OMA Food - ohiomfg.comohiomfg.com/wp-content/uploads/2013-10-25_lb_env_CampbellsSlides.pdf · OMA...

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1 OMA Food Manufacturer’s Day Columbus, Ohio October 24, 2013 Randy Puckett Manager Services & Utilities Campbell’s Napoleon Operations

Transcript of OMA Food - ohiomfg.comohiomfg.com/wp-content/uploads/2013-10-25_lb_env_CampbellsSlides.pdf · OMA...

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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 Operations - AMCOR

Manufactures

285 Million Bottles

Annually

32 People

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Napoleon Operations - Silgan

202 People

Manufactures

1.5 Billion Cans/Year

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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.

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Thank You