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Food For Thought – Reducing Your Energy Costs Through CHP

Combined Heat and Power (CHP) is long established within the food industry. Offsetting grid based power supply and producing hot water, steam or chilled water from a natural gas fuelled reciprocating engine has proved very cost effective.

The advantage of CHP are lower operating costs, less reliance on the electricity grid and improved sustainability in terms of carbon usage.

Over the past 3 years wholesale gas and electricity prices have declined, although both have risen in the past 4 months. However, although the wholesale electricity price has reduced, the supply price to consumers has not and has even risen, departing from the usual gas and electricity supply price following each other. The ratio between gas supply price and electricity supply price is often called the spark spread and this too has increased. A greater spark spread makes the installation of a CHP plant a more viable prospect.

The reason for the increase in electricity supply price over the wholesale price is the additional charges for the Green Energy subsidies, and the increases in power distribution costs.

Most sites have a higher electrical power demand than a heat demand which is also often more varied. However, CHP installations assess the site heat requirement to size an installation i.e. the generator is sized so that the heat supply is optimised to the heat demand. This is the most efficient way of using the energy provided in the natural gas fuel and would be counted as good quality CHP. This also maximises the installation sustainability criteria.

Cost Savings

With the increased spark spread, potentially greater cost savings could be made if the CHP is sized to the electrical power demand rather than the heat demand. The electricity pricing is where the greatest cost savings for a company can be made.

If an existing CHP is controlled to the heat demand and has extra generation capacity, then consideration should be made to increasing output (and potentially dumping heat) for greater site electrical power supply. This should especially be the case during the peak power demand times between 4pm and 7pm. This period is when the wholesale half hourly power price is the greatest and the where the majority of distribution charges are implemented.

Distribution charges are the Distribution Use of System red band (DUoS) and Transmission Use of System (TNUoS or Triad). In the last quarter of 2016 there were two half hour periods when the spot electricity price hit £1000/MWh.

Leading Supplier

Edina is a leading supplier, installer and maintenance provider for gas to power solutions, and is the sole distributor for MWM manufactured gas engines in the UK and Ireland.

With over 400MWe installed across the UK, Ireland and Australia, Edina continues to work with the food processing industry, supporting clients to reduce their energy costs, reduce carbon emissions and deliver improved business competitiveness.

If you would like to discuss the benefits and feasibility of CHP within your business, please contact Edina at info@edina.eu or visit www.edina.eu.

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Tetra Pak Announces Science Based Targets for Climate Impact Reduction

Tetra Pak has pledged that by 2030, the greenhouse gas emissions from its own operations will be at least 40% lower than in 2015. Working with the Science Based Targets initiative, the company also set a goal that by 2040, emissions will be down 58% compared with a year ago.

In doing so, Tetra Pak becomes the first company in the food packaging industry to have its climate impact reduction targets approved by the Science Based Targets (SBT) initiative.

To achieve these targets, Tetra Pak will focus on three areas:

  • Driving energy efficiency, aiming to reduce energy use by a further 12%;
  • Purchasing electricity from renewable sources, investing in renewable energy projects and renewable electricity certificate schemes;
  • Installing onsite renewable energy systems such as solar panels.

In addition, the company commits to reduce GHG emissions across the value chain by 16% per unit of revenue by 2020 from a 2010 base-year.

Mario Abreu, Vice President Environment at Tetra Pak, says: “The collaboration with the SBT initiative has helped us accurately define our greenhouse gas emission targets and set a direction for the company in a scientific way. The new targets ensure we are able to openly and accurately demonstrate the contribution we are making to a low carbon economy among customers and other stakeholders.”

Cynthia Cummis at the World Resources Institute (WRI) says: “The SBT initiative provides a science-based methodology for companies who are serious about incorporating sustainability into their business practice and want to do their part in avoiding the worst impacts from climate change. Tetra Pak is the first packaging company to complete our target review process and we are very pleased to see them join a growing number of companies that understand the benefits of transitioning towards a low-carbon economy.”

SBT is a partnership between CDP, WRI, WWF and UN Global Compact that mobilizes companies to set emissions reduction target in-line with climate science.  Since its launch in 2015, 208 companies have committed to set science-based targets and 33 companies across different industries have had their targets approved by the initiative.

For further information, see here www.tetrapak.com/sustainability

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Unilever Advances Carbon Reduction Commitment at Five UK & Ireland Sites

One year after announcing its bold ambition to become carbon positive by 2030, Unilever has taken another significant step on its renewable energy journey, with the signing of a contract to use biomethane (also known as green gas/biogas) at five of its sites in the UK and Ireland.

Unilever UK & Ireland has signed a deal with a renewable energy company GENeco, which means that from 1 January 2017, its offices in Leatherhead (Surrey) and 100 Victoria Embankment (London), and its food and drink factories in Norwich, Trafford Park and Cork, will use by 10,000 MWh of biomethane to power the sites’ heating and significantly reduce carbon emissions from the sites. With electricity already coming from certified renewable sources, the purchase of a certified supply of bioemethane means that Unilever has become carbon neutral (from energy sources) at these five sites.

The biomethane – which is fully traceable and certified – is generated by GENeco’s anaerobic digester in Avonmouth, which converts inedible food waste and sewage into energy.

This new contract supports the overarching work that Unilever has already undertaken in cutting its greenhouse gas emissions. Since the launch of the Sustainable Living Plan in 2010, the global fast moving consumer goods company has cut its manufacturing greenhouse gas footprint by 39% per tonne of production since 2008 – the equivalent of one million tonnes of CO2 per annum.

Charlotte Carroll, Sustainable Business Director, Unilever UK & Ireland, says: “In 2015, just as world leaders came together for COP 21 (the United Nations Climate Change Conference), our business committed to making our operations carbon positive by 2030. The ambitious target encouraged us to look carefully at our sites through a fresh, sustainability lens which helped to inspire our landmark agreement with GENeco.”

Charlotte Carroll continues:“With Biomethane or ‘green gas’ still in its relative infancy compared to other forms of renewable energy, this agreement marks a significant step forward in helping us source 100% renewable energy for five of our UK and Ireland sites. Recognising that this is only the start of our journey, we hope to build on this great foundation and eventually convert waste from our own operations into energy to truly support a circular economy.”

GENeco has been carbon neutral and zero waste to landfill in its operations since 2013. Biomethane generated at its Bristol site is produced from household food and sewage waste; from here it can be injected into the national gas grid to power thousands of local homes, or used as vehicle fuel.

GENeco managing director Mohammed Saddiq says: “This deal marks a significant step change in the decarbonisation of UK industry and we are very pleased to be working with Unilever to help in their aims to become carbon positive. We believe that in order for the UK to meet the 2020 targets as defined in the Renewable Energy Directive, there will need to be an increasing role for biomethane in the UK’s heat networks.”

In late November 2015, Unilever outlined its ambition to become carbon positive, eliminating fossil fuels from its operations and directly supporting the generation of more renewable energy than it consumes. Through the ambition, which is part of the Sustainable Living Plan, Unilever will:

* Source 100% of our total energy across our operations from renewable sources by 2030

* Source all electricity purchased from the grid from renewable sources by 2020

* Eliminate coal from its energy mix by 2020

* Directly support the generation of more renewable energy than the company consumes and make the surplus available to the markets and communities in which it operates.

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Edina Helps Clients Reduce Energy Costs and Carbon Emissions

Arla Foods Ltd production facility is the most environmentally friendly dairy in the world. Situated outside Aylesbury, Buckinghamshire, this ambitious £150 million project succeeded in creating their zero carbon vision with the application of Combined Heat and Power (CHP) technology.

Spread over a floor space of 6.5 hectares, this inspirational production facility produces 1billion litres of milk per annum and utilises the very best in energy saving and water recycling techniques.

Leading supplier, installer and maintenance provider for gas to power solutions, Edina, supplied two MWM TCG 2020 V20 engines capable of generating a total power output of 4MWe and 3.8MWt. The MWM engines are fuelled by a combination of natural gas mixed with biogas produced from the anaerobic digestion of some of the process waste product.

The natural gas/biogas integration system was designed and supplied by Edina and allows the generators to operate on natural gas only or natural gas with the inclusion of a proportion of biogas.

In addition, the CHP is designed to work in Island Mode Operation, in the event of a power outage at site, the CHP is configured to hold all essential loads until site power is re-established. Edina worked closely with the client to finalise a solution via their load shedding electrical infrastructure.

Commissioned in September 2013, the dairy is the most technological advanced and efficient of its kind and achieves zero waste to landfill. Arla’s ‘mega dairy’ sets a new benchmark in environmental standards on a global scale.

Edina continues to work with the food processing industry across the UK and Ireland, supporting clients to reduce their energy costs, reduce carbon emissions and deliver improved business competitiveness. The inclusion of CHP to any factory will improve sustainability criteria, save on current operating costs and protect from the known future electrical power cost rises from the electricity grid.

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Food and Drink Industry Reaps Benefit of MBR Technology

Water treatment has always been a major topic of interest for the food and beverage industry within the UK. The use of large volumes of water for various washing and cleaning regime’s means that the industry relies heavily on water treatment in order to reduce on their effluent disposal costs and in some cases recycling.

The development of modern Membrane Bio Reactor technologies (MBR) such as the Mitsubishi hollow fibre membranes allow the industry to benefit from compact, high performing treatment plants which are highly automated and easy to operate.

Modern remote access systems with data acquisition and real time monitoring allow plant operators to be in total control of their plants 24/7. MBR Installation references include a number of Branston Ltd, potato washing, packing and processing sites.

Cleaning and the packing of potatoes has a high water usage which brings with it significant economic and environmental issues. Branston needed a safe method to recycle the water rather than continuously drawing water from a borehole.

The process of recycling the wash water is complex as the water has to be purged not only of the inevitable soil content but also of the nitrogen and phosphorus within it from fertilizers and from organic contamination.

Branston announced that: “By working with several local agencies, we have successfully created a water recycling unit which, after just a few months of being up and running, is reducing our mains water usage by an incredible 52%.”

Indeed up to 90% of water at the South West site is now recycled, with any excess waste being safe to discharge off site.

With several award winning plants already supplied to the food and beverage sector MSE Systems has become a trusted partner in the supply of complete water treatment plants within the UK. For further information visit www.msesystems.co.uk.

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Pentair Haffmans Wins UK AD & Biogas Award

Pentair Haffmans has won the 2016 UK AD & Biogas Award, hosted by the Anaerobic Digestion Association (ADBA), in the category of ‘Best Process Optimisation’ for its advanced biogas upgrading technology.

Taking place on the evening of 6 July as part of this years’ UK AD & Biogas Trade Fair, the UK AD & Biogas Industry Awards showcased the very best plants, successes and people across the anaerobic digestion industry in the UK & beyond.

Ivan Williams, Pentair Haffmans Commercial Director and Haffmans Systems Business Leader, comments: ‘’On behalf of the Pentair Haffmans team we are honoured to receive this award from the AD Biogas Association, UK. We are strongly committed to our One Pentair Values of Win Right and Customer First. We highly appreciate the trust our customers continue to show in our products and services and remain dedicated to developing new, innovative and sustainable solutions for an ever changing world.’’

The judging panel recognised the positive impact that Pentair Haffmans’ technology brings to the operation of a biogas upgrading plant. Pentair Haffmans’ Advanced Plus biogas upgrading system recovers 100 per cent of the methane, which eliminates the environmentally-harmful methane slip that usually occurs with other upgrading techniques.

In addition, the CO2 by-product can be recovered and sold, providing plant operators with an additional source of income. The portion of environmentally-harmful greenhouse gases released to the atmosphere is reduced to almost zero, which makes this technology a future-proof investment.

Recently, Pentair Haffmans has extended its product range with the Compact Enclosed Skid CO2 Recovery System that can be connected to any existing biogas upgrading plant. In total, 71 entries across 17 categories were shortlisted for the award. For further information visit www.pentair.com.

CAPTION:

Pictured (left to right): Charlotte Smith, ADBA; Olaf Müller, Vice President Hygienic Process Solutions; Francois Huberts, Haffmans Sales Manager Biogas Systems; Ivan Williams, Commercial Director CO2 & Biogas Systems; Ivan Rigney, Sales Director Food & Beverage Process Solutions UK, Ireland, Russia, & Eastern Europe; Jorgen Ballermann.

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Are We Sailing into a Perfect Storm For Energy Prices?

Believe it or not, UK industry has been enjoying a two-year cheap energy holiday, with costs for 1MWh of power and gas as low as £85-£15 for some. But that mini-era is coming to an end.

Goodbye to Fair Energy Waters

Consider these facts:

  • With commodities priced in dollars, the low post-Brexit pound is already pushing up the cost of heat and power.
  • The non-commodity costs of power are rising faster than inflation, and will surpass £55/MWh for many industrial users in the next 12 months.
  • The closing gap between generation capacity and demand is driving further volatility. Prices spiked as high as £1,000/MWh in May 2016, even before Brexit.*

Indeed, most suppliers’ power price forecasts are now much worse than DECC’s last attempt in late 2014:

basepowergraphicnovember2016

Tinkering at the edges isn’t going to solve this problem and it’s not just about getting a better deal out of your supplier. Riding out the energy price storm means using less energy.

Battening Down the Energy Hatches

First, get a mixed-discipline team together.  Your engineers usually have an idea where the savings can be made, but they will need help to make the case. As a minimum, co-opt someone with commercial skills and the language and influence necessary to get investments and interventions signed off. A senior environmental person is also very useful as energy savings mean carbon savings, and that’s a good supporting story.

Second, it’s impossible to make a valid investment case without data. Collect an hourly picture of energy use for each major plant item throughout the year for the engineering team to analyse for usage and wastage, and calculate how much it will cost to put right.

When the team has identified where savings can be made and what the investment requirements are, then it can make the case for intervention.

In some cases the solution will be behavioural, such as turning off plant when production stops and optimising flow and temperature settings.  In these cases employees will need to feel that adjusting settings will not compromise normal operations. And it helps to share the benefits that savings bring – even if only with praise.

Moving on to technical solutions, there are an increasing number of ‘plug and play’ fixes that are easy to install and have well-documented paybacks. Examples include LED lighting, boiler economisers and variable speed drives. The impact of any of these in isolation is relatively small. However, demonstrating successful payback is really effective in building confidence for more ambitious interventions.

Once some of these are in place, then larger energy saving projects can be considered. Combined Heat and Power (CHP), boiler house refits or ‘de-steaming’ will save the largest sums. BasePower’s own CHP technology is proven to save between 10-20% of the cost of energy supplied; for sites using over 1MW of power this can be a sizeable six-figure sum. The larger savings serve to justify the additional complexity and the need for third party expertise to interpret vendor sales pitches.

It looks like stormy energy waters are ahead for high-energy users in narrow margin industries such as food and drink manufacturing. Ask your electricity supplier for a five-year power price projection if you doubt it. Our advice is to get the team together and start looking at your energy use data now.

For more information contact Basepower on info@basepower.com or visit www.basepower.com.

