green & lean initiatives clare mcenroe tom fuery cdfoods
DESCRIPTION
Green & Lean Initiatives Clare McEnroe Tom Fuery www.cdfoods.com. 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 - PowerPoint PPT PresentationTRANSCRIPT
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
