Green & Lean Initiatives Clare McEnroe Tom Fuery cdfoods

1. Green & Lean Initiatives Clare McEnroe Tom Fuery www.cdfoods.com

2. 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 EDGEWORTHSTOWN 1969 - Pouch/ Alu Tray DRIFFIELD 2004 - Dry IJMUIDEN 2010 - Cans

3. New C&D Foods Group 2012 Mullingar- HQ Driffield - Dry Esbjerg - Pouch / Alutray /Cans Edgeworthstown - Pouch / Alutray IJmuiden - Cans Larkshall - Dry BirkfeldTreats/ Sausages/ Alutray Valladolid - Dry

4. C&D: UK & Ireland Customer Overview Launch dates 1969 – 1975 1976 - 1985 1986 – 1995 1996 -2003 2003 -2009 2010-2013

5. 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

6. Green and Lean – Where to start

7. 8 Different Types of Waste

8. Overview • Energy reduction • Water conservation • Waste awareness

9. 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 !

10. 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

11. 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.

12. Water Savings Cooling Water Reuse 13 m3 Water Softener Regen 3 m3 RO Permeate 6 m3 Iron Filter Backwash 13 m3 13,000m3/annum 35 m3/day

13. 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.

14. Energy Usage at C&D

15. Exhaust Gas Options to Save Energy at the Boiler Steam at 9 bar • 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 Feed Water H F O

16. Boiler Feed Water Pre-heat Condensate Return 80-85C Boiler Feed Water 50-55C Boiler Feed Water 70-75C Retort Return Water 35-40C Soft Water Ambient Temperature 4-15C Steam injection

17. Effects to Date • Average Weekly HFO Consumption • Down by 1800 litres/week • 5.95% reduction per Tonne produced • Average CO2 reduced by 5.6 Tonne/week. 95,000 Litres/annum

18. 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.

19. 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.

20. Green & LEAN C&D

21. Questions ? Clare.mcenroe@cdfoods.com Tom.fuery@cdfoods.com