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
Overview Energy reduction Water conservation Waste awareness
Water usage in C&D Water is most valuable resource 450m 3 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 !
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
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.
RO Permeate 6 m3 Water Softener Regen 3 m3 Cooling Water Reuse 13 m3 Water Savings 35 m3/day Iron Filter Backwash 13 m3 13,000m 3 /annum
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.
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 Options to Save Energy at the Boiler Exhaust Gas Feed Water HFOHFO Steam at 9 bar
Boiler Feed Water 50-55 C Boiler Feed Water Pre-heat Condensate Return 80-85 C Retort Return Water 35-40 C Soft Water Ambient Temperature 4-15 C Boiler Feed Water 70-75 C Steam injection
Average Weekly HFO Consumption – Down by 1800 litres/week – 5.95% reduction per Tonne produced – Average CO 2 reduced by 5.6 Tonne/week. Effects to Date 95,000 Litres/annum
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.
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.