*https://www.ft.com/content/0ac7d2e4-16b9-11e6-b197-a4af20d5575e

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Irish Agri-tech Firm BHSL Secures €13 Million in UK Sales

Irish agri-tech business BHSL has agreed €13 million in sales of its pioneering manure-to-energy technology which is aimed at transforming the environmental impact of the global poultry industry. The 8 new BHSL Energy Centre units are being sold to large UK poultry farms and will all be installed by March 2017.

The patented technology will be shipped from BHSL’s plant in Ballagh, County Limerick, and represents the first fruits of an expansion strategy announced by the company’s chairman Denis Brosnan upon his appointment in October.

BHSL’s technology converts poultry manure into energy, which is then used to provide heating for future batches of chicks. BHSL’s system is the only one available that meets both US and EU environmental regulations, and allows farmers to use manure for power and heat rather than the traditional practice of transporting and spreading it on land as a fertiliser which is increasingly restricted by law due to pollution concerns.

This week BHSL also celebrated a world industry first, with technology it has installed in Maryland in the US and Norfolk in the UK producing electricity for the first time. The ability to generate electricity in addition to heat allows farmers use the power generated for other purposes on farm when there is less demand for heat in the poultry houses. Combined Heat and Power (CHP) solutions which generate electricity will also help farmers play their part in meeting the EU’s 2020 renewable energy targets

BHSL estimates that farms may be able to meet all their energy needs by using their manure as a fuel, thereby reducing costs and improving the sustainability of intensive poultry production.

BHSL has also expanded its sales team, adding 5 new employees to focus on opportunities in Poland, German and the Netherlands, in addition to existing sales and marketing initiatives in the US and UK.

BHSL recently commenced a process to raise at least €7 million in new equity to support its global expansion and open offices in the US, continental Europe and the Middle East. It expects to complete this process by the end of February.

BHSL Managing Director Declan O’Connor comments: “We are very pleased to have agreed sales of 8 new units in recent months, as we implement our commercialisation strategy, and poultry farmers become more aware of the cost savings and environmental regulatory benefits of using our technology. We are preparing for a busy period in the months ahead, with the aim to make sales in excess of €40m in the company’s next financial year.”

BHSL’s founder and Director of Research & Development Jack O’Connor says: “It was always the desire to generate electricity in addition to heat, and it is an exciting milestone to have now achieved this at sites in both the UK and US. Poultry farms have big electricity bills and there is enough manure created to provide both heat and electricity. In fact by generating electricity all the manure on a site can be utilised, completely removing the need to land spread manure which is increasingly considered a pollutant and restricted by law.”

Farmers who use BHSL’s system can benefit from:

  • Reduced environmental impact: A significant reduction in the environmental impact thereby ensuring compliance with an increasingly strict regulatory environment, both in the US and EU
  • Lower energy costs: A potential 95% reduction in energy costs through using heat from the manure as a source for heating a new batch of chicks, who must be started at a temperature of 32 degrees celsius/90 degrees Fahrenheit
  • Improved animal welfare: Improved biosecurity and animal welfare, with reduced risk of diseases
  • Improved performance: Faster growth – chicks reaching target weight 3 days quicker
  • Additional revenue: Revenue earned from the sale of excess electricity and a (non-polluting) fertiliser by-product.

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GEA Awarded Large-scale Contract For Nutritional Powders Plant in New Zealand

GEA has been awarded a contract by Mataura Valley Milk to construct a nutritional powders plant in McNab near to Gore in the south island of New Zealand. The plant will process fresh milk and ingredients into added value nutritional powders as well as standard skim milk and whole milk powders. The value of the order to GEA is a figure in the mid double-digit millions (EUR).

The new plant, expected to begin production for the 2018 season, will produce around 140 tonnes of nutritional powder per day. Included in the GEA scope is a milk reception and standardisation plant, powdered and liquid ingredients handling, batch formulation, evaporation and drying, powder handling and filling into 25kg bags. It will also feature a high degree of process automation and product traceability. Energy efficiency and environmental impact have also been a key focus in the plant design. 

Jürg Oleas.

Mataura Valley Milk is majority-owned by Chinese Animal Husbandry Group (CAHG), a Chinese company. Roughly half of the premium nutritional powder produced by the new plant will be exported to China, where Mataura Valley Milk expects steady growth in demand for this product. 

“This contract, which was long-awaited to win by GEA, serves as further proof of our technological leadership and strong market position in the field of dairy processing,” explains Jürg Oleas, CEO of GEA Group Aktiengesellschaft. “It also demonstrates the continuing investment appetite of our customers as they attempt to satisfy the growing consumer demand on the Chinese market for milk-based infant formula and other high-quality milk products – and that in an environment impacted by regulatory changes. Although the challenging economic conditions mean that GEA’s order intake in the fourth quarter of 2016 will not repeat the record level achieved in the same quarter of the previous year, we are confident that customers throughout the world will continue to invest in our process technologies and place major orders for all product areas and applications.”

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Do Food Retailers Hold the Key to Small Scale AD Success?

The move towards sustainable food retailing shows no sign of slowing down, with consumers more aware of environmental issues than ever before. Research from Globescan revealed that 92 per cent of shoppers think food companies should focus their efforts on securing the future sustainability of food, with two-thirds believing that farmers should be paid more for their produce. As more food retailers start to reap the benefits of marketing lower carbon products, will they now put their money where their mouth is and support the supply chain in developing new anaerobic digestion (AD) infrastructure?

“The vast majority of the UK’s 200 on-farm AD plants have been built with Feed-in Tariff support,” says Charlotte Morton, Chief Executive of the Anaerobic Digestion and Bioresources Association (ADBA). “With that incentive heavily reduced and constrained, we are now looking at how we build the next 200. As many retailers enjoy the ‘green halo’ that comes from marketing low carbon products, is it now time for incentive cuts to be compensated by the support of supermarkets and large food retailers?”

The role that retailers can play in the future of AD is just one of the topics on the agenda at the ADBA National Conference 2016, taking place at One Great George Street, Westminster on 8 December. Now in its eighth year, the 2016 event will bring together industry, academia and policy makers to assess how the UK’s changing relationship with the world and the priorities of a new government can create future opportunities. Key speakers include Matthew Bell (Committee on Climate Change), Rt Hon Caroline Flint MP, Richard Court (National Grid), Chris Huhne (Former Secretary of State for Energy and Climate), Alison Fergusson (Ofwat), Iain Gulland (Zero Waste Scotland) and David Newman (President, World Biogas Association).

Taking a lead on food waste

Another keynote speaker at the ADBA National Conference is WRAP’s Dr Richard Swannell, who will present on the current global food waste challenge and how food waste recycling and AD can help reduce food waste. “The UN Sustainable Development Goal 12.3 sets out a clear challenge to tackle food waste. The aim is to halve per capita global food waste at the retail and consumer levels, and reduce food losses along production and supply chains. There is a strong case to reduce food waste and to increase separate collection and recycling around the world, not only for the benefit of the environment but also consumers, food producers and the AD industry. My talk will consider how the world might manage food waste more successfully, looking at the scale of the challenge ahead of us and also the size of the prize for the sector.”

adindustry2november2016Global AD industry set to reach $1trn and deliver green energy more cheaply than coal

The rewards to be had are great – with its current value set at $19.5bn, significant improvements in AD efficiency and plant operation, through advances in R&I currently being discussed, will see the global biogas industry growing exponentially and producing green energy more cheaply than coal. At the same time AD will be playing a critical role in addressing some of the world’s most imminent and critical challenges, including climate change, waste recycling, wastewater treatment and sanitation, and food and energy security.

According to Charlotte Morton, the UK’s strong research and development base – in partnership with its mature and robust operational sector which comprises over 540 AD plants – means the UK is well placed to take a leading role in the global AD revolution: “Improving the AD process – for example, by looking at ways to match the digestion efficiency being achieved in nature – is just one area of focus for our world-leading academic researchers. With a return to a more supportive policy environment, this could start to deliver the industry’s huge potential around the world. The UK has a golden opportunity to be a global leader in what has the potential to become a $1 trillion biogas industry, exporting expertise and equipment worth billions of pounds, and creating tens of thousands of jobs to replace those being lost in the fossil fuel industries.”

The scale of the opportunity will be a key topic at the ADBA National Conference, which will also cover why England is still lagging behind Scotland, Northern Ireland and Wales in regard to separate food waste collections; where green gas fits in the UK’s energy strategy; how water sector deregulation is changing organic waste markets; and how the biomethane sector will develop between 2017-2021.

For the full programme and to book your place, go to adbioresources.org.

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Tetra Pak Launches New Water-free Lubrication Kit

Tetra Pak has expanded its Technical Services portfolio with the launch of a dry lubrication kit for packaging line conveyor belts and distribution equipment.  The new solution helps customers cut water and electricity consumption, and reduce the man-hours required for machine maintenance.

Traditional conveyor lubrication, known as wet lubrication, uses high quantities of water mixed with oil, leaving both the equipment and factory floor wet. With the new solution, the process is nearly dry. It does not require the use of water but just very small quantities of oil. A drop of food grade oil roughly the size of a pea (80mm3) is directly added to the conveyor belt to reduce its friction with the package.

Tetra Pak dry lubrication kit.

Tetra Pak dry lubrication kit.

Unlike wet lubrication, which uses tens of thousands of litres of water, dry lubrication offers producers a number of advantages, including:

  1. An improved environmental footprint, saving an average of 35,000 litres of water per filling line each year and reduced electricity costs;
  2. A fully automated system that ensures precision;
  3. A 75% reduction in man-hours requested in maintenance; and
  4. Improved health and safety for staff on the operation floor.

Klara Svedberg, Director of Parts, Consumables and Upgrades at Tetra Pak, says: “We are pleased to offer a much more efficient lubrication solution to our customers, helping them to improve operational performance and reduce costs. With an estimated 50% reduction in running costs compared to wet lubrication, the benefits of switching to dry lubrication systems speak for themselves.”

The Tetra Pak Dry Lubrication kit includes the application systems, lubricant and installation. It takes approximately five minutes to install, thereby ensuring minimal disruption to operations.

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Biogas Solves UK’s £64 Million Food Waste Headache This Christmas

No food company deliberately creates unnecessary waste. However, the volume of food waste created over the festive period is typically 30 per cent higher than the rest of the year. Finding a cost-effective, speedy and green way of treating this additional waste can be a headache for food firms at their busiest time of year. Fortunately, there is a solution.

Anaerobic digestion (AD) is an increasingly popular food waste treatment option turning waste into renewable energy – biogas. The last seven years have seen an unprecedented growth in the number of AD plants throughout the UK, rising from less than 50 in 2009 to 381 today (excluding the water sector). A fifth of these plants (79) process food waste, turning this valuable resource into renewable energy and biofertiliser (digestate).

In December, it is estimated that 230,000 tonnes of additional food waste is generated in the UK. If this extra waste was sent to AD, it would create 124 MWe of energy – enough to power 220,000 homes throughout December, or a city the size of Southampton.

The Price of Food Waste

While the priority for food businesses should always be food waste prevention and minimisation, the increased complexity and uncertainty around Christmas ordering and production schedules means that an increase in food waste at this time of year is inevitable. Each Christmas, two million turkeys, 11 million potatoes, 17 million sprouts, 12 million carrots and 7.5 million mince pies are wasted, as shopping habits change and consumption rises. The cost of this additional festive food waste to the UK economy is an eye-watering £64 million per year. But not only does this increase in food waste impact on food firms’ profit margins, there is also an environmental price to pay – leaving food waste to rot in landfill causes the release of methane into the atmosphere, a gas with 25 times the global warming potential of carbon dioxide.

Sending food waste to an anaerobic digestion plant (also knows as an AD plant or biogas plant) significantly lowers greenhouse gas emissions compared to landfill and incineration. A naturally occurring process of decomposition whereby organic material including crops, farm and food waste is broken down, anaerobic digestion is a waste treatment option that is quickly becoming a favourite of food manufacturers, producers and retailers. And it’s not solely down to the associated ‘green halo’ that comes from doing the right thing for the environment; today’s modern AD plants are also a flexible, cost-effective and hassle-free way to treat waste food.

Last Christmas North London-based Willen Biogas turned thousands of tonnes of mince pies into biogas.

Last Christmas North London-based Willen Biogas turned thousands of tonnes of mince pies into biogas.

No Room at the (B)inn

As waste volumes increase during the festive period, waste hauliers’ capacity fills up fast. Food companies can suddenly find themselves faced with a mountain of surplus Christmas food waste that their usual waste carrier is unable to take – or will only treat for a vastly inflated fee. No company wants its waste hanging around for longer than is absolutely necessary, and some sites also have the additional issue of waste permits, which may prohibit them from keeping their waste on site for any length of time. Food firms should plan ahead for an alternative place to send their additional Christmas food waste and seek out their local AD plant.

Headache Gone – Waste Collected Within 24 hours

Last Christmas, food businesses based in London, Essex, Hertfordshire, Bedfordshire and Cambridgeshire sent thousands of tonnes of mince pies, sprouts and turkeys to London-based AD plant Willen Biogas. “We helped a number of local food companies with their last-minute Christmas waste problems, arranging collection, transport, depackaging and treatment of their food waste at short notice,” says Willen Biogas Chairman, Adrian Williams. “Our cost-competitive waste treatment options can be used for one-off loads or we are happy to discuss longer term contracts depending on our client’s requirements.”

Located just off junction 25 of the M25, the state-of-the-art, modern 1.5 MW AD plant processes around 60,000 tonnes of food waste every day – and has capacity to handle any local Christmas surplus. Fitted with sophisticated front-end depackaging equipment, it can handle all types of food waste, including packaged, (with the exception of palletised loads) and accepts deliveries with as little as 24 hours’ notice.

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Emmi Commits Itself to Sustainability

Sustainability and in particular environmental protection have been key issues for Swiss milk processor Emmi for over 20 years. Now, the company is going a significant step further by setting itself specific objectives in four important sustainability-related areas. These objectives have been defined in communication with various stakeholders, including WWF Switzerland. The environmental protection organisation will also continue to support Emmi in implementing and cultivating its sustainability commitment as a critical and demanding partner in future.

Emmi’s sustainability commitments are as follows:

Reduce CO2 emissions by 25 % by 2020 (compared to 2014, in relation to the quantity of processed milk)

To reduce its CO2 emissions, Emmi will continue to lower its energy consumption as well as opting for more sustainable energy sources.

EmmiHintergrundbildProcess milk from sustainable production

To achieve this, all of Emmi’s Swiss milk suppliers will have to meet a catalogue of sustainability criteria by 2020. Particular importance in this regard will be given to the conditions in which the dairy cows are kept – most notably access to open pasture and feed – in the belief that milk production based on roughage is ecologically sensible and conducive to animal welfare. Switzerland provides a solid platform for achieving this natural and economical form of milk production. In return, Emmi is also committed to paying its Swiss milk suppliers an above-average price.

Reduce food and packaging waste by 20 % by 2020

Emmi will achieve this by generating less waste of packaging and raw materials in production and looking for ways to reintegrate waste into the materials cycle. Emmi will also contribute to reducing the food waste of its customers and consumers.

