Energy Efficiency in Process Nov 20th – Aviva Stadium

Future in Food Ireland

Eamonn Diver Engineering Manager

Agenda

•  About Bewley’s

•  Our Sustainability Journey

•  Energy Efficiency to-date

•  Next Steps

Agenda

About Bewley’s

Delivering an exceptional experience is what we have been doing for over 150 years

Campbell Bewley Group

•  Private family owned company

•  5 main operating units – Bewley s (Ireland), Java City (Sacramento), Rebecca s (Boston), Darlington's (UK - 2011), Bolling Coffee (UK - 2013)

•  Group turnover €100m. Over 1,000 employees.

•  Profitable; debt free

•  Approx. 6,000 tonnes of coffee annually

•  3 Production / Distribution Facilities: (Dublin, Meltham & Sacramento)

•  Established 1840. Largest roaster in Ireland and in the top 3 coffee suppliers in the combined Irish and UK market.

•  Ireland’s market leading fresh coffee brand with 90% overall brand awareness.

•  Core business: provision of fresh coffee and related hot

beverage solutions great; profitable programmes for operator

Foodservice –  Over 4,500 wholesale customers, across offices, cafes, hotels,

convenience stores, contract catering operators –  Approx 40% of out-of-home fresh coffee market.

Retail –  Approx 15% of Retail fresh coffee market. –  Over 7% of Retail regular tea market.

Contract Manufacturing –  Private label coffee and tea products for retailers\foodservice

operators

Bewley’s Key Facts

Sustainability is part of our DNA..

. Why this is important ? • Sustainability of quality coffee supply from origin

–  Commodity price movements and the fundamental shortage of coffee –  Climate Change impacts – drought etc.. –  Land-use issues and competition for crops –  Most rapid deforestation is in the regions where the best coffee is produced

• “The right thing to do” – within the Bewley’s ethos. • Board commitment • Meeting consumer demands for traceability and also transparency in relation to ethical and environmental credentials.

–  Our consumer wants to participate i.e. what can I do? – seeking a ‘co-responsibilty’ opportunity. They are looking to business to provide a platform for this.

• Cost savings - more effective and efficient use of resources which usually results in reduced costs. For example, Energy Efficiency, Fuel Efficiency projects etc..

From our origins as a Quaker owned company, Bewley’s have always been committed to working in a sustainable and positive manner with both the natural

environment and the communities within which we operate.

Sustainability in Bewleys

How it works for us

Our strategy is build across 3 pillars of activity 1.  Ethical Trading

–  Direct long term relationships with producers providing a fair economic return for those farmers, suitable living and working conditions for their employees and protection for the natural environment

–  50% of manufactured product is certified – Fairtrade, Organic 2.  Environmental Impact

–  Commitment to a clean, healthy and safe environment and to conduct our activities in an environmentally responsible manner.

3.  Community Responsibility –  Seek to do business in a way that positively impacts upon our

customers, employees and the communities where we operate.

Sustainability in Bewleys The Milestones

1992 • Irish Hospice Support

1996 • Fairtrade Mark

2001 • IOGFA certification

2004 • Direct farm relationship with Nicaragua • ISO14001 Environmental Mgt Standard

2006 • Founding member of government initiative: Traidlinks

2009 • Awarded Carbon Neutral Status

2011 • Launch of our Sustainable Coffee Programme: beeco • ISO 14064 Green House Gases. verifies our GHG emissions

2012 • Origin Green Certification

2013 • Paul 0’Toole – Hon Consul of Nicaragua

2010 • Carbon Disclosure Project - Carbon Leader

Sustainability in Bewleys How it works for us

Central to the success of our Sustainability activities is 1.  Organisational structure

–  Cross-functional “Green Team” –  Regular meetings with progress review against KPI’s –  Updates on all areas of work and related targets are

issued to all employees as part regular business updates. 2.  Board commitment

–  Quarterly progress reports to the board of directors against outlined objectives and targets.

3.  Management incentivisation –  KPI setting and bonus payments incentivise delivery of

targeted sustainability outcomes.

Agenda •  ISO14001:2004 Environmental Management System since 2004

•  ISO14064-1:2006 Attestation of Co2 emissions – since 2011

•  Irish Organics Farmers & Growers Association (IOFGA) Organic Licence & Soil Association Organic Licence.

•  First Certified Carbon Neutral coffee company in Ireland in 2009.

•  Carbon emissions reduction targets through energy management and waste reduction programmes and we have neutralized the remaining emissions through carbon offsetting.

•  Carbon Disclosure Project participant since 2010.

•  In the CDP Ireland Report 2011 and 2012, Bewley’s were deemed to be one of Ireland’s Carbon Leaders.

•  Comparing 2012 with 2007 data –  We have reduced CO2e emissions per tonne of green coffee by 44 %. –  Reduction of 50% of electrical kwh per tonne manufactured. –  Reduction of 46% of thermal kwh per tonne manufactured.

•  Reduction of landfill waste by 37% in 2012 v 2010. Only 8% of total site waste is sent to landfill.

