Energy and Renewable Energy
Goal: Energy consumption – 20% reduction per metric ton of production through improved operational efficiency by 2015. Progress as of Fiscal 2009: Since 2005, we’ve reduced our consumption by approximately 15.8% per metric ton of production globally.
Heinz facilities around the world are installing new energy-saving equipment and implementing new techniques to reduce energy consumption. By focusing on our energy use, Heinz is mitigating the financial impacts of rising energy costs, reducing GHG emissions and eliminating inefficiencies in our factories and offices around the world.
To help meet our energy goals, Heinz has implemented a Global Utility Management Program that assesses facilities around the globe and identifies potential energy saving projects. During Fiscal Years 2008 and 2009, our efforts in North America and Europe resulted in these energy reductions:
When combined, these results reduced the amount of CO2-eq produced by 42,750 tons.
The Program is structured to accomplish the following objectives:
- Establish global factory efficiency improvement goals
- Collaborate with factory managers via regional conference calls to promote the
utility management process - Assign factory utility teams and assessment protocols
- Conduct systemized utility metering and monitoring
- Determine performance indicators by region and business type
- Utilize the Global Data Warehouse for implementation of project tracking
The benefits of implementing these projects include a 2–4% reduction in energy/utility consumption per year, a focused global approach to the evaluation of renewable energy source opportunities and generation, and overall efficiency gains.
Heinz is executing our Utility Optimization Process to upgrade air compressor systems, install steam optimization technology, improve lighting, maximize refrigeration and much more.
Renewable Energy
Goal:15% of energy utilized from renewable resources by 2015.
Heinz is working on mitigating the environmental impacts of its manufacturing processes. This includes increasing utilization of renewable energy sources such as solar, wind and alternative fuels.
In Australia, the Northgate factory employs a methane extraction process from the factory’s waste water treatment plant. The methane gas is used to fuel a biogas steam boiler.
Heinz India installed a cogeneration system that generates electric power and thermal energy for the factory. The cogeneration system employs both renewable resources (rice husks) and fossil fuel sources for energy generation.
Multiple renewable energy projects are under various stages of exploration and development.
A few examples include:
- Wind turbines: Holland, Michigan; Newburyport, Massachusetts
- Solar panels: Stockton, California; San Diego, California
- Biogas generation: Ontario, Oregon; Manchester, England
- Biomass thermal energy generation: Ontario, Oregon; Kendal, England
Asia/Pacific
Australia
The wastewater treatment plant in Girgarre installed a low-energy aeration system that is expected to result in a 50% energy reduction per year.
Methane gas produced from wastewater treatment plant operations at the Northgate facility is being captured and used to fuel a biogas boiler.
Indonesia
An aggressive plan to increase energy efficiency is underway at Heinz Indonesia’s three sites. The improvements include:
- Installing optimization lamps in the warehouse
- Reducing steam loss from leaks
- Increasing the speed of the wheat roaster
- Simplifying the aeration process to reduce the electricity
needed for the blower
India
Optimization lamps in the warehouse.
Though these four projects yield minor CO2-eq reductions (18 tons CO2-eq annually), the implementation and cumulative impact of the projects contribute to our overall reduction goal.
India
Heinz India has made several improvements to optimize energy efficiencies, including:
- Installing a cogeneration boiler (COGEN) and turbine in Fiscal 2009 to produce energy for efficient on-site power generation and steam needed for processing – this equated to an annual savings of 3.5 million mega-watt hours (MMWH).
Cogeneration Boiler
A cogeneration boiler and turbine was installed in India to produce energy for efficient on-site power generation and steam needed for processing.
India
Transparent roofing materials were installed for increased natural lighting.
- Using rice husks as a fuel source in COGEN. The use of rice husks for process steam generation has the following benefits:
- Reduces GHG emissions since rice husks are carbon-neutral and renewable
- Improves local environmental conditions since sulphur and other pollutants are associated with the use of fossil fuels
- Develops the local economy by establishing a market for rice husks and providing jobs for the collection and supply of rice husks
- Eliminates waste since rice husks were previously disposed
- Meets thermal energy requirements of the process industry in a more cost-effective manner
Source: Dinesh Aggarwal, Tata Energy Research Institute, New Delhi - 110003, India, 12 March 2003
- Using transparent roofing materials rather than solid sheeting for increased natural lighting (savings of 6,000 kWh/annually)
China
Energy reduction programs were introduced at Heinz China through employee awareness programs that helped to increase efficiencies, while technological improvements have yielded other positive results.
Thermostat adjustments have conserved energy. Indoor air conditioners were set four degrees warmer (22C to 26C) in the summer and the heat setting was three degrees cooler (19C to 16C) in the winter. New power turn-off rules have been established for when employees leave for the day. Savings have been achieved by turning off computers, lights and central air conditioners.
Lighting is a key area of focus. Energy efficient lights were installed in the production areas and in Fiscal 2010, all warehouse lights will be replaced with energy-saving lamps. Modifications, including automatic switches to turn pumps on/off, were installed in water pumping stations to reduce energy use and unnecessary water flows.
