Sustainability is not a one-and-done project, and it brings together multiple departments. While one person or team may own sustainability initiatives, everyone in the organization should be participating, much the way manufacturers approach sanitation. Yes, there’s a sanitation department, but every operator is expected to make sure their equipment is clean.

“Business should view sustainability as multi-pronged,” said Rasma Zvaners, vice president of government relations at the American Bakers Association (ABA). “For example, some of our members are setting goals that encompass sustainability more broadly. Sustainability is inextricably linked to efficiency and ROI. Regarding sustainability, some bakeries have worked to incorporate initiatives that lower waste, reduce energy and drive efficiencies that boost the bottom line while helping feed the nation.”   

The US Environmental Protection Agency (EPA) has several programs that provide commercial bakeries tools to help track and improve their energy efficiency, including energy intensity tools, best practices for reducing energy consumption and benchmarking systems. Most notable is the Energy Star program, which recognizes commercial manufacturing facilities for being in the top 25% for energy efficiency. Many baking companies already use this certification program to help improve energy consumption, including Flowers Foods and Bimbo Bakeries USA, Horsham, Pa., which the EPA recognized with the 2024 Energy Star Partner of the Year – Sustained Excellence Award. 

The EPA expanded its program with free Energy Star training for plant staff to better manage the bakery’s energy. The classes are held monthly for nine months, and participants receive certification once the course has been completed. 

“Energy Star also offers bakers assistance in energy management at no cost,” Zvaners said. “EPA has also engaged with the Department of Energy (DOE) to provide additional resources for the commercial baking sector.”

Flowers Foods has found assistance with the US DOE through the department’s Better Plants Program. The program helps manufacturers set and meet their efficiency goals. 

“Many of our bakeries participate in the DOE Better Plants Diagnostic Equipment Program to identify and analyze energy leaks and improve equipment performance,” said Margaret Ann Marsh, senior vice president, safety, sustainability and environmental, Flowers Foods, Thomasville, Ga. 

When it’s time to make changes to achieve those energy savings, Marsh said lighting and compressed air are good places to start. LED lighting makes a significant difference in not only energy costs but also lighting levels and reducing heat on the production room floor. Repairing air leaks on compressed air systems will have an immediate impact. Bakers can also go further by installing variable frequency drives, redesigning piping and air nozzles, and using air leak detection tools on these systems.  

When working on capital projects, Marsh said the company works closely with its equipment suppliers to ensure technology is as efficient as possible. The company also works with local utilities to implement energy savings whenever possible.  

While these are the first steps a baking company can take toward implementing a sustainability plan, Marsh said Flowers has started to explore more advanced processes. Heat recovery systems capture waste heat from thermal systems like the oven to be reused for other processes. Water reuse is also a possibility, though its implementation is limited.

“While opportunities to reuse water in baking processes are limited while maintaining high standards for food safety, it is possible to recirculate water for equipment that does not come into direct contact with food products, such as cooling towers and tray washers,” she explained.

The company has started exploring clean energy with a solar installation at Flowers Baking Co. of San Antonio in 2023. The bakery uses a series of photovoltaic solar arrays to reduce its dependence on fossil fuels, reduce greenhouse gas emissions and reduce strain on the power grid during times of high demand. The panels also help deflect heat from the roof to help cool the bakery during San Antonio’s sweltering summers. Marsh said the company has already seen promising results both in energy and cost savings.  

“While some of the more advanced processes and initiatives like solar and renewable energy may have a longer return on investment, the equipment also has a longer life and can support an extended payback horizon,” she said. “Additionally, these tactics can have the added benefit of making the business less vulnerable to fluctuations in energy pricing.” 

While heat recovery, water usage systems and clean energy might feel out of reach to smaller baking companies, Zvaners said these companies can get support from ABA’s Energy and Environment Professionals Group. The group helps companies stay compliant with evolving environmental regulations and offers guidance on sustainability strategies. 

“This collaborative approach allows even smaller operations to implement cost-effective solutions, reduce energy costs and boost their environmental performance,” Zvaners said. 

Collaboration is key to successfully implementing and achieving sustainability targets in a bakery or snack manufacturing facility. As these industries and their suppliers have become more sophisticated at approaching sustainability initiatives, it’s become a more integrated part of doing business. 

“Our sustainability program focuses on projects that have a positive impact on our environment while also adding value to our business,” Marsh explained. “These principles guide our strategy and minimize effects from shifting demands. We also incorporate feedback from retail customers and consumers to ensure we meet their expectations whenever possible.” 

By keeping a holistic view of the business front-and-center, baking and snack companies can keep their eyes on the prize when it comes to both sustainability and profits.

This article is an excerpt from the April 2025 issue of Baking & Snack. To read the entire feature on Sustainability, click here.