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Greener Fields Together Case Study Energy and Climate at Taylor Farms’ Abbott Street Plant

VERIFIED SureHarvest

The Greener Fields Together

Meet Greener Fields Together National Farms Partner:

National Farm program is

Taylor Farms California, Inc. processes fresh produce to make a variety of salads, vegetable and healthy snack products for consumers throughout North America. Operating in Salinas, California and Yuma, Arizona, Taylor Farms makes about one out of every three salads consumed in restaurants and foodservice outlets in the United States.Taylor Farms aligns itself with family farmers in California and Arizona who grow fruits and vegetables for its fresh products.

designed to build and manage a farm supplier network dedicated to examining and improving sustainability in their operations.Through 5P’s of Sustainability™ Verified Case Studies, SureHarvest will assist Greener Fields

5P’s Verified Case Study: Energy and Climate

Together National Farm

As part of its “Green Projects” initiative, Taylor Fresh Foods is

partners to evaluate their

reducing energy use at its processing facilities throughout North

sustainability efforts

America. In early 2011, Taylor Farms California–an affiliate of Taylor

according to the 5P’s.

Fresh Foods–made significant upgrades to its refrigeration and

SureHarevest then conducts

lighting systems at the Abbott Street processing plant in Salinas.

on-site verification to ensure

SureHarvest documented and verified the Abbott Street plant

accuracy and authenticity.

energy program using the 5P’s of Sustainability.™ Sustainabllity Highlights

Taylor Farms has a sophisticated, highly responsive protocol for evaluating success and challenges to its energy savings program. With participation and buy in at every level within the company, Taylor Farms is well positioned to make sustainable, continual improvements for energy conservation at its Abbott Street plant. In 2011,Taylor Farms realized annual energy savings of 1.74 million kWh, enough to power 151 US households per year. These environmental returns on investment are expected to yield a 3½ year return on Taylor Farms’ financial investment in energy upgrades at the plant.

Verified Case Study: Taylor Farms’ Abbott Street Plant Energy and Climate

10

%

REDUCTION

IN TOTAL ENERGY CONSUMPTION These savings were achieved on top of previously recognized accomplishments; the facility received a 2008 and 2009 “Energy Champion Award” from the U.S. Department of Energy.

September, 2012

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SureHarvest

1. Sustainability Principles

ing plant could benefit most from increased

utilizes its

Taylor Farms is dedicated to:

attention and capital spending to meet a variety

5 P’s of

• Adopting effective processing techniques that

of organizational goals such as cost reduction,

Sustainability™

maximize value in production and use of natural

-- a continuous

corporate responsibility, and performance

resources.

monitoring.

improvement business management methodology

• Building a better sense of community among

-- to craft case studies that evaluate

its members and developing goodwill with

the alignment and execution of Greener

customers.

Fields Together National Farm partners’

• Making environmental management decisions

sustainability efforts that contribute to financial profitability, environmental stewardship and social progress. Each case study goes through a verification step to confirm that the reported information is accurate, thorough and authentic.

Principles The core values that define the business strategy Processes

that influence real and tangible factors that can affect us all.

3. Sustainability Practices

Fresh produce arrives at the plant from the farm fields and is cooled to 35-36°F. The produce is maintained at this temperature throughout processing through refrigeration systems. These systems consume between

2. Sustainablity Processes

Dedicated to reducing the amount of energy used in its processing facilities, Taylor Farms

55-65% of the total electrical energy use at the plant. Improving refrigeration energy efficiency was a logical focal point.

took the initiative to make small, medium and

An internal focus team for energy worked with

large energy conservation improvements in

VaCom Technologies, an industrial refrigeration

its Abbott Street processing plant. This facility

company, to target optimal points in the refrig-

was selected through company brainstorming

eration system for improvement. Upgrades to

sessions to identify which areas in the process-

the refrigeration system included installation

The sets of managed activities that create internal and external value

ENERGY USE AND LOSS THROUGH PROCESSING

Practices The methods used to accomplish the desired operational results

PRE-COOLING

PRE-STORAGE

PROCESSING

POST-STORAGE

Performance

• Vacuum Coolers

• Refrigeration

• Refrigeration

• Refrigeration

The metrics and measurements used

• Forklifts

• Air Circulation

• Air Circulation

• Air Circulation

• Lighting

• Processing

• Lighting

• Forklifts

Equipment

to evaluate practice and process results Progress

• Building Seals

• Lighting

The approach used to document,

• Building Seals

communicate and drive continuous

• Compressors

• Forklifts • Building Seals

improvement over time

Verified Case Study: Taylor Farms’ Abbott Street Plant Energy and Climate

September, 2012

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ENERGY SAVINGS EQUIVALENT (US Households) 30

Energy saved in 2011 was enough to power 151 US households for an entire year.

