green & lean initiatives clare mcenroe tom fuery cdfoods

Green & Lean InitiativesClare McEnroe

Tom Fuery

www.cdfoods.com

EDGEWORTHSTOWN 1969- Pouch/ Alu Tray

DRIFFIELD 2004- Dry

IJMUIDEN 2010- Cans

C&D Foods• Established in 1969 (Cans)• 1990 Aluminium trays • 1994 Research Centre 1994• 1999 Can expansion • 2001 Pouch Investment • 2004 Dry Acquisition (UK)• 2006 Major Fire • 2008 Major Pouch investment • 2008 Strategic partnership ABP • 2010 Acquired Nestle plant in Imjuiden (cans) • 2012 Acquired Arovit Group

New C&D Foods Group 2012

Driffield- Dry

Edgeworthstown- Pouch / Alutray

Larkshall- Dry

IJmuiden- Cans

Valladolid- Dry

Birkfeld Treats/ Sausages/ Alutray

Mullingar- HQ

Esbjerg- Pouch / Alutray /Cans

C&D: UK & Ireland Customer OverviewLaunch dates1969 – 1975

1976 - 1985

1986 – 1995

1996 -2003

2003 -2009

2010-2013

LEAN & C&D

• Lean introduced to C&D Foods in 2006• Top level value streams E2E and NPI

(Projects)• Training of Management and Operators

(ongoing)• SMED• Visuals/Controls • Info Points

• Work process flows• SOPs• 5S• OAC

• Kaizen• CI Teams and Control Boards A3 Boards

Green and Lean – Where to start

8 Different Types of Waste

Overview

• Energy reduction

• Water conservation

• Waste awareness

Water usage in C&D

• Water is most valuable resource• 450m3 required per day• Extracted from on site wells• Review carried out of all water treatments and

production processes for ways to conserve water.• Some successes, some rethinks required !

Water Conservation Projects

• Iron Filter backwash reduction• Iron filter back wash reduced from 56 minutes to

16 minutes

• Reduction in softwater used in regeneration process• Reduction in Stage 1 reverse flush from 9 minutes to 5

minutes

• Reuse of RO permeate•Installation of extra RO membrane for RO permeate

• Water reused as soft water• More reuse possible

Water Conservation Projects

• Reuse of cooling water

–Soft water used in cooling tools for pouch filler– Initial project was collection and reuse of softwater. – Correct installation required to reduce contamination risk.– Currently control valves in place, water no longer re-used

but is reduced.

RO Permeate 6 m3

Water Softener Regen 3 m3

Cooling Water Reuse 13 m3

Water Savings

35 m3/day

Iron Filter Backwash 13 m3

13,000m3/annum

Energy Usage at C&D

• Energy is required for– Steam Generation.• Cooking and Sterilising product

– Hot Water.• Cleaning & Sanitising

– Motive Power (Motors, Compressors).• Production and Facilities

– Space Heating & Lighting.

Energy Usage at C&D

• Improve burner efficiency• Recover heat from exhaust gases• Pre-heat boiler feed water• Reduce steam losses• Change Fuels

• Improve burner efficiency• Recover heat from exhaust gases• Pre-heat boiler feed water• Reduce steam losses• Change Fuels

Options to Save Energy at the Boiler

Exha

ust G

as

Feed Water

HFO

Steam at 9 bar

Boiler Feed Water

50-55C

Boiler Feed Water Pre-heat

Condensate Return

80-85C

Retort Return Water

35-40C

Soft Water

Ambient Temperature4-15C

Boiler Feed Water

70-75C

Stea

m

inje

ctio

n

• Average Weekly HFO Consumption– Down by 1800 litres/week– 5.95% reduction per Tonne produced

– Average CO2 reduced by 5.6 Tonne/week.

Effects to Date

95,000 Litres/annum

Waste Awareness

•Waste mapping carried out and displayed the waste generated in the canteen in one day to staff

•Implemented a “bin-less” office

•Set up recycling stations in canteen

•Carried out waste mapping of site.

Learnings

– Challenge the Status Quo– Utilise all resources, workers,

contractors they have the knowledge– Allow for change to happen, monitor closely,

be confident– Keep communicating change to encourage new

idea generation.

Green & LEAN C&D

Questions ?Clare.mcenroe@cdfoods.com

Tom.fuery@cdfoods.com