Enlightening - motivating - insightful: three words that totally capture the essence of an event that left participants excited about sustainability initiatives, energy management opportunities and the benefits of ISO 50001 implementation. A day of peer best practice sharing with Campbell's Company of Canada, St. Marys Cement and Pepsico Foods Canada, resources and web links, and training... It was a day that left a definite imprint on our minds and a sense of urgency that we need to begin or enhance our energy and sustainability programs today.
Excellence in Manufacturing Consortium (EMC) in partnership with Natural Resources Canada (NRCAN) and the Canadian Industrial Program for Energy Conservation (CIPEC), were all extremely pleased to host this very first special event for those in the Food, Beverage and Bio-Processing industries to better understand energy management practices and the practical applications and benefits of ISO 50001.
After a warm welcome and brief overview of EMC, NRCAN and CIPEC - we introduced three key industry stakeholders who have made significant strides in their Energy Management and Sustainability Programs:
Douglas Dittburner, Manager, Power Services - Campbell's Company of Canada
Martin Vroegh, Environment Manager and Fabio Garcia, Plant Manager - Bowmanville - St. Marys Cement
Helmi Ansari, Director of Sustainability and Org. Capability - Pepsico Foods Canada (Keynote Speaker)
Each of these companies have received multiple awards relating to their efforts in as far as energy management and sustainability initiatives and two have been recognized as "10 Companies that are Making a Difference". Having them share their journey's with those present was incredibly motivating and through questions, roundtable networking and discussion, participants were able to develop some practical ideas on how they might implement similar ideas, processes, improve communication, present business cases, and take advantage of opportunities within their own facilities.
Industry expert - Phil Dick, Business Resource Specialist - with the Ontario Ministry of Food and Ministry of Rural Affairs - provided an overview of his experiences and Manual "Leaner and Cleaner is Greener" and ISO 50001 Trainers - Stephen Dixon and Laurie Gregg of the TD Dixon Team examined the opportunities available in ISO 50001 implementation. Table top displays from CEM Engineering, Enbridge Gas Distribution Inc., GE Water & Process Technologies, Hydro One Brampton, Enersource, Ontario Power Authority, Milton Hydro and SAI Global were all on hand to share their expertise as well.
A few highlights from the day's event!
St. Marys Cement - Bowmanville, ON
Martin Vroegh, Environment Manager and Fabio Garcia, Plant Manager (Bowmanville)
We learned a great deal from both Martin and Fabio and certainly came to a whole new appreciation for the cement/concrete industry. Interestingly enough, in addition to the production of cement, metals and steel - did you know that St. Marys is also the largest orange juice producer in the world?
Our speakers noted that 50% of their manufacturing costs are related to energy. As they began their journey to reduce costs, they knew it was essential to foster an understanding of energy usage and a philosophy of energy conservation. They started this by encouraging at home initiatives first - trusting that this would inevitably transcend into plant activities.
St. Marys subsequently developed - E=MC2 - "Energy Management Conservation" - a program that is designed to look for opportunities in energy management and savings and engages employees from all areas of the organization (HR, Procurement, Finance, etc.). Implementation success was achieved through incremental steps which began by recognizing the importance of gaining employee engagement from the beginning and encouraging adoption of energy savings opportunities at home and at work. Their plan:
1. Create Awareness
- Communicating and sharing information as much information as possible related to the E=MC2 - Energy Management Conservation program
- Looking for the inefficiencies and opportunities
- Examining processes
- Conducting the Global Assessment Energy Performance and Benchmarking questionnaire for employees to gauge understanding
3. Create Momentum
- Marketing and image
- Tackling low hanging fruit opportunities (those that had no capital requirements and could bring back an immediate ROI)
- Constantly monitored and continue to monitor wholesale price of electricity to plan operations
- Introduced trigger points and alarms - these are set to go off as pre-determined demand thresholds are approached
- Monitoring and control of software and power usage
- Taking advantage of opportunities to teach how energy is used at home and at work - involvement in promotion and awareness during "Energy Savings & Environmental Week"
4. Training and Workforce Engagement
- Applying systems that result in savings for the organization
- First plant to be ISO50001 certified in North America
- Energy Star participant
- UK Certified in Energy Excellence
Through their E= MC2 - "Energy Management Conservation" Program, they have continued to sustain and build on employee engagement by supplying ongoing information and incentive programs that encourage better and more sustainable practices ie. fridge meter installation, understanding the link between driving habits and fuel consumption, etc. They hold regular open houses and embrace the opportunity to share their journey to help others embrace opportunities of this nature. St. Marys was recently featured in an excellent article by the National Post - "The Power of Teamwork" - that highlighted their energy saving activities!