25 20 15 10

Each house equals five US households’ annual energy use.

5

Apr

May

Jun

Jul

Aug

Sep

Oct

of state of the art refrigeration software and

health and comparison data used to measure

hardware technologies.

performance on a quarterly basis. Additionally,

Other key steps include installation of top of

energy use performance is tracked remotely by

the line air compressors with modern insulation systems, automated doors to maintain low temperatures inside the plant, and improved lighting placement and fixtures.

Nov

VaCom and reports are generated for Taylor Farm’s use on a quarterly basis. 5. Sustainablity Progress

Taylor Farms has a sophisticated, highly responsive protocol for evaluating success and challenges to their energy savings program that values full participation and buy-in at every level in the company, starting from the ground up. Through its process of continual improvement, Taylor Farms evaluates practice efficacy and future energy savings on a regular basis.

A state of the art computer system enables engineering staff to achieve optimal power usage to meet refrigeration needs throughout the plant.

4. Sustainablity Performance

Taylor Farms utilizes a range of metrics to assess the energy use reductions achieved as a result of the equipment upgrades and practice improvements made at the Abbott Street plant.

K I L O W AT T HOURS

SAVED

EVERY M I N UTE Operating seasonally from April to November, the Abbott Street plant is saving about 7,200

The energy focus group communicates regularly

kWh of energy every day,

through email and group meetings. Weekly

enough to power 1,500 HD

operation and maintenance meetings are

TV’s for the day.

conducted between the Engineering Department and refrigeration contractor. Taylor Farms carries out monthly internal energy use reviews and holds quarterly meetings to review usage and system performance with VaCom. To keep its guiding principles current and evaluate company-wide performance, Taylor Farms holds an annual managers’ meeting. Prior

Total energy use is evaluated using Pacific Gas

to the annual meeting, each department holds

and Electric (PG&E) on-line tools that allow

smaller group meetings to generate ideas and

month-to-month and year-to-year comparisons of

evaluate high-level issues to optimize effective-

energy usage and resulting savings. Taylor also cal-

ness at the managers meeting. Employee input is

culates energy use of each large refrigeration unit

valued and suggestions help identify areas for

in real-time, which provides a baseline of system

improvement.

Verified Case Study: Taylor Farms’ Abbott Street Plant Energy and Climate

5.0

September, 2012

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Energy and Climate at Taylor Farms’ Abbott Street Plant

Taylor Fresh Foods, Inc. (known as Taylor

The Greener Fields Together National

SureHarvest is an agri-food sustainability

Farms) was founded by Bruce Taylor and

Farm program was launched in 2012,

solutions company delivering practical

several partners in 1995 with the quest

intent to build and manage a supplier

strategies, proven technologies, and

of becoming “America’s Favorite Salad

network of national farms dedicated to

exceptional services to accelerate financial

Maker”. Headquartered in Salinas, Cali-

examining sustainability in their opera-

profitability, environmental stewardship

fornia, Taylor Farms is the world’s largest

tions. Through the completion of 5P’s of

and social progress.

producer of fresh-cut vegetables. Taylor

Sustainability™Verified

Farms has strategically positioned itself

reporting, the program will reveal

with eleven US processing plants and

the efforts being made toward more

one in Mexico to supply its customers

sustainable operations.

and end consumers with the freshest and

Sustainability process areas in the

initiatives. Our services are often coupled

Greener Fields Together National Farm

with farm management and sustainability

program include:

program management software technolo-

• Community

gies to provide turnkey solutions.

greatest tasting products industry wide. Taylor Farms California, Inc.—an affiliate of Taylor Fresh Foods—operates seasonally in Salinas, California and Yuma, Arizona. From April until mid-November, Taylor Farms California processes fresh produce in their processing facilities in the Salinas area. In mid-November operations shift south to Taylor Farm’s processing plant in the Yuma area. For more information, please visit www.taylorfarmsfoodservice.com

Case Studies and

• Employee Wellness • Energy and Climate • Packaging • Pest Management • Soil Management • Waste Management • Water Management

Clients span the agri-food value chain and benefit from SureHarvest’s market-leading expertise and experience in the design, execution and verification of sustainability

SureHarvest is the pioneer in adapting business process approaches (e.g.Total Quality Management, Six Sigma, Lean, etc.) to the more variable conditions of farming, harvest logistics, and packing/shipping. Titled the 5 P’s of Sustainability™, this business process management approach is

The Greener Fields Together effort will

used as the principal strategic framework

demonstrate the commitment farmers

for creating value with our customers.

are making toward ensuring a future for food.

For more information, please visit www.sureharvest.com

For more information, please visit www.greenerfieldstogether.org

Verified Case Study: Taylor Farms’ Abbott Street Plant Energy and Climate

September, 2012

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