EmmiYogurtpureInvest in the development of employees

Emmi’s aim is for every single one of its 5,750 employees to have personal development objectives. This will not only contribute to employee satisfaction, but is also designed as a tool for combating skills shortages. By 2020, Emmi therefore aims to be in a position to fill half of its vacancies with internal candidates.

By setting itself these objectives, Emmi aims to develop in areas that are particularly important to sustainability. In addition, it will support flagship projects in each of the four focus areas that it considers to be particularly pioneering or exemplary from a sustainability perspective and that could influence the further development of its own sustainability commitment.

Emmi will publish an up-to-date review and initial measures to achieve its sustainability commitments in its Sustainability Report (to be released in summer 2017).

True sustainability is a competitive advantage

Competitive pressure among milk processors has steadily risen in recent years. Emmi’s goal in this competitive environment is clear: to position itself as a provider of innovative, high-quality products. An integral part of this positioning is a credible, ambitious commitment to sustainability.

Urs Riedener, chief executive of Emmi.

Urs Riedener, chief executive of Emmi.

According to Urs Riedener, CEO of the Emmi Group: “Consumers are increasingly demanding true commitment from companies. However, they also reward this commitment with their loyalty. In this respect, Emmi’s ambitious sustainability efforts are an important prerequisite for future business success.”

After reporting extensively on numerous sustainability aspects throughout its entire value chain in recent years, Emmi is now going a decisive step further by committing itself with respect to the public and wider society to highly specific objectives in four particularly relevant areas.

WWF as a sparring partner

The commitments in these four focus areas were developed over several months in close communication with various stakeholders. Emmi’s main aim in doing so was to compile a range of expectations that it could then evaluate internally in terms of feasibility.

A particularly valuable partner in this process proved to be WWF Switzerland, which supported Emmi with valuable know-how related to climate protection and agriculture as well as carrying out a critical review of Emmi’s business activities. The WWF also demands that its partner companies set ambitious goals in their commitment to sustainability. To achieve these goals, Emmi will require the continued support of external specialists. The partnership with WWF Switzerland that was recently approved by the Emmi Board of Directors will ensure the company can count on this support. In return, Emmi is committed to maintaining openness and transparency with regard to its sustainability commitment.

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Emmi Switches to 100% Renewable Hydroelectricity From BKW

Emmi has committed to reducing its CO2 emissions by 25 % by 2020. In an important step towards meeting this objective, the largest Swiss milk processor is switching to sustainable electricity. To this end, it is set to rely entirely on renewable energy and on BKW as its partner. BKW will supply Emmi with around 110 gigawatt hours of hydroelectricity a year – enough to meet the needs of all Emmi facilities in Switzerland.

As part of its commitment to sustainability, Emmi has decided to rely entirely on hydroelectricity for all of its 36 facilities in Switzerland, enabling the largest Swiss milk processor to reduce its annual CO2 emissions by 14000 tonnes.

BKW was already supplying several Emmi locations with electricity. Based on the positive experiences, as well as its know-how and extensive offering, Emmi has now opted for a full supply from BKW. From 2017, BKW is set to supply all Emmi production sites in Switzerland with around 110 gigawatt hours of electricity each year for a period of three years.

Max Peter, Head of Retail and Supply Chain Management Switzerland at Emmi, says: “With its innovative and flexible procurement model, BKW will enable us to optimally satisfy our electricity requirements as well as take an important step towards meeting our CO2 reduction targets.” Christoph Matter, Head of Sales at BKW, adds: “We are delighted to be able to supply an important customer in Emmi with sustainable hydroelectricity throughout Switzerland.”

Other services that Emmi will be able to benefit from besides the supply of electricity include the BKW Club. Comprising a wealth of information – from the latest analyses of load profile valuations on the stock exchange to the monitoring of defined limits – this online tool provides compact assistance for the energy industry and is available to all of BKW’s major customers.

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Scotch Whisky Industry Renews Commitment to Sustainability

A commitment to environmental sustainability lies at the heart of the Scotch Whisky industry which has now unveiled even more ambitious green targets, from responsible water use to cutting greenhouse gas emissions. The Scotch Whisky Environmental Strategy – first launched in 2009 and the only one of its kind covering an entire Scottish industry – has been refreshed to broaden its remit to reflect an evolving world and changing business operations.

The Scotch Whisky Association (SWA), which manages the strategy for the industry, says it recognises the need for a thriving natural environment. Scotch whisky is made from three raw materials – water, cereals and yeast – and the industry has a responsibility to minimise its use of natural resources and its impact on the environment.

The refreshed strategy has four themes with voluntary targets to be met by the industry by 2020 and 2050:

* Reducing energy use and greenhouse gas emissions. By 2050 some 80% of primary energy will come from non-fossil fuels, such as anaerobic digestion and solar power. In 2008 this figure was 3% and increased to 17% by 2014.

* Responsible water use. Distilling water efficiency will improve by 10% by 2020. This target is based on companies optimising efficient water use at their production sites.

* Embracing a ‘circular economy’ in the industry supply chain. The aim will be to use resources for as long as possible, extracting maximum value from them and recovering and regenerating materials. For example, by 2020 no general waste will go to landfill, compared with 13% in 2008, and product packaging will be 100% recyclable.

* Sustainable land use. The goal is to ensure a secure supply of high-quality raw materials, namely cereals and wood. This includes encouraging the use of wood sourced from sustainable oak forests to manufacture new casks.

Julie Hesketh-Laird, Scotch Whisky Association deputy chief executive, says: “The refresh of the Scotch Whisky Industry Environmental Strategy is a clear sign of bold industry intentions on sustainability. Sound environmental management is an industry priority and goes hand in hand with business growth. Our strategy is collective, building on the work of individual Scotch whisky producers. And strong support from governments and our supply chains will be needed to help deliver on our ambitions. The strategy remains the only one in Scotland covering an entire industry. It sets out challenging voluntary goals that will protect the natural environment for generations to come.”

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Lucozade Ribena Suntory Targets Energy Savings with Wonderware

Lucozade Ribena Suntory, one of the leading soft drinks businesses in the UK and Ireland, has partnered with Human Machine Interface (HMI) leaders Wonderware UK & Ireland, to monitor and improve its energy performance. Formed in 2014, Lucozade Ribena Suntory is part of Suntory Beverage & Food Europe. The company’s UK site is a 53 acre facility based in Coleford, Gloucestershire, where it produces Lucozade Energy, Lucozade Sport, Lucozade Zero and Ribena. The factory produces over 1.2 billion bottles of drink each year.

Lucozade Ribena Suntory has partnered with Wonderware UK & Ireland as part of the company’s goal to reduce its factory’s energy consumption by 5% year-on-year. In order to make reductions the company required a complete breakdown of site energy usage, so looked for an expert driven energy management solution. Lucozade Ribena Suntory’s mission is to reduce its impact on the environment and work in harmony with people and nature. The partnership with Wonderware will help the company understand its energy consumption in more detail, supporting the business in achieving this goal.

The company has now implemented Wonderware System Platform, which can be attached to Lucozade Ribena Suntory’s individually metered systems to convert the raw energy data into actionable information, allowing LRS to better understand its energy consumption patterns and costs and to identify potential inefficiencies.

lucozaderibenaukplant2compressedBuilt like an operating system for industrial applications, Wonderware System Platform provides configuration, deployment, communication, security, data connectivity and is capable of connecting to hundreds of field devices and plant systems.

Lucozade Ribena Suntory is also using Wonderware’s Operational Intelligence Software dashboards to raise awareness of energy consumption and promote behavioural change. The real-time feedback and live usage data on the dashboards will allow team members to see how their individual actions can have an impact on energy use across the site. This focus on employee behaviour change has already worked for Lucozade Ribena Suntory in the field of health and safety. The company recently announced 365 days without Lost Time Accidents, mainly as a result of individuals taking ownership of health and safety on-site.

Gary Burford, Energy and Sustainability Manager at LRS, says: “Energy management is a continuous improvement activity and we’ve already undertaken in excess of 26 energy saving projects in the last four years.  To make further improvements, we need to understand where we are using energy across the site and improve the visibility and accessibility of that information to allow us to make changes.”

He adds: “We believe the graphical interfaces and real-time data offered by the Wonderware solutions will engage our people, giving them an immediate awareness of their impact on energy usage and empowering them to make the small changes that can, over time, deliver big results.”

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Coca-Cola HBC Italia Cuts Carbon Footprint With ENER-G Trigeneration Technology

Coca-Cola HBC Italia will reduce its carbon footprint by 15% and save 40% on its energy costs after installing an ENER-G combined cooling, heat and power (CCHP) system. The ENER-G CCHP (trigeneration) technology is providing 40% of Coca-Cola HBC Italia’s energy needs at its Marcianise production facility in Campania, southern Italy (www.coca-colahellenic.it) .

The 1280 kWe decentralised energy system is supplying hot water, steam, cooling and electricity to provide 60% of the site’s power demand, 80% of its cooling and almost all of its steam requirements.

This is dramatically reducing Coca-Cola HBC Italia’s reliance on energy supplied from the grid and will achieve annual carbon dioxide savings of 1,343 tons, which is equivalent to the carbon that would be offset by a  1,271 acre forest.

ENER-G designed, installed and commissioned the containerised natural gas CHP system utilising a high efficiency MTU engine. The system is connected to a 500kW absorption chiller and a recovery boiler for the production of steam. It has a thermal capacity of 715 kWth.

The CCHP system produces hot water, steam and chilled water for use in the production and bottling process. This is distributed to the production area and bottling lines via a network of pipes, designed and built by ENER-G.

The high efficiency plant is expected to produce around 7,500 MWh of electricity per year and to operate 6,500 hours per year.

Christian Stella, Managing Director of ENER-G Italia, said: “We are very pleased to collaborate with  Coca-Cola HBC Italia, which is a global sustainability leader. Beverage producers require large amounts of energy for applications such as process cooling, sterilisation of bottles and for cleaning installations. Proper management of energy use through the installation of a cogeneration plant is one of the most forward-looking investments in this field, with numerous benefits in terms of increased plant efficiency, lower energy costs, reduced CO2 emissions and fast turnaround times.”

Coca-Cola HBC Italia is part of the Coca-Cola Hellenic Group and produces famous brands such as Coca-Cola, Fanta, Sprite and Nestea at its Marcianise production facility.

CHP technology converts gas into both electricity and heat in a single process at the point of use. The low carbon process works by generating electricity on-site and recovering the majority of the heat created in the process, in contrast to conventional power stations where heat is wasted into the atmosphere through power station cooling towers.  Distribution losses are also avoided since energy generation takes place on-site.

ENER-G, which is headquartered in the UK and has its Italian operation in Milan, has over 30 years’ experience and a strong track record in delivering end-to-end CHP solutions for industrial and commercial customers, and has around 1,400 units totalling over 500MW under contract.

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Nestlé Waters Helps Swiss Farmers to Fuel Their Crops and its Factory

A joint project between Nestlé Waters and Groupe E Greenwatt to build Switzerland’s largest biogas plant has focused on producing renewable energy while supporting Swiss farmers. Manure is burned in the biogas facility, which powers the nearby Henniez water bottling site, reducing the plant’s CO2 emissions by 30%.

The project begins and ends with the network of local farmers. In return for their cows’ manure, they receive a highly sought after fertiliser which is organic and nutrient dense – the final product of the fermentation process in the biogas plant. The farmers then reuse it on their crops, saving money as they need to purchase less fertiliser. This exchange is cost neutral and helps create sustainable farming business as they recover valuable nutrients that would be otherwise lost.

The premium fertiliser produced by the biogas plant is easily absorbed by plants, and produces fewer ammonia emissions for the environment.

Nestlé Waters financed feasibility studies and sought partners in 2009, examining possible causes of damage to the Henniez water source. With the collaboration of Groupe E Greenwatt, a facility to produce renewable energy was built next to the bottling plant. The electricity generated from burning the manure, along with coffee waste from local Nespresso and Nescafé factories is sold to the Swiss grid. The heat from the plant powers the Henniez facility, reducing CO2 emissions by 50%.

Supporting sustainable agriculture in this eco project is good for the farmers, the environment, and Nestlé Waters. Henniez’s Sustainability Manger Michel Marcuard says: “It wasn’t easy in the beginning. We had to win the farmers’ trust and convince them that we weren’t going to harm their livelihoods. But now it’s a great partnership – a win-win.”

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Cider Waste Blending Key to Bio-energy Tankering Contract Success

Lanes Group plc has won a three-year contract with fast-expanding beverage manufacturer Bevisol to take away drinks production effluent for anaerobic digestion. It is making daily tanker collections of 150 cubic metres of waste water created during cider production at the Bevisol plant in Ledbury, Herefordshire. Bevisol has an agreement with Severn Trent Water to send its production effluent to the water company’s anaerobic digestion plants.

Under an agreement with the utilities company, the main destination for the drinks effluent is Severn Trent Water’s new anaerobic digestion unit at Netheridge sewage treatment works near Gloucester.

However, Bevisol has developed a method for blending effluent so it has the right chemical and biological balance to be treated at Severn Trent Water’s other anaerobic digestion plants, if necessary.

Bevisol Projects Manager Tim Powell says: “Because we can guarantee that our effluent has the right pre-treatment balance for whichever plant it is going to, Severn Trent Water’s costs are minimised, so our disposal fees are reduced as well. Lanes Group’s tankering service is the third element in a supply chain that has benefits for all concerned, which is an ideal situation.”

Bevisol invited Lanes Group to take part in a competitive tendering exercise to transport the effluent because Lanes already provides a tankering service for Severn Trent Water, managed from its utilities hub in Stafford.

Lanes Group’s Severn Trent Water Contract Manager Roland Leslie says: “We are delighted to be supporting Bevisol in this way. We have a dedicated driver making up to five journeys a day in a 30,000 litre tanker to service Bevisol’s requirements. Our close working relationship with Severn Trent Water means we can provide Bevisol with all the support it needs to ensure their production effluent is managed effectively.”

Lanes Group expects to transport 40,000 cubic metres of cider effluent a year for Bevisol. The drinks company develops and manufactures a range of alcoholic drinks and related products for the beverage industry.

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English Brewery Reduces Energy Cost Per Litre By More Than 80%

Babcock Wanson’s TPC 400B Thermal Fluid Heater has been installed into Freedom Brewery’s Abbots Bromley site in Staffordshire as part of its Wort Boiler system.  Together with many other updates to the process, this has resulted in reducing the overall energy costs per litre brewed by more than 80%.

The UK’s original craft lager brewer, Freedom Brewery is dedicated to creating the highest-quality award winning lager in the most sustainable way possible.  The company has undertaken a number of steps as part of its commitment to reducing its environmental impact, including moving from steam to thermal fluid heating.

Whilst thermal fluid heaters are used extensively in many industries, the brewery sector has traditionally used steam as the heating method of choice.  With the upsurge of micro breweries, this is slowly changing as, unlike steam boilers, thermal fluid heating systems are compact, easy to use and offer substantial savings in total energy and maintenance costs.

The TPC 400B is a fully automatic coil type, multi-pass thermal fluid heater complete with integrated burner, control system and safety devices.  It provides optimal distribution of the heat, high fluid velocity in the exchange tubes and continuous flow monitoring to ensure long thermal fluid and system life and the highest level of safety.

