Baking&Snack - July 2011 - 90

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SUSTAINABILITY

oven is more stable,” Mr. Battino explained. “I don’t have side-toside variation in temperature or very little variation in moisture. The process is more stable so the [product] quality is improved, and a lot of times, you can improve the throughput of the oven.” Likewise, spending a little bit more on an energy-efficient motor usually means getting better windings, bearings and seals. Product quality improves in the long run, he said, because the better-built motor is more reliable, which reduces downtime. FYI ON ROI. After optimizing an oven, the next step involves exploring simple modifications such as adding waste heat recovery, upgrading burners or adjusting the fuel and air mixture to improve the operation even further. With existing facilities, the goal involves identifying the opportunity to conserve resources, quantifying how much it costs and figuring out the payback to make a good business decision. “If it’s a 3½- or a 4-year payback, we say, ‘Let’s go for it.’ What we found at PepsiCo is that the expected rate of return in resource conservation projects is much lower than the actual return on investments as a whole,” Mr. Battino explained. “We usually get

▲ Eric Battino, PepsiCo’s supplier sustainability manager, describes the company’s “Green Productivity Machine” during the recent Biscuit & Cracker Manufacturers’ Association’s technical conference.
BISCUIT & CRACKER MANUFACTURERS’ ASSOCIATION

operates mechanically and electronically but also how the fryer integrates into the overall processing line and how to make it operate more efficiently. Specifically, he determines the fryer’s energy and water usage as well as waste production. Optimizing a piece of equipment saves money, but it also has other benefits. “When I’m making an oven use energy more efficiently, the temperature of the

what we expected or a little better return; then we start tweaking it and get even more of a return out of the project. For ReCon projects, we have actually lowered the hurdle rate and made it easier to fund these projects at our sites.” In addition to a robust ROI, many ReCon projects are low-risk, especially when compared with investments in equipment for new product launches. In some cases, the project may simply involve stocking energy-efficient T-8 lamps that use 25 watts and have the same lumens as a previous generation that required 32 watts. No project or significant capital investment needs to be made all at once. As lights burn out, a bakery or snack operation replaces them with more energy-efficient ones. “It’s one of the quickest ways you can lower costs that go directly to your bottom line,” he said. “How much effort does it take to turn off a switch, close a valve or lower the air pressure on a compressed air system? It’s a great way to mitigate increases in commodities. It’s a great motivator to get people to become more sustainable.” Perhaps the most efficient sustainable initiatives to lower overhead costs involves eliminating rubbish. Again, Mr. Battino said, the investment is minimal. “There

Sustainability as a Journey
Benchmarking energy and water usage as short as a decade ago often proved difficult and expensive, but wireless technology and other information-gathering control systems now make it much easier to measure, track and analyze how efficiently a snack or bakery manufacturing facility operates. “It used to be a very laborious process,” said Eric Battino, supplier sustainability manager at PepsiCo, which is based in Plano, TX. “It wasn’t timely. It was tough to get the detail you needed. Now, it’s almost instantaneous. You now have actionable data in a timely manner, and technology has made that possible.” Advances in technology, he said, mean that new opportunities for improving plant efficiencies through sustainability programs will become more affordable in the future. In other words, Mr. Battino said, identifying the proverbial low-hanging fruit of tomorrow is an ongoing process that continues to change. Much of it simply involves training and engaging a company’s workforce on best practices. “With today’s technology, you can pinpoint an issue and take action where in the past it might have taken weeks or months,” he said. “Now, you are taking action immediately to eliminate losses in the process. Technology improves our ability to manage our operations better day to day and shift to shift.” www.bakingbusiness.com


