Operations

Midwest North Pride

Beloit, WI Operations#1 in All We Do!

Mike StahlTechnical Manager

Operations

Midwest North Pride

Frito Lay Beloit Service AreaFrito Lay Beloit Service Area

Region Profile:

• 45% DC

• 55% Bin

TCN DCBloomington DC

Madison DC

MFSC

FVSC

Davenport DC

Des Moines DC

Omaha DC

• 8 DC’s: TCN, Bloomington, Milwaukee, Omaha,

Madison, FVSC, Des Moines, Davenport• 202 Bins• 600MM units Annually• 44.8MM cases in 2008 (Plan)• 1118 Vehicles (2nd Largest Fleet)• 2nd Largest Geography (8 States)• 85% of potatoes sourced from Wisconsin

Oak Brook DCCarol Stream DC

Summit DC

Northbrook DC● Beloit

Operations

Midwest North Pride

Make Move

Sell Support

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Technology

Practices External

3PepsiCo Confidential

Frito Lay Beloit, WI The Pre-Eminent Green Company

Operations

Midwest North Pride

Water Natural Gas Electricity

Gal /

Lb

BTU

/ L

b

kw

h /

Lb

36%

21%

3000

3200

3400

3600

3800

4000

4200

4400

4600

4800

'99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '091

1.5

2

2.5

'99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09

51%

Frito Lay Beloit – A Pre-Eminent Green Company in Wisconsin

•2010 Wisconsin Manufacturer of the Year Award Grand Sustainability Award

•2010 Business Friend of the Environment Award

•2010 EPA Waste Wise Partner of the Year Award

•2009 Wisconsin Green Tier Acceptance

•2009 Wisconsin DNR Clean Air Award

•2009 Governors Award for GHG Emission Reductions

•2008 – City of Beloit proclaims FL Eco-Friendly Business

500

550

600

650

700

'99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09

Tradition of Excellence

Operations

Midwest North PridePeople Engagement Processes….

Daily Performance Reviews/Action Planning on the Frontline……

Resource Conservation Tracking…gas, water, electrical per pound usage

Operations

Midwest North PrideSustainable Processes….

Structured MX Systems Infrared and Ultrasonic Scanning

Boiler Room Set point or Status

Booster Pumps Range 80 to 100 PSI

Booster Pumps Pump A or B A B A B A B A B A B A B A B

Trace Line Skid Return Temperature

Feed Water Pump A or B A B A B A B A B A B A B A B

RO System Running in Auto Yes No Yes No Yes No Yes No Yes No Yes No Yes No

Water Meter Usage

Boiler Running 1 or 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

Boiler 1 usage

Boiler 2 usage

Softeners Running Yes No Yes No Yes No Yes No Yes No Yes No Yes NoCompressed Air

System Set point or Status

Glycol Pressure PSI

Glycol Pump A B A B A B A B A B A B A B

Glycol Incoming Temperature < 75

Centac 400, Oil Temperature < 114 deg F

Centac 500, Oil Temperature < 120 deg F

Site Air Pressure > 88 psi

Sullair 450, Interstate Temperature < 225 deg F

Dryers range 34-39 deg F

Team Member Initials:

Sunday Monday Tuesday Wednesday Thursday Friday Saturday

1st Shift Powerhouse Walk Period ________________

Week ________________

Quarterly Combustion Checks and Tuning of Ovens and Heat Exchangers

Weekend Load Optimization ….. Compressor shedding, boiler turndown, etc.

Other Resource Conservation Activities

Operations

Midwest North Pride

High Efficiency Burners UpgradeHigh Efficiency Burners Upgrade

PC Stack HR Phase IIPC Stack HR Phase II

Wet Cake Electric GeneratorWet Cake Electric Generator

WWT Blower VFDWWT Blower VFD

Power Correction CapacitorsPower Correction Capacitors

Nitrogen PSA Generation Nitrogen PSA Generation

MPC 50 Broach Mx ScheduleMPC 50 Broach Mx Schedule

Compressed Air OptimizationCompressed Air Optimization

MPC 50 Broach to dry StarchMPC 50 Broach to dry Starch

Air Compressor WHRAir Compressor WHR

BioMass Boiler – In ProgressBioMass Boiler – In Progress

PC50 Stack Heat Recovery Eng.PC50 Stack Heat Recovery Eng.

