Baking & Snack - May 2024 - 15

SPECIAL REPORT
Sustainability
Bimbo Bakeries USA, for instance, monitors the number
of BTUs per pound of product produced as one factor to
gauge efficiency. It also measures sustainability in a practical
way that everyone understands.
" We're a low-margin business, so 25 or 30 years ago,
the word 'sustainability' wasn't there, but we always tried
to get the greatest amount of product out to the market
with the least amount of resources, " observed Chris
Wolfe, senior director of environmental sustainability
for Bimbo Bakeries USA.
Marsh described sustainability as a core factor
of efficiency.
" Establishing processes that enable maximum production
volume with the fewest number of resources
will help companies operate as efficiently, and thereby
as sustainably as possible, " she said. " This includes minimizing
downtime, energy, waste and water. "
Companies like Flowers that are leading the industry
in sustainable baking practices have also started to explore
and implement more advanced processes such as
heat recovery, where wasted heat is captured and reused
for other processes.
" BECOMING AN ENERGY
STAR-CERTIFIED FACILITY
TAKES TEAMWORK AND
DEDICATION, AND OUR
BAKERIES ARE ENERGIZED
WHEN THEY MAKE THE LIST. "
Margaret Ann Marsh, Flowers Foods
" Our sustainability program is aligned with our corporate
strategy and focused on driving financial returns, "
Marsh said. " As we invest in our operations -
whether it's new bakeries, production lines or upgrades
to existing equipment - sustainability is integral to the
design process. Incorporating efficiency improvements
into capital projects upfront is fiscally advantageous because
it costs less than retrofitting an existing piece of
equipment. From an ROI perspective, it's important that
any sustainability projects make business sense, taking
into consideration current and forecasted future needs. "
Mexico City-based Grupo Bimbo, parent company of
Bimbo Bakeries USA, will sometimes extend the traditional
two-year ROI for sustainability initiatives.
" We will go out beyond that time because of what it
can achieve from a sustainability perspective, " Wolfe
said. " We look at where other investments are being
made, and if we plan to be there for the long haul, it
makes it a little easier for us to justify a longer ROI. "
He added incorporating green initiatives
into a new facility is often easier
than retrofitting an existing one.
Bimbo Bakeries USA has facilities
that are more than 100 years
old and others that are less
than 20 years, which makes
them relatively " new " in the
baking industry.
" Our new bakeries are one
floor, " Wolfe said. " We're then
able to leverage all the state-of-theart
equipment, but we have some
older bakeries that are four stories high
and pose a challenge. We try to develop
programs that are site-specific because that's much
more actionable. We typically go into a bakery and evaluate
individually. We replicate technologies where we can and,
in other cases, where we can adapt. "
Harvesting low-hanging fruit
Dutrow pointed out several ways bakeries can lower
operating costs. She highly recommended upgrading to
low-emitting diode (LED) lighting where possible to reduce
energy use and related costs. They are also lower
maintenance because they can last longer. Further, some
LEDs may not be made of glass, making them better for
food safety.
Another energy-saver involves optimizing compressed
air, which is frequently used on packaging lines
and in some other applications. Fixing leaks, right sizing
compressors and reducing pressure when possible are
some energy-saving suggestions.
Marsh echoed lighting and compressed air as good
places to start.
" Upgrading to LED lighting can make a significant
difference in a bakery's energy footprint with the added
advantage of improved lighting levels and reduced
heat on the bakery floor, benefiting team members, " she
pointed out. " Assessing compressed air systems to identify
and repair air leaks can have an immediate impact.
Other compressed air upgrades include investing in systems
with variable-frequency drives, redesigning piping
and air nozzles, and using air-leak detection tools to ensure
optimal performance. "
Dutrow advised not to forget motor management.
When replacing a motor, specify an efficient version that
will cost less over the lifetime of the motor. Moreover,
check the insulation on ovens to make sure it's still effective
or can be improved. Are there places where insulation
was removed and not put back in place after servicing
the oven?
Another common practice is shutting off unused
www.bakingbusiness.com / May 2024 Baking & Snack 15
Sustainability is
closely linked to
efficiency and can
play a critical role in
the profitability of an
operation.
Sosland Publishing
http://www.bakingbusiness.com
Baking & Snack - May 2024

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