Environmental Impact Credentials

Agenda

Bewley’s Manufacturing Facility

Electricity

Gas

Products

Energy Efficiency: “Producing the same throughput of product using less energy or producing a higher throughput of product using the same energy without impacting on quality”

Improved Energy Consumption Patterns + Greater Efficiency

= Reduced Costs

Agenda

Journey To Energy Efficient Manufacturing

•  2007 Engineering manager attends 3 day “Energy Mapping” seminar

run by SEAI

•  2007 Energy audit undertaken by engineering manager

•  Energy is consumed even at zero output! Baseline

•  SEU’s of both Thermal & Electrical energy identified as part of energy

audit

•  Opportunities for improvement identified (“low hanging fruit”)

•  2010 Energy audit undertaken by Blue Sky Projects

•  Opportunities for improvement implemented (capex projects)

•  2012 Energy audit commissioned by Green Business

•  Further opportunities for improvement identified

Agenda

Energy Mapping

•  Energy Procurement

•  Energy Bills Analysis

•  Identification of Significant Energy Users

•  Energy Measurement Techniques

•  Resourcing

Agenda

Process Related Improvements

•  Improvements in operational procedures of packing lines – saving of 35,000kWh/annum = €4,200

Agenda

Process Related Improvements

Grinding Test Grinding Run on20 mins 40 mins 15 mins

•  Coffee grinding cycle improvements – saving of 30,000kWh/annum = €3,600

•  Introduction of some basic controls decreased cycle time by 40%

Agenda

Upgrade to Roaster Controls

Agenda

Education & Awareness

Agenda

Insulation Upgrade 2011

•  Coffee roasting equipment as well as various piping etc had insulation replaced.

•  This resulted in 10% savings in Thermal energy consumption

Agenda

Lighting Upgrade 2011

•  400w high bay fittings replaced with 200w units incorporating occupancy sensors

•  120w twin 5’ fluorescents replaced with T5 49w single tube fittings •  Lighting in 2011 accounted for 23% of total site consumption •  Lighting in 2012 accounted for 12% of total site consumption •  Energy saving of 50% achieved as part of the lighting upgrade •  Payback was 1.6 years.

Agenda

Metering of SEU

•  SEU of both thermal & electrical equipment have had sub-metering fitted •  Data from meters is collected using a monitoring & targeting system which has

been designed and installed by the in-house engineering team

Agenda

Monitoring & Targeting

Agenda

Efficiency Improvements 2007 - 2012

0#

0.1#

0.2#

0.3#

0.4#

0.5#

0.6#

0.7#

0.8#

2007# 2008# 2009# 2010# 2011# 2012#

kWh/kg&Electrical&

50% Reduction 2007 - 2012

Annual Electrical Energy Usage Per KG of Product

0#

0.2#

0.4#

0.6#

0.8#

1#

1.2#

1.4#

1.6#

1.8#

2007# 2008# 2009# 2010# 2011# 2012#

kWh/kg&Gas&

46% Reduction 2007 - 2012

Annual Thermal Energy Usage Per KG of Product

Origin Green Ambition for 2017

•  13% reduction of Electrical energy consumption per tonne manufactured by 2017 on 2012.

•  13% reduction of Thermal energy per tonne manufactured by

2017 on 2012. •  This Means

–  Further Site Energy Efficiency Projects led by our Green Team –  Monitoring, Targeting & Reporting of consumption –  Commitment form all levels of staff –  Energy Awareness campaigns

Energy Improvement Target

Agenda

Next Steps

Energy Saving • Green Business Audit Recommendations

–  Process Heat Recovery at Roaster – 3 year payback –  Further Lighting Control Enhancements

• Nitrogen Filled Tires for Company Vehicles • Oxygen Enriched Combustion • Energy Awareness Training Water Saving • Rain Water Harvesting / Well Water Drilling Waste Improvement • Oxygen Enriched Combustion • Energy Awareness Training

Agenda

Heat Recovery

Therma 2 Roaster

•  Recovery of waste heat from roast exhaust which exits at 340 c •  Capital investment of €50k would yield annual saving of €16k •  Payback = 3 years +

Agenda

Performance Improvement Opportunities in Bewley’s Fuel Based Roasting System

Agenda

Innovative Thinking – Ideas for Development

Oxygen Enriched Combustion:

•  Oxygen enrichment raises the flame temperature by

eliminating the diluents effect of nitrogen in air

•  An economical source of Oxygen is the key in this case

•  The process of Nitrogen generation produces pure

Oxygen as a by-product

Nitrogen Filled Tyres

•  Replacing air in tires with Nitrogen will improve MPG >5%

Agenda

Energy usage has been significantly reduced since 2007

•  Before any energy-saving measures can be undertaken within an

organisation, it is first necessary to collect comprehensive energy data

through an auditing process

•  It is important to justify any capital investment project by carrying out a

financial appraisal of the project

•  It is possible to establish the existing energy consumption of a facility

through an energy audit, however this only produces a picture of past

energy consumption – In order to keep control of subsequent consumption,

it is necessary to initiate a monitoring programme

•  In many applications there is the potential for recovering heat energy that

otherwise goes to waste.

If we measure it, we can manage it!

Thank You