Post on 02-Dec-2018
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OMA Food
Manufacturer’s Day
Columbus, Ohio
October 24, 2013
Randy Puckett
Manager Services & Utilities
Campbell’s Napoleon Operations
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Campbell’s Napoleon, Ohio
3.1 Miles Around the Perimeter
- 949 Acres
- 56+ Acres Under Roof
- Two Manufacturing Plants
East Plant (Soups & Sauces)
West Plant (Beverages)
- Water Treatment Facility
- Waste Water Facility
- 60 Acre Solar Field
- Anaerobic Digestion Facility
Campbell’s - Largest Operation
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V-7 Plant
Napoleon Site Overview – West Plant
History
1933…V-8 brand created
1938… Standard Brands built West
plant
1948 … Campbell Soup Company
Purchased V8 Acquiring the Napoleon
Facility from Standard Brands
2004…Amcor PET Packaging plant
built
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Napoleon Site Overview – East Plant
History
1957 … Soup Plant Operations
Start-Up
1958-68 … 3 Warehouse Expansions
Totaling 299K sq. ft.
1989 … Warehouse Expansion
(378K sq. ft.)
2006 … Warehouse Expansion
(344K sq. ft.)
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Napoleon Products Manufactured
Campbell Red & White Prego
Chunky Soups Select Soups
V-8 Red Juices V-8 V Fusion
Microwavable Bowls Pre-Printed Shrink
Away From Home Splash/V Fusion Tea
Pace Salsa and Picante Spaghetti O’s
Swanson Broths Slow Kettle
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Manufacturing Profile
• Cases Manufactured (F’13 Act.) 105 MM
• SKU’s Manufactured ~ 514
• Sales Value (List) of Production $1.9 Billion
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Napoleon Plant 2020 Destination Goals
Napoleon 2020 Destination Goals Base Line
(2005) 2020 Goal 2013
2013 vs. Baseline
50% less water use per metric ton mfg 11.9 5.97 10.5 -12%
35% less energy use per Ton mfg 2.96 1.92 2.09 -22%
40% renewable electricity 0% 40% 14.6%
50% less Green House Gas Emissions 0.297 0.148 .08 -73%
2020 Destination Goals Base Line
(2008) 2020 Goal 2013 Status
95% Solid Waste recycle rate 58% 95% 89%
+31 pts
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The Path to Sustainability
• Natural Gas Boilers
• Heat & Water Recovery
• BNB Solar Power Project
• CH4 Digester Project
• Recycling – Source Separation
• Conservation Action Project
• Spray Irrigation
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Napoleon Green Initiatives-Natural Gas Boilers
Phase I & II
• Approx. $20MM Capital repair & replace projects
• Replaced the 70’s vintage gas and #6 fuel oil boilers
& moth-balled the 50’s vintage coal boilers
• 13% greater efficiency
• 38% reduction in Napoleon emissions without
coal & #6 fuel oil
• Napoleon emissions reduction reflects a 9%
reduction in US emissions & 6.8% reduction in
world wide emissions, with corresponding $50K
reduction in emission charges
• Eliminates 71 annual tons of NOx emissions &
447 annual tons of SO2 emissions
• 62K metric tons equivalents reduction
• All 3 new gas boilers operational early F12
Elimination of #6
Fuel Oil Usage Elimination
of Coal
Reduce
Air
Emissions
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Napoleon Cooker Water & Heat Recovery Project
• Installed new pumps, heat exchangers, chillers,
meters & piping
• System became operation FEB 2008
• Reduced water use by 1.5MM gallons per day
• Recovering heat to reduce fuel use & steam
requirements
• Annual savings approx. $1.25MM
Project Description: System to recirculate the cooling water around all process vessels at the Napoleon Plant.
Approx. $3.4MM project cost.
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Condensing Economizer – Napoleon, Ohio
• 4% increased efficiency
• Even with low natural gas prices -
$0.2MM annual savings
• Recycled the steel from the old ash
silo to build the entire structure –
$0.1MM construction cost savings
Condensing
Economizer
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• 9.8 Megawatts covering approx. 60 acres of land
• Owned by Enfinity BNB Napoleon Solar, LLC
• Equipment supplied by SunPower & installed
by Vaughn Industries
• 23,040 high efficiency solar modules/panels
• Produces approx. 15% of the Napoleon Plant’s
energy requirements
• Eliminated approx. 250K metric tons of CO2
greenhouse gas.