New Zealand
Various energy-saving projects were implemented at the King Street and Tomoana facilities. At Tomoana, an ammonia waste heat recovery system was installed to recover waste heat from the compressed ammonia gas. The recovered heat is then transferred to a potable water system.
During Fiscal 2009, reductions achieved for this system were:
Gas – 5,296 GJ (5,019 MBtu)
CO2-eq – 296.6 Tons (56kg of CO2-eq/GJ for Natural Gas)
New Zealand
An ammonia waste heat recovery system was installed at Tomoana to recover waste heat.
Europe
At our European facilities, we conducted a number of utility assessments in the various countries where we operate. These assessments have identified opportunities to reduce or operate more efficiently. We have implemented the following projects.
Fiscal Years 2008 and 2009 Utility Optimization Projects Included:
- Factory lighting upgrades
- Boiler/steam optimization projects
- Air compressor system upgrades
- Refrigeration optimization
- Process heat recovery
- Water reclamation
- Landfill waste optimization
- General utility improvements
Results for Fiscal 2008/Fiscal 2009:
These reductions eliminated 45,500 tons of carbon dioxide, which is equivalent to the carbon sequestered by 1.1 million trees grown over a period of 10 years.
Russia
Equipment that adjusts the ways power is utilized resulted in a 15% reduction in energy consumption at the Ivanovo manufacturing site. In addition, the facility is practicing employee behavioral-based energy saving initiatives as the result of an internal energy awareness campaign. Other improvements include repairing steam leaks in the factory and upgrading the boiler’s burner control system for efficient fuel use.
Poland
In Poland, electricity, gas, oil and water are monitored at the Pudliszki and Międzychód sites. Progress and improvement protocols are discussed at monthly meetings. Between Fiscal 2005 and Fiscal 2009, the following results per unit of production were achieved:
Pudliszki Site
Gas/oil: 13% reduction
Electricity: 3% reduction
Water: 42% reduction
Międzydhód Site
Gas/steam: 26% reduction
Electricity: 38% reduction
Water: 25% reduction
Poland
Energy meeting in Poland where energy progress and improvement protocols are discussed.
Italy
Energy savings are being realized at Heinz Italy’s Ozzano Taro and Latina factories. Annual savings of more than 1,000 MWh were achieved from installing a variable speed air compressor, replacing fluorescent lamps with electronic high-efficiency lamps, installing an inverter on an existing air compressor and utilizing an energy-usage optimization program.
United Kingdom
A new boiler plant was installed at the Kitt Green facility in Wigan to replace a gas and gas-oil fired steam generating plant that required an operator 24/7. The new plant operates with a thermal efficiency of about 92% compared with the plant’s previous 75% efficiency. In addition, horizontal sterilizers were installed to improve the quality of the steam and increase the life of steam transferring equipment.
Annual Energy Saved: 16,848,000 kWh (574,821 therms)
Annual CO2-eq Saved: 3,198 tons
United Kingdom
A new boiler plant was installed at the Kitt Green facility in Wigan.
North America
All North American factories were assessed for opportunities to improve utility efficiencies. These reviews resulted in 92 projects to drive improved energy utilization.
Fiscal Years 2008 and 2009 Utility Optimization Projects Included:
- Factory lighting upgrades
- Boiler/steam optimization projects
- Air compressor system upgrades
- Refrigeration controls system upgrade
- Process heat recovery
- Water reclamation
- Waste recycling optimization
Results for Fiscal Years 2008 and 2009:
These combined results reduced the amount of carbon dioxide generated by 53,000 tons. This reduction is equivalent to planting 1.3 million trees and growing them for 10 years – the amount of trees and time needed to absorb this quantity of carbon dioxide.
United States
The Fort Myers, Florida, facility has also experienced success from utility optimization. An oven exhaust project included a modification to achieve minimal energy loss out of the stack. In addition, the installation of baffling under the conveyer belt helped to minimize air infiltration to the cooking space and also the size of the space. The successful project has reduced exhaust fan energy consumption through the use of variable speed drives; reduced natural gas usage by minimizing the wasting of hot air generated; and reduced the steam load by holding more moisture in the oven.
Other improvements at Fort Myers include installing variable frequency drives on freezer fans, which ultimately reduces the load on ammonia compressors; recovering heat from sauce after it’s cooked to preheat other products; and optimizing the operation of the refrigeration system to utilize only the amount of refrigeration energy necessary.
At the Heinz facility in Escalon, California, the cooking systems were modified to include the installation of eductors, pumps that move liquids and gases throughout the production process. These modifications contributed to the reduction of 15,362 MMbtu of natural gas per year and further reduced GHG emissions by 831 tons.
Canada
Heinz Canada replaced lift trucks fueled by liquid petroleum gas with vehicles powered by electricity. The new vehicles require less energy and generate fewer carbon emissions, thus reducing their environmental impact.
Rest of World
Venezuela
Repairing steam leakages in the factory’s pipes and fittings system and upgrading boilers in the burner control system increased energy efficiencies.