PROBLEM: When you need to plan a new bakery, expand an existing one or simply improve current efficiency; how do you make the right selections from the never-ending list of available options?

SOLUTION: Spend adequate time in developing the concept for your project and focus on the details in the beginning, not at the end where changes are costly or impractical. Once all the details have been properly sorted out, detailed engineering will go quickly and smoothly, as will the construction/installation of your project.

The Austin Co., Irvine, Calif., has some advice for those planning a new bakery, or expanding an existing one — to get started, go back to the basics:

• Learn from successes — look at where your plants shine and make sure your new project incorporates those elements.
• Learn from mistakes — look at where your plants have problems and make sure your new project finds a way to eliminate them.
• Conduct focused planning meetings to consider every important aspect of the plant. When considering maintenance access: Can you safely and easily reach critical points? For sanitation, ingredient, product and spare parts storage: Have the right people participate in these planning sessions. For example, when looking at sanitation, have the cleaning crew participate in the meeting. Very important ideas will come from those doing the work day-in and day-out.
• If you're looking at a new plant, the right site can make a big difference. Two very similar sites can produce dramatically different financial results based on incentives. Use an incentive professional, experienced in baking industry plants. There is a difference.
• Rely on industry leaders. Use people who have invested in serving your specific needs, as opposed to generalists. They are in it with you.
• The shortest path from start to finish is a straight line — try to achieve straight — line flow for production.
• The surest way to achieve quality is to avoid complications — simplify the design and you will get better quality, less waste and better margins.
• When choosing materials and equipment, ask vendors for references and check these references. Find out how the product stood the test of time after six months and two years down the road.
• Plan for flexibility — leave yourself some options with the layout and building to quickly respond to growth, changes in the market and other variables. It increases the value of the plant to your company.

Remember “the devil is in the details.”