Snyder’s-Lance Sustainability “Green” Initiatives at the Hanover, PA Manufacturing Facility

Energy Sustainability is an energy/waste strategy or procedure that meet the needs of the present without compromising the ability of future generations to meet their own needs.

Here at Snyder’s-Lance Inc, we are committed to reducing our carbon footprint and waste disposal. This not only benefits the company but it benefits the community and future generations to come.

Some of the initiatives completed here at the Hanover Manufacturing Facility include: A Solar Farm which is capable of producing 3.5 MW of power Lighting projects using smart sensors, induction ballast and fluorescent fixtures Gas Meter data logging system & components Compressed Air audit by the Department of Energy and the Alabama University Waste and by product recycling projects

The sun's rays give off approximately 1,000 watts of radiant energy per square meter. The solar cells that you see on calculators and satellites also called photovoltaic (PV) cells, which as the name implies (photo meaning "light" and voltaic meaning "electricity"), convert sunlight directly into electricity. A module is a group of cells connected electrically and packaged into a frame (more commonly known as a solar panel), which can then be grouped into larger solar arrays. Photovoltaic cells are made of special materials called semiconductors such as silicon, which is currently used most commonly.

What Creates Solar EnergyWhat Creates Solar Energy

Basically, when light strikes the cell, a certain portion of it is absorbed within the semiconductor material. This means that the energy of the absorbed light is transferred to the semiconductor. The energy knocks electrons loose, allowing them to flow freely. PV cells also have one or more electric field that acts to force electrons freed by light absorption to flow in a certain direction. This flow of electrons is a current, and by placing metal contacts on the top and bottom of the PV cell, we can draw that current off for external use, say, to power a calculator. This current, together with the cell's voltage (which is a result of its built-in electric field or fields), defines the power (or wattage) that the solar cell can produce.

The power produced is in DC (direct current) form which needs to be converted to AC (alternating current) before the energy is useful.  The power is converted to AC through a device called an inverter.  From the inverter, the power is run through a piece of equipment called a drive.  The drive then connects directly into the switch gear which supplies the power for the plant from the grid.  A grid is a power circuit supplied through the local power company.  The drive is a smart device which senses current flowing across the grid.  When the drive senses no power across the grid, it cuts off all power produced from the solar farm from entering the plant or back feeding into the grid.  Current in a electrical circuit can flow in any direction as long as there is a ground or continuity.  This is why the drive must cut the power off.  When the drive kicks out, it takes 15 minutes for it to reset before producing power again from the solar farm.  If the grid is still down after the drive resets, the drive will not repower until the grid comes back online.  This means during all power loses, the plant and the corporate building will remain without power until the grid comes back online.

Solar Panel Energy ConversionSolar Panel Energy Conversion

The photoelectric effect was first noted by a French physicist, Edmund Bequerel, in 1839, who found that certain materials would produce small amounts of electric current when exposed to light. In 1905, Albert Einstein described the nature of light and the photoelectric effect on which photovoltaic technology is based, for which he later won a Nobel prize in physics. The first photovoltaic module was built by Bell Laboratories in 1954.

In the fall of 2010, Snyder’s-Lance Inc. broke ground on a 15,092 panel solar farm covering 26 acres. This is the largest ground based solar farm in the Pennsylvania. The solar farm is expected to save approximately 30% of the energy consumed by the Hanover manufacturing facility. This power generation is expected to reduce greenhouse gas emissions in excess of 230 million pounds of carbon dioxide over a 25 year span. This compares to energy consumed by 111 million miles driven by cars or more than 11 million trees would need to be planted to equal the same level of carbon dioxide reduction. As our president and COO of Snyder’s-Lance, Carl Lee stated in the ground breaking ceremony, “the solar farm shows the commitment that Snyder’s-Lance has made to creating snack products in a more sustainable way. Our goal has always been to make ‘better for you’ snacks and now they are also better for the earth as well.

3.5 MW Solar Farm3.5 MW Solar Farm

Located directly across the street from Snyder’s of Hanover manufacturing plant and corporate headquarters.

