“The numbers don't lie,” says Stephan Wechsler, president of Empire Bakery Equipment, Hicksville, N.J. “In some cases, all we need to do is show the customer that they can save more in energy costs than the lease payment itself, allowing them to actually return money to their bottom line. It's easy to see that ultimately, it's more expensive not to upgrade.”

Even when changes do require additional dollars, efficiency-minded companies, such as FullBloom, believe the payoff is worth the price.

“We have always been a values-driven company,” Trilevsky says. “I have often made decisions that cost more because of this. I believe we have an obligation as business owners to lead and to make the right decision, even if it costs money, because it is for the greater good. If businesses do not set the precedent who will?”

Work with like-minded suppliers

When redesigning a production space, it's crucial to connect with suppliers that share your mindset. When Guttenplan set out to install solar panels on its roof, it took its time finding the right partner.

“It was neither easy nor hard, but it takes a sustained effort,” Littenberg says.

With a greener sensibility starting to pervade the baking industry, it's becoming easier to find suppliers who are in sync with forward-thinking bakeries.

“Equipment suppliers and their sales representatives are at the ready to offer solutions,” Trilevsky says. “High-quality brands especially value relationships and building a customer for life. They have a great deal of expertise, offer a different perspective and can suggest numerous options, many of which may not even be something they sell.”

Although finding the right suppliers and solutions for your company may take time and effort, the measures you take today will pay off tomorrow, the next day and well into the future.

“All of this energy efficiency is more than just good for your wallet, it's good for the environment,” Wechsler says. “By reducing your fuel, electric and water consumption, you're reducing your carbon footprint—and that benefits everyone.”

Top 10 ways to improve efficiencies

Paul Stiller, principal engineer, Summit Energy, Louisville, Ky.

1. Energy usage and cost awareness

   Employees can make a significant impact when they know the financial impact of their actions.

2. Refrigeration, freezer controls

   Head pressure should generally not be constant, and suction pressure can usually be increased part of the time, at least.

3. Air compressor controls

   Fixing air leaks is a waste of time if the compressor controls do not respond properly.

4. Oven draft control

   Negative pressure impacts combustion and increases operating cost, and it also may impact product quality.

5. Electric demand management

   Know when a peak occurs and be sure only essential equipment is running at that time.

6. Work hard to make energy usage correlate to production

   Fixed loads are not easy to spot in 24/7 bakeries. Track and analyze your usage versus production; quantify, track and work to reduce the fixed load.

7. Fan and pump control

   Fully open output valves and dampers; use speed control or resize the impellers to reduce flow.

8. Demand ventilation

   Introduce enough outside air to maintain required interior conditions, no more and no less.

9. Boiler controls

   Burner modulation, optimum excess air and oxygen trim are essential for large steam supplies.

10. Utility interlocks

    Compressed air, ventilation, product transport systems, process cooling and lighting should automatically adjust to requirements (and be reduced when not necessary).