PepsiCo aimed to reduce emissions below regulatory limits by replacing its 25 MW gas-fired boiler with a sustainable thermal energy storage system.  The project had some challenges: managing costs and pioneering the integration of thermal storage into the plant Defining the scope strategically and ensuring financial feasibility were key to its success.  and permitting services for the transition to a green thermal energy system The Volt Project is the first of its kind in the Netherlands—a pioneering pilot for PepsiCo, Eneco, and Kraftblock in using green thermal energy at an industrial scale.   the system will power production with renewable energy cutting 98% of CO₂ emissions and saving thousands of tons annually Despite financial and regulatory challenges Arup’s expertise in industrial decarbonisation ensured that the project remained viable.   this innovative approach has set a new standard for sustainable manufacturing demonstrating how food production can transition to net zero while maintaining operations Arup provided engineering and design services to support PepsiCo’s transition to a green thermal energy system We designed the new potato intake building and starch collection canopy Our civil engineers developed cable routing for the new power infrastructure and coordinated with PepsiCo’s process consultant and a pipe bridge for thermal oil transport Our engineers integrated Kraftblock’s thermal storage system while HVAC and ventilation solutions improved plant efficiency Our team assessed demolition impacts and supervised construction to integrate new infrastructure with plant operations reducing the project timeline from 70 to 28 weeks.  If you'd like to speak to one of our industry and manufacturing experts about any of the issues raised on this page or a potential collaboration then please get in touch by completing the form By subscribing, you agree to our Terms of Use and Privacy Policy Dutch architecture practice Space Encounters has taken a property built in the 1980s and reworked it to become suitable for a growing family “AB House” features a distinctive pitched roof the home is set within an area that is divided into hundreds of small islands – each of these pieces of land occupied by one family home The architects saw the project as a chance to make the house more suitable for modern-day living while updating its sustainable credentials yet distinct example of how living in the countryside can be made more sustainable and adapted to changing demands for contemporary living,” they say Archive HOUSING News & Analysis on Food & Beverage Development & Technology 23-May-2023 Last updated on 23-May-2023 at 14:17 GMT Powering food and drink manufacturing processes with green energy, instead of fossil fuels, significantly reduces a company’s carbon footprint. But relying solely on green energy is a challenge: at some periods of the day the sun and wind is unable to generate enough energy to power manufacturing processes, while at others, a surplus is produced. This was a concern for snacks and drinks major PepsiCo, who has been looking to integrate more renewable energy into its Broek op Langedijk production plant – where the company makes Lay’s and Cheetos crisp products – in the Netherlands. “We needed to disconnect from [natural gas] and move to renewable energy,” recalled Katharina Stenholm, PepsiCo’s outgoing SVP chief sustainability officer, Europe. But at the same time, the solution had to be ‘cost competitive’. “There is obviously a lot of inflation going into food prices, so we are determined to find sustainable solutions that do not imply higher costs.” The solution was developed in collaboration with PepsiCo’s energy partner Eneco, and leverages technology from German start-up Kraftblock: a thermal battery that stores excess green energy for later use. Storing excess green energy with thermal batteries Kraftblock’s technology works thanks to an ‘innovative’ material capable of storing temperatures up to 1,300˚C. Once heat is transferred from the heat transfer medium – in PepsiCo’s case, from hot air heated by wind energy – to the storage system, it can be used for a period of up to two weeks. At the Broek op Langedijk site, the stored energy is being used to heat thermal oil, which in turn, heats cooking oil to fry PepsiCo crisps. During the night and in off-peak periods, PepsiCo is now able to source cheaper renewable electricity from North Sea windfarms and convert it to hot air. This heats up Kraftblock’s iron ‘nuggets’ to 800˚C in ‘super’ insulated storage units. In parallel, PepsiCo uses direct electrification to power two of its electric thermal oil boilers. During the daytime, and peak periods (when energy costs are higher), PepsiCo can switch off its electric thermal oil boilers, extract heat from the storage units in the form of