FP 2019 Green Plant

Thank you for participating in Food Processing's Green Plant of the Year poll. Each of the nominated plants has submitted an essay to win your vote. Please read their self-descriptions below and vote for one. The winner will be profiled in our October issue.

1. Please vote for one *This question is required.

CHOBANI's state-of-the-art Twin Falls, Idaho, plant is the largest yogurt factory in the world. It's been recognized for doing more with less – less energy, less water, less waste – including being named an Idaho Power Top Ten Energy Saver in 2015. The plant boasts a reverse-osmosis system that recovers and recycles the water strained from yogurt during production and a recently upgraded LED lighting system that reduces energy intake by over 3M kWh annually.
Chobani recently unveiled an addition to the facility with their Twin Falls Innovation & Community Center. The building uses 30% less water, including 50% less water for landscaping, and 25% less energy for lighting, heating, and cooling than a typical U.S. office building. Plus, 55% of construction waste was recycled and diverted from landfills. The Center is on track for LEED Silver certification and features:
• 11,000+ square feet of “smart glass” that automatically tints based on sunlight availability
• An expansive skylight that reduces needs from the all-LED lighting system
• 30,000-square-feet of roofing material reflects sunlight and reduces heat absorption
• Recycled, environmentally-friendly materials used in construction
• Chilled beam technology to reduce energy usage.
SMITHFIELD FOODS’ Orange City, Iowa facility, which produces pet food blends and treats and has an annual production volume of over 100 million pounds, has demonstrated continued sustainability and resource conservation while increasing production by 22% since 2014. Through a series of procedures and initiatives, the facility has reduced energy usage by 12%, water usage by 31%, and greenhouse gas emissions by 29%. The facility has maintained its status as a third-party ISO 14001:2015 certified facility based on its comprehensive Environmental Management System. ISO 14001 is a distinguished certification that is considered the international gold standard for environmental management.
The facility also achieved zero-waste-to-landfill certification in 2018 through increased recycling and waste reduction by partnering with a local provider to recycle cardboard and plastic material used for packaging. Additionally, materials from the plant previously determined as waste for the landfill are now used to generate renewable energy at a waste-to-energy facility.
The facility’s sustainability efforts continuously extend into the local community with the ongoing support of the National Conservation Foundation Envirothon program, which engages students in environmental problem-solving. The facility has also made several donations to the Orange City Fire Department and Sioux County Sheriff’s Department, among other organizations.
OSI GROUP's Riverside, Calif., facility opened in 2014 to process vegetables and fresh salsa. The plant received a California Green Business Certificate in 2016, and J.D. Franklin, plant manager, was featured in a 2016 Keep America Beautiful spotlight. Initiatives include:
• Green design: Includes recycled construction materials and a high-efficiency T-8 lighting system while prioritizing natural lighting. Premium efficiency motors and variable frequency drives (VFDs) help save energy.
• Waste to landfill: Has had zero waste to landfill status since beginning operations; won a city Outstanding Waste Reduction Award in 2015.
• Ensuring water quality and conservation: Closed loop process water systems, including self-contained hand wash stations, along with a wastewater pre-treatment system and wastewater reduction plan.
• Providing optimum air quality: Highly efficient compressed air system with air dryers combats moisture, oil and particulates.
• Operations and energy efficiencies: Electricity and gas usage are closely monitored to deliver year over year efficiencies. High-efficiency boilers and hot water heating systems, along with increased insulation and optimized refrigeration systems, keep the plant running.
• Environmentally consciousness culture: Operates a ride share program for employees, encourages participation in carpools and public transportation; active in the local adopt-a-street program, and received the 2015 Riverside Chamber of Commerce Beautification Award.