Baking&Snack - March 2013 - 31

Q&A: EFFICIENCY
Jim Kline

Be prepared. Like the Boy Scout motto, the key to a successful and
efficient startup of a production line involves as much advanced
planning as possible, according to Jim Kline, president of The
EnSol Group, Erwinna, PA. Like captains of a ship, bakery engineers must map out the journey and pay extraordinary attention
to details to ensure the bakery or snack operation can handle unexpected events that often happen when ramping up production
on a new line.
With active projects in Africa, Ecuador, Vietnam and St. Kitts,
The EnSol Group works around the world to assist bakeries before,

during and after the startup phase. Mr. Kline, who serves as a contributing editor and columnist for Baking & Snack, has installed
dozens of new lines and managed the day-to-day operations
of bakery and snack plants for more than 30 years, including as
director of engineering for Bestfoods Baking Group and George
Weston Bakeries.
In this interview with Editor Dan Malovany, Mr. Kline provides
words of wisdom on avoiding the headaches and pitfalls during a
startup and insight on the best practices involved in getting a new
line up and running in the smoothest possible way.

Securing Smooth Sailing
Get some practical advice on how to avoid the headaches and pitfalls
that typically happen when starting up a production line.
Dan Malovany: What is the most
important thing to ensure an efficient startup?
Jim Kline: Certainly it is the planning that
starts before the equipment is purchased.
How will the equipment or the process be
integrated into the bakery? Will it fit in
the line, for that matter, in the door? What
utilities are required, and do you have
them available? Is permitting of any type
required? What will be required to successfully operate the equipment? How will
people interface with the equipment? What
skills will be required? How will the skills be
obtained? How many people will be needed?
These are all questions and planning factors
to consider early on in the process.
A successful startup requires attention
to detail — anticipating needs; preparation

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of materials; assembling and preparing the
trainers; scheduling of people; coordinating line time and availability; planning for
the different skill requirements of operations, maintenance and sanitation; having
the proper tools to operate and maintain
the equipment; and consideration of different languages. All this needs to be
planned and addressed well in advance of
the startup.

efficiency is required? What power efficiency is required? Does it need to
be BISSC-certified? Does it have to be
UL-approved? What labor effort do you
want associated with it? How is it to be
controlled and what voltage is available?
Training requirements and the necessary
documentation should both be specified.
Also, state how you will measure equipment performance for acceptance.

What specifications should be put
into purchase orders and contracts before buying equipment?

What is most efficient way to start
up a production line?

“Functional specifications” are critical.
These would include things like setting
the guidelines and expectations for the
products to be made — product sizes
and production rates. What operating

Have the operators, maintenance and
sanitation personnel and their supervisors trained, and have spare parts in place.
Commission each piece of equipment on
the line, assuring each piece is ready to
perform. Once all the equipment is ready,

March 2013 / Baking & Snack / 31

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Baking&Snack - March 2013

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