Baking & Snack - October 2010 - 35
36
Because mixers are typically the largest consumer of
electricity, the company located the bakery's electrical room close to them to reduce cabling and installation costs.
Flowers also earned significant energy savings with a
new design for the two Ingersoll-Rand air compressors.
The air line's loop is configured as its receiver, and compressed air is produced only as needed rather than being
kept constantly available. "A lot of power is wasted on
air compression at other bakeries," Mr. Benton observed.
Management of boiler capacity differs as well. The
bakery has two boilers, and the system shuts off entirely
as demand permits, rather than keeping the second boiler on constant standby.
Flowers equipped Bardstown with an emergency propane system and an electrical generator because the region is subject to ice storms. So far, however, weather has
not interrupted bakery operations.
IDEA LAB. Having designed and commissioned so
many new bakeries in recent years, Flowers managers
look at these activities as a way to improve operations
throughout the company's facilities. The new sites pro-
V V I_
FF
vide an opportunity to "push the outside of the envelope"
and to do so in a real-time, results-oriented setting.
"All of the innovative ideas we pursue are executed
in the field at the bakeries," Mr. Benton said. "The challenge for Ken and me is to build a big, efficient plant
that is flexible enough to meet the changing demands
of the marketplace."
For its next bakery, currently in the planning phase,
the building's design will incorporate several lessons
from data gathered from Bardstown. "The next time
around, the emphasis will be on LEED, on power consumptions and efficiencies of a different kind, and those
factors will determine who supplies our equipment," Mr.
Benton noted.
Being the low-cost producer, however, will remain
the driving force for manufacturing going forward.
The new data simply provides a new benchmark that
the company can use to identify additional costs to
eliminate in the future, Mr. Benton explained. "We're
all long-term bakery people, and we were taught by
others who were drilled in the art of baking. Now,
we have the technology to better understand the science," he said.
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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
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