Case study

All steamed up about chocolate at Cadbury Claremont

Financial Dividends Annual cost savings $36,000 Payback period 3 years

Environmental Dividends Water savings 8,640 kilolitres per year Coal savings 390 tonnes per year Greenhouse gas emissions avoided 790 tonnes of CO2 per year Coal ash reduction 97 tonnes per year At the Claremont crumb plant, milk and sugar are combined and dried into a crumbly mixture which is later combined with cocoa to make milk chocolate. The eco-efficiency team implemented a strategy to improve the use of steam and water at the plant. In early 2008, the team engineered the capture of high pressure steam used in drying the milk and sugar mixture. The steam is then re-used in the plants hot air dryer, and then transferred to the boiler as preheated feed water for further steam production. This process has added significantly to pre-heated boiler feed water volumes collected from other areas in the factory. Significant environmental and cost benefits are associated with this project.

Continuously improving manufacturing efficiency is an objective of production sites all around the world. Cadbury P/L is familiar with the challenge. Recent efforts have focused on the crumb plant at the companys chocolate factory near Hobart. Cadburys eco-efficiency team regularly identifies opportunities to improve efficiency and sustainability at the site, as the company prepares for a low carbon future.

The change to operations will save coal and water used to produce steam. Less greenhouse gas emissions and coal ash waste (ash left over from burning coal) will be produced. Each year it is estimated coal use will be reduced by about 390 tonnes; coal ash reduced by 97 tonnes; and potable water use reduced by at least 8,640 kilolitres. Greenhouse gas emissions will also be reduced by about 790 tonnes per annum. Capital expenditure on the project for the low pressure and flash steam vessels, condensate pump, associated pipe work, scaffolding, platforms, and installation was $112,000. The Tasmanian Governments CleanBiz grant scheme contributed $35,000 to the project. With expected savings of about $36,000 per year, projected pay back on the investment (including the grant) was three years, at the current cost of energy production. Subsequent energy price increases brought the pay back period to less than two years. Cadburys involvement in CleanBizs training and support program provided a good opportunity to focus closely on the crumb plant. However, the company recognises that resource efficiency is not just about projects, but about a systems approach that is based on continual improvement. Other examples of resource efficiency initiatives by the company include: - collecting cooling water used in the crumb plant (about 6,000 KL/yr) and re-using it on the adjacent Claremont golf course;

- using Australian invented starch based biodegradable chocolate trays. Participating in the Global Reporting Initiative shows the companys willingness to monitor and report on the aspects of their business that impact on the environment. The company is also conducting a purple goes green environmental campaign, and has pledged a 50% reduction of net absolute carbon emissions by 2020. Profile of the business
The chocolate making facility was established in Tasmania in 1921. Cadbury Pty Ltd is the second largest confectionary manufacturer in the world. The Claremont factory is one of many sites that manufacture the companys confectionary products. The Tasmanian facility employs about 850 people and produces around 45,000 tonnes of chocolate per year. The companys commitment to environmental sustainability is reflected in their policy, which reads, in part We minimise our impact on the environment around the world; look after the health and safety interests of our employees, and seek opportunities to improve the local environment in the communities in which we operate. We believe that such an approach will generate and sustain significant environmental, social and financial benefits, contributing to our objective of long term sustainability.
Cover page images - Left: Cadburys registered trademark. Centre: Cadbury personnel near recent plant modifications; from left Marcus Bealey (Technical Specialist), Ken Holmes (Environment, Health and Safety Manager), and Clinton Luckock (Environmental Specialist). Right: The new low pressure steam condensate vessel, high pressure flash steam vessel, and condensate return steam driven pump.

Above: Steam discharge at the crumb plant prior to the CleanBiz project.

Above: Greatly reduced steam discharge at the crumb plant (also the discharge point was moved) the remaining discharge is a work in progress.

We are looking at all opportunities to reduce our carbon and water footprint, and become a more sustainable business. This helps ensure our long term future in Tasmania. Ken Holmes, Environment, Health and Safety Manager, Cadbury Claremont Factory

Contact
Cadbury Pty Ltd
Clinton Luckock ph: (03) 6249 0111 Clinton.Luckock@cadbury.com 100 Cadbury Road, Claremont Tasmania