At Freedom Brewery the thermal fluid circulates through the external Wort Boiler which, due to the use of thermal fluid, does not require rating as a pressure vessel.  Once at temperature, the wort thermosyphons through the heat exchanger without the need to use a copper casting pump thereby ensuring very simple operation and further reducing site electrical costs.  A very precise heat transfer to the process is achieved through an integrated control system to enable Freedom to achieve the quality it is has become renown for whilst also reducing overall fuel costs.

Commenting on their decision to move away from steam, Andrew Taylor, Director at Freedom Brewery, says: “We chose thermal fluid because it was more cost-effective to install and run, has a smaller space requirement than steam and provides a greener solution.”

Since being installed, Andrew is extremely pleased with the TPC 400B Thermal Fluid Heater’s performance: “the heater has performed in excess of expectations. It is compact, much faster to bring into operation than a steam boiler and, because it does not use steam as the heat transfer medium, is much cheaper as there is no water treatment and no condensate return.”

But for Andrew ultimately the reduction in energy costs have really been the most outstanding factor: “Our energy costs per litre brewed are now a sixth than they were before!”  That’s partly because the system precisely matches fuel input to plant energy requirements for highest practicable operating efficiency.  With lower energy input demand also comes lower total exhaust emissions – another environmental benefit for Freedom Brewery.  Substantial savings are readily achieved; Babcock Wanson claim between 20-50% energy savings can be made by using a TPC B thermal fluid heating system when compared to the transfer of the same amount of heat using traditional steam boilers.

Using thermal fluid as opposed to water has other key benefits including removing the problems caused by scaling if water treatment malfunctions or freezing due to low ambient temperatures, as well as improved safety.

Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs, from steam boilers, thermal fluid heaters, rapid steam generators and hot water boilers to VOC and odour treatment by thermal oxidation, water treatment or process air heating solutions.  The company aims to help optimise customer’s energy production with high quality products and efficient service. For more information, contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk.

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Irish Agri-Tech Firm BHSL Enters US Market with $3 Million Poultry Pilot Project

Irish agri-tech business BHSL has agreed a $3 million pilot project with the State of Maryland to trial its pioneering manure-to-energy technology which is aimed at transforming the environmental impact of the global poultry industry.

The patented BHSL Energy Centre to be used in the project was recently shipped from BHSL’s plant in Ballagh, County Limerick and will be fully operational by October. The State of Maryland has provided $1 million funding to support this pilot project, with the balance of the $3 million investment funded by BHSL.

BHSL’s technology converts poultry manure into energy, which is then used to provide heating for future batches of chicks, or sold back into the electricity grid. BHSL’s system is the only one available that meets both US and EU environmental regulations, and has over 110,000 operational hours on UK farms

Maryland is one of six states in the US that surround Chesapeake Bay, where, after decades of intensive agriculture, many fields are overloaded with phosphorus. Over 1 billion chickens are produced in the region each year (12% of total US production), resulting in the production of an estimated 1.2 million tonnes of manure, which is contributing pollutants that flow into the Bay, causing severe environmental problems including algal bloom and damage to fish  and shellfish stocks.

With 11,000 commercial poultry farms in the US producing 7.5 billion chickens each year, BHSL is targeting the US as a key export market.  BHSL’s system is already fully operational on 2 UK farms with further installations anticipated in 2016. The company is already building a very strong sales pipeline for product delivery in 2017 in other export markets such as New Zealand, Poland, Germany, Holland, Italy and Saudi Arabia.

Declan O’Connor, Chief Executive of BHSL, comments: “The potential size of the US market opportunity for BHSL is conservatively estimated at over $500 million. In the Chesapeake Bay region alone over 1bn chickens are reared each year and state governments are increasingly aware of the environmental challenges the poultry manure by-product poses for the Bay and the water sources that flow into it. Our unique solution can both reduce costs and increase revenue for the farmers while solving the environmental challenge they face. We are very excited about the potential to grow our sales in the US following the State of Maryland demonstration.”

Ann Swanson, Executive Director of the Chesapeake Bay Commission, says: “BHSL’s solution has the potential to play a very significant role in reducing levels of pollution in the Bay. We have been looking for options to address the Bay’s environmental challenges while supporting the farm community.   If it works, it will be one of those win-win situations, with a financial benefit to the farmer and a positive environmental impact. I hope that the pilot project is successful so that other farmers are encouraged to do the same.”

Jack O’Connor, founder and brother of CEO Declan, is BHSL’s Chief Technology Officer who designed the patent-protected system. Jack O’Connor says: “Ten years ago our family poultry farm in Limerick was on the verge of closure as it couldn’t operate within strict new EU regulations on ground water pollution. That gave me the idea to develop this miniature fluidised bed technology which has now been tried and tested, with over 110,000 hours of successful operation on farms in Ireland and the UK. BHSL is now aggressively ramping up its sales operations and we see a major global opportunity to export our product and add jobs to our team of 28 who already work in the business.”

BHSL’s system works by collecting poultry litter left behind on a chicken house’s floor, which is then burned in a heated layer of sand suspended over jets of air in a process called fluidised bed combustion or FBC. The process creates the energy that heats the chicken houses and any excess energy can be sold as electricity back to the power grid. The main by-product is an ash that can be sold as fertilizer that is non-polluting and only 8% of the volume of the original material used, making it cost effective to transport to grain-growing areas outside of the Chesapeake Bay watershed.

Based on farmer Bob Murphy’s 112 acre farm in Rhodesdale, Maryland, the impact of the BHSL system will be closely monitored by researchers from the Universities of Maryland and Georgia to ensure all findings are verified by an independent third party.

Murphy’s farm produces 3,650 tons of manure annually which historically has been trucked to other farms for use as fertiliser, but that is not a long-term solution as other farms, like Murphy’s, will soon have soil phosphorus concentrations that exceed agreed limits. The pilot project is supported by Mountaire, which is the poultry company Bob Murphy’s farm grows chickens for, and is the 7th largest chicken producer in the US, selling over 330 million birds each year.

CAPTION:

Jack (left) and Declan O’Connor.

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A ‘Smart Factory’ For Nestlé Vera Naturae

A new state-of-the art bottling plant for Nestlé Vera Naturae mineral water has been opened in Castrocielo in Italy. The factory, built at a cost of over SFr17 million (€16 million), is a flagship for Nestlé Waters in environmental sustainability and energy consumption. It offers ‘best in class’ performance, especially in water consumption and energy savings.

While all energy used in the plant is derived exclusively from renewable sources, the new bottling plant also uses photovoltaic systems, LED lights, and heat recovery and retention systems, thereby ensuring the entire site is carbon neutral throughout.

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Heineken Ireland’s Brewery Marks 160 Years in Ireland

HEINEKEN Ireland, a leading beer and cider company, has published its sustainability report for 2015, demonstrating that sustainability is embedded throughout the business and is a key growth driver. HEINEKEN Ireland is on a ten year sustainability journey through its ‘Brewing a Better World’ programme. Launched in 2010, this programme sets ambitious sustainability targets for the Irish business to achieve by 2020.

Maggie Timoney, managing director of HEINEKEN Ireland, comments: “Our company is built on a brewing heritage that began in Cork 160 years ago and we are very proud to celebrate this important anniversary. Our Brewing a Better World programme is core to our overall company strategy and sustainable business for the future. We combine a love for our craft, a passion for quality and a commitment to the responsible consumption of our products to ensure we will be around for another 160 years. I am pleased that we are well on our way to achieving our 10 year sustainability targets.”

Half way through its 10 year sustainability programme, HEINEKEN Ireland has made solid progress, outlined in the company’s 2015 annual update:

* HEINEKEN Ireland supports 1,000 local suppliers, multiple service providers and injects €100m into the economy;

* The Lady’s Well Brewery in Cork brews 100% of the draught beer sold in the Irish market and 100% of the malted barley used comes from over 750 local farmers;

* HEINEKEN Ireland’s water consumption of 3.1 hectolitres per hectolitre of beer is one of the most efficient usage rates within the HEINEKEN global network;

* CO2 emissions in production have decreased by 10% since 2010;

* 100% of HEINEKEN’s fridges are ‘green’ resulting in an improvement of energy efficiency of 45%;

* 10% of Heineken® media spend is invested to make moderate consumption aspirational;

* In 2015, HEINEKEN Ireland worked with over 50 community groups.

Maggie Timoney concludes: “It is imperative for us to continue to focus on reaching and exceeding our environmental targets but it’s also important to highlight that sustainability at HEINEKEN Ireland means much more than this. We are committed to supporting our local communities, our employees, our customers and our industry. Having a sustainable business that has a positive impact on the society in which we operate remains our ultimate goal.”

CAPTION:

Pictured at the launch of HEINEKEN Ireland’s 2015 sustainability report ‘Brewing a Better World’ are: Lord Mayor of Cork Chris O’Leary; Maggie Timoney, managing director of Heineken Ireland; and David Stanton TD.

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Groupe Lactalis and BasePower Enter Combined Heat and Power Agreement

Groupe Lactalis, the global leader in cheese and the second largest dairy company worldwide, has made a commitment to significantly lowering energy costs and CO2 emissions in an energy partnership with CHP developer BasePower. Lactalis has signed a Power Purchase Agreement for the installation of a Combined Heat and Power (CHP) system at The Caledonian Cheese Company in Stranraer, Scotland, whose brands include Seriously Strong Cheddar, McLelland Mature Cheddar and Galloway Scottish Cheddar, as well as several private label brands for leading UK food retailers.

BasePower, who will develop and build a fully containerised CHP system on The Caledonian Cheese Company manufacturing site, has financed the Power Purchase Agreement. BasePower will oversee the scheme’s operation, which is projected to generate 77% of all the site’s electricity consumption, supply 24% of heat usage and save at least 2,000 tons of CO2 per year. With construction already under way the project is targeted to be operational by December 2016.

Mark Taylor (pictured), Group Managing Director of Lactalis McLelland, says: “In the face of increased competition and uncertain investment in UK energy infrastructure, we are delighted to be partnering with BasePower on this projectwhich underscores our commitment to keep Lactalis at the forefront of cost competiveness and environmental performance.”

George Fowkes, Director of BasePower, comments: “This project at The Caledonian Cheese Company site is a perfect example of how energy-intensive industries like food and beverage manufacturing can really exploit on-site power generation to deliver energy cost savings. We are looking forward to working with Lactalis on their next stage of development as Scotland’s most innovative dairy manufacturer.”

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Swiss Cows Help Henniez to Produce Green Energy

Nestlé Waters has opened Switzerland’s largest agricultural biogas production facility. The Valbroye plant will provide renewable energy for the nearby Henniez bottled water plant and the Swiss power grid, as well as natural fertiliser for local farms.

The facility will generate enough green electricity to power more than 1,000 households annually.

27 local farms will provide 25,000 tonnes of manure per year to the biogas plant, thereby reducing CO2 emissions by 1,750 tonnes per year.

The plant will also recycle and reuse coffee grounds from Nescafé and Nespresso production sites in Switzerland.

Using the electricity generated, the Henniez plant will increase its overall use of renewable energy to more than 50 percent.

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Tetra Pak Commits to 100% Renewable Electricity by 2030

Tetra Pak has joined RE100, committing to increase its use of renewable electricity from 20% today to 100% across all global operations by 2030. The announcement was made at the recent Clean Energy Ministerial forum in San Francisco, US.

Charles Brand, Executive Vice President, Product Management and Commercial Operations at Tetra Pak, said: “Signing up to RE100 reflects our on-going commitment to minimising our climate impact and increasing our use of renewable resources. We have set an ambitious target to ensure carbon emissions across our value chain are capped at 2010 levels through to 2020, and we are making excellent progress. In 2015 emissions were down 15% from the 2010 baseline, despite a 16% increase in production.”

He added: “Since setting our climate goal we have maximized our efforts to reduce energy consumption; committing to a renewable electricity target is a natural next step. By joining RE100 we will benefit from expert guidance and peer-to-peer learning on renewable electricity options in different markets.”

Mark Kenber, CEO of The Climate Group, said at the forum: “The demand push from corporates is as important as supportive government policy – bold action by businesses, cities and governments sends a strong market signal and means we can hold global warming below two degrees far more quickly. The Clean Energy Ministerial is shining the spotlight on RE100 as a model of best practice in galvanizing the switch to renewable energy, and the leadership of influential companies – such as Tetra Pak, which is joining RE100 today – shows the business case for 100% renewables is as strong as ever.”

RE100 is a global, collaborative business initiative led by The Climate Group in partnership with CDP to drive demand for, and delivery of, renewable power.

Tetra Pak’s decision to join RE100 once again underscores its commitment to tackle climate change, and comes just six months after the company joined the Paris Pledge for Action at COP21.

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Another Green Milestone For Muntons

Following the unveiling of its £5.4 million anaerobic digestion plant in 2015, Stowmarket-based Muntons has further improved its environmental credentials by achieving zero waste to landfill. Muntons is a leading global player in the supply of malts, malt extracts, flours and flakes and many other malted ingredients relevant to the food and drinks industry exporting around half of its production. In addition Muntons also manufactures an extensive range of beer, wine and cider making kits, which are also sold globally.

As of May 2016 Muntons has now managed to divert 100% of its non-hazardous waste away from landfill – all waste is recycled or recovered.

Last year Muntons reported that just 29kg of its waste went to landfill. A feat in itself achieved by either treating, reusing, recycling or recovering over 99.999% of the non-hazardous waste generated on site.

The zero landfill figure this year was achieved using a number of tactics – initially by trying not to create waste in the first place. Where this was unavoidable, the wastes being sent to landfill were clearly identified and alternative ways sought to recycle or recover these using physical and biological processes.

Manufacturing and Sustainability Director Dr Nigel Davies comments: “We have worked hard over the past decade to reduce year on year the levels of total waste produced and waste disposed of via landfill. We are proud to announce a figure of zero to landfill which we feel is an achievement worth publicising, however we also believe there is more that can be done and in the coming years we will strive to get even more value out of waste streams.”

He continues: “We are keen to further demonstrate our commitment to the circular economy and show that sustainability can bring in revenue and offset other cost for our business, our environment and society.”

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Powering Mars UK With Wind

The energy it takes to make MARS® bars, WHISKAS® cat food, EXTRA® gum and UNCLE BEN’S® rice in the UK is now provided by a new wind farm in Moy, Scotland. Through a partnership with Eneco UK, the 20-turbine wind farm, located just south of Inverness in the Scottish Highlands, will generate electricity equivalent to what powers all 12 Mars UK sites solely with renewable energy.

This means Mars Incorporated is one step closer to decreasing its dependency on fossil fuels and reducing harmful greenhouse gas emissions that contribute to climate change. Mars achieved its goal of reducing greenhouse gas emissions from its operations by 25% in 2015, and continues to work towards eliminating them entirely.