hot air and then use a hot air to thermal oil heat exchanger to supply energy to its production processes. “We now have the opportunity to store renewable energy, which means we can pull energy at off-peak times when the prices are favourable…and take energy during nights and weekends, even if our demand is not high – to store and use later. That’s the novelty and beauty of this solution,” Stenholm told FoodNavigator. Replacing natural gas with sustainability electricity will lead to a reduction of around 50% CO2, with the aim of achieving a 98% reduction. Installing new technology at scale is never an easy process. And as Stenholm explained, the solution, co-developed in partnership with Eneco, was not as simple as ‘taking it off the shelf and plugging it in’. “The novelty of the technology brings its own challenges,” she told this publication. “Another challenge is when you integrate something into an existing site – it’s always more complicated that at a greenfield site.” The company’s decarbonisation project aligns with its PepsiCo Positive (pep+) agenda: the snacks major has pledged to reduce greenhouse gas (GHG) emissions by more than 40% by 2030 and achieve net zero emissions by 2040. Within its own operations, PepsiCo plans to reduce GHG emissions by 75% by 2030. Looking to new innovations, such as Kraftblock’s thermal battery technology, is part of the solution, explained Stenholm. “We have teams dedicated to sourcing solutions for the unsolved problems, and it’s probably not a coincidence that we are in the Netherlands – because the Netherlands is a very supportive environment for new innovative technologies.” When scouting for new solutions, the company is conscious of its supply base, too. Sometimes, PepsiCo’s traditional suppliers will develop a new solution, but more often the ‘breakthrough’ technologies come from start-ups, she explained. “A company like PepsiCo has the opportunity to help start-ups with great ideas [link with] established players with an industrial footprint. “We can help them come together and [create] something that scales faster that a start-up could perhaps do themselves.” “PepsiCo has long had a strong vision and commitment to its sustainability agenda and pep+ provides the entire organisation with a clear roadmap to sustainably grow and bring value to the planet and people,” Jagannathan commented. “We’re taking significant action to deliver on that vision and I look forward to continuing my work embedding pep+ into our decision making and wider business strategy.” ‘Digitization is an unstoppable trend’: Why PepsiCo is digitalising food banks across Spain05-Apr-2023By Oliver MorrisonAs part of the Community Program of the PepsiCo Foundation in Spain, PepsiCo has been supporting the digital transformation of the biggest food bank in Madrid. PepsiCo trails paper-based packaging for Walkers Baked08-Mar-2023By Gill HyslopThe snacking giant is testing paper-based outer packaging on its Walkers Baked 6-bag multipacks, following a successful trial with Walkers 22- and 24-bag multipacks last year. Recent success for Welsh food and drink as it targets international marketsPaid for and content provided by Welsh Government Mastering mouthfeel: The importance of mouthfeel in making brands thrivePaid for and in partnership with Tate & Lyle Rethinking eggs for a resilient food future a ‘matter of necessity’Paid for and content provided by CSM Group (CSM Ingredients & HIFOOD) Please select what you would like included for printing: Copy the text below and then paste that into your favorite email application Enter your phone number above to have directions sent via text This site is protected by reCAPTCHA and the Google Privacy Policy and Terms of Service apply Service map data © OpenStreetMap contributors PepsiCo produces potato chips in Broek op Langedijk in the Netherlands the fragile products are packed and stacked in cartons as secondary packaging A new system that reliably secures cartons stacked on pallets against slipping was to reduce adhesive costs and customer complaints The food company opted for hot melt technology from Nordson Potato potato chips have been produced in Broek op Langedijk in the Netherlands since 1958. The Langedijk farmers wanted to open up another market for their potatoes. Over the years, the plant developed into the largest potato chips factory in Europe. Today, the production facility belongs to the food and beverage group PepsiCo which employs around 300 people in Broek op Langedijk the plant produces Lays‘ brand potato chips stacks them on Euro pallets and delivers them up to twelve to 14 layers of boxes are stacked on top of each other „We have three palletizing systems that assemble and stack the cartons fully automatically for transport we can increase the quantity to 100 pallets per hour This means that up to 1,200 cartons of different sizes can be processed per hour.