“Telling Your Sustainability Story” - Ohio EPAepa.ohio.gov/Portals/0/general...

“Telling Your Sustainability Story”

Frito Lay Inc. – Wooster, Ohio

Frito-Lay North America

• Convenient foods leader

• $14 billion annual sales

• Division of PepsiCo

• 50,000 employees

• Strong presence across U.S. &

Canada

• Headquarters - Plano, TX

• 75+ year history

Broad Portfolio

Wooster Frito-Lay Manufacturing Plant

Overview • Operation for 70 Years (1947)

• Product Lines o 2 - PC Fryers

• Lays, Ruffles

o 2 - Tortilla Chip Fryers • Doritos, Tostitos, Santitas

o 1 – Frito Fryer • Fritos

• Volume o Average Year – 80 MM Pounds Produced

o Full Mix Warehouse -1999

• PepsiCo Center of Excellence Award for ReCON Climate Energy Stage 1

(2015)

• PepsiCo Center of Excellence Award for Environmental Stage 1 (2014)

• Ohio EPA’s Encouraging Environmental Excellence Award in 2013 (Silver

Level)

• Frito Lay Ambassador Award Community Service, Received in 2011 & 2012

• Ohio Environmental Council’s Environmental Achievement Award, Received

Honorable Mention in 2010

• Governor’s Award for Environmental Stewardship 2008

• US EPA Performance Track Site - Accepted into the Program in 2008

• 17 Consecutive Years of “Well-Controlled” Environmental Audit Scores

• Frito Lay Ambassador Award Community Service Runner-Up Award - 2005 &

2006

• Business Award (Recycling & Waste Reduction)

o Stark-Tuscarawas-Wayne Joint Solid Waste Management District - 2005

• Adopt A Highway Involvement – 17 years (Service Award Received - 2016)

• Received Gold Star Status - 2004

Wooster Site Environmental Achievements

Encouraging Environmental Excellence

http://www.youtube.com/watch?v=5bWogzBFqhc

Published on Sep 11, 2014

Ohio EPA Director Craig W. Butler visited Frito-Lay in Wooster, Ohio on

August 20th to recognize the company for its continuing effort in

environmental stewardship. He toured the plant and recognized the

company for being one of the first businesses to earn a silver level

award under Ohio EPA's Encouraging Environmental Excellence (E3)

program.

http://www.youtube.com/watch?v=5bWogzBFqhc

Corporate Sustainability Performance with Purpose is PepsiCo’s vision

to deliver top-tier financial performance over the long term by integrating

sustainability into our business strategy

• Products

• Planet

• People

Planet Environmental Sustainability means finding innovative

ways to cut costs and minimize our impact on the

environment through energy and water conservation as

well as reduced use of packaging material.

We anticipated the need to take environmental

stewardship to a whole new level at the start of the new

millennium, recognizing that environmental sustainability

was becoming a core component of sustainable

success. We began to put in place the systems,

processes and metrics needed to drive continuous

improvement in energy and water conservation as well

as packaging and waste reduction.

1)Develop a Green Team

2)Training

3) Documentation

4) Plan, Do, Check, Act Cycle

5) Community Involvement

Keys to Sustainability

Developing A

Green Team

• Our Green Team is a Cross Functional Team

oManagement

o Sanitors

o Processing

o Packaging

oMaintenance

o Receiving

• Each Unit Leader is an expert in their program

o Program Ownership is important

Developing A

Green Team

• Continual Improvement o Look for opportunities to

grow your team

o Reward & Recognition

• Competent Program

Owners o Invest in your People

• Training

• Education

• Communication

Pam Carter

Environmental

Coordinator

General

Jorge

Castellanos

EHS Manager Rex Carter

Storm Water

Potable Water

Tracy Houchins

Hazardous

Chemical

Management

Donna Gardner

Sustainability/P2

Jill Mosley

Waste

Management

Sue Suppan

Spill Response

Mark Robinson

Wastewater

Sylvia Staten

Air

Wooster Site Green Team Unit Leaders

Plus Supporting Team

Members across all shifts

Wooster Frito Lay Plant

Training

Facility Awareness Activities o Site Earth Day Celebration

• General Awareness Training

o Eco Hero of the Month

o Frito Scoop (Company Publication)

o Period Regulatory Meetings

o Jumbotron

o Billboards

o Site Reward & Recognition

• Hi5

• Way2Go

https://vision.appreciatehub.com/ui/greatwork/index.html

Wooster Frito Lay Plant

Training

Focus Group Training o Work Groups with Greater Potential to Impact

the Environment • Sanitation

• Central Lab Technician (Quality)

