Baking & Snack - May 2004 - 53

INFORMATION UPDATE

Deadlines near
for bakeries
that signed up
for voluntary
programs
to replace
ozone-depleting
substances.

Cool Alternatives
I
n December 2001, the US Environmental Protection Agency unveiled a
voluntary program providing incentives for baking companies to phase
out ozone-depleting refrigerants such as
R-22. In February 2002, EPA finalized its
Bakery Partnership Program, created with
consultation from the baking industry.
The partnership program came about after audits at two bakery companies alleged
leakage of ozone-depleting substances
(ODS). In September 2000, Meyer's Bakeries, Inc., Hope, AR, settled its corporate-wide
violations with EPA by paying a civil penalty
of $3.5 million. And in July 2003, Sara Lee
Baking Group, St. Louis, MO, agreed to a
settlement in which it paid $5.25 million
in civil penalties, because of alleged ODS
violations at 57 of 67 Earthgrains Baking Co.
facilities. During the investigation, Sara Lee
purchased Earthgrains.

A UNIQUE OPPORTUNITY
R-22, aka Freon, is a hydrochlorofluorocarbon (HCFC), which destroys the stratospheric
ozone layer that protects us from ultraviolet
rays. R-22 is fairly common refrigerant and
can be used over a wide range of evaporator
temperatures from 50°F for air conditioning
to -40°F for freezers. However, according to
the 1995 Clean Air Act, R-22 must be phased
out of any new equipment by 2010 and can
no longer be produced after 2020.
The bakery partnership program, which
is the only one of its kind for any industry,
according to Charlie Garlow of EPA's Air
Enforcement Division, required companies
to either retrofit to alternative non-ODS
refrigerants or to retire equipment that used
ODS by April 26, 2002. Bakeries that did
not meet this deadline were assessed fines
of $10,000 per appliance and received per
pound penalties for refrigerant leaks that
crossed a certain threshold. Final deadline

for penalized companies participating in the
partnership program to comply with the program is July 15, 2004 for Class II ODS.
Forty-five companies signed up for
the bakery partnership in early 2002, Mr.
Garlow said. These companies represented
more than 250 baking plants and greater
than 1,100 pieces of industrial process
refrigeration appliances that were affected
by the agreement, meaning that they contained more than 50 lb of refrigerant.
"Even before the baking partnership began, most of those who signed up already had
non-ODS refrigerants in the majority of their
equipment," Mr. Garlow pointed out, noting
that more than 800 of the 1,100-plus pieces of
equipment used non-ODS refrigerants.

ROUND TWO
Following the initial program, which Mr.
Garlow characterized as "very successful,"
several companies indicated that they did
not find out about it in time and wanted to
participate in a similar program.
Thus, in April 2003, EPA announced
the Refrigerant Use Bakery Order, a second
opportunity for bakeries to convert to nonODS refrigerants. Bakery companies had
until July 15, 2003, to sign up for the bakery
order and a year after signing to complete
the changeover from ODS to non-ODS
refrigerants. The second agreement was
simpler, and companies that abide by the
order would not be assessed penalties and
would not have to go through the audits that

R-22 Replacements
Refrigerant

Characteristics

R-417A

A blend of R-125, R-143a and R-134a intended for retrofitting R-22
air-conditioning and refrigeration systems, R-417A runs at a slightly
lower suction and discharge pressure than R-22 and has proven
to work with all standard equipment components and materials
used in R-22 manufacturing systems. The refrigerant's impact on
retrofitted process equipment will be noticeable but not severe. It
is compatible with synthetic and mineral oils, but in some applications, polyol ester (POE) lubricants may be needed.

R-407C

A blend of R-32, R-125 and R-134a, it has similar properties
to R-22 in air conditioning equipment, a slight decrease in
capacity and efficiency. Nevertheless, R-407C can be used in
essentially the same equipment with only minor engineering
modifications. R-407C can be used in medium-temperature R-22
refrigeration systems. Retrofitted R-22 systems need the residual oil
flushed with POE.

R-404A and R-507A

R-404A is comprised of R-125, 143a and 134a, while R-505A is a
mixture of R125 and R-143a. These two blends are very similar
and are intended for low- and medium-temperature refrigeration.
They can be used to retrofit lower-temperature R-22 systems while
significantly lowering the discharge temperature. They require POE
lubricants and existing oil must be flushed.

One Shot

A direct replacement for R-22 in low-temperature applications, it is
compatible with various oils, so no oil change is required.

(ASHRE No. pending)

May 2004 / BAKERS PRODUCTION MANUAL / 53

Baking & Snack - May 2004

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