Water Savings Project: Rethinking Pepper Processing

 
 
 
 

In January 2024, one of our facility teams embarked on an ambitious project to transform our chile pepper processing flow. This project aimed to enhance efficiency and sustainability, addressing the labor-intensive and water-consuming method previously used.

Historically, the process involved rinsing blanched peppers with cold water before grinding, leading to significant water usage. In 2023 alone, the plant recorded using 4,446,000 gallons of water just for this cold water rinse of the peppers.

The innovative approach introduced by the teammates on this project allowed the plant to blanch the peppers and immediately use them in the grinder and salsa cooking process, eliminating the need for cold water rinsing. This breakthrough did not compromise the flavor, texture, or food safety of the final product.

Key Achievements

  • Water Savings: In 2024, the Dahlia plant used 38% less water compared to 2023, saving approximately 4,563,000 gallons of water.

  • Cost Savings: The new process resulted in a significant savings inf water expenses in 2024 compared to the year prior.

  • Reduced Overtime: Previously, the area saw 15% overtime work for teammates. Thanks to the this water-savings project, overtime was eliminated, offering a better work-life balance for the team. A rested team works safely and makes the best food!

This project stands as a testament to the Dahlia plant's commitment to innovation and sustainability. By reimagining the production process, the plant not only achieved significant water and cost savings but also improved the working conditions for its team. This project is a shining example of how thoughtful changes can lead to impactful results, paving the way for a more sustainable future in food production.

 
 
 
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