Baking & Snack - October 2010 - 25

25
operation will likely create new criteria for improving
the company's 39 other plants and for developing additional parameters for designing facilities and even selecting what equipment it buys, noted Ken Buxton, senior
staff engineer for Flowers Foods. "We typically build off
of what we found works in the past," he said. "We learn
from our successes and our mistakes."
Because of this learning process, the Bardstown facility, not surprisingly, resembles the company's more
recently built bread and bun bakeries that opened at
Denton, TX, in 2004 and at Newton, NC, in late 2006.
In fact, its bread line, which produces 10,000 loaves an
hour, is a near replica of the line at Newton. What may
not be so apparent to the eye are how Bardstown's energy
management system as well as other advances in process
technology provide different ways for Flowers not only
to remain the industry's low-cost producer, but also to
more consistently control product quality. For an engineering team that learns from the past, that's the ultimate
win-win proposition.
"RSEnergyMetrix is the key to making us better
going down the road from an efficiency standpoint,
from a productivity standpoint and from a quality
standpoint," Mr. Benton explained. "This program has
given us an education and an opportunity to see what's
going on. In the past, we thought we knew what was

happening, but we weren't exactly sure. Now, we have
hard numbers and facts.
"With this bakery, everything is measurable, so it's going to be our baseline in the future," he said. "That is what
makes this plant unique, more than any other plant we
have right now."
Mr. Benton and Mr. Buxton also discovered their first
big jaunt into energy conservation may result in building future facilities that could be certified for Leadership
in Energy and Environmental Design (LEED), the green
building rating system developed and administered by
the US Green Building Council. Reviewing a checklist
for LEED certification, in fact, they discovered that the
company had been pursuing green initiatives albeit under the name of good manufacturing practices. "It's always been on our mind when we think about efficiency
and about saving more money, but we just never had a
name for it," Mr. Buxton said.
Specifically, the review pinpointed several surprising areas of savings that the company had previously taken for
granted. For instance, it revealed that the bakery's ventilation system consumed the second largest amount of energy,
▼ (From left) Robert Benton, corporate vice-president of manufacturing;
Billy Donaldson, plant president of Flowers Baking Co. of Bardstown; Eric
Lewis, the bakery's manufacturing manager; and Ken Buxton, senior staff
engineer, oversaw the start up of the operation in Bardstown, KY.

October 2010 / BAKING & SNACK



Baking & Snack - October 2010

Table of Contents for the Digital Edition of Baking & Snack - October 2010

Contents
Baking & Snack - October 2010 - 1
Baking & Snack - October 2010 - 2
Baking & Snack - October 2010 - 3
Baking & Snack - October 2010 - Contents
Baking & Snack - October 2010 - 5
Baking & Snack - October 2010 - 6
Baking & Snack - October 2010 - 7
Baking & Snack - October 2010 - 8
Baking & Snack - October 2010 - 9
Baking & Snack - October 2010 - 10
Baking & Snack - October 2010 - 11
Baking & Snack - October 2010 - 12
Baking & Snack - October 2010 - 13
Baking & Snack - October 2010 - 14
Baking & Snack - October 2010 - 15
Baking & Snack - October 2010 - 16
Baking & Snack - October 2010 - 17
Baking & Snack - October 2010 - 18
Baking & Snack - October 2010 - 19
Baking & Snack - October 2010 - 20
Baking & Snack - October 2010 - 21
Baking & Snack - October 2010 - 22
Baking & Snack - October 2010 - 23
Baking & Snack - October 2010 - 24
Baking & Snack - October 2010 - 25
Baking & Snack - October 2010 - 26
Baking & Snack - October 2010 - 27
Baking & Snack - October 2010 - 28
Baking & Snack - October 2010 - 29
Baking & Snack - October 2010 - 30
Baking & Snack - October 2010 - 31
Baking & Snack - October 2010 - 32
Baking & Snack - October 2010 - 33
Baking & Snack - October 2010 - 34
Baking & Snack - October 2010 - 35
Baking & Snack - October 2010 - 36
Baking & Snack - October 2010 - 37
Baking & Snack - October 2010 - 38
Baking & Snack - October 2010 - 39
Baking & Snack - October 2010 - 40
Baking & Snack - October 2010 - 41
Baking & Snack - October 2010 - 42
Baking & Snack - October 2010 - 43
Baking & Snack - October 2010 - 44
Baking & Snack - October 2010 - 45
Baking & Snack - October 2010 - 46
Baking & Snack - October 2010 - 47
Baking & Snack - October 2010 - 48
Baking & Snack - October 2010 - 49
Baking & Snack - October 2010 - 50
Baking & Snack - October 2010 - 51
Baking & Snack - October 2010 - 52
Baking & Snack - October 2010 - 53
Baking & Snack - October 2010 - 54
Baking & Snack - October 2010 - 55
Baking & Snack - October 2010 - 56
Baking & Snack - October 2010 - 57
Baking & Snack - October 2010 - 58
Baking & Snack - October 2010 - 59
Baking & Snack - October 2010 - 60
Baking & Snack - October 2010 - 61
Baking & Snack - October 2010 - 62
Baking & Snack - October 2010 - 63
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Baking & Snack - October 2010 - 65
Baking & Snack - October 2010 - 66
Baking & Snack - October 2010 - 67
Baking & Snack - October 2010 - 68
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Baking & Snack - October 2010 - 70
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Baking & Snack - October 2010 - 72
Baking & Snack - October 2010 - 73
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Baking & Snack - October 2010 - 78
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