Total solar farm size: 3,546,000 watts Total number of panels: 15,092 panelsTotal power produced per year: 4,277,000 kWhTotal are of land used: approximately 28 acres including the fenceTotal time to build: 8 monthsTotal length of wires used: 82 milesTotal number of people required to complete construction: 30 peopleThe solar farm will generate approximately 30% of energy used in the Hanover, PA manufacturing plant. The plant alone spent approx. $110k per month in electric.The solar panels are designed to withstand golf ball size hail up to 90 mphThe solar panels are oriented at a 39 degree angle and facing 180 degrees south.To get power to the manufacturing plant from the solar farm, the system is set up so that DC power from the solar collectors is converted to AC power by seven large inverters. It is then transmitted to the plant’s main service on the other side of Route 116 through heavy underground cables.The solar farm is designed to operate on any available light and not just on direct sunlight, so even on cloudy or overcast days, it will still generate energy. This is the largest ground based solar system in PennsylvaniaThe Snyder’s-Lance solar project has led to increased employment throughout the Pennsylvania solar industry: RMK hired 8 people to help complete the Snyder’s-Lance project and used several sub-contractors who were previously unemployed.

Solar Farm Project OverviewSolar Farm Project Overview

The Hanover facility over the past 2 years has taken lighting to next level as technology improves and government rebates have become available. The following lighting projects have been completed or plan to be completed over the next 6 months:

Plant Lighting/Electrical Reduction Plant Lighting/Electrical Reduction InitiativesInitiatives

Demand Response Program with Hess Corporation - $30k per year savings Warehouse lighting conversion from 458W HPS to 300W fluorescent motion sensor – 50% reduction in electrical usage Plant lighting conversion from 458W HPS to 220W fluorescent motion sensor – 55% reduction in electrical usage T12 fixture conversions to T8 in office and plant – roughly a 5-10% savings Parking Lot Lighting conversion from 458W HPS to 152W induction ballast – 60% electrical usage reductionWall Pack lighting conversion from 250W HPS to 40W induction ballast – 70% electrical usage reduction

Gas Metering Data Logging Gas Metering Data Logging System for Hanover Production System for Hanover Production

EquipmentEquipmentThe Hanover, PA manufacturing facility used 316,395 MCF of natural gas in 2009. Natural gas is the largest commodity used in the production of pretzels & chips.The Hanover plant currently has 11 production lines:

(8) Pretzel ovens with cookers(3) Chip lines (Potato Chips, Tortilla Chips & Pellet Chips)

In March of 2010, each oven, cooker & heat exchanger was equipped with a gas meter. Each gas meter was tied into a PLC monitoring system which captures the data. The data is then compiled into a spreadsheet in various forms. The various forms are captured by each hour per line, 24 hrs per line and by shift per line. “Real Time” baseline data has been collected since the beginning of August 2010. The team has utilized the data by leveraging it on the daily shift end reports and analyzing the lbs/MCF per product for efficiencies. This has helped improving cost cards and scheduling products which are produced more efficiently on certain lines.

Dept of Energy Compressed Air Dept of Energy Compressed Air Assessment and Energy Assessment and Energy

SavingsSavings The Hanover, PA manufacturing facility used 22,000,000 kWh in 2008. Compressed Air is one of the most costly pieces of equipment in reference to electricity usage and is typically termed the “Fourth Utility”. The compressed air system in Hanover Facility consists of two sub systems tied together and utilizing 4 compressors at all times:

(3) compressors in the warehouse (2-125HP & 1-100HP)

(2) compressors in the caustic room (2-125HP) In April of 2009, the Hanover Plant applied to the Department of Energy for a free Compressed Air Assessment to help reduce our usage and measure a baseline for continuing improvements and cost justification. No cost was incurred by Snyder’s Lance Inc.

The three day assessment consisted of measuring every compressor load and determining the overall plant compressed air load.

It was determined that one compressor could be dropped off line and the over all manifold pressure was dropped by 10psi.

This equated to a $50k savings per year.

Hanover Plant Waste & Recycling Hanover Plant Waste & Recycling InitiativesInitiatives

The Snyder’s-Lance has realized waste is a costly by-product of manufacturing and moving forward, we must reduce our loading to landfills. Reducing our waste not only helps keeps our cost down, it also provides additional income and takes another step toward sustaining our community. Through various vendors locally, we have found ways to utilize our waste in other industries. Since the beginning of the year, the Hanover facility has generated approximately $800k in revenue from waste versus sending it to landfills. Corrugated Cardboard – Various vendors use our card board Recycled Cartons from store & co-packers – Various vendors use for retail Meal Bags – Used for storage by vendor Salt waste – used in animal feed Pretzel fines – used in other food industry products as filler Potato starch – used in animal feed Food waste – used by local farmer for animal feed Scrap Metal – recycled by local metal recycling facility Office paper – recycled locally Edible oil waste – used for various other industries