“ Project Manager and Spark Line Lead Trainer NWE at PepsiCo The cardboard pallets are transported fully automatically in the factory and then transported by truck via interim storage to the wholesaler for delivery As this can sometimes be rough and extremely bumpy It must also be possible to unstack them easily PepsiCo used to secure the cartons for transportation with a cold glue system increasing difficulties had become apparent here There were repeated uncertainties regarding the handling of the system and the associated equipment there were high operating costs and difficulties further down the supply chain for example when already stacked pallets had to be restacked The cold glue system only allows this within a defined period and cartons were damaged during subsequent restacking and destacking In combination with the P4 pressure management system the ProBlue Flex melter allows the electrical control signal and pressures to be changed This allows the adhesive application to be programmed depending on the load applied by the cartons Against this backdrop and with a view to the Group’s goal of manufacturing its products sustainably those responsible decided to optimize the transport of the pallets and invest in new An internal team – consisting of Darko Despotovic and Martijn van Zuydam – drew up the basic specifications as part of a Six Sigma Green Belt project The new system had to contribute to cost savings in adhesive consumption without compromising pallet stability The amount of adhesive should be adjustable depending on the carton positions on the pallet The same applies if a problem repeatedly occurs in a specific pallet position with a certain carton combination in the supply chain the sustainable solution should contribute to reducing the CO2 footprint The decision was made in favour of Nordson’s melter technology as the company was already one of the preferred suppliers and offered its customers comprehensive support in addition to innovative and high-precision application technology one ProBlue melter was installed per palletizer in combination with the P4 pressure management system The MiniBlue II SureBead hot melt applicators PureFlow hoses and RediFlex II holders were also added The use of plastic film in logistics can be reduced with secure pallet stabilization PepsiCo in the Netherlands has invested in a new system to prevent cartons from slipping during transportation „The ProBlue melter has a modular design so that it can be individually adapted to the user’s requirements,“ explains Erik van Gulik The device is characterized by a fast heat-up time and can optionally be equipped with an adhesive tracking system which allows users to easily measure and monitor the volume and application of the adhesive The P4 pressure management system allows the electrical control signal and pressures to be changed and the exact amount of adhesive applied to be monitored This makes it possible to program the application of the adhesive depending on the load of the cartons This means that less adhesive is applied to the lower cartons which are more heavily loaded by the weight of the cartons stacked on top and stand securely The latter can easily swing back and forth on the pallet during transportation and must therefore be secured more strongly The MiniBlue II SureBead hot melt applicators apply the adhesive reliably and their precise stitch pattern ensures that adhesive is used sparingly PepsiCo packs its products in cartons of different sizes which is why four applicators are installed on each palletizer in such a way that they always apply the adhesive to the varying outer edges taking into account the different carton dimensions PureFlow hoses use innovative technology to ensure the quality of the adhesive used and thus prevent material impairments such as curing or coking they help to reduce the downtime that can be caused by hose changes or nozzle blockages They are installed with RediFlex II holders to ensure optimum flow of the adhesive PepsiCo put the new melter system into operation in February 2023 „We have achieved our goals and reduced the CO2 footprint thanks to the lower adhesive consumption but this is not due to the hot melt technology but to its integration into the company’s overall system We assume that we can reduce the costs for the adhesives alone by around 40,000 euros per year we have drastically reduced the number of customer complaints and rework This alone is expected to save us around 100,000 euros per year.