Barry Parkin, Chief Sustainability and Health & Wellbeing Officer at Mars, comments: “The UK has been home to Mars for 84 years. We’re proud the brands that we make here will now be manufactured using renewable electricity, and that we are reducing our carbon footprint in the UK and around the world. As with our wind farm in Lamesa, Texas, Moy will contribute significantly to our effort to eliminate fossil fuel energy use and greenhouse gas emissions from our global operations by 2040 as part of our ‘Sustainable in a Generation’ program. The Moy Wind Farm is part of our innovative and long-term approach to achieving our goal to be a successful and sustainable business for generations to come.”

With a capacity of 60 MW and an annual output of over 125,000 megawatt-hours, the wind farm will supply renewable electricity to UK sites that produce Mars’ brands. The power generated is equal to 34,000 average UK households.

CAPTION:

New Moy wind farm in Scotland will power the equivalent of all Mars UK factories and offices.

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The Energy Crisis is a Powerful Opportunity For UK & Ireland Businesses

The energy landscape is fundamentally changing. As more renewable energy sources come online, our power infrastructure needs more ‘flexibility’. For the electricity grid operators in the UK and Eire, this means they need to find new ways to balance energy demands. Demand side response is the answer.

The National Grid in the UK and EirGrid in Ireland have a long-term vision for a smarter and more flexible energy infrastructure. Endeco Technologies provide the answer. Endeco Technologies work in partnership with the grid operators to deliver a unique technology-led solution that enables widespread participation in demand side response schemes.

Virtual Power Plant

This vision is delivered by Endeco Technologies’ ‘Virtual Power Plant’, which enables customers to join together to balance the electricity grid and reap lucrative financial rewards in return. This not only contributes to a more sustainable energy system, it presents new opportunities for energy intensive companies to participate in the grid balancing schemes.

Unlocking Powerful, Long-term Revenues

These schemes, operated by the National Grid and EirGrid offer multi-layered benefits for participating companies. For grid operators, adding stability to the system reduces the need for coal and gas fired reserves to be ready to supply power at short notice.

For the end-user, Endeco Technologies unlock powerful, long-term, recurring revenue streams from these mechanisms to provide a generous income from the Grid; the ability to avoid price peaks; plus the cost-benefits of load flexibility when renewable sources are available.

No Risks and No Impact

Endeco Technologies’ unique technology platform connects energy intensive assets and automatically adjusts power consumption in real-time to balance the Grid. All of this is achieved without risk or impact on customer operations.

What’s more the technology is designed to deliver a seamless transition between new revenue schemes launched by the grid operators.

Trusted and Proven

Endeco Technologies have successfully deployed their award-winning technology at over 200 sites in the UK and Ireland. Customers, who include many companies in the food sector such as the Brady Family in Ireland and Brakes Group in UK, can testify to the benefits of participation. These schemes can help to boost competitiveness, improve sustainability and make a significant contribution to the bottom line.

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Glenmorangie Appoints Aquabio to Design and Build New Wastewater Treatment Plant

As part of its major programme of environmental improvement, The Glenmorangie Company has nominated water treatment specialist Aquabio, to design and build the core technology package for a new wastewater treatment plant at Glenmorangie Distillery at Tain, Ross-Shire in Scotland.

The Anaerobic Digestion Plant uses natural biological processes to both reduce output in distillery waste water by up-to 95 per cent, and create energy in the form of methane rich biogas. The biogas will replace some of the fossil fuels currently used at the distillery to heat the stills in which the spirit is made. The Plant will also improve the standard of wastewater discharge. United Utilities have been appointed as overall main contactor for the construction phase and have appointed Aquabio to provide the remaining mechanical and electrical work on the project.

The low energy Anaerobic Membrane Bioreactor Plant (AnMBR LE™ ) has been designed to improve the quality of the effluent being discharged to the Dornoch Firth to help meet corporate requirements in addition to providing the site with biogas which will be reused as fuel within the site boiler system.

“Our experience and track record in successfully delivering industrial wastewater process projects was a key factor in the company’s decision to award us this prestigious contract,” says Steve Goodwin, Managing Director of Aquabio. “Glenmorangie is a global name and Aquabio and our group company Freudenberg are very excited and proud to be involved with such a premium brand.”

Construction work has started with the plant due to be fully operational in early autumn this year.

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Green Energy From First Milk Cheese

Clearfleau, a leading British provider of on-site treatment solutions for the food and beverage sector, is commissioning its most complex plant to date, which will feed bio-methane into the gas grid in rural Cumbria. The plant has been designed and built for Lake District Biogas, which will operate the site for twenty years taking feedstock from dairy co-operative First Milk’s Aspatria creamery site. This comprises low-strength wash waters such as process rinses, supplemented by whey permeate (cheese production residue after protein extraction for use in energy supplements). This is pumped to the AD plant from the creamery.

By feeding the bio-methane into the gas grid, the facility will produce over £3 million per annum in cost savings and revenue, while supplying up to 25% of the creamery’s energy requirements.

This is the first on-site Anaerobic Digestion (AD) plant in the dairy industry in Europe to feed bio-methane to the gas grid, generated exclusively by digesting its cheese making residues. When the plant is operating at full capacity later this Spring, it will treat 1,650 cu m per day of process effluent and whey and generate around 5MW of thermal energy.

It will produce 1000 cu m of biogas per hour, of which over 80% will be upgraded for injection into the national grid. At least 60% of the bio-methane will be used in the creamery for steam generation, with the balance being used by local businesses and households in Aspatria.

Revenue benefits include 20-year index-linked, Government-backed incentive payments, with about £2 million per annum in support through the Government’s RHI scheme and a further £1 million through the sale of gas to the wholesale market and from the Feed in Tariff scheme for the power generated in the CHP engine.

The new plant, with its state-of-the-art British technology, will take over from the outdated aerobic plant. This will have saved First Milk from having to upgrade the old inefficient plant, reducing their effluent treatment costs and carbon footprint, while cutting operational costs, which are borne by Lake District Biogas. Additional benefits from the deployment of on-site digestion in the dairy processing sector include reduced energy and off-site disposal costs.

Clearfleau1May2016CompressedClearfleau’s unique process takes the feedstock from the Aspatria creamery site, comprising low-strength wash waters such as process rinses, supplemented by whey permeate (cheese production residue after extracting protein used in energy supplements).  The liquid is then pumped into the AD plant from the creamery where the bugs convert the fats and sugars in the feedstock into biogas.

This is stored in the gas dome before being upgraded to bio-methane – 80% of the biogas is fed to a membrane based upgrade unit that removes carbon di-oxide from the gas to produce bio-methane with a comparable thermal value to North Sea gas (some biogas is also fed to a CHP unit to provide power to run the treatment plant).

 

Gordon Archer, Chairman of Lake District Biogas, says: “Completion of this £10 million project on time, given the weather conditions in Cumbria this winter, has been a major achievement for the project team and Clearfleau.  This is the largest AD plant on a dairy processing site in Europe dedicated to handling the residual materials from the cheese making process and we look forward to working with Clearfleau on future projects.”

Craig Chapman CEO of Clearfleau, says: “Dairy processors can generate value from their residues with a better return on investment than for other more conventional treatment and disposal options.  This project, generating biogas solely from creamery residues is based on British engineering and is transforming the way in which the dairy industry manages its residues.  This shows how sustainability can be an integral part of our food supply chain.  We are looking at other dairy projects as more companies realise the energy potential of their residues.”

As an initial step, Clearfleau refurbished the existing aerobic plant to enable First Milk to significantly reduce levels of phosphate in their effluent, which is discharged to the River Ellen.  Supported by the Environment Agency, this will ensure an early delivery of new tighter discharge standards, which are required by the Water Framework Directive.

Clearfleau’s on-site AD technology is proven to reduce the chemical oxygen demand (COD) of the production residues by at least 95%.  Aerobic polishing will then remove residual COD and nutrients (nitrates and phosphates) to allow safe river discharge.

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Byworth Receives a Queen’s Award For Enterprise

Byworth Boilers has been named a winner of the Queen’s Award for Enterprise in Innovation. The UK’s highest accolade for business success, the award was received in recognition of Unity, Byworth’s revolutionary boiler house control system. The first of its kind on the market, Unity has achieved outstanding results in its respective field of innovation.

The prestigious awards are made annually by HM The Queen, and are only given for the highest levels of excellence demonstrated in each category. They are judged following a rigorous and highly competitive entry process.

Byworth2May2016Rewriting the Rules

Byworth was seeking an innovative product to solve the problem in the market. Unity was first touted as an idea in 2007 to the existing controls’ manufacturers; but after years of getting nowhere trying to persuade them to take on the development, Byworth felt so strongly that the industry was missing the key technological advancement, it appointed its own team to develop the idea into the finished product. After a two-year development plan, Unity was born.

Encourage and Nurture Innovation

Numerous departments at Byworth have had and continue to have a role in its development contributing to its success. Unity as a physical entity is not merely enough, without the pioneering capabilities from the people ‘on the ground’ it would not sustain its competitive edge.
How has Unity Changed the Industry?

Byworth1May2016The innovative product controls and manages a boiler house as one entity rather than relying on various third party control systems; creating a considerably more efficient and configurable boiler house for the customer.

Data is accessible from the cloud; enabling plant managers to optimise the relationship between boiler and process by understanding when large peaks and troughs are happening.

The intelligent use of data allows site managers and operators to react more quickly to plant conditions, reducing the number of start-stop cycles, fuel and water usage.

Essentially, having better control makes the customers’ plant safer and more efficient, as well as reducing emissions.

For further information visit www.byworth.co.uk.

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Dawn Meats is Double Winner at Green Awards

Dawn Meats, which has operations in seven locations around Ireland, and many more across the UK and Europe, has been awarded in two categories at the prestigious Green Awards 2016, an annual event at which the cream of Ireland’s green industry is recognised. The Waterford-based meat processor was awarded ‘Green Large Organisation of the Year’ and the ‘Sustainable Supply Chain Achievement Award’.

Niall Browne, Dawn Meats CEO comments: “We are delighted to have won these two prestigious awards. They recognise the combined efforts of hundreds of people from Dawn Meats over many years who work towards our company goal of being Europe’s most sustainable meat company. Dawn Meats has set itself demanding 2020 targets to reduce water and energy intensity by 40% and emission intensity by 50%. It is particularly rewarding to receive the sustainable supply chain achievement award after our many years of working collaboratively with our primary farmer suppliers and our customers.”

Dawn Meats has actively promoted initiatives over several years to engage with farmers, research organisations and other interested stakeholders in supporting sustainable agriculture. The company established a demonstration suckler beef farm in 2015 at Newford, Athenry. The Newford farm aims to share best practice in grassland management, breeding, animal health and welfare which will support environmentally and commercially sustainable beef production. Dawn Meats will host an open day on the 25th of May at Newford Farm and all interested parties are welcome. For more information, visit http://www.newfordsucklerbeef.ie/.

Still family-owned, Dawn Meats was established in 1980 and has grown to a business with over €1 billion in annual revenue, employing 3,300 staff in eight countries. Supplying a range of leading super market, food service and restaurant businesses, Dawn Meats exports to over 40 countries. The company has forged close relationships with 15,000 Irish farmers from whom it directly sources grass-fed cattle and lamb for processing at its seven Irish plants.

CAPTION:

Dawn Meats has been awarded in two categories at the prestigious Green Awards 2016. Pictured at the awards are (left to right): Tom Hyland, Dawn Meats; David O’Flynn, Group Corporate Social Responsibility Manager, Dawn Meats; and Padraig Ryan, Group Sustainability Manager, Ornua.

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Sidel Helps Nestlé Waters Achieve Worldwide Energy Savings

As the result of a worldwide energy-saving programme, Sidel has supported Nestlé Waters in achieving reductions in its energy consumption at production sites in countries around the globe. Consequently, the world’s leading producer of bottled water has achieved energy savings equivalent to the consumption of more than 20 ovens, representing savings of more than Eur1 million a year.

Nestlé Waters first undertook the conservation programme in 2010 when it challenged its long-term supplier, Sidel, to rationalise the energy consumption of all its production equipment. With over 96 production facilities situated in 35 producing countries around the world, Nestlé Waters naturally places a high priority on improving the environmental performance of its processes, as well as keeping its operating costs to an absolute minimum.

Sidel, the leading provider of production equipment and services for liquids in PET, has worked with Nestlé Waters for over 50 years. The companies recently celebrated this landmark milestone in their lengthy collaboration. This relationship has resulted in many important and significant developments within the beverage industry.

Focus on Blow Moulders

Both companies were already well aware that blow moulding machines generally account for as much as 70% of the total energy consumption of a complete beverage bottling line. When charged with reviewing the efficiency of the company’s electrical energy usage, Sidel started by carrying out a pilot Eco audit on two of Nestlé Waters’ blow moulders.

NestleWatersLogoMay2016After monitoring and measuring the electrical consumption of the blowers, Sidel identified corrective energy-saving measures to Nestlé Waters. One such recommendation was the installation of oven-top reflector lamps to maintain energy in the ovens of the blow moulding machines. This achieved a reduction in the electrical power consumption required for the preform heating process equivalent to turning off 20 preform ovens. Despite this significant energy saving, optimal performance is maintained.

Nestlé Waters was particularly pleased with results attained by the recommendations when they were implemented. “As we achieved around 20% in energy savings, we were really satisfied with the performance resulting from the upgrades to the first two blowers,” explains Stephane Bosshart, Corporate Chief Engineer at Nestlé Waters. “So much so, that based on these results, we decided to apply a full Eco-programme to share those best practices on all of our blowers worldwide.”

Global Deployment

In close collaboration with Sidel, the energy conservation programme was deployed in all Nestlé Waters’ plants worldwide. Local Sidel Services™ teams planned and supplied all the necessary resources for the different interventions at sites in over 30 countries. They also provided technical support for the project. By the end of 2015, nearly 130 Sidel blow moulding machines were successfully converted with the oven-top reflector lamps. All of them will have given a return on investment (ROI) of between six and 24 months.

“The upgrades of oven-top reflector lamps have achieved real improvements,” comments Eric Baronnet of Nestlé Waters. “For example, they have delivered a reduction in the use of blower energy in US plants of up to 25%.” Advances such as those achieved in the US all contribute to an annual saving of over Eur1 million in Nestlé Waters’ plants worldwide.

Sustainable Approach

Both Nestlé Waters and Sidel are fully committed to achieving outstanding energy savings and contributing to improvements in the environmental performance of products. Working on a continuous sustainability improvement plan, Sidel classifies its production lines according to energy consumption. The company also analyses the reasons for potential waste of energy within the whole blow moulding machine, including the oven, the compressor and the chiller. With Nestlé Waters, Sidel has again collaborated to develop an energy-saving simulator in order to rate the blowers in terms of consumption and to enable solutions to optimise performance.

Part of the Tetra Laval group, Sidel has offices worldwide, including eight production sites and eight training centres.

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IPN-QuadCore – Delivering Enhanced Fire and Thermal Performance From Insulated Panels

Once upon a time, strong environmental ratings for a building were considered nice-to-haves – the preserve of clients with big budgets and architects with significant design responsibility. However, advances in environmentally-friendly building technology, coupled with a strong business case for sustainability, have effected a market shift that is pushing the environment up the agenda like never before.

Even discounting the impact of tightening building and energy regulations, the increasing prevalence of building assessment methodology ratings in the property market has been enough to drive this change.