• Maintenance

• Receiving

• Management

External Training Opportunities o Webinars

o Conferences

Wooster Frito Lay Plant Documentation

EMS Based On ISO 14001 Standards

o Written Policies and Procedures

• Individually Numbered, i.e. EHS-XX-XXX

Integrated PepsiCo, HQ and Site Specific

Requirements

o Program Documentation

• Environmental Filing System

oHard Copy

oElectronic

• Environmental Calendar

omyEHS

Plan o Recognize an opportunity

and plan a change.

Do o Test the change. Carry out a

small-scale study.

Check o Review the test, analyze the

results and identify what you’ve learned.

Act o Take action based on what you

learned. If the change did not work, go through the cycle again with a different plan. If you were successful, incorporate what you learned from the test into wider changes. Use what you learned to plan new improvements, beginning the cycle again.

Wooster Frito Lay Sustainability Strategy

Wooster Frito Lay Plant Reduction Activities

P2/Sustainability o Analyze Aspects

o Set Objectives & Targets

o Waste Reduction/Inventory

Focus on ReCon o Utility Reduction

• Water

• Natural Gas

• Electric

Elements of Pollution Prevention

Source Reduction

– Prevents Waste Before it is Created

Recycle / Reuse

– Reprocessing a Waste for Other Beneficial Use

– Using a Product Again for its Originally Intended

Purpose

Recover/Treatment

– Physically/Chemically Alter Waste to Lessen its Impact

on the Environment

Disposal

– The Final Release of Waste to the Environment

Zero Landfill Mission

Mission • Zero Landfill Waste for Frito-Lay operations

Program Goals • Reduce Landfill Volume by:

– Reducing/eliminating usage of non-recyclable materials

– Increase effectiveness of recycling

• Increase recycling revenue.

Business Case • Significant Sustainability Statement

• Decrease Waste Expense

• Increase Recycling Revenue

<1% of all

Waste Streams

Go to the

Landfill

Waste Inventory

• We started

tracking our waste

streams in 1999.

• Site visit from

OCAPP to

evaluate

additional

opportunities for

recycling

Wooster Zero Landfill Progress

0

0.5

1

1.5

2

2.5

GOAL

2014

2015

2016

2017

.59%

Started in 2008 with a Dumpster Dive!!

.49%

1.00%

.87%

Waste Recycling Activities

Additional Baler Installed

• Bale Packaging Film,

Seasoning Bags and Shrink

Wrap

Waste Reduction Activities

Energy Efficient High

Powered Hand Dryers

• Replaced Paper Towel

Dispensers (12)

Waste Reduction Activities

New Copiers

o Default Setting is

Double Sided

o Scanning

Capabilities

• Purchase 30%

Recycled Office Paper


Feed Waste Recycling o Finished Waste (Dry)

Recycled as Animal Feed

Additive


Wet Waste Cake

o Recycled into Animal

Feed Additive

Waste Reuse Activities

Starch Production

o Remove Solids From

Wastewater

o Wastewater effluent

loadings reduced,

saving significant

surcharge costs


Centrifuge Installation

o Dewater solids from

clarifier and blend

tank

o TSS removal of at least

85% for a monthly

average

o Wet Waste Cake is

Recycled into Animal

Feed Additive


Product ReUse

o Food Bank Donations

Cases of Product are

donated routinely to local

food banks in need

o ~ 25,000 cases of product

donated in 2016


Primary Clarifier Installation

o Skimmed Grease Reused for

Electricity Generation

o Reduced TSS/COD discharged to

City POTW

o Partnership with Quasar Energy

Group

Primary Clarifier Installation


Beneficial Reuse:

Compost Potato Dirt

o Compost is sent to a

local compost facility

Compost Generation

Waste Reduction

Activities

OLD BATTERY STORAGE

NEW FAST CHARGE

BATTERY STATIONS

Fast Charge Battery

Stations

Reduced number of batteries

per lift, from 3 to 1 on site. Less

chemical reporting and less

waste generated.

