Len Kretchman, a former wide receiver at North Dakota State, lived in the small town of Fergus Falls, Minn., and worked with schools in the food service industry. Sometime in the mid-90s, Len said, his wife, Emily, suggested he create a mass-produced peanut butter and jelly sandwich without the crust.
The project appealed to Len’s business instinct: a simple idea with a complex logistical problem to solve. The Kretchmans started in their kitchen with a loaf of bread, one jar of peanut butter, one jar of jelly and a few drinks.
“We’re not recreating the atomic bomb here,” Len said. “We’re trying to make a peanut butter and jelly sandwich … It was two people standing there, goofing off, probably having a beer and a glass of wine and saying, ‘What do you think of this?’”
The first decision they made was that the sandwich should be round.
“The moon is round, the sun is round, the Earth is round, it’s our favorite shape,” Len said. “Do you have to go to a committee and survey people on what the shape should be? No. It’s round. So we got that nailed down.”
Next, he grabbed a cup from his kitchen cabinet.
“If you asked moms how they (took the crust off a sandwich) 30 years ago, they’d say: ‘I found a glass in my cupboard that was the right dimension and I pressed on the bread and I cut the crust off,’” Kretchman said. “And that’s what we did!”
They added a crimp to the edges of the crustless bread, which was easy, but then had to figure out how to keep the jelly from oozing, which was not. Every time they thawed their creations, the jelly bled into the bread and ruined the sandwich. Much trial and error followed.
“We finally put the blob of jelly in the middle of the bread and then covered it with peanut butter and encased the jelly so it doesn’t leach into the bread,” Kretchman said. “That was key. That was our gee-whiz moment.”