BREEAM and LEED Accreditation

Interestingly, more and more stakeholders view BREEAM and LEED accreditation as fundamental attributes for their buildings, as vital indeed as location, floor space and construction cost. The traditional view has been that these certifications increased the kerb appeal of premises – helping to seal the deal when all the other boxes were ticked. But increasingly, the market is recognising the financial gains associated with enhanced thermal performance and sustainably constructed buildings.

So how will the industry respond to the market’s desire for better buildings? First, we need to define a truly environmentally-friendly building. Broadly speaking, it is one that will have a minimal impact on its surrounding environment and contribute positively to the wider world.

To achieve this goal the environmentally friendly building should reduce energy consumption to a minimum, be constructed using products that mitigate environmental impact with a low carbon footprint, that will perform for the duration of a building’s desired life, and finally, that can be readily recycled when the building has finished it functional life.

KingspanFebruary2016

New Technology

Kingspan’s new high performance insulated panel meets all of these needs, by utilising revolutionary new hydrid IPN-QuadCore technology. IPN Quadcore delivers industry-leading thermal performance, delivering significantly reduced energy consumption. While its superior fire protection and unique structural and thermal performance guarantee ensure it will perform as-built for 40 years. Finally, the unique microcell technology developed by Kingspan Insulated Panels ensures the manufacturing process is as efficient as possible, and every IPN-QuadCore panel can be fully recycled at end-of-life to ensure no building waste ends up in landfill.

All of this not only means that IPN-QuadCore adds six valuable BREEAM points to a building, it also potentially adds value, with a recent University of Maastricht study showing the cumulative impact on rental yields of environmentally-friendly buildings1. This results in better buildings that work harder for owners and tenants, and a better environment for everyone.

1 Supply, Demand and the Value of Green Buildings, Chegut et al, http://usj.sagepub.com/content/51/1/22.abstract.

Please contact Kingspan to discover how IPN-QuadCore technology can enhance the environmental performance of your project – Tel 00353 42 96 98500, E-mail aidan.doyle@kingspan.com or visit www.ipn-quadcore.co.uk.

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ENERGY MANAGEMENT – Tangerine Confectionery – A Customer’s Perspective

Tangerine Confectionery is a leading UK independent manufacturer of sugar confectionery and branded popcorn. The reasons behind their success include commitment to excellence, innovation, product quality, dedication to the customer and a determination to protect and promote traditional skills in UK manufacturing.

Rob Overton, Engineering Manager at Tangerine Confectionery, explains: “We were increasing our capacity of the factory which meant building some new stoves to cure the product. The boiler we had was from 1925 and had in the past only been working  single shifts, whereas now it was going to be working 24hours a day. It was going to cost money whatever we did so we thought now’s the time to get a new boiler for the extra capacity we needed and have something we could leave unattended for long periods.”

Rob, while researching possible suppliers found that: “Other manufacturers don’t necessarily do all the manufacture in this country – particularly the shell, the most critical part of the entire boiler. I wanted everything from a well-regulated country like Britain.”

Byworth1January2016The Benefits and Beyond

One of the real benefits Rob has already identified was the automatic closing of valves, and linking the extensive scheduling options to what their stoves are doing over the weekend (when he doesn’t have many people in the factory and the steam demand profile is different). Rob can envisage opportunities in the future whereby the stoves could tell the boiler when to start.

Unity, while significantly ahead of its competitors, remains in continual development. With each Unity customer, Byworth gains new insight into how they can develop the platform further, adding yet more value to the end-user.

Service – A Long-term Support

Unity’s remote accessibility options add a whole new dimension to service support. The shift from a largely mechanical system to a fully digital system offering a wealth of new information could be daunting but with remote access, Byworth’s engineers can see exactly what the site personnel are seeing and offer much more meaningful phone support.

Byworth2January2016The year-round remote monitoring means that Byworth are aware of problems at the same time as the engineers on-site, and with the trending of data there has actually been a couple of occasions that Byworth have been able to give advice that avoided significant down-time.

Rob Overton makes the point that with Unity, it is much more likely that we can foresee the events that would lead to a problem and stop it before the problem transpires.

Technological Advantages

Unity can be used on multiple devices to ensure optimum operation and visibility of your process.

Rob Overton is logged into Unity via his smartphone: “It means that if something’s happening over the weekend or if there’s a few people in the factory, I can just look at it to see what it’s doing and when there is a problem I receive an email alert.”

Unity can be connected remotely either by LAN, WAN or via a 3G M2M connection. Machine to machine (M2M) devices exchange information and perform actions without manual intervention as an integral part of the ‘Internet of Things.’

Byworth4January2016Summary

Unity offers unprecedented levels of visibility and fingertip control of every aspect of boiler house technology. It supports the rapid development and worldwide adoption of the Internet of Things as well as the continued growth of M2M technology offering a more meaningful service visit through:

* A –  predictive maintenance and

* B – pre-accessing problems as they develop – Thus, avoiding costly unplanned downtime or abnormal running conditions.

From a central user interface, a built-in touch screen, or remotely via PC, tablet or smartphone, Unity operators can view processed boiler house data and trends relating to numerous boiler and ancillary values.

All alarms and tests conducted are logged and can be exported to a network printer if required; whilst a straightforward ‘traffic light’ warning system keeps users up-to-date with any changes in plant conditions and draws focus to areas requiring attention or adjustment.

This comprehensive, ‘joined up’ approach to the management of multiple processes gives Unity its unique advantage over other control systems, which typically employ third party applications to control each aspect of the boiler house.

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Solar Boost For Northern Ireland Food Producer

Armagh-based food producer Linwoods, which employs almost 300 people and is known for its premium bakery products, fresh dairy and health foods, has invested in 200 rooftop solar panels as part of a significant £2 million development of its site. Linwoods has appointed Kingspan Energy to install a new 50kW solar PV system which will create savings of £355,000 for the company over the next 25 years.

Mel Courtney, General Manager of Kingspan Energy, says: “Solar PV energy is a growing resource in Northern Ireland’s renewable energy sector.   It is helping companies like Linwood’s make significant long term savings in its energy bills and operate in a much more environmentally friendly way, generating electricity in different energy conditions and climates including overcast days as well as sunny ones.

“Linwoods’ PV system offers a financial return of almost £15,000 annually and £355,000 over the 25 years, generating 872,000kWh of green electricity as well as offsetting 453 tonnes of CO2.  A PV system works by converting daylight into electricity. It is the only cost-effective and widely used renewable technology that guarantees the on-site production of green electricity and it can be fitted on a new building or as part of a refurbishment project.”

John Woods, Managing Director of Linwoods, says:  “Our business is strongly focused on innovation, development and growth. Therefore, it is important that we look at all aspects of continuous improvement.  The Solar PV installation not only generates a financial return in reducing our energy costs but is an excellent way of reducing CO2 emissions. Of course we are delighted to be in a position to use proven new technology to help us to manage energy costs, but the benefits to the environment are not to be under-estimated.  We value our rural location in the heart of ‘Orchard County’ and we are eager to demonstrate our respect for this beautiful corner of Ireland by being environmentally aware and responsible.”

Established 50 years ago, family run company has grown into a multi-million pound manufacturing and distribution business, with an extensive and developing international customer base. Linwoods has recently invested in new, state of the art technology, re-designed packaging and an extended product range for the bakery division reinforcing the company’s commitment to meeting consumers’ changing needs, and keeping the family-owned business ahead in the dairy, bakery and health foods sectors.

CAPTION:

John Woods, (left) Managing Director and Patrick Woods, Sales & Marketing Director, Linwoods are pictured with Mel Courtney, General Manager, UK and Ireland, Kingspan Energy Ltd with a sample of one of the 200 rooftop solar panels which is being installed as part of a £2million development at the companies Armagh site.

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Tougher Food Recycling Targets in Scotland

Thousands of organisations in Scotland are being urged to act on new regulations to tackle food waste which came into effect on 1 January. Premises where food is prepared, sold or consumed, from hotels to hospitals, will have to separate any waste greater than 5kg per week for recycling or face a fine up to £10,000.

As well as restaurants, cafes and pubs, the rules are likely to apply to any shops that serve food. Nursing homes, hospitals and colleges or schools with canteens will also be affected. However, organisations can avoid the costs of sending their waste for recycling by treating it on-site using a range of portable technologies that are able to process the waste to generate heat, steam or even electricity or that can create valuable by-products, such as compost.

For sites where it may not be economical or practical to recover value from food waste, there are innovative technologies available to collect it or reduce volumes by up to 90%, both of which can help cut expensive removal charges.

Currently, many organisations dispose of waste through the sewerage system, sometimes using macerators to help the process. This will largely become illegal under the regulations which were passed by the Scottish Parliament in 2012. Under the provisions, waste contractors must provide high quality collection and treatment services to enable businesses to keep to the new rules.

Ian Hewson, Commercial Development Manager at Business Stream, which is part of Scottish Water, says: “Finding efficient and affordable alternatives to the sewerage system for food disposal is a big challenge for some of our clients. That’s why we’ve been looking at other options for helping them to treat the waste on-site, which will enable them to comply with the legislation, avoid recycling costs and even benefit from usable by-products as we move into 2016. We’re working with specialist suppliers to provide a wide range of support options that will help businesses and other organisations to make the necessary changes and we would encourage those that will be impacted by the legislation to get in touch with us.”

The new regulations are aimed at helping to achieve the Scottish Government’s long-term targets of recycling 70% of all Scotland’s waste and only 5% of remaining waste ending up in landfill by 2025.

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Danone and Veolia Form Global Alliance on Climate Change

Food group and beverage giant Danone and Veolia, the global resource management group, have announced an innovative strategic partnership focusing on the water cycle, waste management, sustainable agriculture and energy efficiency, to meet the challenge of climate change. Creating economic, social and environmental value, this global alliance is one of a kind. It is part of Danone’s new climate policy, which calls for zero net carbon emissions by 2050 for operations within its direct and shared scope of responsibility.

Danone and Veolia, both large French corporations and leaders in their respective markets, believe it is essential to transform consumption and waste management practices, and transition into a circular economy. The two companies are joining forces to share their expertise and, in so doing, explore the full range of innovative solutions in four major areas: water cycle management, waste management, sustainable agriculture and energy efficiency.

This unique alliance is built on a genuinely collaborative approach in which complementary skills contributed by each partner are harnessed to create shared value. Priorities include securing access to water resources and sustainable management of plastic packaging—issues that are central to Danone’s new climate policy targeting zero net carbon emissions in the long term.

Specific projects have already been identified in France and other countries for the alliance to start rolling out in 2016. Deployment will be gradual, building on lessons learned in a first round of pilot projects.

Among the projects is the development of “zero liquid discharge” plants to ensure optimum recycling of water resources, and the creation of production units for recycled plastic to ensure a secure supply source. Other circular economy projects are also in the pipeline. They include producing biogas by combining factory bio-waste with manure from local farms, and optimizing energy consumption by making expert use of alternative energy sources.

Emmanuel Faber, CEO of Danone.

Emmanuel Faber, CEO of Danone.

Emmanuel Faber, chief executive of Danone, says: “With this alliance, Danone continues to innovate in the social and environmental spheres by encouraging the emergence of entirely new forms of cooperation that promote change. By teaming up with Veolia, we are ensuring a secure source of strategic resources and optimizing their utilization, since our climate policy is an integral part of our mission and our business.”

“Both the form and the goals of this alliance make it a truly unique initiative in creating economic, social and environmental value,” says Antoine Frérot, chairman and chief executive of Veolia. “We are working with Danone to help them reach their 2020 goals while benefiting from major scope for business development. Our expertise is being invested to optimize water, waste and energy management across all of their processes.”

Veolia designs and provides water, waste and energy management solutions that contribute to the sustainable development of communities and industries. In 2014, Veolia supplied 96 million people with drinking water and 60 million people with wastewater service, produced 52 million megawatt hours of energy and converted 31 million metric tons of waste into new materials and energy.

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Understanding the Suitability of LED Lighting For the Food and Drink Industry

In an effort to run greener, leaner and more sustainable facilities, many food and drink companies have considered making the switch to LED lighting in their production, packaging, warehousing and/or commercial outlets. In fact, interest in and adoption rate of LED for both new construction and retrofit has been growing rapidly over the last two years.

There has been an increasing recognition of LED lighting as a fast and easy change that can deliver a near-instant boost in both sustainability and profitability. However, when presented with LED as a lighting alternative, many facility managers are quick to acknowledge the potential savings, but balk at the cost.

“While there’s no denying that LED fixtures carry an up-front price tag, existing systems have an ongoing cost without the undeniable positive return on investment delivered by LED,” explains Aidan MacDermott, CEO of Energy Automation Systems, a leading specialist in LED Lighting for all internal and external applications.

There are two common misconceptions about the installation of LED lighting – they are too expensive; and they are not bright enough or are otherwise unsuitable for specific applications. Both of these objections are unfounded.

LEDs are too expensive

In the last two years the up-front cost of an LED upgrade has reduced dramatically through massive advances in technology. In addition your existing lighting system has maintenance, labour and parts costs that your LED system will not, virtually eliminating the cost of lighting maintenance for up to 10 years. This allows companies to remove outside contractors that maintain lighting, or free up internal skilled workers to focus on projects that drive efficiency and production.

EnergyAutomationSystems3December2015“This means that LED offers a lower ‘Cost of Ownership’. Companies that make the switch mostly see a payback on their investment in just one year. Additionally there are Incentives available, often up to 30% of the project costs, to encourage businesses to switch,” points out Aidan MacDermott.

More importantly LED fixtures consume up to 90% less wattage than conventional fixtures, allowing companies to cut their energy bill by tens of thousands of Euros per year. Also, crucially for industries that require a lot of refrigeration LEDs produce less heat than conventional fixtures helping reduce the load on AC and refrigeration systems.

Consequently, the installation of LEDs offers significant benefits for food and drink companies:

* Lower Entry Levels

* Incentives, Grants available

* Maintenance Free System for 10 years

* Reduction in external contracting

* Massive reduction in ongoing Energy Costs straight onto the bottom line.

LEDs aren’t bright enough or are otherwise unsuitable for my application

“Traditionally the layperson evaluates a light based on the wattage of the bulb. We don’t tend to think in terms of lumen output, efficiency and colour rendering. When looking at a new lighting project we need to retrain ourselves to think in these terms,” says Aidan MacDermott.

EnergyAutomationSystems2December2015He adds: “Many facility managers think they need to replace a 1,000-watt bulb with a 1000-watt bulb to get the light levels they desire. That’s not the case with LEDs. As a rule of thumb the LED could be just 1/3 the wattage of the existing fitting.”

Furthermore, LEDs do not degrade over time at the same pace of conventional lighting. Conventional lighting drops to 80% output in the first few months, which is one reason why you never get even light across the facility. To compensate, facilities often over-light with high-wattage bulbs or are changing bulbs on a regular basis. LEDs, on the other hand, lose very little lumen output over the course of a 10-year life span, which means you get brighter, more efficient light over a longer time.

