Powering food and drinks manufacturing processes with inexperienced vitality, as an alternative of fossil fuels, considerably reduces an organization’s carbon footprint. However relying solely on inexperienced vitality is a problem: at some intervals of the day the solar and wind is unable to generate sufficient vitality to energy manufacturing processes, whereas at others, a surplus is produced.
This was a priority for snacks and drinks main PepsiCo, who has been trying to combine extra renewable vitality into its Broek op Langedijk manufacturing plant – the place the corporate makes Lay’s and Cheetos crisp merchandise – within the Netherlands.
“We would have liked to disconnect from [natural gas] and transfer to renewable vitality,” recalled Katharina Stenholm, PepsiCo’s outgoing SVP chief sustainability officer, Europe. However on the similar time, the answer needed to be ‘value aggressive’. “There may be clearly a number of inflation going into meals costs, so we’re decided to seek out sustainable options that don’t indicate increased prices.”
The answer was developed in collaboration with PepsiCo’s vitality associate Eneco, and leverages know-how from German start-up Kraftblock: a thermal battery that shops extra inexperienced vitality for later use.
Storing extra inexperienced vitality with thermal batteries
Kraftblock’s know-how works because of an ‘revolutionary’ materials able to storing temperatures as much as 1,300˚C. As soon as warmth is transferred from the warmth switch medium – in PepsiCo’s case, from scorching air heated by wind vitality – to the storage system, it may be used for a interval of as much as two weeks. On the Broek op Langedijk web site, the saved vitality is getting used to warmth thermal oil, which in flip, heats cooking oil to fry PepsiCo crisps.
In the course of the evening and in off-peak intervals, PepsiCo is now in a position to supply cheaper renewable electrical energy from North Sea windfarms and convert it to scorching air. This heats up Kraftblock’s iron ‘nuggets’ to 800˚C in ‘tremendous’ insulated storage items. In parallel, PepsiCo makes use of direct electrification to energy two of its electrical thermal oil boilers.
In the course of the daytime, and peak intervals (when vitality prices are increased), PepsiCo can swap off its electrical thermal oil boilers, extract warmth from the storage items within the type of scorching air after which use a scorching air to thermal oil warmth exchanger to produce vitality to its manufacturing processes.
“We now have the chance to retailer renewable vitality, which suggests we are able to pull vitality at off-peak instances when the costs are beneficial…and take vitality throughout nights and weekends, even when our demand shouldn’t be excessive – to retailer and use later. That’s the novelty and great thing about this resolution,” Stenholm advised FoodNavigator.
Changing pure gasoline with sustainability electrical energy will result in a discount of round 50% CO2, with the intention of attaining a 98% discount.
Challenges in implementation
Putting in new know-how at scale isn’t a simple course of. And as Stenholm defined, the answer, co-developed in partnership with Eneco, was not so simple as ‘taking it off the shelf and plugging it in’.
“The novelty of the know-how brings its personal challenges,” she advised this publication. “One other problem is whenever you combine one thing into an present web site – it’s at all times extra difficult that at a greenfield web site.”
When it comes to logistics, for instance, Kraftblock’s batteries must be situated comparatively near the thermal oil boiler home on-site, we have been advised. “So we needed to rethink the logistics on the location to facilitate the area wanted for this new unit.” Operations, too, are an element, on condition that the Broek op Langedijk plant is considered one of PepsiCo’s prime 20 snacks websites. “While you’re putting in [new technology] right into a manufacturing facility working on daily basis, you want to watch out about how you intend it, in an effort to preserve producing whereas putting in.”
The set up marks the primary in Europe, and inside PepsiCo’s enterprise worldwide, to totally decarbonise the operation of a snacks plant. The corporate has put in two items at its Broek op Langedijk web site, with plans to put in a 3rd if the pilots are profitable.
Scouting for innovation
The corporate’s decarbonisation challenge aligns with its PepsiCo Constructive (pep+) agenda: the snacks main has pledged to cut back greenhouse gasoline (GHG) emissions by greater than 40% by 2030 and obtain internet zero emissions by 2040. Inside its personal operations, PepsiCo plans to cut back GHG emissions by 75% by 2030.
Trying to new improvements, similar to Kraftblock’s thermal battery know-how, is a part of the answer, defined Stenholm. “We now have groups devoted to sourcing options for the unsolved issues, and it’s most likely not a coincidence that we’re within the Netherlands – as a result of the Netherlands is a really supportive atmosphere for brand new revolutionary applied sciences.”
When scouting for brand new options, the corporate is acutely aware of its provide base, too. Generally, PepsiCo’s conventional suppliers will develop a brand new resolution, however extra typically the ‘breakthrough’ applied sciences come from start-ups, she defined. “An organization like PepsiCo has the chance to assist start-ups with nice concepts [link with] established gamers with an industrial footprint.
“We will help them come collectively and [create] one thing that scales sooner {that a} start-up might maybe do themselves.”
This month marks Stenholm’s departure from the corporate, which suggests PepsiCo’s sustainability ambitions will now be overseen by a brand new chief sustainability officer in Europe. Archana Jagannathan was main on local weather, vitality and water throughout Europe for PepsiCo, in addition to being vp for sustainability within the UK and Eire, previous to taking up the brand new function.
“PepsiCo has lengthy had a robust imaginative and prescient and dedication to its sustainability agenda and pep+ gives your entire organisation with a transparent roadmap to sustainably develop and produce worth to the planet and folks,” Jagannathan commented. “We’re taking vital motion to ship on that imaginative and prescient and I sit up for persevering with my work embedding pep+ into our resolution making and wider enterprise technique.”