Campbell's Company of Canada - Toronto, ON
Douglas Dittburner, Manager, Power Services
Campbells Soup Company is a leading food and beverage manufacturer for more than 140 years. Campbell's set ambitious goals for 2020 which involves cutting their environmental footprint in half, reducing energy use by 35% per tonne of product, sourcing 40% of energy used from renewable or alternative energy sources, reducing water usage by 20% and recycling 95% of their waste generated on a global basis and advancing sustainable packing initiatives with renewable, recyclable or recycled content materials. Their mission statement speaks to the underlying importance of "commitment" not just today - but "every day". They are actively involved in the Energy Leaders Consortium and their Corporate Social Responsibility Report clearly outlines their global commitment and concentrated focus on creating a more sustainable environment. Did you know that 68% of all of their ingredients are within a 3-hour drive of their facility!
Presently, on a global basis, 85% of their waste is recycled and they have been successful in saving more than 4.4 billion gallons of water since 2008 and reducing greenhouse gas emissions by 83,000 metric tonnes in 2012.
In 2013, the team at Campbell's in Toronto spent a week doing a "Zero Loss Analysis" (ZLA) and identified a number of energy savings project ideas. They drilled it down to the top 12 and categorized the opportunities that might render the best results, looking at things such as:
- High Efficiency Lighting
- Standby Cookers - Reduction of Standby Time
- Powerhouse Topping Turbine
- ACC Process Production Changes
- Flash Steam Recover
- Implementing BOD Reduction Technology
- Reroute Reclaimed Tempered Water from Storks
- Water and Heat Recovery from ACC Cooling Water
- Compressed Air System Process Changes
- Steam Trap Repair/Replace
- Behaviour based opportunities
- Condensing economizer
- Thermal Breaks for Loading Docks Areas
They developed a new Energy Team:
- Established a Charter, Vision and Mission
- Set up training and meetings
- Developed an energy team name and special logo
- Looked at ways to build knowledge and awareness
- On Earth Day, as an example, exhibits were set up by various providers for employees
- Prepared shut down lists and audits that identified opportunities
- Led an energy idea campaign that resulted in an "idea database" from more than 156 ideas generated!
- Established an energy board with weekly tips, etc.
Doug shared an interesting story relating to steam traps. Campbells has 438 of them and 28 of their traps were leaking. They figured that steam losses equated to almost 2,137 tons per year and when converted into dollars, that meant annual losses just for these 28 traps alone amounted to $64,952 on an annual basis.
Similarly, thinking about opportunities of this nature, a simple tap dripping once per second can culminate in about 86,400 drips/day which translates into 2,082 gallons/year! Preventing that leakage can also result in phenomenal savings.
Using their experience with the Steam Traps, the Team at Campbell's used that example to develop a "WANTED" poster that looked for other ideas - encouraging employees to look for similar savings opportunities! Our speaker referenced a great quote by Dr. Seuss in this regard:
"Think left and think right and think how and think high. Oh the thinks you can think up if only you try!"
There are any number of reasons why a company needs to focus on Sustainability - and for Campbells Soup Company, the three critical pieces all centre around:
Doug encouraged us all to help save the planet, it's the only one we have that has soup!
Ontario Ministry of Food and Ministry of Rural Affairs (OMAF/MRA)
Phil Dick, Business Resource Specialist
Well known to those in the sector, Phil has considerable experience working with infrastructure, energy and environmental opportunities in Ontario's food industry. We were delighted to have him provide an overview of his "Leaner and Cleaner is Greener" Manual. This book contains lots of wonderful information, resources, best practices and case study scenarios. His presentation was titled "Intelligent Technology and the 8-5-3 Method - Managing CO2 as a Gross Margin Benefit" and addressed the opportunities through the 3 C's (cost, calories (energy) and carbon) via 8-5-3 (8 technologies in food plants, 5 zones, and 3 steps).
Phil mentioned that any efficiency projects should be cumulative and left us with the thought that planning is imperative and that "If you do a great project at the wrong time - it can shut a plant down..." He spoke in reference to the background, methods and targeting opportunities for 3C utility management. Phil also shared thoughts around readying and opportunities and types of support available including potential funding via GF2 (Growing Foward 2).
If you would like more information on the "Leaner is Cleaner and Greener" Manual and 8-5-3 steps or in learning how GF2 might be applicable to your organization in this regard, please feel free to contact Phil at anytime (email@example.com).
Frito Lay - Pepsico Foods Canada
Helmi Ansari, Director of Sustainability and Org. Capability
Perhaps one of the most compelling presentations delivered at this event was that from our Keynote Speaker which broached the topic of Sustainability - what does it really mean and what can we do and more particularly on the inroads PepsiCo Foods has made on their global Sustainability journey. Helmi spoke with passion and such confidence, and backed up his discussion with relevant and impactful examples of why we need to embrace every opportunity to reduce - if not eliminate - reuse wherever we possibly can - and recycle as much as we can right now. Beginning and sustaining practices that reduce energy, water and waste usage and look at more efficient methods and practices are critical.
