The Customer

Using prime ingredients and an unparalleled standard of excellence, this frozen bread manufacturer continues the traditions of quality, consistency, and good taste established by the founder over 50 years ago.


As the country's population changes, so do preferences and expectations related to food choices. A notable demographic segment is the millennial, or Gen Y (aged roughly 16 to 36), who lean toward two factors: flavor and convenience. Research has shown that they regard food as an "experience" or "expression" rather than just a source of nutrition. Companies that offer natural ingredients and multiple variations for preparation will appeal most to this influential buying group, as well as individuals of all ages looking to prepare wholesome, delicious options for in-home meals.


A well-earned reputation for excellence and consistency has created customer demand and reliance for this company's range of products. To maintain consumer trust, and ensure best practices for product fabrication, Energy Recovery Partners provided assessment, equipment installation, engineering, and project management for one of the company's primary manufacturing facilities.

The Project

Each manufacturing environment has its own, unique requirements that deserve careful attention; within a worksite that uses flour as a primary ingredient, a key consideration is the potential for combustion if the material is mishandled. The challenge was to design a system with velocity that exceeds 4,200 feet per minute to eliminate flour dust in the ductwork. Working with the company's IT team to precisely manage ongoing electrical and control configurations, ERP delivered a turnkey solution:

  • A customized system was required for six of the collection points located near mixers. Automatic blast gates, designed to shut off airflow before water was added to the other ingredients, were implemented to keep moisture from entering the ductwork. Timed sequencing that eliminates "dropping the dust" in the ductwork was also incorporated.
  • Specially designed stainless steel hoods were implemented at the remaining collection points, each requiring a specific design to service its own area.
  • The collector, complete with back blast damper, was located outside the building to ensure safety throughout the facility.
  • Plant upgrades assure compliance with National Fire Protection Association (NFPA) standards for preventing dust explosions.

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