Resource efficiency in the UK cider sector

Transcription

1 Case Study: UK Drinks Sector Resource efficiency in the UK cider sector Reducing water, material and packaging use in the cider sector.

2 Resource efficiency in the UK cider sector 2 WRAP s vision is a world without waste, where resources are used sustainably. We work with businesses, individuals and communities to help them reap the benefits of reducing waste, developing sustainable products and using resources in an efficient way. Find out more at Front cover photography: Stainless steel cider vats. Courtesy of NACM While we have tried to make sure this is accurate, we cannot accept responsibility or be held legally responsible for any loss or damage arising out of or in connection with this information being inaccurate, incomplete or misleading. This material is copyrighted. You can copy it free of charge as long as the material is accurate and not used in a misleading context. You must identify the source of the material and acknowledge our copyright. You must not use material to endorse or suggest we have endorsed a commercial product or service. For more details please see our terms and conditions on our website at

3 Resource efficiency in the UK cider sector 3 Contents Contents... 3 Summary Review... 4 Packaging... 4 Water use... 5 Clean in Place (CIP)... 7 Waste water... 7 Product loss avoidance... 9 Organic resource... 9 Conclusions... 10

4 Resource efficiency in the UK cider sector 4 Summary Review The UK cider industry produces 9.4 million hectolitres annually. A resource map that shows key inputs, the production stages involved and waste and loss streams is below. The cider industry 1 has a large number of small-scale manufacturers though large manufacturers are responsible for a higher market share of product (over 70% 2 ). Both large and small-scale manufacturers can realise opportunities for improvement through, for example, economies of scale and developing closed loop solutions where production and processing are co-located. Key opportunities 281 tonnes of stretch-wrap conserved equates to a sector saving of 400,000 A sector-led approach to light-weighting bottles Reducing water use and recovering value from wastewater streams Key opportunities to improve resource efficiency are outlined below. Packaging Cider is packaged in many formats including kegs, PET, cans and glass, with 6.8 million hectolitres packaged for individual unit sale. Glass is increasingly being used, for example premium brands tend to be associated with heavy glass bottles, and this offers significant opportunity for light-weighting. Some brands have made substantial progress (such as Heineken UK reducing the Bulmers Original bottle mass by 30% 3, and Thatchers reducing bottle weight by 21% for a range of ciders 4 ), but this has the potential to be rolled out more widely across the industry. Small-scale manufacturers purchase small volume 1 BBPA (2010) Statistical Handbook 2 Mintel (2008) Cider, Market Intelligence Heineken (2009) Environment at a glance 4 WRAP (2008) Light-weighting beer and cider packaging

5 Resource efficiency in the UK cider sector 5 bottles and therefore have less control over design; however, a sectorled approach may offer greater opportunities. There is typically less focus on secondary packaging than on primary, though savings are often more easily achieved here. Stretch-wrap is used across all sectors to stabilise pallet loads, yet little attention is given to efficient usage, resulting in excessive plastic consumption. Within the cider sector, an estimated 281 tonnes 5 of material could be saved by more efficient practice, achievable by ensuring the correct equipment is used, staff are trained and machinery is set up correctly. Based on the November price of virgin plastic film, 281 tonnes of wrap conserved equates to a sector saving of 400,000. Water use Data collected for this review shows that typical water use per litre of product is currently 3.36 litres. The companies providing these (confidential) data are operating with good practice, and average actual usage may be slightly higher, though it will also vary depending on the scale of the business. Metering of water use throughout production lines was apparent only in a small number of sites, and this is considered a critical first step to allow for better understanding of key opportunities. Cost of metering is highlighted as a barrier by many stakeholders, though payback is often realised through leak detection and hidden savings that can be made once inefficiencies are shown. Best practice in water use per litre of product was 2.38 litres 7, which was achieved after the site installed numerous water meters throughout all processing stages. 5 WRAP (2011) Reducing packaging waste in the UK drinks sector 6 Price taken from WRAP market values, November ing_reports/index.html 7 Confidential industry waste reviews, 2011

6 Resource efficiency in the UK cider sector 6 Figure 1: Stainless steel cider vats. Courtesy of NACM Recycling of water onsite, through different processes, offers both environmental benefits and cost savings. These include a reduction in water use and lower effluent discharge costs. Water used in boilers and pasteurisers is relatively uncontaminated, and can be recycled for use in lower quality uses around the site. Steam condensate can also be collected and reused, offering energy savings due to heat capture. Through introduction of these techniques, Shepton Cider Mill, producing Gaymers and Magners cider, reduced water consumption by 22% 8. Cleaning water is a high volume use with organic materials, in particular, being difficult to remove and often consuming higher than necessary volumes of water due to inefficient cleaning methods. Clean in place (CIP) improvements should be an area of focus for the sector, and these are considered below. 8 C&C Group Plc (2011) Corporate Social Responsibility Report

