Traditionally, piping systems used for cold storage and cold processing in food plants have been welded steel or other types of metal. They're heavy, complex to install and have to be insulated on-site, after installation. But Tasteful Selections' plant used 3,000 ft. of pre-insulated ABS pipe and fittings from GF Piping Systems (www.gfps.com).
All these things were worked into the design phase of the new facility. Bender acknowledges that planning this level of sustainability was made easier because this was a greenfield project.
One large energy-saving attribute was the installation of variable frequency drives (VFDs) on more than 400 motors. “The VFD’s start the motors slowly and run them at the minimal speed needed for the process and throughput," he says.
All those potatoes dirty a lot of bins, about 1,000 a day. So the company contracted Exeter Engineering to design and build an efficient bin-washing system.
The plant has achieved a CalGreen certification, a state initiative Bender likens to the Green Building Council's Leadership in Energy and Environmental Design (LEED) certification. In fact, the plant was designed to LEED guidelines, and the Benders hope to get that certification in the future.
And they're not done yet.
In the next 30 days, Tasteful Selections will implement a process to bring even more of what is now potato wastewater back into the process. The building's roof was designed for solar panels, for which Bender is now seeking bids. "We are hoping to have solar panels by next year," he proclaims.
Also built-in is the possibility to use natural gas for cogeneration. Electric car charging stations are in the plans, too.
So are higher-value product line extensions. Bender says having such an efficient plant will enable Tasteful Selections to grow even more.