The Baking Industry’s Workforce Challenges & Solutions

How Palermo’s is Tackling Workforce & Maintenance Challenges 

Palermo’s Pizza has found a way to make workforce development and maintenance training more effective, cutting inefficiencies while keeping employees engaged. During the recent webinar, Wendy shared how they’re taking a proactive approach to solving industry-wide challenges. 

One of the biggest game-changers has been implementing QR codes into their training operations. Employees simply scan a QR code on their badge to check into training sessions—eliminating manual attendance tracking and freeing up valuable administrative time. This approach makes training part of the regular workday instead of requiring costly overtime or extra staffing to cover shifts. 

Palermo’s also prioritized multilingual learning, making training more accessible for their diverse workforce, which speaks over eight different languages. To further streamline learning, they transitioned training to mobile platforms, so employees can access information as easily as checking a timecard. 

But what really sets Palermo’s apart is their structured career pathways. With over 700 job titles, the company has mapped out clear progression routes, so employees know exactly what’s required to move up. The WorkForge LMS (Learning Management System) assigns training automatically based on job roles, ensuring new hires start learning from day one. 

“People stay when they see a future here,” Wendy said. “It’s all about making training easy, accessible, and tied to real career growth.” This approach has led to an 83% retention rate, proving that structured training leads to better workforce stability. 

These strategies aren’t just benefiting Palermo’s—all food manufacturers can take a page from this playbook. Implementing technology-driven training, multilingual accessibility, and structured career paths can improve retention and workforce efficiency industry-wide. 

The Hidden Cost of Maintenance & Downtime 

While workforce shortages are a major concern, another challenge facing the baking and snack industry that Tim and Wendy addressed is maintenance and operational efficiency. Companies are realizing that a lack of skilled workers doesn’t just impact hiring—it also affects equipment reliability and production uptime. 

In 2021, bakeries spent $415 million on repairs and maintenance, highlighting just how critical proper equipment upkeep is. The American Bakers Association estimates that by 2030, the industry could be short 53,000 workers, many of whom would be in key maintenance roles. Without the right training, companies risk unplanned downtime, which can halt production and lead to significant losses. 

To combat this, structured preventative maintenance training is becoming a must-have. Palermo’s has invested in cross training its operators to handle basic maintenance tasks, ensuring production doesn’t stall due to minor issues. This strategy not only reduces unplanned downtime but also empowers employees with new skill sets, making them more valuable in the long run. 

Tim reinforced the importance of proactive maintenance, noting, “The cost of unplanned downtime is astronomical. Companies that prioritize training their operators to handle routine maintenance can save millions in lost production time.” 

“Downtime is the enemy in high-speed production,” Wendy emphasized. “Training employees to recognize early warning signs of equipment failure can save thousands in lost production.” 

Cross-training and knowledge capture are also helping food manufacturers retain critical expertise. As experienced employees retire, companies need to ensure that knowledge isn’t lost. By digitizing training content and using video-based modules, companies can preserve and transfer valuable maintenance know-how to new employees. 

The Future of Training in Baking & Food Manufacturing 

Looking ahead, companies that prioritize on-demand, easily accessible, and structured training paths will have a major advantage. Cross-training employees to handle multiple roles ensures flexibility, while tracking progress through digital platforms helps tailor learning programs to real workforce needs. 

Predictive maintenance training is also gaining traction. Instead of reacting to equipment failures, employees are learning to use data insights to prevent breakdowns before they happen. Investing in structured learning doesn’t just help employees—it boosts efficiency and keeps production lines running at full capacity. 

“If training is inconsistent, productivity takes a hit,” Wendy said. “Investing in workforce development is an investment in your bottom line.” 

The Bottom Line: Smarter Training, Better Results 

The key takeaway? Training isn’t just about onboarding—it’s about building a workforce that drives long-term success. By integrating workforce development with preventative maintenance strategies, bakeries and food manufacturers can reduce turnover, cut downtime, and improve overall efficiency. 

As Wendy put it, “When training is easy to access and career paths are clear, employees don’t just stay—they thrive.”