http://www.bakingbusiness.com

Baking&Snack - July 2011

Table of Contents for the Digital Edition of Baking&Snack - July 2011

Baking&Snack - July 2011
EDITORIAL - Engineering a New Era
MyPlate becomes new food icon
MyPlate receives mixed reviews
Commentary: Icon offers new hope for grains
NEWS IN BRIEF
Safeway Joplin plant assists
NEWS - DSM completes US innovation center
NEWS - Food Channel predicts Top 10 dessert trends for 2011
NEWS - Shearer’s hits home run
NEWS - Egg Board’s website focuses on functionality
NEWS/PEOPLE
WHEAT IMPROVEMENT - GM Gets Moving Again
WHEAT IMPROVEMENT - Organic Not Buying GM Story
WHEAT IMPROVEMENT - Global Debate on GM Wheat
WHEAT IMPROVEMENT - Change of Tech
WHEAT IMPROVEMENT - Here and Abroad
WHEAT IMPROVEMENT - Traits of Interest
Joseph Campione - Authentic Value
Joseph Campione - In the Spirit
Joseph Campione - In the Family
ARTISAN MARKETING - Ahead of Its Time
ARTISAN MARKETING - Educating Consumers
ARTISAN MARKETING - In-store Bakery vs. Bread Aisle
NEW ON THE SHELF
SODIUM REDUCTION - a Grain of Salt
SODIUM REDUCTION - Sodium: Down for the Count Globally
INGREDIENT APP - Sweet & Stable
INGREDIENT NEWS
BAKING PANS - a Pan of Action
BAKING PANS - Thermal Stability
BAKING PANS - Increasing the Life of Pans
BAKING PANS - Release Coatings
BAKING PANS - On Schedule
SPARE PARTS - When They Need It NOW
SPARE PARTS - In the Vault
INDUSTRY INSIGHT - Product Report Card
SUSTAINABILITY - On a ReCon Mission
SUSTAINABILITY - Making Recycling Pay
SUSTAINABILITY - Sustainability as a Journey
COMMODITIES Q&A - a chance for Change
PRODUCTS & PACKAGING
INDUSTRY IMAGES - an International Affair
Tortilla Tech
CALENDAR OF EVENTS
MARKETPLACE
AD INDEX
NEW PRODUCT SPOTLIGHT - Delicious in Pink
Baking&Snack - July 2011 - Baking&Snack - July 2011
Baking&Snack - July 2011 - 2
Baking&Snack - July 2011 - 3
Baking&Snack - July 2011 - 4
Baking&Snack - July 2011 - 5
Baking&Snack - July 2011 - 6
Baking&Snack - July 2011 - 7
Baking&Snack - July 2011 - 8
Baking&Snack - July 2011 - 9
Baking&Snack - July 2011 - EDITORIAL - Engineering a New Era
Baking&Snack - July 2011 - 11
Baking&Snack - July 2011 - 12
Baking&Snack - July 2011 - 13
Baking&Snack - July 2011 - Commentary: Icon offers new hope for grains
Baking&Snack - July 2011 - NEWS IN BRIEF
Baking&Snack - July 2011 - Safeway Joplin plant assists
Baking&Snack - July 2011 - 17
Baking&Snack - July 2011 - NEWS - Food Channel predicts Top 10 dessert trends for 2011
Baking&Snack - July 2011 - 19
Baking&Snack - July 2011 - NEWS - Egg Board’s website focuses on functionality
Baking&Snack - July 2011 - NEWS/PEOPLE
Baking&Snack - July 2011 - 22
Baking&Snack - July 2011 - 23
Baking&Snack - July 2011 - WHEAT IMPROVEMENT - GM Gets Moving Again
Baking&Snack - July 2011 - 25
Baking&Snack - July 2011 - WHEAT IMPROVEMENT - Organic Not Buying GM Story
Baking&Snack - July 2011 - 27
Baking&Snack - July 2011 - WHEAT IMPROVEMENT - Global Debate on GM Wheat
Baking&Snack - July 2011 - 29
Baking&Snack - July 2011 - WHEAT IMPROVEMENT - Change of Tech
Baking&Snack - July 2011 - 31
Baking&Snack - July 2011 - WHEAT IMPROVEMENT - Here and Abroad
Baking&Snack - July 2011 - 33
Baking&Snack - July 2011 - WHEAT IMPROVEMENT - Traits of Interest
Baking&Snack - July 2011 - 35
Baking&Snack - July 2011 - Joseph Campione - Authentic Value