• Operational and generating electricity DEC 2011
Napoleon Green Initiatives – Solar Power Project
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Napoleon Green Initiatives – CH4 Digester Project
CH4 Digester - Start-Up in Process
A community digester to produce bio-gas
to make electricity and sell back to Campbell.
Campbell’s Waste:
• Waste Treatment Sludge
• Reed Canary Grass
• Plant Food Waste
• V7 Operation Pomace
• Off Condition Product
• Includes a de-packaging operation to
handle off-spec and overage product
• Parent company is CH4, local project is
Napoleon Biogas, LLC
• Converts waste to methane which will power 2 gen sets producing up to 2.8 megawatts
• Will produce approx. 40% of the West Plant’s energy requirement (24/7 production)
• Between solar and digester approx. 40% of the plants energy source will be green power
Model Facility
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Napoleon Green Initiatives – CH4 Digester Project
Week of 12/21/2012 Actual Facility Pictures
Organic waste material will be diverted
from local landfills and converted to
methane that will then be used to
generate electricity.
Week of 10/19/2012 Week of 9/28/2013
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Napoleon Green Initiatives - Recycling
• Through July 2013 (Fiscal Year 13) the facility recycle/reuse rate was 89%
• FY14 plans include implementation of aerosol can puncture equipment. The aerosol cans will then be recycled
as scrap metal vs. going out as hazardous waste, driving Cost savings
• Used oil. New vendor purchasing our used oil for recycling vs. incurring disposal costs, driving Cost Savings
• Napoleon BioGas Start-up
• Continue employee awareness through training, activities & communications, and source separation
Landfill, 10,837 tons,
11%
Recycle, 6,730 tons,
7%
Re-Use, 50,732 tons,
53%
Farms, 4,984 tons,
5%
Land Applied, 21,203 tons,
22%
Digester, 2,073 tons,
2%
Method of Disposal FY 13 Total Tonnage Landfill
Fuels
Recycle
Re-Use
Farms
Land Applied
Treated - Recycled
Digester
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Bio-Lime
Plastic Pails and Lids
Rubber Boots
Portable & Stationary
Waste Hoop Rings
Source Separation Tool Cardboard Rolls
Ink & Toner Cartridges
Napoleon Green Initiatives - Recycling
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Main Lab
Plastic, Cans, and Glass
Chopped
Green Banding
Plastic Bottles
Bailed Cardboard
Bailed Netting
Napoleon Green Initiatives - Recycling
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• Wetland Establishment
• Landowners participating – 2
• Acres established – 31
• Cost-share expended - $25K
• Cover Crops
• Landowners participating - 60
• Acres established – 3,000 X 3 Years
• Cost-share expended - $110K
• Controlled Drainage
• Landowners participating - 18
• Acres established – 1,434
• Cost-share expended - $146K
(All Numbers 2013 Data)
Conservation Action Project - Ohio
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• Nitrogen Reduction
• CAP prevented 86.4 tons of nitrogen from
entering the Maumee River Watershed
Conservation Action Project - Ohio
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Napoleon, Ohio - Spray Irrigation
Napoleon also has a 640 acre land treatment system used to treat 5.0
million gallons per day (MGD) during the warm months of the year.
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Climate Leadership Award
Campbell was nominated for Food Processing Magazine’s Green Plant of the Year Award.
The nomination was based on Campbell’s partnership with CH4 Biogas to create Electric Power from the
organic waste from the Campbell’s – Napoleon Facility. The partnership will allow the Napoleon Plant to
divert 50% of production waste away from the landfill; Achieving a 95% recycle rate; Replacing 25% of
annual electricity use with renewable energy; and reducing greenhouse gas emissions by 16,000 metric
tons annually.
Campbell has been named a winner of the inaugural Climate Leadership Awards, recognizing corporate
leadership in addressing climate change and reducing carbon pollution.
The company was recognized in two categories for aggressively managing and reducing greenhouse gas
emissions and for establishing aggressive greenhouse gas reduction goals.
The awards were presented by U.S. Environmental Protection Agency, the Association of Climate Change
Officers, the Center for Climate and Energy Solutions, and The Climate Registry at the Climate Leadership
Conference in Fort Lauderdale, Fla.
In its 2010 Corporate Social Responsibility Report, Campbell announced a series of 2020 Environmental
Sustainability Destination Goals that detailed how the company planned to cut the environmental footprint of its
product portfolio in half. These long-range goals were intended to accelerate the progress made between 2006
and 2010, when the company reduced greenhouse gas emissions from 4.78 tonnes of CO2 per 1,000 adjusted
cases of product produced to 4.38 tonnes.