See new food packaging & processing solutions at PACK EXPO in Chicago
Discover new food packaging and processing innovations from 2,500+ suppliers, all under one roof at PACK EXPO International in Chicago.

Eye on Sustainability

From packaging reductions and recycling projects to water, compressed air, and other utility savings, food and beverage processors have not taken their eyes on the ball when it comes to protecting the planet.

Come to PACK EXPO to meet the SEMA award winners and discuss their sustainability projects.
Come to PACK EXPO to meet the SEMA award winners and discuss their sustainability projects.

In the era or rising inflation, shifting consumer habits, and post-pandemic operational planning, sustainability remains front and center for food and beverage manufacturers.

Concerns about environmental and social well-being are becoming less abstract and more tangible, according to a recent report from the Hartman Group. The research says consumers are reconsidering what sustainability really means to them, how different components of sustainability affect them, and whom they will hold responsible for addressing these challenges.

In the report, 78% of consumers said they are familiar with the term sustainability, yet only 15% can identify a sustainable company. In addition, 28% of consumers told the Hartman Group they are willing to pay more for products from companies that support their values.

All this business intelligence is, of course, extremely important for food and beverage manufacturing success. Consequently, despite the many challenges faced during the height of the COVID-19 pandemic, processors never shifted their eyes away from environment matters. 

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Each year, ProFood World recognizes the leading projects undertaken by food and beverage facilities across North America with its Sustainability Excellence in Manufacturing Awards (SEMA). Given for one-time projects as well as ongoing programs, the awards honor companies and individuals that seek to go beyond environmental compliance. In 2020, ProFood World added a new category to the SEMA awards—the Processor/Supplier Partnership Category—to recognize the growth and importance of collaboration between processors and industry suppliers in protecting the planet.

All entries were judged by a team of food industry peers. The winners will be honored at a special session at PACK EXPO Las Vegas on Sept. 27.

FIRST PLACE | Program Category

B&G Foods’ Water Reduction Program Empowers Employees to Make a Difference

With a goal to minimize its environmental impact, B&G Foods’ Cincinnati Crisco facility has been on a journey to reduce water usage for the past 10 years. In 2020, the plant implemented several water-reduction projects, including the revision of temperature settings for process operations; installation of an air-cooled air handling unit in place of a water-cooled unit; and implementation of program changes to automate water valve shutoffs, according to Plant Engineer Karen Hales. “These changes resulted in a reduction of water usage by 19.5% vs. the prior year, despite an increased production volume of 38%,” she states. The 2020 project’s return on investment was achieved in four months. 

Installation of an air-cooled air handling unit in place of a water-cooled unit at B&G Foods’ Cincinnati facility has significantly reduced water usage.Installation of an air-cooled air handling unit in place of a water-cooled unit at B&G Foods’ Cincinnati facility has significantly reduced water usage.

Since 2011, the site has reduced water consumption by more than 250 million gal, equaling a greater than 75% reduction. The program benefits not only the company in terms of lower costs, but also the community and future generations by conserving a valuable natural resource. “With a focus on minimizing water use, this program can be integrated into many manufacturing and community programs,” Hales explains. “We have also shared our learnings with many other manufacturing sites.” 

Key facets of the program include eliminating once-through water applications, optimizing process temperature settings, automating water shutoffs, maintaining water systems, and driving continuous improvement with data analysis.

Hales says the water reduction program has evolved over the past 10 years at the Cincinnati Crisco site. “On this journey, we have incorporated learnings from other manufacturing plants on water reuse, partnered with consultants, and tapped into our employees’ insights and knowledge,” she says.

Installation of an air-cooled air handling unit in place of a water-cooled unit at B&G Foods’ Cincinnati facility has significantly reduced water usage.Installation of an air-cooled air handling unit in place of a water-cooled unit at B&G Foods’ Cincinnati facility has significantly reduced water usage.

“Continuous improvement is achieved by data collection, trend analysis, feedback communication, and the continued mindset to challenge the status quo,” Hales states. “Our motto, which we share with all new employees to the site, is ‘Our actions can impact the Earth…Welcome to Team Earth.’”

SECOND PLACE | Program Category (Tie)

Conagra Brands Succeeds With Compressed Air, Steam, and Vacuum Leak Reduction Project

This award-winning initiative involved Conagra Brands’ Menomonie, Wis., facility purchasing an ultrasonic imager. The imager detects compressed air and steam leaks in the facility and provides a survey for every leak that is detected, including an ultrasonic picture showing exactly where the leak is, the CFM rate of the leak, and the associated annual energy savings in kilowatt hours, depending on the local electricity prices. “We developed a program where maintenance will go out and use the imager to find air and steam leaks,” says Maria Peers, senior manufacturing system engineer.

Conagra Brands’ Menomonie, Wis., team displays the ultrasonic imager that helps it identify air leaks.Conagra Brands’ Menomonie, Wis., team displays the ultrasonic imager that helps it identify air leaks.

"The area planner creates the work order for the leak to be fixed,” says Peers. “We have a tracker where we document all leaks, including the summary report from our partner vendor with the potential cost savings and kilowatt hours saved, the work notification, work order number, and date of completion. We review the status of the leaks monthly.”

After five months, the Menomonie facility saved 152,829 kWh of electricity, equal to saving about $17,000, by fixing compressed air leaks. The ultrasonic imager allows the plant to identify leaks while equipment is running. The project eliminated more than 95 metric tons of scope 2 greenhouse gas emissions.

“The imager was purchased in March 2020, and we started using it shortly after then,” says Peers. “Prior to purchasing the new imager, we were able to see how the unit worked to make sure it was worth the investment.”

The payback was realized in less than six months. “This tool makes it very easy to identify and understand how large a leak is and the associated electricity cost,” adds Peers.

SECOND PLACE | Program Category (Tie)

Conagra Brands Facility Pursues Zero Waste Recycling

At Conagra Brands’ Waterloo, Iowa, facility, “stars and bars” are small pieces of plastic created when formed cups are cut and separated. “Our stars and bars have long been a recycling challenge, because a foil lid stock is attached to the plastic,” states Plant Manager Steve Schultz. Recycling the waste has been a challenge for the past several years, forcing the facility to landfill this material, affecting the site’s landfill diversion efforts.

Working with a new vendor allows Conagra Brands’ Waterloo, Iowa, facility to ship waste instead of landfilling it.Working with a new vendor allows Conagra Brands’ Waterloo, Iowa, facility to ship waste instead of landfilling it.The Waterloo facility worked with its material supplier, which recently partnered with a recycling center, to invest in equipment to delaminate the foil from the plastic, making both materials more readily recyclable.

“With this new vendor, we are able to divert about 80,000 lb of plastic from the Waterloo, Iowa, landfill per month, which represents over 10% of the site’s total waste,” according to Schultz. “By recycling these materials, we are limiting our impact associated with plastics in landfills.”

There has been a significant labor reduction at the plant since completing this project. “Prior recycling efforts constituted baling the stars and bars, which is a labor-intensive task,” explains Schultz. “The new method requires far less hands-on work, reducing exposure to ergonomic and other types of hazards.”

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