LEDs are now designed to enhance the look of food in retail and display outlets. They are also available IP rated for moisture and dust as well as shatter proof to comply with Health and Safety Regulations.

Financial and Environmental Advantages

LED lighting makes smart financial and environmental sense for food and drink applications. “For any size company, facility or entrepreneur looking to make every penny count, LED lighting is one way to reduce total operating costs and optimize sustainability. LED are the low hanging fruit of the drive to reduce our Carbon Footprint and be more environmentally conscious,” says Aidan MacDermott. “It’s a massive bonus that this comes with a great financial pay off.”

Energy Automation Systems is the preferred supplier for many ‘Blue Chip’ companies and currently provides numerous large OEM customers and end users with bespoke solutions meeting their exact needs and solving their issues.

For an initial consultation on how a LED retrofit would benefit your business and how to claim the Incentives that are available contact Gerry on 085 1419 518 or email:gerry@easilightandpower.com.

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Coca-Cola HBC Announces New Carbon and Water Commitments

Coca-Cola HBC, a leading bottler of the brands of The Coca-Cola Company, has announced new water and carbon commitments after being named by the Dow Jones Sustainability Indices (DJSI) as the world sustainability leader in the beverage industry. Coca-Cola HBC intends to reduce water use intensity by 30% by 2020, compared to 2010 and direct carbon emissions intensity by 50% over the same period.

The company’s approach to sustainability was endorsed in September when Coca-Cola HBC was named beverage industry leader by the Dow Jones World and Europe Sustainability Indices for the second consecutive year. Coca-Cola HBC was also ranked eighth out of the top 100 companies listed on the Financial Times Stock Exchange (FTSE 100) Index for its carbon reporting by Carbon Clear and ranked first within the beverage sector.

CocaColaHBGraphicDecember2015Dimitris Lois, chief executive of Coca-Cola HBC, says: “Sustainability is an integral part of our culture, visible in every aspect of our business. Being ranked by DJSI as world sustainability leader in the beverage industry inspires us to continuously raise the bar. It is our pleasure to make these commitments related to our water and carbon footprint. Our partnerships with stakeholders and our communities have been fundamental to our achievements so far and will continue to be instrumental in meeting our new commitments, supporting the global action to reach the Sustainable Development Goals recently endorsed by the United Nations.”

This is the eighth year that the company has been included in the DJSI, the global benchmark for corporate sustainability, due to its rigorous assessment process and its focus on best-in-class companies.

Coca-Cola HBC has a broad geographic footprint with operations in 28 countries, serving a population of approximately 589 million people. Coca-Cola HBC offers a diverse range of non-alcoholic ready to drink beverages in the sparkling, juice, water, sport, energy, tea and coffee categories.

Of the 2,500 companies across different industries, invited to participate in the DJSI assessment worldwide, Coca-Cola HBC ranked beverage industry best with a total score of 87/100. This was 34 points higher than the industry average. The company was ranked industry best in eight criteria: code of business conduct/compliance/anti-corruption, environmental policy, packaging, raw materials sourcing, human capital development, health & nutrition, social reporting, and talent attraction & retention.

Annual highlights of Coca-Cola HBC’s 2014 integrated report include:

* An ‘A’ rating by CDP, formerly the Carbon Disclosure Project

* 7.8 % direct and indirect carbon emissions reduction (Scope 1, 2 and 3)

* €4.3m invested in energy efficiency projects

* 4.3% improvement in energy intensity

* €5.8m invested in water saving projects, saving 1.1million m3 water

*4.1% improvement in water intensity

* 82% Sustainable Employee Engagement Index.

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Mondelez International Accelerates Action on Climate Change With New 2020 Global Sustainability Goals

Mondelēz International has announced its sustainability goals for 2020, an ambitious end-to-end approach to reduce its carbon footprint. The new goals include reducing absolute carbon dioxide emissions from manufacturing in line with science-based targets; reducing deforestation within its agricultural supply chain; focusing water-reduction efforts in high-priority locations; and eliminating packaging material. By leveraging its position as the world’s largest snack company and focusing where it can make the greatest impact, Mondelēz International continues to build on its heritage of leadership in sustainability.

“Our Sustainability 2020 goals place us at the forefront of the fight against climate change and support our ambition to be the leader in well-being snacks, while reducing costs and generating efficiencies that accelerate our growth,” says Hubert Weber, Executive Vice President and President of Mondelez Europe. “In 2014, we were a year ahead of schedule in accomplishing our 2015 goals for packaging, greenhouse gas emissions and net waste. These new goals take our commitment a step forward using the power of our global resources and partners to drive meaningful change at scale.”

Hubert Weber.

Hubert Weber.

Working with leading organizations, the new goals focus on reducing key end-to-end environmental impacts — from the field through distribution. By 2020, the company will:

* Reduce its carbon footprint by:

– Adopting science-based targets to reduce absolute CO2 emissions from manufacturing by 15 percent. This aligns with current approaches to setting science-based targets to support the global effort to limit climate change to less than 2º C. The company is also switching from reporting emissions per tonne to a more demanding absolute basis; and

– Addressing deforestation within the company’s key agriculture supply chains, primarily in cocoa and palm oil. The company will measure and report publicly the resulting end-to-end carbon footprint reduction.

* Cut its water footprint by reducing absolute incoming water use in manufacturing, focusing on priority sites where water is most scarce. The company aims for 10 percent reduction at those priority sites.

* Reduce waste by eliminating 65,000 tonnes of packaging, without contributing to food waste; and

* Reduce total manufacturing waste by 20 percent.

To secure key raw materials and support smallholder livelihoods, Mondelēz International will continue to invest and expand its signature Cocoa Life program to empower 200,000 cocoa farmers in six key origins. Ultimately, the company aims to source all of its cocoa sustainably, mainly via Cocoa Life. It will also maintain its European Harmony wheat program and go beyond this by creating a global approach to wheat.

“Our Sustainability 2020 initiatives on energy, water and waste reduction will improve efficiency and create the fuel to accelerate growth. The goals also support our cocoa and wheat programs to ensure we have a sustainable supply of these key raw materials,” adds Hubert Weber.

The goals are a part of Mondelēz International’s Call for Well-being, a call to action focused on four areas that are critical to the well-being of the world and where the company can make the greatest impact: sustainability, mindful snacking, communities, and safety.

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AD Operators See Performance Benefits With Micronutrient Technology

The latest micronutrient technology can boost productivity – and profits – for food waste anaerobic digester (AD) operators. Licensed operators are increasingly treating food waste through ADs for the production of constantly generated renewable energy in the form of biogas, which can either be used on-site to reduce reliance on costly fossil fuels or sold as electricity under Government incentive initiatives like the Feed-In Tariff scheme.

However, it is rare for an AD to have the complete range of nutritional elements present for optimal bacterial growth. Shortages of specific micronutrients, which are critical components of enzyme systems in the bacteria, often occur.

Omex2November2015This can mean that the digester plant and connected system do not run at full efficiency with a consequential loss of performance and output.

OMEX Environmental have formulated Nutromex TEA, a bioavailable micronutrient mix, used in the anaerobic process to boost the availability of essential trace elements and help to improve bacterial performance and increase the methane content of biogas production.

This helps commercial operators to run plants at optimum levels, maximising revenue streams and return on investment through increased profits.

Visit www.omex.co.uk for further Information.

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Barley Straw Shows Potential as Transport Biofuel Raw Material

The hemicellulose sugars of barley straw can be effectively fermented into biobutanol, when starch is added during the pre-treatment or fermentation process, shows a new University of Eastern Finland study.

Seeking to find alternatives to ethanol as a fuel, the study established optimal pre-treatment conditions for turning straw lignocelluloses and barley starch into fermentable sugars that can be used in the production of biobutanol. The hemicellulose sugars of barley straw (eg xylose) released during pre-treatment can be effectively fermented into biobutanol, when starch is added to the fermentation broth. The study found that the cooperation of xylanase and surfactants with cellulase during the hydrolysis of straw significantly increased the efficiency of cellulose utilisation in butanol fermentation. Moreover, the pre-treatment liquor of fresh barley silage was efficiently used for butanol fermentation, indicating the feasibility of utilization of green field biomass preserving by “silage” technique in biorefining processes.

In recent years, global warming and climate change have attracted widespread interest in biorefining and in particular the transport of biofuels production. Butanol as a competitive renewable biofuel is superior to ethanol in many aspects such as higher energy density, lower volatility and hygroscopicity, and less corrosion to existing infrastructure. Importantly, it can be directly used in automobile engines without modification. At present, sugar or starch-based biomass (sugarcane molasses, corn and wheat) are the main feedstocks for butanol production. Climatic and social sustainability of large-scale transport fuels production from these raw materials is under wide-ranging debate. The possible solution for obtaining enough fermentable substrates is the efficient utilization of plentiful lignocellulosic biomass available on earth. Barley has been regarded as a good supplement to corn biofuel production as well as a replacement for the production of biofuels.

The findings were originally published in Bioresource Technology and Chemical Engineering Research and Design.

The doctoral dissertation by Ming Yang, MSc (Agr.&For.), entitled The use of lignocellulosic biomass for fermentative butanol production in biorefining, is available for download at http://www.metla.fi/dissertationes/df202.htm

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Energy Cost Savings at Molson Coors UK

Molson Coors has reduced its carbon emissions by 6.5% and saved more than £750,000 from the first year of operation of its new energy centre based at its Burton Brewery site in the UK. Through efficiency improvements in steam production, compressed air and refrigeration during the brewing process, Molson Coors has saved 8.3 million kWh of gas and 4.4 million kWh of electricity.

“We’re extremely happy with the progress that has been made as a result of our energy centre. The cost savings made have been utilised and re-invested into our brands, service and breweries,” explains Victoria Segebarth, supply chain director of Molson Coors UK & Ireland. “This has given us the opportunity to delight the world’s beer drinkers and focus on being first choice for customers and consumers, while still keeping our beer print to a minimum.”

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2 Sisters Sustainability Plan Under way

Sisters Food Group, one of the UK’s largest food manufacturers, has started up a potato-powered energy plant as a first step in a new sustainability plan which aims to generate 35,000 tonnes of carbon savings a year and slash the group’s carbon footprint by 20% by 2018. The new bio-refinery at 2 Sisters’ Cavaghan and Gray chilled food factory in Carlisle is the first waste-powered plant of its kind in the world to be used in food manufacturing. It uses four patented anaerobic digestion processes which are linked to extract gas. When fully operational it will produce 3,500 MWh/year in electricity, equivalent to the average annual electricity use of around 850 UK homes, and generate around 5,000 MWh/year in steam.

The energy and steam will be used to help power the Carlisle factory and slash its carbon footprint as the first step in an energy transformation project which will see bio-refineries developed at up to ten 2 Sisters factories over the coming three years. Following these initial installations, the energy-from waste plants could be installed at all 43 factories owned by the 2 Sisters Food Group.

The four-storey-high bio-refinery at Carlisle will be powered using potato waste arising from the plant’s mashed potato and pie manufacturing lines. Diverting this waste to power production will help 2 Sisters meet its goal of ensuring zero-waste to landfill by 2017. The residual waste left after the bio-refining process has been completed can also be re-used as fertiliser – completing a circular journey that could take it back to one of 2 Sisters’ 700-farms and away from landfill.

The bio-refineries are part of an ambitious three-year sustainability plan Feeding Our Future that 2 Sisters has launched to ensure it cuts its carbon footprint by 20% by 2018.

When all the bio-refineries are installed the group expects to make 35,000 tonnes of carbon savings a year. It will also cut 20,000 lorry journeys that would have been used in removing waste which will now be re-processed to generate energy.

The bio-refineries are being run by renewable energy expert H2 Energy in partnership with 2 Sisters Food Group.

Andrew Edlin, group sustainability director for 2 Sisters Food Group says: “As one of the UK’s largest food manufacturers the 2 Sisters Food Group has a responsibility for protecting the environment and ensuring we take a leadership role as a responsible corporate citizen. The launch of the Feeding Our Future sustainability plan sets out clear goals for achieving this. The bio-refinery is a world-first for the food industry, using a new type of super-efficient technology to generate energy from potato waste. We are looking to use this system to open up to ten further energy plants at other 2 Sisters factories over the coming 3 years, using potato and other food waste to generate energy and steam.”

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PepsiCo Sustainability Initiatives Deliver $375 Million in Cost Savings

PepsiCo has announced that its environmental sustainability programs saved the company more than $375 million since its goals were established in 2010. The savings were achieved through the continued progress of the company’s water, energy, packaging and waste-reduction initiatives. During the same time period, the company delivered double-digit net revenue and operating profit growth – demonstrating that investments in sustainability are mutually beneficial for business and society.

These efforts are part of the company’s commitment to Performance with Purpose, which is PepsiCo’s vision to deliver financial performance over the long term by integrating sustainability into its business strategy, leaving a positive imprint on society and the environment. The company’s achievements and progress are detailed in its 2014 Corporate Sustainability Report, Global Reporting Initiative (GRI) Report and first-ever sustainability microsite, howwillwe.com.

“Performance with Purpose helps drive our business growth and prepares us to meet the needs of our changing world,” says Indra Nooyi, chairman and chief executive of PepsiCo. “As leaders gather this month to adopt the UN Sustainable Development Goals, PepsiCo will reflect on progress made to date and renew its focus on doing more in the years ahead. By continuing to apply our scale and capabilities to address shared societal challenges, we will further strengthen our company and the communities where we operate.”

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Nestlé Tops Category in Dow Jones Sustainability Index

A ‘zero water’ factory in Mexico, a UK confectionery factory that turns waste into renewable energy are just two examples of the kind of work that has helped Nestlé achieve an industry leading score of 99 out of 100 in the ‘Environmental Dimension’ of the 2015 Dow Jones Sustainability Index (DJSI). The DJSI is a globally recognised independent benchmark that measures company performance across three dimensions: Economic, Environmental and Social.

With an overall score of 89 out of 100 in the DJSI ranking, Nestlé was among the top performing food product companies. In the Index’s ‘Environmental Dimension’, its score of 99 is the highest in the industry, which underlines its commitment to water stewardship and environmental sustainability.

For instance, Nestlé is committed to achieving water efficiency and sustainability across its operations, and one example is the introduction of ‘zero water’ technology at its dairy factory in Jalisco, Mexico, which allows the plant to operate without using any local groundwater.

The UK provides another example of new, more sustainable production processes: an anaerobic digestion system at Nestlé’s Fawdon confectionery factory turns confectionery waste into renewable energy and clean water.

Nestlé’s status as the leading Nutrition, Health & Wellness company was recognised with a top score of 100 for Health & Nutrition in the Index, a testament to work done in areas including product innovation and renovation.

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John Dewar & Sons Surges Ahead With Sustainability Practices

The Dewar’s Aberfeldy Distillery in the heart of the Scottish Highlands is known for its rich tradition of producing some of the world’s finest Scotch – while at the same time, setting industry-leading sustainability standards.

The late 2014 instalment of a biomass boiler at the Aberfeldy site cut the carbon footprint at the home of Dewar’s blended scotch whisky by a whopping 90 percent.

