Manufacturing: food and drink Ten Quick Wins to cut costs, save energy and streamline production

April 18, 2011 - PRLog -- Food and drink manufacture is a highly competitive industry so it is essential to maintain a tight control on production costs. Keeping energy and water consumption to a minimum helps a businesses bottom line. And of course it has the added effect of reducing environmental impact.

Energy consultant Sam Jones of SUSTAIN Lincolnshire has developed a ‘Ten Quick Wins’ plan aimed specifically at helping food and drink manufacturers cut back on energy useage. The suggestions highlight areas where improvements could be possible with relatively little effort and quick pay back times. In general, these actions would represent the first steps in reducing environmental impact and further improvement will be possible through the development and implementation of a more comprehensive environmental management plan.

10 QUICK WINS

Reduce electricity consumption
1. Improving energy monitoring is the key to managing energy consumption. If you are on a maximum demand electricity tariff you should be able to obtain half-hour data from your supplier. Calculating your useage during non-operational hours will help identify waste – what’s being left on unnecessarily?
The Carbon Trust helps provide guidance on improving energy monitoring and management. http://www.carbontrust.co.uk/cut-carbon-reduce-costs/calc...
2. Compressed air is an expensive commodity and air compressors are only about 10 per cent efficient. Inspect systems regularly for leaks. A drop of one bar (psi) can result in a six per cent reduction in electricity consumption. Find out how to test for leaks: http://www.carbontrust.co.uk/cut-carbon-reduce-costs/prod...
3. Refrigeration is a major expensive. Studies have shown there are between 15 and 20 per cent efficiency savings to be made. The first step is to minimise the heat load by allowing products to cool before they are refrigerated. Check out this guide:  http://www.ior.org.uk/ior_/images/pdf/general/REI-G5%20Si...  

Segregate waste to save money
4. Cross contamination of waste streams can lead to higher disposal costs – especially in the case of hazardous waste which carries a premium. Separate waste at source - train staff and colour code bins if it’s helpful. Negotiate waste contracts carefully to minimise costs and maximise recycling.

Design packaging for efficiency
5. Waste can be reduced through clever design while retaining the integrity of the product. Think about efficient distribution when designing packaging too. And avoid systems that require heat shrinking.
The Guide to Evolving Packaging Design published by WRAP is available online: http://www.businesslink.gov.uk/bdotg/action/layer?topicId=1082980364&r.s=e&r.l1=1079068363&r.lc=en&r.l3=1083106864&r.l2=1082900135&r.i=1083107227&r.t=RESOURCES#
Also see Reduce Your Environmental Impact by Good Packaging Design: http://www.businesslink.gov.uk/bdotg/action/layer?topicId=1082980364&r.s=e&r.l1=1079068363&r.lc=en&r.l3=1083106864&r.l2=1082900135&r.i=1083107227&r.t=RESOURCES#

Reduce water use
6. Where possible water used in the manufacturing process should be re-used – in other processes, if not the same one.
7. Adjust flow rates of water to suit production using a gate valve or flow restrictor.
Read Water Minimisation in the Food and Drink Industry and a case study document: http://envirowise.wrap.org.uk/uk/Sectors/Food-and-drink/GG349-Water-Minimisation-in-the-Food-and-Drink-Industry.html
http://www.fdf.org.uk/publicgeneral/federationhousecommitwaterreduc.pdf

Work with your supply chain
8. A collaborative approach can make it easier to improve efficiency and reduce waste. Work with suppliers and customers. Can packaging be re-used and backloaded onto delivery vehicles? Can products be pre-prepared? There are potential money savings and efficiencies across the entire chain.
9. Purchase powders in pellet form or big bags which create less residue.

Improve reporting and raise awareness
10. Report waste as a percentage of production to focus minds on its importance. Targets to reduce waste can then be set.

SUSTAIN Lincolnshire is a project offering free support to help small and medium sized businesses introduce environment management systems. Energy consultants work with qualifying companies to identify areas where they can save money through reduced energy consumption with the knock on effect of a reduced environmental impact.

SUSTAIN’s consultants offer free help to enable individual businesses formulate and introduce an environmental management system. In some instances help is also available to identify grants to help towards the cost of the work.
For more information contact the SUSTAIN team on 01522 589964, email sam.jones@pect.org.uk or visit the website http://www.pect.org.uk/sustain