Belt Press Upgrade Belt Press Upgrade

Compressed Air to C. BlowerCompressed Air to C. Blower

Adsorption ChillerAdsorption Chiller

Biomass Boiler StartupBiomass Boiler Startup

WH to ElectricityWH to Electricity

TC1 Stacks Heat RecoveryTC1 Stacks Heat Recovery

UVGI Technology in HVACUVGI Technology in HVAC

Revised SOP in WWTRevised SOP in WWT

Initiate Air StudyInitiate Air Study

Effluent Pump Recycle H2O Effluent Pump Recycle H2O

Air Compressor WHR

Air Compressor WHR

PC Stack Heat Recovery Phase IPC Stack Heat Recovery Phase I

WWT OptimizationWWT Optimization

Boiler EconomizerBoiler Economizer

Demand ExpanderDemand Expander

2007 2008 2009 2010 2011 - Projected

Bio-Solid FertilizerBio-Solid Fertilizer

Long Range Strategic Planning

Technology Tactics > 150% of Target

Operations

Midwest North PrideWaste Heat Recovery Projects…..GHG Reduction Enabler

3000 MT Scope 1 CO2e Emissions

Operations

Midwest North Pride

0

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2005 2006 2007 2008 2009

Frito Lay Beloit, WI – GHG Emissions

Combining People, Systems and Technology Blended Approach

24% Reduction7,100 MT CO2e

Operations

Midwest North PrideBeloit “Near Net Zero” Strategy

Biomass BoilerBiomass Boiler TC Waste Heat RecoveryTC Waste Heat Recovery

Beloit MBBR TreatmentBeloit MBBR Treatment

LEED GoldLEED Gold

PC Waste Heat RecoveryPC Waste Heat Recovery

Waste Heat KaizensWaste Heat Kaizens

c Zero Landfill (1st site in FLNA)Zero Landfill (1st site in FLNA)

Sustainability LeadershipSustainability Leadership

Electrical KaizensElectrical Kaizens

Operations

Midwest North Pride

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2005 2006 2007 2008 2009 2010 2011 2012 2013

Continued Waste Heat Recovery and other technologies enable another 40% GHG emission reduction from current day performance…..

Establishes an option for future zero carbon footprint growth….

Beloit remains competitive with sister plants in Topeka, Kansas and Frankfort, Indiana…..

Frito Lay Beloit – GHG Flight Plan (scope 1)

60% GHG Reduction <10 Years17,800 MT CO2e

Like 3400 vehicles of the road

Operations

Midwest North PrideFleet Resource Conservation Initiatives

EPA SmartWay Certified Fleet…..Gap Farings, Auto Tiring Inflation, etc.

Leveraging Idle Free Technology….Wabasto Heaters

30% Idle Reduction26,000 Gallons YTD

230 MT CO2e

Driver MPG Challenge Contest Every Period

Operations

Midwest North PrideFrito Lay Beloit – A Zero Landfill Leader @ <1%

Continuing the Journey to ZeroPeople, Processes and Technologies in Place

Landfill Reduction

0

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140000

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Months

Po

un

ds 2008

2009

2010

55% Landfill Reduction

Operations

Midwest North Pride

We have goals aligned to our Pre-Eminent Green VisionWe have goals aligned to our Pre-Eminent Green Vision

45%

50%

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1999 2007 2017

% B

TU

/ L

b

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1999 2007 2017

% k

wh

/ L

b

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1999 2007 201760

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2004 2007 2017

% G

AL

Water Natural Gas

Fuel

50%

% G

AL /

Lb

75%

14PepsiCo Confidential

Electricity