Baking & Snack - July 2021 - 80

ENERGY MANAGEMENT
and add the names into a drawing for gift cards. This was
just one way to increase excitement and raise awareness
of this important issue. It builds this idea of ownership
over something that can seem small for one leak but that
can create great collective impact across 46 bakeries. "
Another area where bakeries can save is through optimization
of equipment.
" In the baking industry there's a lot of conveyor systems,
a lot of motors. How many of those motors do
you really need? Maybe try disconnecting a few and see
what happens, " Mr. Tunnessen said. " To do that you've
really got to get people involved who know these systems
as well as people who can observe what's happening.
All of that involves really getting more of the plant
folks engaged. "
At New Horizons bakery, success was all about reducing
waste and improving efficiencies by concentrating
on where the line would break down and why and eliminating
bottlenecks. The plant also upgraded equipment.
" We changed a lot of our conveyors, we cut down on
Lowering the air
compressor psi
even a little helps
save energy.
Flowers Foods
resistance by motors and how many we had on the line, "
Mr. Delaney said. " We changed and configured how we
process a product through. We got rid of pinch points.
We had better efficiencies in sanitation cleaning, and we
had less downtime. We manufactured more product in
less time for less energy use. We had more training for
employees; we had better material handling, better packaging
of the product. "
The key was cutting down on the number of bad
doughs at the plant, which eliminated the need to make
them twice.
Some of the most recent improvements made at
include new LED lighting,
Flowers Foods bakeries
compressed air upgrades, enhanced heat recovery for
hot water and heating the facility, and refrigeration upgrades,
Ms. Marsh said.
Once bakeries have identified the best places to save
money, implementation is next, which is never easy.
" WE MANUFACTURED MORE
PRODUCT IN LESS TIME
FOR LESS ENERGY USE. "
Billy Delaney, New Horizons Baking Co.
" What the treasure hunt will do is identify an action
plan for a site, but you still need to assign responsibility
for implementing it, " Mr. Tunnessen said. " If you're the
plant manager you need to keep on top of 'What are we
going to do first? What's our timeline? How do we keep
track of how we're doing?' Those things are the stuff
that's easy to fall down on but are really key. "
But the completion of one event is just the beginning
for many bakeries. At New Horizons, improvement is
a continual event, Mr. Delaney said. And as companies
look to reduce their carbon footprint, Mr. Tunnessen
expects more discussion to focus on decarbonization
moving forward. That means making plants as efficient
as possible.
Flowers Foods works across several channels to make
improvements to meet long-term sustainability goals.
" We work to instill an empowered culture of sustainability
and energy savings across our network, " Ms.
Marsh said. " Part of this progress includes best-practice
sharing, partnerships across industry and with national
organizations, capital projects or plant upgrades, and
working with providers and local officials to identify energy
grants that incentivize sustainability projects. "
Once a treasure hunt is completed, Mr. Tunnessen encourages
bakeries to celebrate their successes and continue
to search for and make improvements. The EPA recognizes
bakeries that complete the Energy Star Challenge
and those that achieve Energy Star certification, which
means a plant is one of the most efficient in the nation.
" Make sure after you do the treasure hunt and things
get implemented, celebrate that success, " he said. " Even if
it's at a weekly production meeting or putting up something
on a bulletin board. Because it just reinforces that
this is the type of stuff we value in our organization. "
*
80 Baking & Snack July 2021 / www.bakingbusiness.com
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Baking & Snack - July 2021

Table of Contents for the Digital Edition of Baking & Snack - July 2021

Baking & Snack - July 2021 - Intro
Baking & Snack - July 2021 - 1
Baking & Snack - July 2021 - 2
Baking & Snack - July 2021 - 3
Baking & Snack - July 2021 - 4
Baking & Snack - July 2021 - 5
Baking & Snack - July 2021 - 6
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Baking & Snack - July 2021 - 8
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