“ http://www.nordson.com Prüfen Sie bitte Ihren Posteingang oder Spam-Ordner Die IFFA bildet den gesamten Markt für die Verarbeitung Verpackung und den Verkauf von Fleisch und alternativen Proteinen ab Damit bietet sie der globalen Nahrungsmittelbranche eine Plattform für Innovation und Vernetzung 03MaiGanztags08IFFAInternationale Leitmesse – Technology for Meat and Alternative ProteinsMesse Frankfurt, Ludwig-Erhard-Anlage 1 Frankfurt am Main, 60327 Deutschland Damit bietet sie der globalen Nahrungsmittelbranche eine Plattform für Innovation und Hunderte Aussteller präsentieren ihre neuesten Innovationen und Produkteinführungen aus den Bereichen Grafik Als regionale Fachmesse für die Verpackungsindustrie bietet die EMPACK ein komprimiertes Update zu den wichtigsten Innovationen und Branchenlösungen Das macht sie unverzichtbar für alle Anbieter und Anwender aber kompakten Überblick verschaffen wollen Schutz- und Transportverpackungen bis hin zur Kennzeichnung und automatisierten Lösungen: Hier finden Sie ein breitgefächertes Angebot für Ihre täglichen Anforderungen – von Start-ups wie von Großkonzernen und entlang der gesamten Prozess- und Wertschöpfungskette Außerdem: allerbeste Networking-Möglichkeiten inmitten Ihrer Zielgruppe und ein vielfältiges Rahmenprogramm von Experten aus der Region Das macht die EMPACK zu einem hocheffizienten und gleichzeitig stressfreien Messeerlebnis 07MaiGanztags08EMPACK DortmundRegionale Fachmesse für die VerpackungsindustrieMesse Dortmund, Rheinlanddamm 200, 44139 Dortmund, Deutschland Das macht sie unverzichtbar für alle Anbieter und bestehend aus 5 Veranstaltungen in der ganzen Welt und einem digitalen Portal das sich mit hochwertigen Verpackungen beschäftigt Eine Zusammenkunft von Verpackungsinnovationen auf denen kreative Verpackungsunternehmen Luxusprodukte für die internationale Markengemeinschaft präsentieren Das größte Treffen für Verpackungsexperten aus verschiedenen Bereichen: Schönheit Nachhaltigkeit und digitale Konzeptideen zu inspirieren 07MaiGanztags08LUXE PACK New Yorkthe leading trade show for luxury packagingNew York, Javits Center, Javits Center New York Als Besucher der iba können Sie sich auf die neuesten Innovationen der Branche freuen und haben die Möglichkeit sich mit anderen Branchenexperten auszutauschen Die iba bietet zudem ein vielfältiges Rahmenprogramm mit zahlreichen Workshops Seminaren und Vorträgen zu aktuellen Themen Ob iba.ACADEMY oder iba.SPEAKERS AREA – mit vielseitigen Angeboten und Formaten stehen auch Austausch Vernetzung und Wissenstransfer im Fokus der Messe Hier finden Sie alle weiteren Informationen rund um die iba – von A wie Anreise bis Z wie zukunftsweisend 18MaiGanztags22Iba 2025Weltmesse für Bäckerei, Konditorei und SnacksMesse Düsseldorf, Stockumer Kirchstraße 61 Düsseldorf, Nordrhein-Westfalen 40474 Deutschland Messe Düsseldorf Stockumer Kirchstraße 61 Düsseldorf, Nordrhein-Westfalen 40474 Deutschland Die iba bietet zudem ein vielfältiges Rahmenprogramm 27MaiGanztags28PETnology EuropeStrategy and Technology Conference for the PET Packaging IndustryRapperswil-Jona, Oberseestrasse 10, Postfach 1475, 8640 Rapperswil-Jona, Schweiz Die IPACK-IMA ist die internationale Fachmesse für Verarbeitungs- und Verpackungsmaterialien und -technologien für die Food- und Non-Food-Welt das sich an die gesamte FMCG- und Gebrauchsgüterindustrie richtet Eine integrierte und vernetzte Ausstellungsplattform die sich auf vier Hauptzielmärkte konzentriert: Lebensmittel auf Getreidebasis Pharmazeutika sowie Technologie- und Verpackungssektor 27MaiGanztags30Ipack-Ima 2025Fachmesse für die Verarbeitung- und Verpackung von Food- und Non-FoodMesse Mailand, Strada Statale del Sempione 28 Mailand, 20017 Rho Italien 03JunGanztags04EMPACK HamburgRegionale Fachmesse für die VerpackungsindustrieHamburg Messe - Eingang Süd, Halle B6, Karolinenstraße 20-22, 20357 Hamburg Die CosmeticBusiness ist eine einzigartige Quelle für neue Kosmetikprodukt-Ideen und bündelt das gesamte Netzwerk für deren effiziente Konzeption und Umsetzung Als einzige internationale Fachmesse bringt sie jährlich in Deutschland exklusiv Kosmetikunternehmen mit all ihren Lieferanten für die Entwicklung Verpackung und Vermarktung des gesamten Kosmetikproduktportfolios zusammen Als Stimmungs- und Trendbarometer ist sie unverzichtbar für Entscheider der Branche 04JunGanztags05CosmeticBusinessInternationale Fachmesse für die KosmetikindustrieMünchen - MOC Center, MOC Veranstaltungscenter Lilienthalallee 40 München, Bayern 80939 Deutschland MOC Veranstaltungscenter Lilienthalallee 40 München Als Weltleitmesse für intelligente Automation und Robotik vereint die automatica alle Schlüsseltechnologien am Technologie-Standort München und bringt Industrie Forschung und Politik zum konstruktiven und zukunftsweisenden Austausch zusammen Mehr noch: Sie bietet einen Überblick über Entwicklungen Innovationen und Lösungen und sorgt so für die notwendige Orientierung und Investitionssicherheit in einer Zeit der Umbrüche Damit die Vision von der automatisierten zur autonomen Produktion sukzessive Realität wird – und