Baking & Snack - December 2020 - 66

ENERGY MANAGEMENT

it's how the plant is operated and maintained that's often
the more important factor.
" It's not uncommon to see older plants that have been
optimized operating more efficiently than newer plants, "
he said. " Newer equipment and technology can have
an impact. But if it's not operated efficiently, it will still
waste energy. "
The biggest driver for energy efficiency, he added, is
production. Bakeries that operate at or above their designed production levels are usually more efficient than
bakeries operating at lower production levels on an energy-intensity basis. Most manufacturing plants require
a fixed energy load to operate, whether at 50% or 100%
production capacity. Reducing fixed energy use and
minimizing energy use that varies with production are
the main strategies for improving efficiency.

" WE FEEL WE CAN MAKE BETTER
DECISIONS BY NOT LOOKING AT
WHAT THIS MEANS FOR THE NEXT
FOUR WEEKS, BUT WHAT IT MEANS
IN FOUR YEARS OR 10 YEARS. "
Jamie Richardson, White Castle
Ms. Marsh suggested that two areas of opportunity
for energy savings involve lighting and compressed air.
Since 2015, more than 30 Flowers bakeries have upgraded to LED lighting.
" Lighting is an easy way to save energy because it's
automatic and doesn't require changes in workforce behavior or processes. " she said. " One of the added benefits of LED lighting levels is the reduction of heat in
the bakery. "
Compressed-air systems, she added, are a highly inefficient user of electricity. When upgrading those systems,
Flowers' corporate engineering team works closely with
bakery teams to choose equipment features that will improve energy efficiency while still meeting bakeries' needs.

A LEED-ing indicator
A facility's age does play a role in some instances.
Mr. Adebayo noted that two of BBU's newest bakeries in
Breinigsville, Pa., and Rockwall, Texas, are Leadership in
Energy and Environmental Design (LEED) Gold and Silver
certified buildings. During construction, the company
invested in heat recovery systems, instead of traditional
boilers, which provided a huge amount of energy savings.
Other features included day-harvesting of light, energyefficient motors and other energy management systems.
" Those heat recovery systems allowed us to turn the

66 Baking & Snack December 2020 / www.bakingbusiness.com

bakeries basically into one giant heat distribution area
where we take the heat from the ovens and oxidizers
and move it to produce steam for proof boxes, " he said.
" That process eliminates the need for natural gas boilers
to produce steam. If you walk into those bakeries, they
don't have a single boiler in the building. That amounts
to huge savings in energy. "
BBU has explored retrofitting older bakeries with heat
recovery and other systems, but Mr. Adebayo said it's often more costly than designing a bakery from scratch.
Meanwhile, White Castle, which operates two wholesale bakeries in Ohio and Indiana that produce its
signature slider buns, calls its sustainability program
" Naturally Focused. " The overarching initiative explores
sustainability and how it fits into the business philosophy of the family-owned company.
" We feel it's about taking the long view, " said Jamie
Richardson, vice-president for White Castle. " We feel
we can make better decisions by not looking at what this
means for the next four weeks but what it means in four
years or 10 years. "
The chain received LEED Gold certification for operating systems as well as interior and exterior design elements in its new home office, which opened in 2019 in
Columbus, Ohio. The building features environmentally
friendly carpets, paint and ceiling tiles. Additionally,
low-energy lighting uses 52.1% less electricity while natural gas usage is 98.7% less than the old offices. Overall,
he said, the building uses 19% less energy than a building of comparable size.
" Our new office has very flexible floor plans, "
Mr. Richardson said. " Everything is movable and can be
taken off the walls. "
The larger, open design also provided benefits since
the pandemic struck, allowing for physical distancing
for people while they're working in the office.

Greater progress ahead
As energy management improves, the EPA updates Energy
Star ratings and has a revised EPI for cookie and cracker
bakeries to benchmark efficiency and determine eligibility
for Energy Star certification.
" The updated EPI benchmark reflects the efficiency improvements made across the cookie and cracker sector over
the past 10 years, " Mr. Tunnessen said. " With the new EPI,
some previously certified bakeries will now need to improve their efficiency to qualify for Energy Star certification
since the benchmark has been raised. "
BBU took energy management to a new level. Mr. Wolfe
noted that 2020 was the first full year that its wind farm has
been operational via a Virtual Power Purchase Agreement
that generates the equivalent of 100% of its total electrical consumption and returns it to the grid. Grupo Bimbo,


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Baking & Snack - December 2020

Table of Contents for the Digital Edition of Baking & Snack - December 2020

Baking & Snack - December 2020 - 1
Baking & Snack - December 2020 - 1
Baking & Snack - December 2020 - 2
Baking & Snack - December 2020 - 3
Baking & Snack - December 2020 - 4
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