Baking & Snack - August 2018 - 114


Power outages can be short
blips on the radar or stretch
on for hours. It's important
bakers have a plan in place
to protect workers, product
and get things up and running as soon as possible.
Flowers Foods

portant that the bakery has a plan in case of an outage. That will ensure every employee knows his or her
role in implementing the strategies necessary to optimize any back-up power available.
The highest priority of any plan is employee safety.
This includes installing proper safety systems, such
as emergency lights, and training facility personnel
to react appropriately during a power outage. "Such
systems and protocols must remain in effect even if
power is lost," Mr. Gause said.
Mr. Hughes suggested a thorough power outage
plan will address outage management, oven restart
and the UPS system. "Executing a restart plan effectively can minimize losses in mixing, dough preparation and post-bake operations," he said. "If a shortduration outage is seen, ovens can be restarted and
back up to operating temperature in a relatively short
amount of time."
The outage management plan will determine each
employee's role in getting the bakery started again.
Mr. Zavilla said assigning priorities and expertise to
each area. "Have a list and designate mechanics to different areas," he said.
As a part of this plan, each production line needs
its own protocol. Employees need to know what products are on the line and the restart procedures for
each piece of equipment.
One of the most critical parts of a bakery, the oven

114 Baking & Snack August 2018 /

Bakers might also
consider alternative
sources of energy
such as solar and wind
power to supplement
a generator.
should have its own plan for restart, and it should be
the first piece of production equipment brought back
online as it can take the longest in the event of a total
shut down. "It could be 45 minutes to get that oven
system up and running," Mr. Zavilla said. Then he
suggested prioritizing emptying the downstream side
of production so upstream product has a place to go
once everything is running again.
For the UPS system, it's important to know how
it will be used and for how long. These systems can
power the oven, control systems and other equipment
but have a limited usage time, so it's important that
everyone is clear on that information.
When considering the potential loss of power, bakers need to know what their production needs are in
terms of starting back up. "From there, systems and
protocols can be put in place to meet their needs and
wants during a loss of power," Mr. Gause said. These
protocols and systems can not only keep product intact but also keep employees safe and get everything
moving again.


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