grandma’s Shortbread Crescents

By Lorrie Baumann

Flathau’s Fine Foods is known to specialty food retailers mostly as a baker of cheese straws and shortbread cookies, but the company started out 25 years ago as a caterer for corporate events and weddings. The Flathau cheese straws, chocolate chip cookies and white chocolate macadamia cookies were big hits at those affairs, but when Founder Jeff Flathau decided to take a chance to expand his market with a trip to Atlanta’s gift market, he thought he might want to expand his product line as well. “I wanted to do shortbread,” he said. “We were humming along there, and had the catering, so I didn’t have to make a living out of the cookie business,… but I really wanted to get the business changed and get the packaged cookie business going.”

As he thought about shortbread, Flathau remembered the crescent cookies that his grandmother had made for him when he was a boy. After she’d passed along the recipe, Flathau baked the cookies and tasted them eagerly, only to realize that, while the cookies were good, what had made them really special was that his grandmother had baked them for him. That wasn’t an experience he could pass along in a package, so, regretfully, he continued his search for a great recipe.

Then, one day, he came home from work to find his wife, Heather, bashing away with a hammer on a bag of peppermint candy. “I thought she was off her rocker,” he said. “She’s in the carport with a hammer and a Ziploc bag, and she’s bashing at it to crush peppermint candy to put inside the shortbread.”
Then Heather took some of that crushed candy and mixed it a batch of cookie dough that had started with Jeff’s grandmother’s recipe for crescent cookies and been doctored on by Heather. And when she’d baked that off, there was the magical experience that Jeff had been hoping for when he’d asked his grandmother for that recipe. “That little bit of pulverized candy gives it a distinct flavor along with a little crunch from the candy inside the cookie,” he said. “They say necessity is the mother of invention. We needed something that would sell, and we needed something with a long shelf life.”

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Flathau’s now has seven different flavors of its shortbread cookies. The original Peppermint Snaps flavor was followed by Raspberry Snaps, then Key Lime Snaps. Butterscotch, Lemon and Cinnamon followed. The latest flavor was All-Natural Shortbread Cookies – a classic shortbread with no candy inside and no dusting of powdered sugar, which won a silver sofi Award in 2017 to add to the two previous sofi Awards on Flathau’s shelf – one for Butterscotch Snaps and one for Raspberry – along with a wide range of other awards from various food and gift shows.

The cookies are offered in several different package sizes. A 4-ounce carton retails for $4.95, a 6-ounce carton retails for $6.49. There’s a 7-ounce Maddy’s carton that retails for $6.95, and the 8-ounce Flathau’s carton retails for $7.95. Flathau’s also offers a 6-ounce can of cookies that retails for $11.95. The can is modeled after a paint can, but it’s made of plastic and it’s reusable. “People use it for putting pins in or collecting pennies,” Flathau said. “We get people calling us and telling us that they have cans that are seven or eight years old.”

A 16-ounce can in a design similar to the 6-ounce can retails for $21.95. “It’s great for holiday gifts,” Flathau said. “We have a Holiday Assortment in the large can that has Cheese Straws, Plain Shortbread, Key Lime and Peppermint Shortbread.” The assortment also retails for $21.95. “The Holiday Assortment is one of our top sellers during Christmas,” Flathau said. “People like the choice, and it’s 24 ounces of each in the can, so it’s a good assortment.”

The cookies have a 9-month shelf life and are all still made in Mississippi. Flathau’s Fine Foods is a founding member of Genuine MS, a Mississippi state program that recognizes products that are grown or made in the state. Flathau’s also offers private label products. For more information, call 601.606.3899 or email flathauj@aol.com. Visit on the web at www.flathausfinefoods.com.