The Châteauguay-based cereal bar manufacturer Yourbarfactory is riding high. After several years of strong growth, it is preparing to launch a third production line, a $12 million investment.

From bar preparation in a new kitchen to its packaging, the new production line will eventually allow the company to generate $18 million per shift, explains Marie-Ève Bibeau, head of the organization. The plant will be able to operate 24/7 with the hiring of 25 employees and the addition of evening and night shifts.

Yourbarfactory manufactures bars for major local and international retailers. According to Martin Joyal, head of sustainability, the company works with Canadian businesses such as Metro Inc., Loblaws, and IGA Inc., as well as American brands like Costco and Walmart.

The company has seen its production increase by 85% since 2020. Lacking space even before launching the new line, the company purchased land behind its plant on Bélanger Street for expansion. The new building is expected to total between 50,000 and 60,000 square feet.

In addition to increasing its production, the company has invested $5 million in the automation and digitization of certain tasks. In August 2021, it automated the process of placing bars into boxes and then packing those boxes into transport crates. “That whole process was very manual and required a lot of labor. With the current labor shortage, this allows us to not only increase our production but also maintain our production capacity with fewer people,” says Ms. Bibeau.

A Green Factory

Yourbarfactory’s plant received Leadership in Energy and Environmental Design (LEED) certification in 2019.

This certification is awarded to buildings designed with a focus on water conservation, energy efficiency, the use of more sustainable materials, recycling, and indoor air quality, among other factors.

For example, the company reuses heat from its equipment to warm the plant and offices. In summer, the cold air from refrigerators replaces traditional air conditioning. This approach helps the company save significantly—it spends about $18,000 per month on heating, compared to a similar facility that might spend around $100,000, according to Mr. Joyal.

“High-tech office buildings in downtown areas are easy to make greener because you don’t have to worry about workers operating machinery in a factory,” says Mr. Joyal.

When transporting products by truck, the company uses an aluminum cover to maintain the bars at the right temperature instead of refrigerators. (Photo: Le Soleil de Châteauguay – Paula Dayan-Perez)

Other Examples?

When transporting products by truck, the company uses an aluminum cover to keep the bars at the right temperature instead of refrigerators. Additionally, food waste is sent to a company that recycles it into animal feed. The air is filtered once per hour, and windows allow natural sunlight to enter. Trees cut down for the construction of the new building will be repurposed for furniture making.