Energy Efficiency in Process Nov 20th – Aviva Stadium
Future in Food Ireland
Eamonn Diver Engineering Manager
Agenda
• About Bewley’s
• Our Sustainability Journey
• Energy Efficiency to-date
• Next Steps
Agenda
About Bewley’s
Delivering an exceptional experience is what we have been doing for over 150 years
Campbell Bewley Group
• Private family owned company
• 5 main operating units – Bewley s (Ireland), Java City (Sacramento), Rebecca s (Boston), Darlington's (UK - 2011), Bolling Coffee (UK - 2013)
• Group turnover €100m. Over 1,000 employees.
• Profitable; debt free
• Approx. 6,000 tonnes of coffee annually
• 3 Production / Distribution Facilities: (Dublin, Meltham & Sacramento)
• Established 1840. Largest roaster in Ireland and in the top 3 coffee suppliers in the combined Irish and UK market.
• Ireland’s market leading fresh coffee brand with 90% overall brand awareness.
• Core business: provision of fresh coffee and related hot
beverage solutions great; profitable programmes for operator
Foodservice – Over 4,500 wholesale customers, across offices, cafes, hotels,
convenience stores, contract catering operators – Approx 40% of out-of-home fresh coffee market.
Retail – Approx 15% of Retail fresh coffee market. – Over 7% of Retail regular tea market.
Contract Manufacturing – Private label coffee and tea products for retailers\foodservice
operators
Bewley’s Key Facts
Sustainability is part of our DNA..
. Why this is important ? • Sustainability of quality coffee supply from origin
– Commodity price movements and the fundamental shortage of coffee – Climate Change impacts – drought etc.. – Land-use issues and competition for crops – Most rapid deforestation is in the regions where the best coffee is produced
• “The right thing to do” – within the Bewley’s ethos. • Board commitment • Meeting consumer demands for traceability and also transparency in relation to ethical and environmental credentials.
– Our consumer wants to participate i.e. what can I do? – seeking a ‘co-responsibilty’ opportunity. They are looking to business to provide a platform for this.
• Cost savings - more effective and efficient use of resources which usually results in reduced costs. For example, Energy Efficiency, Fuel Efficiency projects etc..
From our origins as a Quaker owned company, Bewley’s have always been committed to working in a sustainable and positive manner with both the natural
environment and the communities within which we operate.
Sustainability in Bewleys
How it works for us
Our strategy is build across 3 pillars of activity 1. Ethical Trading
– Direct long term relationships with producers providing a fair economic return for those farmers, suitable living and working conditions for their employees and protection for the natural environment
– 50% of manufactured product is certified – Fairtrade, Organic 2. Environmental Impact
– Commitment to a clean, healthy and safe environment and to conduct our activities in an environmentally responsible manner.
3. Community Responsibility – Seek to do business in a way that positively impacts upon our
customers, employees and the communities where we operate.
Sustainability in Bewleys The Milestones
1992 • Irish Hospice Support
1996 • Fairtrade Mark
2001 • IOGFA certification
2004 • Direct farm relationship with Nicaragua • ISO14001 Environmental Mgt Standard
2006 • Founding member of government initiative: Traidlinks
2009 • Awarded Carbon Neutral Status
2011 • Launch of our Sustainable Coffee Programme: beeco • ISO 14064 Green House Gases. verifies our GHG emissions
2012 • Origin Green Certification
2013 • Paul 0’Toole – Hon Consul of Nicaragua
2010 • Carbon Disclosure Project - Carbon Leader
Sustainability in Bewleys How it works for us
Central to the success of our Sustainability activities is 1. Organisational structure
– Cross-functional “Green Team” – Regular meetings with progress review against KPI’s – Updates on all areas of work and related targets are
issued to all employees as part regular business updates. 2. Board commitment
– Quarterly progress reports to the board of directors against outlined objectives and targets.
3. Management incentivisation – KPI setting and bonus payments incentivise delivery of
targeted sustainability outcomes.
Agenda • ISO14001:2004 Environmental Management System since 2004
• ISO14064-1:2006 Attestation of Co2 emissions – since 2011
• Irish Organics Farmers & Growers Association (IOFGA) Organic Licence & Soil Association Organic Licence.
• First Certified Carbon Neutral coffee company in Ireland in 2009.
• Carbon emissions reduction targets through energy management and waste reduction programmes and we have neutralized the remaining emissions through carbon offsetting.
• Carbon Disclosure Project participant since 2010.
• In the CDP Ireland Report 2011 and 2012, Bewley’s were deemed to be one of Ireland’s Carbon Leaders.
• Comparing 2012 with 2007 data – We have reduced CO2e emissions per tonne of green coffee by 44 %. – Reduction of 50% of electrical kwh per tonne manufactured. – Reduction of 46% of thermal kwh per tonne manufactured.
• Reduction of landfill waste by 37% in 2012 v 2010. Only 8% of total site waste is sent to landfill.
