Foremost Farms: Innovating Energy Efficiency into…

Energy Management

Efficiency & Profitability

In the competitive world of dairy production, where efficiency and innovation drive profitability, Foremost Farms is a shining example for other producers wanting to save money AND make money. The Appleton plant, one of eight Foremost Farms plants in Wisconsin, created an energy team to create ways to grow a sustainable dairy operation. In just five years, the Appleton plant now leads the charge achieving remarkable energy management milestones.

A Dedicated Energy Advisor

The Genesis of an Energy Team

Foremost Farm Appleton’s energy efficiency journey began in 2019. The facility, known for producing 127 million pounds of award-winning cheeses annually; products like mozzarella, provolone, and whey protein concentrates cater to global markets while showcasing Wisconsin's dairy excellence. Faced with limited resources and an overwhelming workload, energy conservation was not priority. However, the realization they were missing out on cost-saving opportunities fueled the decision to prioritize energy management and create the team.

Today, the energy team meets monthly and is comprised of engineers, maintenance experts, and corporate managers, alongside key collaborators like their utility, We Energies, and their Focus on Energy Advisor (EA), Kevin Kohlbeck.

Bridging Challenges with Innovation

With Kohlbeck onboard, Foremost Farms harnessed several incentive programs to tackle inefficiencies such as Prescriptive, Custom, Biogas, and Low PB offerings. Their partnership with Focus on Energy and We Energies not only unlocked financial incentives but also brought critical expertise to optimize energy-saving strategies.

Mark Mueller, Maintenance Manager at the Appleton plant, also credits the plant’s Focus on Energy Advisor Kevin Kohlbeck for his crucial role in helping Foremost Farms achieve energy management milestones.

“Kevin’s expertise in energy savings and his ability to help us apply that knowledge have been incredibly valuable. He not only helps us figure out funding for projects but also guides us through savings calculations, ensuring our efforts yield tangible benefits,” Mueller said.

Speaking about We Energies’ contribution, Mueller added, “The support we’ve received from our utility provider has been phenomenal. Their deep knowledge and practical application strategies have been instrumental in moving projects forward.”

He was equally enthusiastic about the creation of the energy team, citing their long-term impact. “Absolutely, it is a win-win situation. It saves money in the long run, pushes projects forward, and continues to pay for itself,” Mueller emphasized.

Achievements and Future Vision

The energy team's success transcends cost savings. It has reshaped how Foremost Farms perceives energy conservation. Significant projects have gained traction across other locations, driven by a corporate sustainability program inspired by the Appleton team's success. The facility achieved milestones like custom steam system upgrades and insulation enhancements, with incentives exceeding $250,000. A groundbreaking boiler project under consideration promises to propel Foremost Farms’ sustainability journey even further.

These advancements have already yielded substantial energy savings while fostering a culture of constant innovation. Employees now actively seek new energy projects, integrating conservation into their routine operations.

Foremost Farms exemplifies how industries can align operational efficiency with sustainability. Their success story proves that with the right focus and partnerships, even longstanding challenges can transform into opportunities for growth and innovation.