7 Resource efficiency in the UK cider sector 7 Clean in Place (CIP) CIP is a critical use of water, with organic materials present in fruit juice in particular requiring more intense cleaning, requiring about 1-2l/l of product 9. Areas to review include: optimising plant process design; removing product and gross soiling prior to cleaning; incorporating the internal recycling of water and chemicals; staff training; carefully setting operating programmes which coincide with the real cleaning requirements of the process; minimising detergent loss to drain; and using water efficient spray devices. CIP systems can be complex, especially if multiple systems are in place. It is sensible to have a CIP engineer visit the site, to ensure current systems are working at their optimum, before investing in retrofitting newer systems. Waste water The cider industry lends itself conveniently to wetland ecosystem treatment (WET) systems, as they are often next to orchards/farmland and have the space required for such a system. Sheppy s Cider in Somerset has a 4 acre WET system that is accommodated within the 370 acre farmland in which Sheppy s is located. These systems include a series of specially designed earth banks, reed beds and ponds, allowing wastewater to flow through. Microbial and plant action removes contaminants, whilst allowing many species of plant, animal and other living organisms to thrive. Benefits of WET systems can be seen outside of the initial objective of natural treatment of wastewater and pollution control. Larger cider manufacturers are unlikely to have available land for use in these systems, and should 9 Industry input, 2011

8 Resource efficiency in the UK cider sector 8 consider alternate means of treatment, such as effluent separation for AD. Figure 2: Sheppy s Cider Mill WET System. Construction being carried out Courtesy of NACM Cider wastewater content is seasonal linked to natural production cycles. At peak times, the discharge has high chemical oxygen demand (COD) and suspended solid streams. To avoid high discharge costs companies store large volumes on site which are then diluted to reduce the organic content and discharged later in the season. This approach does not recover the value within the water for example as a feedstock for energy recovery through AD. If effluent separation was carried out high COD/suspended solid streams could be stored until sufficient volume is obtained for off-site recovery. Figure 3: Sheppy s Cider Mill WET System Thriving wetland less than three years later, the system saves Sheppy s an estimated 240,000 per year and has been adopted by wildfife and birds in abundance

9 Resource efficiency in the UK cider sector 9 Product loss avoidance Cider orchards vary in their productivity. Production processes are also not uniform. Typical yield from cider apples is around 80% indicating improvement potential for example through benchmarking production and improved process efficiency. Fill inefficiencies were apparent across all packaging formats. Both under-and over-fills can be caused by numerous factors, though they are mostly linked to inherent process variability. It is good practice to run trials of variability (ensuring first that the check-weigher is accurate and not responsible for incorrect measuring). If variance is acceptable, the likely reason for inaccuracies may be human error indicating that staff training may be beneficial. If variance is high, a more technical reason may be apparent, and a more detailed, technical review required; the original equipment manufacturer should be contacted. Organic resource Typical yield from cider apples is around 80%. About 36,000 tonnes 10 of pulpy remains, or pomace, is left after production and has a value as animal feed or as feedstock for anaerobic digestion (AD) plants and should be recovered where possible. WRAP research suggests that no pomace, which is a by-product, is sent to landfill, with the vast majority, 31,000 tonnes, sent for animal feed 11. Some smaller companies return pomace to land but this appears to have limited benefit. A growing area of interest appears to be in pharmaceutical and cosmetic markets 12, with Heineken UK (producers of Bulmers and Strongbow ciders) extracting antioxidant and phytochemicals present in pomace for use in these arenas. 10 Including pomace from apple juice production 11 Confidential industry waste reviews, and stakeholder interviews, Industry interviews, 2011

10 Resource efficiency in the UK cider sector 10 Conclusions There are several focal points for maximising resource efficiency within the cider sector in the UK and these are listed below. Improve monitoring. Metering along the production line allows for understanding of hotspots, and detection of leaks. Hotspots of inefficiency can be targeted and managed. Improved CIP. Frequent reviewing and improving on CIP is essential, as developments and improvements are available. Ensure staff are trained on the details of the system, and cleaning is understood, so systems are not running at higher levels than necessary. Effective wastewater management. Consider effluent separation to recover value in the organic content of effluent; for example, utilising for AD. Where land availability allows, consideration should be given to WET systems over disposal to sewer. Maximise value from organic by-product. Review value gained from pomace/organic remnants of harvest. If no local farmers are able to utilise as animal feed, check local AD facilities. Consideration should also be given to alternatives such as pharmaceuticals and cosmetic markets, as used by Heineken UK.

11 Resource efficiency in the UK cider sector 11

12