“Traditionally, distilleries are heavy users of fossil fuel – and that’s not good for the environment,” says Iain Lochhead, Operations Director at John Dewar & Sons, part of the Bacardi group of companies. “At John Dewar & Sons, we had many ideas for reducing fossil fuel usage and explored several options, but we settled on a biomass boiler.”

“Investment in biomass marks a sea change in the industry approach,” says David Williamson, Public Affairs & Communications Director, for the Scotch Whisky Association (SWA). “Moving away from boilers that use heavy fuel oil – to more efficient wood pellets – helps reduce energy costs and lower emissions into the environment. So we develop the industry as we nurture local surroundings and deliver a sustainable industry.”

“We estimate that under the current production schedule, we will reduce our carbon emissions from fossil fuel sources by up to six thousand tons per year of carbon dioxide at the DEWAR’S Aberfeldy Distillery,” adds Iain Lochhead.

As part of the Bacardi group of companies, John Dewar & Sons honors the spirit of sustainability with these benchmarks at its five malt distilleries:

* 34 percent reduction in greenhouse gas emissions since 2006

* 46 percent reduction in water use since 2009

* 30 percent reduction of waste to landfill since 2010.

The biomass project is part of a broad scope of sustainability initiatives for John Dewar & Sons. Since 2006, when Bacardi began tracking its global impact on the environment, it has reduced non-renewable energy use by nearly 28 percent and decreased its greenhouse gas emissions from production by more than 28 percent.

John Dewar & Sons Ltd. employs 300 people at seven locations throughout Scotland. The company currently operates whisky distilleries in Aberfeldy, Macduff, Aultmore, Craigellachie and Nairn with ageing, blending, bottling and packaging facilities in Glasgow and additional maturation facilities in Poniel in Central Scotland.

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Mondelez International Reports Good Progress Against Global Well-being Goals in 2014 Report

Mondelez International has published its Call For Well-being 2014 Progress Report.  The report details how the world’s leading snacking company exceeded many key environmental goals and took significant steps forward to meet its remaining global well-being targets by 2020.

“We firmly believe that we can grow our business, while improving the well-being of the planet.  Through our Call For Well-being, we bring a business mindset and the power of our global resources together to drive change,” says Irene Rosenfeld, Chairman and CEO. “We’ve made important progress against key metrics to reduce our environmental footprint, evolve the nutrition profile of our portfolio and secure sustainable agriculture supplies.  Working together with employees, partners and suppliers, we can deliver enduring solutions for our business and society.”

Launched in 2013, the company’s Call For Well-being is focused on four areas that are critical to the well-being of the world and where Mondelez International can make the greatest impact: sustainability, mindful snacking, safety and community. Over the last year, the company has scaled its agricultural commodity sourcing programs, reduced its environmental footprint, increased portion control options to help consumers snack mindfully and united community partners, suppliers and employees to help drive positive change locally and globally.

Following are key highlights of the company’s progress toward achieving its goals:

Sustainability

  • Exceeded goal to reduce manufacturing waste by 15 percent by 2015. Through 2014, there was a 57 percent reduction – four times the original goal.
  • Achieved goal to reduce greenhouse gases by 15 percent in manufacturing – a year ahead of schedule.
  • Eliminated 89 million pounds of packaging – nearly doubling the original target of 50 million pounds by the end of 2015.
  • Met goal of having 100 percent of palm oil be RSPO (Roundtable on Sustainable Palm Oil) – two years ahead of commitment. At end of 2014, 70 percent of the palm oil Mondelez International sourced was traceable back to the mill.
  • On target to sustainably source key commodities. At the end of 2014, 12 percent of cocoa, 61 percent of coffee and 60 percent of our Western European biscuits were sustainably sourced.
  • More improvement is needed to reach goals of reducing water and energy use in manufacturing by 15 percent by end of 2015. At end of 2014, incoming water usage decreased by 10 percent per tonne of product; manufacturing sites worldwide reduced energy per tonne by 7 percent.

Mindful Snacking

  • On target to deliver 25 percent of revenue from Better Choice products by 2020. In 2014, 22.4 percent of revenue was from Better Choice options, which meet a stricter set of nutrition criteria.
  • On target to increase individually wrapped portion control options 25 percent by 2020. Since 2012, Mindful Portion products grew by 16 percent.
  • Making progress on nutrient targets. Since 2012, increased whole grains by 23 percent across the portfolio, and on target to achieve 25 percent increase in whole grains by 2020. On track to meet sodium reduction goal of 10 percent by 2020, having reduced sodium by 2 percent across global portfolio since 2012. More work is needed to reach goal to reduce saturated fat by 10 percent by 2020. At end of 2014, saturated fat declined across entire portfolio by 1 percent.
  • Strengthened its marketing to children policy. Starting in 2016, will no longer advertise products directly to children under age 12, irrespective of the product’s nutritional profile.

Safety

  • On target to achieve world-class safety performance. In 2014, compared to 2013, achieved 26 percent reduction in lost time injury frequency rate and a 24 percent reduction in Total Incident Rate for all employees in manufacturing.
  • On target to achieve FSSC 22000 (Food System Safety Certification) for all internal manufacturing facilities by 2015. In 2014, 90 percent of manufacturing sites were certified.

Communities

  • On target to meet goal to invest $50 million in healthy lifestyle community partnerships. In 2014, allocated over $30 million (64 percent) to programs across 13 countries.

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Cleantech Firm NVP Energy Among the Big Winners at the UK’s Top Water & Energy Awards

NVPEnergyJune2015NVP Energy, a clean-tech company with an innovative technology that can turn wastewater into a revenue generator for end users in the municipal and industrial wastewater industries, was recently the recipient of two prestigious awards from the UK Water and Energy sectors not to mention a substantial grant from the UK Department of Energy and Climate Change.

On the 21st of April, NVP Energy beat off stiff competition to be announced the winner of the Most Innovative New Technology of the Year award at the Water Industry Achievement (WIA) Awards in Birmingham. The WIA Awards, now in their 9th year, is the only awards ceremony of its kind that rewards outstanding innovation in the UK Water industry, in particular technologies that are seen to be breaking new ground and exceeding customer expectations. NVP Energy’s Managing Director Michael Murray said: “this award reflects the pioneering and advantageous nature of the Lt-AD technology and the associated impact it can have on the bottom line of a business and the health of our planet.”

Fresh from winning that award, NVP Energy then went on to win its 2nd innovation award in two days when it was announced the winner of the Innovation Award for Energy from Waste at the Environment & Energy (E&E) Awards on the 22nd of April. The 16th annual E&E Awards which were held at the National Motorcycle Museum in Birmingham recognised the top UK and Irish companies who push the boundaries of innovation and showcase the very best advancements in green technologies. According to M.D. Michael Murray, “Winning both of these awards is a testament to the unique and innovative nature of the Lt-AD technology and they reinforce the technological and environmental benefits the Lt-AD technology can bring to the global wastewater and energy industries”.

In addition to this impressive recognition, NVP Energy is one of the few companies to be successfully awarded the Energy Entrepreneurs Fund (EEF) Phase 4 from the Department of Energy & Climate Change (DECC) thus further reinforcing the high calibre of the Lt-AD technology. The EEF grant will financially support the delivery of a full scale Lt-AD reactor at a large Food & Drinks customer’s wastewater treatment plant in the UK by March 2016. Speaking after the signing of the offer letter, Michael Murray M.D. said: “This is a hugely important milestone for NVP Energy as it will allow us to validate the technology at full-scale at a time when wastewater treatment plant operators are seeking new superior wastewater treatment technologies to replace their outdated energy-intensive systems”. Once the project is complete, the demonstration reactor will showcase the Lt-AD system and the commercial benefits to the target markets (Food & Drink wastewater; Municipal wastewater) as prospective end-users will be able to visit the site during the project and witness the benefits of the technology at first hand for themselves.

These recent awards and grant successes follow the success NVP Energy had at the start of the year when it was one of only 155 companies out of 2662 companies throughout Europe to be awarded Horizon 2020 Phase 1 SME funding.

NVP Energy Contact Information
Michael Murray, Managing Director

M (Irl). +353 (0)87 667 7007          M (UK). +44 (0)7733 943 909

  1. michael.murray@nvpenergy.com

W. www.nvpenergy.com

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Bernard Matthews Launches ‘The Big Green Plan’

Bernard Matthews, the UK’s largest turkey producer, has launched ‘The Big Green Plan’ – a programme of green energy initiatives that will make the business the UK’s greenest farmer and to put sustainability at the very heart of the business.

The plan’s six major goals mean that by end of 2016 Bernard Matthews will be 100% self-sufficient from renewable green electricity and by 2020 will be 100% carbon neutral, send zero waste to landfill, have reduced its carbon emissions by 35%, reduced the weight of its packaging by 25% and reduced its water usage by 20%.

Rob Burnett, chief executive of Bernard Matthews, says: “Sustainability is central to our long term business strategy. We’re already generating a large proportion of our energy needs from renewable sources including solar, wind, waste and biomass and are well placed to be generating 100% of our electricity sustainably by 2016.”

“Our Big Green Plan is ambitious and will require everyone in the business to work together to achieve these tough targets. But for the business to remain sustainable in the future we need to ensure we become more efficient in the way we use energy.”

To achieve its goals, Bernard Matthews has rolled out a number of green energy projects that reach every single part of its business, from farm to factory, and are for the long-term, looking beyond immediate success to a sustainable future.

BernardMathewsLogo2013To date it has gained over £100 million of investment from multiple green energy investors, which has allowed the business in partnership with developers to plan, develop and build the following key green energy projects that will ensure it meets its targets:

Biomass – Bernard Matthews has already completed the largest UK roll out of 209 biomass boilers, across 30 of its turkey farms, to help reduce its reliance on fossil fuels.

Wind – The turkey producer is installing nine large scale wind turbines at three farms across Norfolk and Suffolk, each generating 2.3MW of ‘green’ electricity – equivalent to powering nearly 700 homes. 4 are already built and generating energy.

Solar – The business has already built a 55 acre solar farm in Suffolk, which can generate up to 10.1MW of electricity.

Anaerobic Digestion – Bernard Matthews has partnered with two leaders in the anaerobic digester sector and has already built a £4.2 million anaerobic digestion plant to generate power from factory wastes.

BernardMatthewsTurkeyTurkey Litter Pelleting – Pending new legislation it may soon be possible to burn turkey litter in biomass boilers. If this gets the green light, it would allow us to recycle 10,000 tonnes of turkey litter, in order to generate heat and replace use of LPG.

Energy efficiency – By comprehensively metering its energy usage, and reusing and recycling heat and cold water, Bernard Matthews will be able to reduce its usage of non-renewable energy sources by up to 30%.

Gas to grid – Bernard Matthews is also looking at ways to develop anaerobic plants that produce gas that can be treated and piped directly into the national grid for domestic use.

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No Steam – No Whisky!

One road, one distillery, one pub, one shop and one community – Jura is an island with a unique spirit. Tracing its origin back hundreds of years, whisky-making runs through this island and its people.

Byworth Boilers visited the Isle of Jura to meet with the distillery’s Engineering Manager, Andy Jardine, to get his perspective on business with Byworth; the benefits of better boiler life; improved efficiency; uptime and improved customer satisfaction.

1 – What were the biggest issues you had with your previous boiler?

“The 18 year old boiler had repeated NDT failures and needed regular repairs. If you have a day’s lost production that means you don’t have 8000 litres to sell in 10 years’ time. This was also one of the reasons for installing two smaller boilers in place of a big one.”

2 – Why did you decide on Byworth and two Yorkshireman2 boilers?

“I chose Byworth because the price was competitive, and the promise of improved efficiency was appealing. I liked the feel of the company and felt comfortable in the early sales process.”

3 – How was the project from start to finish?

“It all went very easily for me which is what I wanted because of my workload. When I place an order for something, I just want it to happen properly, with minimal input from me.”

4 – Have you seen any significant costs and energy savings?

“We’re already seeing about a 12% fuel volume reduction with the new boilers – [they] are already providing return on investment on the whole package.”

“The figure I look at is the volume of fuel required to make 1 litre of alcohol. This takes out the variation of fuel cost and production level to give realistic savings from just the new boilers compared with the old one.”

“If the fuel price goes back up to what it was then the savings will be larger.”

Byworth2May20155 – Have you reduced your carbon footprint?

“Using less fuel reduces your carbon footprint and that’s multifaceted because using less fuel reduces carbon all through the fuel supply chain. The reduction means maybe two less lorries a month having to come to Jura.”

6 – Was there anything remarkable that stood out from our product/service offerings?

“Unity’s [Byworth’s control system] remote support stands out. That is Engineers being able to go in and keep an eye on things remotely – you don’t get the feeling that Byworth have fitted the boilers, then walked away, instead you know that they’re keeping an eye on them.”

7 – Having access to trend data, has Unity drawn your attention to any changes in the condition of the plant?

“Yes. That is me being nosy and wondering why there is a change in the plant! Now I can phone up the distillery and say why weren’t you taking steam at 3 am!?”

“It gives me more insight and control, whereas before I was not aware of all the issues they’d have.”

ByworthLogo8 – What would you say are the main benefits of a new boiler to anyone that has a boiler older than 10 years?

“There is an obvious improvement in technology as we have seen in Unity and with the supplied burners becoming more and more efficient.”

“The overall fuel efficiency is something you don’t get with the old boilers.”

Discover more from this story and others at www.byworth.co.uk/explore/case-studies.

Posted in Energy, EnvironmentComments Off on No Steam – No Whisky!

Anaerobic Wastewater Treatment Plant and CHP Unit Chosen at Independent UK Brewer

Today’s best practices in water treatment, focus on achieving operational efficiencies, energy reduction, environmental impact minimisation and waste-to-energy solutions. An independent brewery was looking to do just that. The brewery assessed best available treatment technologies before making a decision on which anaerobic process would fulfil their needs.

The Downflow Anaerobic Carrier System (DACS)® was the chosen technology, offering a number of significant operational and performance benefits, including an attractive source of revenue benefits to the brewery in the form of renewable energy and ‘green’ tariff’s

The Science Bit

DACS is a unique anaerobic treatment process using high performance flocculated anaerobic biomass, captured within a proprietary carrier system.

The wastewater with entrained biological solids flows into the DACS reactor via a simple feed pipe arrangement located at the top of the reactor. From here the wastewater passes by gravity, down through the fluidised carrier bed – treated wastewater passes out from the DACS reactor at its base.

The down flow action prevents the liberation of C02 and H2S within the process reactor, consequently DACS biogas is exceptionally pure (>90% methane). DACS provides even more benefits, most noticeably in terms of CAPEX, OPEX, and guaranteed process security.

At the brewery in question, all of the biogas created by the DACS anaerobic treatment plant will be combusted in a new Combined Heat and Power system. The products of this combustion will be electricity and heat energy, both of which will be reused by the brewery.

The DACS treatment plant has been designed to fit within a small section of land that was available to the brewery. The complete operational plant and all its ancillaries, are enclosed within a start-of-the-art building, providing the lowest possible environmental impact.

Posted in Energy, EnvironmentComments Off on Anaerobic Wastewater Treatment Plant and CHP Unit Chosen at Independent UK Brewer



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