Clif Bar’s Baking Unit, Idaho, US

Clif Bar Baking Company owns and operates the new 300,000ft² facility constructed in Twin Falls. Credit: Babcock Design Group.

The state-of-the-art Clif Bar bakery is located on a 90-acre site in Jayco Industrial Park. Credit: PRNewsFoto/Clif Bar & Company.

The new bakery produces Clif Bars and Clif Kid ZBars. Credit: Richard Thomas.

The front entrance of the bakery. Credit: Clif Bar & Company.

The front entrance of the bakery. Credit: Clif Bar & Company.

Clif Bar & Company, a nutritious and organic foods producer based in California, US, initiated the construction of its first owned and operated bakery in Twin Falls, Idaho, in March 2015.

The new state-of-the-art bakery produces two of the company’s products, including Clif Bars and Clif Kid ZBars to meet current and future demand in the market. It enables the company to bring innovative new food to market with a low environmental footprint.

The plant helps boost the local economy as it requires large amounts of organic ingredients, some of which could be supplied by local grain growers.

Construction of the bakery began in 2015 and the facility was officially opened in August 2016. The facility employs 214 people.

Location of Clif Bar’s new bakery in Idaho

The bakery was constructed at Jayco Industrial Park, which is located south of the Chobani Greek yoghurt plant in Twin Falls. The location was chosen based on the five values set by the company, namely sustainability, brand, people, community and planet.

Construction of Clif Bar baking plant in Twin Falls

Clif Bar initially announced its plans to build a state-of-the-art bakery in 2013. The Twin Falls Urban Renewal Agency (TFURA) and the Twin Falls City Council unanimously approved the development deal of the project in October 2013.

The bakery is a 300,000ft² facility, constructed on a 90-acre (36.42ha) area located by Champlin Road and Eldridge Avenue.
Construction works for the project were carried out in phases, with the first phase requiring an estimated investment of $90m. The facility is designed to accommodate future expansion with a combined capital investment potential of $160m, which will provide up to 450 full-time jobs.

The city and TFURA invest approximately $25m to improve the water, wastewater, street and transportation systems, as well as the canal and public utility systems in the area for supporting the project.

Design and features of the Clif Bar bakery

The state-of-the-art bakery features elements and landscapes inspired by the local community. It houses state-of-the-art processing and packaging equipment, a small amphitheatre for company meetings and celebrations, employee break rooms with direct access to outdoor areas, and a walking and baking trail.

It is equipped with energy-efficient systems and skylights to provide natural light throughout the plant.

Production at the new bakery in Twin Falls

The new bakery produces two of the company’s popular products, Clif Bars and Clif Kid ZBars. Two baking lines were installed during the first phase of construction.

Based on market demand, the company will incorporate additional lines to increase the plant’s capacity or to produce different products.

Clif Bar is an energy bar made of organic rolled oats and wholesome ingredients and is specially designed for athletes and adventurers requiring sustained energy.

Clif Kid ZBar is a soft-baked whole grain energy snack bar specially designed for kids, which contains a nutritious blend of carbohydrates, protein, fat and fibre to help maintain energy levels.

Contractors involved with the baking plant development

Construction and design contracts for the project were awarded to state and regional firms. Salt Lake City-based Babcock Design Group provides the building and site architecture design, while Stock Construction Management Services offer construction services.

The landscaping contract was awarded to the Land Group and engineering design was provided by DC Engineering. Twin Falls-based company EHM Engineers provided civil and structural engineering, while process engineering was provided by OES.

Sustainability features

The project is designed to be environmentally sustainable to achieve the highest possible LEED certification by focusing on reducing waste, conserving water and utilising energy-efficient systems.

A processing and packaging system installed in the plant is highly energy-efficient, which maximises output per unit of energy. The plant features the latest technology for capturing heat, which is otherwise wasted, and use the same in product manufacturing.

Smart lighting control systems maximise the use of natural light instead of electric lights, reducing energy consumption. A cool roof was installed to improve energy efficiency and reduce pollution and greenhouse gas emissions.

The outdoor spaces include landscaped areas with habitats for butterflies and bees to help improve pollination in the area. The plant implements eco-friendly operations such as waste and paper use reduction and incentives to employees for minimising their footprint.