Shearer’s Foods

Shearer’s Foods Inc. is a growing snack manufacturing company that was founded in 1974 by the Shearer family. They began by hand-making kettle chips in a 2,500 square foot facility; today Shearer’s operates in more than 1,000,000 square feet and has more than 1,800 employees across plants located throughout the United States.

Project

Bob Shearer set out on a mission to make Shearer's Foods a leading example of sustainable practices in the food manufacturing industry. To aid in this, Shearer’s contracted Worthington Energy Innovations, then Professional Supply, Inc., to develop energy models, and design and implement systems for a new state-of-the-art 45,000 square foot chip manufacturing plant in Massillon, Ohio. Worthington's engineering team developed innovative waste heat recovery recovery strategies that captured rejection heat from the chip manufacturing processes in order to substantially reduce the facility’s need to purchase energy. Worthington Energy Innovations was also instrumental in assisting Shearer's in the completion of vital documentation and system commissioning required for the pursuit of United States Green Building Council® Leadership in Environmental & Energy Design (LEED)® certification.

Results

The Shearer’s plant in Massillon became the world’s first LEED® Platinum certified food manufacturing plant.

Worthington's system design helped contribute to the use of 30% less energy per pound of product when compared to similar facilities, while minimizing the site’s carbon footprint. Following the initial success at Massillon, Worthington was brought back in to continue development of these innovative strategies for a 60,000 square foot addition to this plant, including the use of waste heat recovery to condition process water ahead of anaerobic pretreatment. Additionally, Worthington extended its expertise to the retrofit and automation of the energy systems at the Shearer's Brewster, Ohio plant.
 
Download: Shearer's LEED® Platinum fact Sheet