Customized labeler/tape-seal applicator for a clubstore-sized PET container of mini donuts allows Sara Lee Bakery Group to focus on baking.

Ever wonder why donuts have holes in the center? For Sara Lee Bakery Group (SLBG), the real issue facing these sweet-tooth-satisfying, wheel-shaped breakfast delights wasn't the hole at all, but was finding an innovative way to more effectively package its powdered-sugar-covered and chocolate-frosted taste treats.

Ever wonder why donuts have holes in the center? For Sara Lee Bakery Group (SLBG), the real issue facing these sweet-tooth-satisfying, wheel-shaped breakfast delights wasn't the hole at all, but was finding an innovative way to more effectively package its powdered-sugar-covered and chocolate-frosted taste treats. Today, SLBG's mini Donut Gems are available in a spacious 2-lb tub, made of crystal-clear polyethylene terephthalate polymer, which crumbled SLBG's traditional packaging methods in favor of a clever combination labeling/tape-sealing technique. The attractive container appeals to both customers and consumers while offering product security and protection, effectively sealing in donut freshness without compromising shelf life. But as with any gem, the packaging project for this sweet little item needed polishing and shining in order to meet the market challenges. Located in Madison, WI, and operating as a commercial baking facility originated by the Gardner family in 1926, SLBG produces desserts, breads, buns and cake donuts in addition to the mini Donut Gems. "A major retailer approached us and requested that we develop a large, bulk-type container for the Donut Gems, per their specifications and requirements," explains Steve Vial, plant manager. "Until this package was developed, there really wasn't anything else as large as this for [mini] donuts in the marketplace. We revised our packaging processes to handle it, and an internal operational paradigm shift ensued, with respect to the container-sealing process using a tamper-evident tape."