Environmental Impact Credentials
Agenda
Bewley’s Manufacturing Facility
Electricity
Gas
Products
Energy Efficiency: “Producing the same throughput of product using less energy or producing a higher throughput of product using the same energy without impacting on quality”
Improved Energy Consumption Patterns + Greater Efficiency
= Reduced Costs
Agenda
Journey To Energy Efficient Manufacturing
• 2007 Engineering manager attends 3 day “Energy Mapping” seminar
run by SEAI
• 2007 Energy audit undertaken by engineering manager
• Energy is consumed even at zero output! Baseline
• SEU’s of both Thermal & Electrical energy identified as part of energy
audit
• Opportunities for improvement identified (“low hanging fruit”)
• 2010 Energy audit undertaken by Blue Sky Projects
• Opportunities for improvement implemented (capex projects)
• 2012 Energy audit commissioned by Green Business
• Further opportunities for improvement identified
Agenda
Energy Mapping
• Energy Procurement
• Energy Bills Analysis
• Identification of Significant Energy Users
• Energy Measurement Techniques
• Resourcing
Agenda
Process Related Improvements
• Improvements in operational procedures of packing lines – saving of 35,000kWh/annum = €4,200
Agenda
Process Related Improvements
Grinding Test Grinding Run on20 mins 40 mins 15 mins
• Coffee grinding cycle improvements – saving of 30,000kWh/annum = €3,600
• Introduction of some basic controls decreased cycle time by 40%
Agenda
Upgrade to Roaster Controls
Agenda
Education & Awareness
Agenda
Insulation Upgrade 2011
• Coffee roasting equipment as well as various piping etc had insulation replaced.
• This resulted in 10% savings in Thermal energy consumption
Agenda
Lighting Upgrade 2011
• 400w high bay fittings replaced with 200w units incorporating occupancy sensors
• 120w twin 5’ fluorescents replaced with T5 49w single tube fittings • Lighting in 2011 accounted for 23% of total site consumption • Lighting in 2012 accounted for 12% of total site consumption • Energy saving of 50% achieved as part of the lighting upgrade • Payback was 1.6 years.
Agenda
Metering of SEU
• SEU of both thermal & electrical equipment have had sub-metering fitted • Data from meters is collected using a monitoring & targeting system which has
been designed and installed by the in-house engineering team
Agenda
Monitoring & Targeting
Agenda
Efficiency Improvements 2007 - 2012
0#
0.1#
0.2#
0.3#
0.4#
0.5#
0.6#
0.7#
0.8#
2007# 2008# 2009# 2010# 2011# 2012#
kWh/kg&Electrical&
50% Reduction 2007 - 2012
Annual Electrical Energy Usage Per KG of Product
0#
0.2#
0.4#
0.6#
0.8#
1#
1.2#
1.4#
1.6#
1.8#
2007# 2008# 2009# 2010# 2011# 2012#
kWh/kg&Gas&
46% Reduction 2007 - 2012
Annual Thermal Energy Usage Per KG of Product
Origin Green Ambition for 2017
• 13% reduction of Electrical energy consumption per tonne manufactured by 2017 on 2012.
• 13% reduction of Thermal energy per tonne manufactured by
2017 on 2012. • This Means
– Further Site Energy Efficiency Projects led by our Green Team – Monitoring, Targeting & Reporting of consumption – Commitment form all levels of staff – Energy Awareness campaigns
Energy Improvement Target
Agenda
Next Steps
Energy Saving • Green Business Audit Recommendations
– Process Heat Recovery at Roaster – 3 year payback – Further Lighting Control Enhancements
• Nitrogen Filled Tires for Company Vehicles • Oxygen Enriched Combustion • Energy Awareness Training Water Saving • Rain Water Harvesting / Well Water Drilling Waste Improvement • Oxygen Enriched Combustion • Energy Awareness Training
Agenda
Heat Recovery
Therma 2 Roaster
• Recovery of waste heat from roast exhaust which exits at 340 c • Capital investment of €50k would yield annual saving of €16k • Payback = 3 years +
Agenda
Performance Improvement Opportunities in Bewley’s Fuel Based Roasting System
Agenda
Innovative Thinking – Ideas for Development
Oxygen Enriched Combustion:
• Oxygen enrichment raises the flame temperature by
eliminating the diluents effect of nitrogen in air
• An economical source of Oxygen is the key in this case
• The process of Nitrogen generation produces pure
Oxygen as a by-product
Nitrogen Filled Tyres
• Replacing air in tires with Nitrogen will improve MPG >5%
Agenda
Energy usage has been significantly reduced since 2007
• Before any energy-saving measures can be undertaken within an
organisation, it is first necessary to collect comprehensive energy data
through an auditing process
• It is important to justify any capital investment project by carrying out a
financial appraisal of the project
• It is possible to establish the existing energy consumption of a facility
through an energy audit, however this only produces a picture of past
energy consumption – In order to keep control of subsequent consumption,
it is necessary to initiate a monitoring programme
• In many applications there is the potential for recovering heat energy that
otherwise goes to waste.
If we measure it, we can manage it!
Thank You