Ensuring Resource Efficiency: Cutback in Production Costs Though Reduction of Raw Material
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Bakery Campinense Campina Grande, Paraiba / Brazil
The bakery, Panificadora Campinense, was founded in the 1980s, in the city of Campina Grange, Paraíba, Brazil. Its main products are bread, pastries, biscuits, cakes, and other wheat-based products. During the production of bread in the rolling step, wheat flour is wasted while dusting the dough. This waste amounted to two fifty-kg sacks of flour per week. After applying the PREMA Good Housekeeping Guide, the staff members were more aware of this problem and realized the need for changes and reduction in waste generation.
During the rolling step, dough is unified to form sheets massa sovada (Portuguese sweet bread) and other special breads. At this step, the baker dusts the dough with flour, which consumes up to two sacks of flour every week.
Actions taken within the enterprise (after the application of the PREMA GHK guide)
Raising staff awareness of the need to save raw materials.
Daily preparation of flour and water to prepare bakery products, instead of doing it only every third day.
No investment, but a change in the manager’s attitude and staff awareness
Annual cost avoidance
Sack of wheat flour R$ 90.00 (₱ 37)
Waste of two sacks per week = R$ 9.360.00/year (₱ 3.858)
Waste of ½ sack per week = R$ 2.160.00/year (₱ 890)
Savings: R$ 7.200.00/year (₱ 2.967)
Pay Back Time
As staff members have become aware of the waste of wheat, practices changed to allow for the daily preparation of the needed amount of water/wheat mixture, thus reducing the amount of flour needed to only ½ a sack per week.
Environmental benefits arise through waste reduction of 3.900kg of flour per year as well as through a reduction in the use of nylon plastic sacks per year.
The space used to store the packing material was emptied and given another use. The improved procedure helped create a cleaner working environment and increased workers’ satisfaction.
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