Did you know?
- The population is doubling every 65 years or so...
- That in 1912 there was only about 1 Billion people... today, every 12 years that passes adds 1 Billion more people...
- 30% of the world's food supply is impacted by drought and that 1/3 of our supply is dependent upon glacier fed rivers for food...
- The long term trend for fish is near total collapse... there are 438 dead zones in the ocean...
- Sadly, waste is the single largest creation of our species... in nature the life cycle naturally reuses waste... think of a tree...
- The single largest structure is a NY landfill which is now closed and re-purposed as a park...
Helmi referenced a book that he recently read entitled "Slow Death by Rubber Duck" by Rick Smith and Bruce Lourie that addressed issues around micro pollution. He also spoke of other issues including:
- Climate change
- Species extinction
- Energy present and future
- Emerging global Water crisis
- Need for Ecological management for economic stability and growth
- The global opportunity around addressing human Hunger
He suggested that business, people and government really need to work together and that not unlike the Scouts motto "Leave no Trace" - this has to be the only goal. With that in mind, Helmi shared an overview of the PepsiCo Foods Journey.
In the early 90's, they developed Green Teams and in 1999 had dedicated resources and goals established. It wasn't until 2008, that they officially began their journey to Near zero waste. Through the years they have implemented many different projects, have won several awards and were recently featured in the National Geographic who did a case study on their Near net zero energy plant in Arizona. Their global commitment is outlined in their Corporate Responsibility Report http://www.pepsico.com/download/PEP_Annual_Report_2012.pdf.
- What: COMPLIANCE - conservation - sustainability
- How: PEOPLE (Process and Technologies) - engaged teams - technically competent
Helmi mentioned some of the initiatives that they have put in place or are tackling up and down the supply chain:
- They are diligently working with suppliers... looking for savings opportunities...
- They measure everything! He even had a team do a "dumpster dive" and through that, they identified 58 categories of waste and members were then tasked with finding someone who could use it. They pulled $4 Million in revenue from landfill opportunities. And, in reusing their boxing 6-7 times, they have generated almost $45 Million in savings!
- Most LEED certified plants in NA
- By talking with their drivers (they have 1500 in Canada with daily routes) and implementing GPS systems to maximize delivery options, they were able to save $1 Million in associated transportation costs! They were also the first fleet to employ all Electric delivery fleets as part of their overall fleet to achieve zero carbon/emissions with those vehicles!
- Currently they are working on a net zero frying footprint for Sunchips and the utilization of potato water to help make potato chips
Helmi left participants thinking about how every single thing can have an impact on the bottom line. So far, PepsiCo has been able to cumulatively save almost $80 Million in Canadian plants alone. He said that we should all be on a similar quest - that is for all mankind to live well, forever, and that we can do 'well' by doing 'good'.
ISO 50001 - Energy Management Systems Standard - Workshop
Stephen Dixon and Laurie Gregg - TDS Dixon
Our Best Practice presentations spoke to the benefits they found in implementing ISO 50001 and both mentioned that this was one standard in particular wherein there was an ROI to put against costs. As identified by all of our participants, energy management and sustainability begins with each of us and the challenge now is how to move energy savings initiatives up the ladder - ISO 50001 is designed to help with that.
ISO 50001 is a program designed to help organizations implement an Energy Management System (EnMS) that allows companies to measure, track, manage and continually improve energy performance.
Benefits (from NRCAN - ISO 50001 Energy Management Systems Standard, 2012):
By adopting ISO 50001, companies of all types and sizes can
- reduce energy costs and greenhouse gas emissions
- make better use of the energy-consuming assets
- evaluate and prioritize the implementation of energy-efficient technology
- market themselves as energy efficiency leaders to both customers and suppliers
For more information on the ISO 50001 program, please visit the NRCaN website at: http://oee.nrcan.gc.ca/industrial/cipec/13120.
Without a doubt, it was a day that left us eager to embrace the opportunities in our own organizations and excited to share the possibilities with others!
Table Top Exhibitors:
CEM Engineering - www.cemeng.ca
Enbridge Gas Distribution Inc. - www.enbridge.com
GE Water & Process Technologies - www.ge.com
Hydro One Brampton - www.hydroonebrampton.com
Enersource - www.enersource.com
Ontario Power Authority - www.powerauthority.on.ca
Milton Hydro - www.miltonhydro.com
SAI Global - www.saiglobal.com
Special thanks to our Guests from St. Marys Cement, Campbell's Company of Canada, PepsiCo Foods Canada, OMAF/MRA, and TDS Dixon, all of our Table Top Exhibitors and Participants!
All the best as always,
Sr. Community Development and Food and Beverage Manager
firstname.lastname@example.org - 519-372-6009