Sie und Ihr Unternehmen an ihr wachsen können 24JunGanztags27automaticaDie Leitmesse für intelligente Automation und RobotikMesse München, Messegelände München, Bayern 81823 Die ÉDITION SPÉCIALE von Luxe Pack ist eine neue Veranstaltung die sich in Paris dem Thema Luxusverpackungen widmet und wichtige redaktionelle Inhalte sowie die besten angepassten Lösungen der Hersteller zur Bewältigung der aktuellen Herausforderungen für die Branche bietet 01JulGanztags02ÉDITION SPÉCIALE By LUXE PACKMesse für Nachhaltigkeit von LuxusverpackungenParis - Carreau du Temple, 4 Rue Eugène Spuller, 75003 Paris, Frankreich Paris - Carreau du Temple 4 Rue Eugène Spuller, 75003 Paris, Frankreich die sich in Paris dem Thema Luxusverpackungen widmet und wichtige redaktionelle Inhalte sowie die besten angepassten Lösungen der Hersteller zur packaging journal finden Sie im Katalog von fachzeitungen.de © ella Verlag und Medien GmbH There are no manned forklift trucks driving about loading truck trailers with boxes of chips at PepsiCo’s Broek op Langedijk site in the Netherlands the recently installed Joloda loading system saves 30 minutes/load as it pushes 42 pallets of chips into an extra-long truck in one fully automated operation The Flat Floor Trailerskate Dock flexible loading system the result of close collaboration between the loading specialist Joloda the logistics provider Kühne + Nagel and the truck manufacturer Heiwo features sensor intelligence from SICK as standard Speed is the key competitive advantage in the world of fast-moving consumer goods That is why companies are always searching for new ways of automating operational processes to meet the requirements of ‘just-in-time’ philosophy A prime example is PepsiCo’s fully automated loading system at Broek op Langedijk in the Netherlands The PepsiCo loading bay is buzzing with activity “Normal trailers and extra-long trucks are constantly being loaded and unloaded here They are used for the shuttle to the Kühne + Nagel warehouse in Utrecht,” said Wouter Satijn The extra-long trucks (also known as Eurocombis) have a 21.5 m load bed - big enough for 42 pallets “The driver just has to connect his Eurocombi to the loading bay control system and the loading system does the rest,” explained Satijn In the warehouse everything is geared towards just-in-time processing: the automated palletiser system ensures the individual boxes are placed in perfect alignment on the pallets Each pallet is then taken to the Joloda automatic dock “The pallets are arranged in three groups: 16 pallets then 16 again on the Trailerskate conveyor “When the roller gate on the auto dock opens two bracket-mounted SICK DT500 long-range distance sensors come down They measure the depth of the trailer and check whether the trailer is correctly equipped because normal 13.6 m trailers are loaded and unloaded here as well as the extra-long Eurocombis: it is important to Kühne + Nagel to be able to decide at the last moment whether whatever trailer is nearby should collect a load from Broek op Langedijk.” Satijn continued: “If the SICK sensors detect a depth of 13.6 m then 16 plus 10 pallets can be loaded into the vehicle the system pushes all 42 pallets into the loading tunnel of the Eurocombi.” The actual loading of the trailer uses the risor plate technology developed by Joloda Satijn said: “The stationary auto dock and the trailer each have a system with compressed air hoses under the rails the rails lie slightly lower than floor level On the rails there are long ‘skates’ on which the pallets lie.” Satijn continued: “The compressed air makes the pallets float a few centimetres above the conveyor and allows them be moved into the truck Once the pallets have reached the correct position in the trailer the pressure in the hoses is dropped and the rails sink back below floor level.” SICK technology fulfils an important role here Four PBS pressure sensors monitor not only the pressure while the pallets are being lifted “This ensures that the skates are not retracted until the system is no longer pressurised,” said Satijn Four PBS pressure sensors from SICK located in the box below the load bed             SICK's DT500 long-range distance sensor The automated loading system saves an enormous amount of space in comparison to the use of manned forklift trucks: space which can now be used flexibly for other purposes This also improves safety at work and personal protection there is hardly any mechanical load on the trailers because of the compressed air lifting system “It is very important to us that all of the details satisfy our quality requirements That also applies to components we purchase from third parties This is why we choose reliable market leaders such as SICK it is a great advantage that SICK thinks proactively when problem solving,” summarised Wouter Satijn.