Baking&Snack - July 2011 - 37
Baking&Snack - July 2011 - Joseph Campione - In the Spirit
Baking&Snack - July 2011 - 39
Baking&Snack - July 2011 - 40
Baking&Snack - July 2011 - 41
Baking&Snack - July 2011 - Joseph Campione - In the Family
Baking&Snack - July 2011 - 43
Baking&Snack - July 2011 - 44
Baking&Snack - July 2011 - 45
Baking&Snack - July 2011 - 46
Baking&Snack - July 2011 - ARTISAN MARKETING - Ahead of Its Time
Baking&Snack - July 2011 - ARTISAN MARKETING - Educating Consumers
Baking&Snack - July 2011 - 49
Baking&Snack - July 2011 - 50
Baking&Snack - July 2011 - 51
Baking&Snack - July 2011 - ARTISAN MARKETING - In-store Bakery vs. Bread Aisle
Baking&Snack - July 2011 - 53
Baking&Snack - July 2011 - 54
Baking&Snack - July 2011 - NEW ON THE SHELF
Baking&Snack - July 2011 - 56
Baking&Snack - July 2011 - 57
Baking&Snack - July 2011 - 58
Baking&Snack - July 2011 - 59
Baking&Snack - July 2011 - 60
Baking&Snack - July 2011 - SODIUM REDUCTION - a Grain of Salt
Baking&Snack - July 2011 - SODIUM REDUCTION - Sodium: Down for the Count Globally
Baking&Snack - July 2011 - 63
Baking&Snack - July 2011 - 64
Baking&Snack - July 2011 - 65
Baking&Snack - July 2011 - 66
Baking&Snack - July 2011 - INGREDIENT APP - Sweet & Stable
Baking&Snack - July 2011 - 68
Baking&Snack - July 2011 - 69
Baking&Snack - July 2011 - INGREDIENT NEWS
Baking&Snack - July 2011 - 71
Baking&Snack - July 2011 - 72
Baking&Snack - July 2011 - BAKING PANS - a Pan of Action
Baking&Snack - July 2011 - BAKING PANS - Thermal Stability
Baking&Snack - July 2011 - 75
Baking&Snack - July 2011 - BAKING PANS - Increasing the Life of Pans
Baking&Snack - July 2011 - BAKING PANS - Release Coatings
Baking&Snack - July 2011 - BAKING PANS - On Schedule
Baking&Snack - July 2011 - 79
Baking&Snack - July 2011 - SPARE PARTS - When They Need It NOW
Baking&Snack - July 2011 - 81
Baking&Snack - July 2011 - SPARE PARTS - In the Vault
Baking&Snack - July 2011 - 83
Baking&Snack - July 2011 - INDUSTRY INSIGHT - Product Report Card
Baking&Snack - July 2011 - 85
Baking&Snack - July 2011 - SUSTAINABILITY - On a ReCon Mission
Baking&Snack - July 2011 - 87
Baking&Snack - July 2011 - SUSTAINABILITY - Making Recycling Pay
Baking&Snack - July 2011 - 89
Baking&Snack - July 2011 - SUSTAINABILITY - Sustainability as a Journey
Baking&Snack - July 2011 - 91
Baking&Snack - July 2011 - 92
Baking&Snack - July 2011 - COMMODITIES Q&A - a chance for Change
Baking&Snack - July 2011 - 94
Baking&Snack - July 2011 - PRODUCTS & PACKAGING
Baking&Snack - July 2011 - 96
Baking&Snack - July 2011 - 97
Baking&Snack - July 2011 - INDUSTRY IMAGES - an International Affair
Baking&Snack - July 2011 - 99
Baking&Snack - July 2011 - 100
Baking&Snack - July 2011 - Tortilla Tech
Baking&Snack - July 2011 - 102
Baking&Snack - July 2011 - 103
Baking&Snack - July 2011 - CALENDAR OF EVENTS
Baking&Snack - July 2011 - 105
Baking&Snack - July 2011 - MARKETPLACE
Baking&Snack - July 2011 - 107
Baking&Snack - July 2011 - 108
Baking&Snack - July 2011 - 109
Baking&Snack - July 2011 - 110
Baking&Snack - July 2011 - 111
Baking&Snack - July 2011 - 112
Baking&Snack - July 2011 - AD INDEX
Baking&Snack - July 2011 - NEW PRODUCT SPOTLIGHT - Delicious in Pink
Baking&Snack - July 2011 - 115
Baking&Snack - July 2011 - 116
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