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Byline: Anissa Vicente-Rivera Staff Writer

That all-beef patty, special sauce Special sauce is the sauce used in the McDonald's Big Mac hamburger. The name derives from a 1975 advertising campaign featuring a list of the Big Mac's ingredients: Two all beef patties, special sauce, lettuce, cheese, pickles, onions on a sesame seed bun. , lettuce, cheese, pickles and onions wouldn't mean a thing without that sesame seed bun to hold it all together.

Three years after McDonald's signature sandwich was introduced to the masses, company leader Ray Kroc Ray Kroc (October 5, 1902 - January 14, 1984) took over and franchised the then single-restaurant McDonald's Corporation from 1955. (The first McDonald's restaurant was started by Richard and Maurice (Mac) McDonald in 1940.  turned the Harold Freund Baking Co. in Glendale, asking them to open a kitchen exclusively for the golden arches The Golden Arches are the famous symbol of McDonald's, a fast-food hamburger chain based in Oak Brook, Illinois, USA. They were introduced in 1953, when Dick and Mac McDonald began franchising their company, as part of the standard building design: a pair of stylized arches, one .

Freund, which still operates in Glendale, started a new operation called Fresh Start Bakeries to accommodate Kroc.

Thirty years later, the Fresh Start Bakeries operation - which has since been sold - is still churning out Big Mac buns from a 55,000-square-foot facility in Industry. The plant also does Ronald McDonald's baking for the Egg McMuffin sandwiches.

Plant Manager Bob Mitchell Bob Mitchell may refer to:
  • Bob Mitchell (UK politician) (1927–2003), British Labour Member of Parliament for Southampton Itchen and Southampton Test
  • Robert C. Mitchell (born 1931), Ontario politician
 says he ``and the clown go a long way.''

The mass bakery operates on the very principles Kroc used to turn a San Bernardino San Bernardino, city, United States
San Bernardino (săn bûr'nədē`nō), city (1990 pop. 164,164), seat of San Bernardino co., S Calif., at the foot of the San Bernardino Mts.; inc. 1854.
 burger stand into an international brand.

In 1954, Kroc, a salesman for a milk shake milk shake

a solution of sodium bicarbonate administered to racehorses by stomach tube 4 to 6 hours before racing to produce a metabolic acidosis. Promoted as a means of producing relief from tying-up and delaying the onset of fatigue by producing additional buffering to counteract
 mixer, stopped into a drive-in restaurant where brothers Dick and Mac McDonald Richard "Dick" J. McDonald (February 16, 1909 – July 14, 1998) and Maurice "Mac" McDonald (November 26, 1902 – December 11, 1971) were two early American fast food pioneers, originally from Manchester, New Hampshire, who established the first McDonald's  had eight mixers whirring whir  
v. whirred, whir·ring, whirs

To move so as to produce a vibrating or buzzing sound.
To cause to make a vibratory sound.


Kroc seized on the idea of speedy service, bought the restaurant and a year later started the Illinois-based chain famous for having served ``billions and billions'' of burgers.

To that end, Fresh Start, the largest single-purpose bakery in the world, churns out more than 1.5 million pieces of baked goods each day, according to General Manager Rob Crawford.

To start, a flour mix is fermented. Then following the same bread-making procedures used in any kitchen, it is mixed, divided, cut into dough balls, flattened into pans, left to rise, baked, cooled and sliced. It is also dated and packaged into special trays that protect the baked goods during transport.

``The entire process takes two hours from start to finish,'' Mitchell said.

Within two days of coming out of the massive ovens, the bakery's buns are delivered three times a week to 800 McDonald's from Paso Robles Robles is a common surname in the Spanish language meaning oaks, and may refer to:
  • Alfonso García Robles (1911-1991), Mexican diplomat and politician
  • Aurora Robles (born 1980), Mexican fashion model
  • Charlie Robles (born 1943), Puerto Rican musician
 to northern Mexico, Mitchell said. Restaurants elsewhere are supplied by other Fresh Start Bakeries in the U.S., Guatemala, Spain and Sweden, among other places.

The company is not only about bread, but about quality control. The Industry plant's 142 employees check dough weight, coloring, the height and width of buns, even sesame seed coverage.

``I can't go to the grocery without taking a loaf home and looking at the coloring and all that,'' said quality assurance supervisor Patty Loutherback.

For McDonald's, which has 28,000 restaurants serving more than 43 million people a day in 120 countries, quality is more than hyperbole.

Twice a year, Fresh Start and seven other contractors gather to work on new products, such as the recently introduced tortas, and to study the finer points of a burger.

Crawford said it's to make sure ``a Big Mac in New York New York, state, United States
New York, Middle Atlantic state of the United States. It is bordered by Vermont, Massachusetts, Connecticut, and the Atlantic Ocean (E), New Jersey and Pennsylvania (S), Lakes Erie and Ontario and the Canadian province of
 looks, tastes and smells like a Big Mac you'll get in L.A.''


--Industry-based Fresh Start Bakeries:

--Produces 96,000 buns an hour

--Produces 16,800 English muffins an hour

--Uses 160,000 pounds of flour a day.


photo, box


Baker Mark Melvin checks McDonald's buns for proper cut, color, size and sesame seed distribution.

Greg Andersen/Staff Photographer

Box: BUN BITES (See text)
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No portion of this article can be reproduced without the express written permission from the copyright holder.
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Title Annotation:Business
Publication:Daily News (Los Angeles, CA)
Date:Jan 14, 2001

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