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Living Our Principles: Process
LEED Plant
In 2008, Hormel Foods broke ground on a new food processing plant in Dubuque, IA, that is designed to meet Leadership in Energy and Environmental Design certification requirements.
In July 2008, we broke ground on a new food processing facility in Dubuque, IA, that will add capacity to produce Hormel® Compleats® microwave meals and other grocery products. The plant is designed to incorporate substantial energy and water savings systems. Once construction is finished, we expect to meet Leadership in Energy and Environmental Design (LEED) certification requirements when the facility is completed. LEED is a rating system developed by the U.S. Green Building Council to promote the design and construction of high-performance green facilities.
Hormel® Compleats® are shelf-stable microwavable meals that offer convenience and value for consumers.
If the plant meets LEED certification requirements when it opens in early 2010, it will be one of the first food industry facilities to do so. To achieve this goal, our plant team is integrating the components listed below during the construction of the 39.5-acre plant campus:
- Using recycled content for the shell of the plant — precast concrete, steel and other materials. The frame alone will top 58 percent recycled content;
- Managing construction waste by using separate dumpsters for scrap wood, steel, concrete and paper-based materials;
- Installing a heat recovery system that retains heat from ammonia, air compressors, boilers and other systems. The captured heat will be routed to a holding tank and used to heat the plant’s offices and preheat water for plant washdown;
- Using a gray water system that will replace 100 percent of the water used to flush toilets. LEED typically awards credits for gray water use at 20 percent to 30 percent in the typical commercial/office application;
- Employing a low-maintenance, no-irrigation landscape across the 39.5-acre campus;
- Designating preferred parking for car-/van-poolers;
- Providing showers for bicycle commuters and all employees; and
- Installing reflective white membrane roofing and concrete paving for passive cooling and heat island effects.
Sustainability Best of the Best
We expanded our Best of the Best competition to include a sustainability category in 2008. Plants applying for this award demonstrated how their employees are working to achieve goals through special projects targeted toward decreasing the plant's impact on the environment.
To encourage innovative solutions among our plants, we expanded our Best of the Best competition in 2008 to include a sustainability category. Plants applying for this award have to demonstrate how their employees are working to achieve goals through special projects that are targeted toward decreasing the plant’s impact on the environment.
Thirty-three entries were submitted for judging. A panel of 10 judges reviewed and scored each entry to select five finalists. Each finalist team then presented for a panel of judges via an Internet-based platform. Below is a synopsis of these projects.
The Austin (MN) Plant focused on a plant-wide initiative to reduce energy and water consumption and to improve recycling. They used checklists, increased communication efforts and developed operator training. These efforts contributed to a 200,000 gallons per day water reduction, a year-over-year recycling increase of 9 percent and flat energy use despite increased year-over-year production levels.
The Diamond Crystal Brands plant in Savannah, GA
made plant-wide waste management and recycling improvements. The plant developed a relationship with a new recycler who was willing to accept additional materials, increased discussion about recycling during team meetings and created a centralized pick-up location for recyclable materials. These efforts reduced the year-over-year total for solid waste sent to the landfill by 24.5 percent.
The Jennie-O Turkey Store Barron (MN) Plant also deployed team-wide recycling and waste management improvement projects. Plant-wide communications focused on a “green energy lifestyle” and incorporate messages about increasing recycling.
The Jennie-O Turkey Store Faribault (MN) Plant used communications, feedback, audits and follow-up with employees across all divisions to generate a year-over-year water savings. The water reuse program saved more than 4 million gallons, which also reduced annual spend for energy, water treatment chemicals and sanitation labor.
Rochelle Foods in Rochelle, IL, made a comprehensive effort to reduce energy, water and solid waste. Their program focused on expanding recycling and reducing energy and water consumption. They contribute ongoing success to communications showing measurable progress resulting from each employee’s dedicated efforts.
After the judges scored each project and presentation, a Sustainability Best of the Best Champion was selected. The inaugural winner was the Austin Plant's entry.