Kwh reduction in charging batteries


Carton Re-Use Program

• Re-Use KD’s vs. New

• 93.7 % Used KD’s in 2016


Carton Recycling

• Recycling vs. Landfill

Wooster Frito-Lay Plant Resource Conservation

• Focus On Reduction of Utilities

oNatural Gas

oWater

o Electricity

0

500

1000

1500

2000

2500

3000

3500

4000

4500

2004 2014 2015 2016 2017

Natural Gas (BTU/lb of

Product Produced)

Natural Gas Usage

Since 2004

Reduced by

15%

Natural Gas Reduction Activities

PC Heat Exchanger

Replacement (2)

Old Heat Exchanger

New Heat

Exchanger


PC Heat Exchanger

Stack Heat Recovery

• Reclaimed Heat is

used to dry starch

Before

After


Annual Burner Tuning

• Energy Efficiency

0

0.5

1

1.5

2

2.5

3

3.5

2004 2014 2015 2016 2017

Water (Gal/Lb of

Product Produced)

Water Usage Since 2004

Reduced By

35%

Water Reduction Activities

Replaced Clean In

Place High Pressure

Nozzles

o From 8010 Style to

8002 Style

• Replaced 400+

Nozzles

• Energy Cost

Savings/Yr


Installed Low Flow

Bathroom Fixtures

• Sensor Exposed

Flushometer for Water

Closets, Battery-

powered 1.6 gpf

• Sensor Activated

Faucets Water-

efficient flow rate of

0.5 gpm

Water is reused to clean

potatoes in the Flume

Area. This system,

designed by our

employees, allows dirt particles to separate and

water to be reused for

potato washing. The solids

are removed and composted which reduces

TSS/COD discharged in our

wastewater to the City of Wooster.

The dry cleaning method is encouraged by Frito-Lay.

Use a broom to clean-up instead of spraying product down the drain


PC Flume Recycle Water


Water Leak Elimination

• Weekly Water Leak

Audits Conducted By

Maintenance

• Different Department

each week

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16

0.18

2004 2014 2015 2016 2017

Electric (Kwh/lb of

Product Produced)

Electric Usage

Since 2004

Reduced by

21%

Electric Reduction Activities

Packaging Automation

• Energy Cost Savings/Yr

Vacuum Pump

Before

After


Electric Upgrades

o Switch Gear

Replacement

o Transformer Reduction From Two Units to One

• Energy Cost Savings/Yr

Increase Reliability,

Reduce Power

Outages/Shutdowns

Vacuum Pump


Energy Star Rated Reflective Roofing

• Kwh Reduction

http://www.energystar.gov/index.cfm?c=home.index


Stober Gearbox

Replacements

o Energy Efficient


Install LED Lighting

o Entire Facility

• Auto Sensors

o Energy Cost Savings

• Waste Reduction

OLD

NEW


Install LED Lighting

o Parking Lots

• (HID to LED)

• Light Sensors

• Energy Cost Savings

• Waste Reduction


Rapid Roll Doors in

Packaging

• HVAC Air remains in

the Packaging

Department

• Keeps Electrical

Equipment Cooled

Properly

~ Energy Efficiency


FL710 Conversion to Water

Cooling

o Old system used

compressed air

o Current system re-

routes water going to

PC Washboxes and

Corn Duck Ponds to

pass by the FL710

units, cooling them in

the process

Vacuum Pump

• Education o EDC’s Earth Fest

o Ohio OEC Lobby Day

o OARDC Scarlet, Gray & Green Fest

o Local School Presentations

• Hands On o Adopt A Highway Litter Pick-

Up

o Hiking Trail Clean-up (TWC)

o Burning River Fest in Cleveland

• Meetings o Wooster Area Safety

Council o Northern Ohio Chapter Air

& Waste Management

Wooster Site Green Team Community Service

Thank you for the opportunity to

share our Sustainability Story!

Questions??

Working together to move beyond compliance to

enhance and preserve our Environment for the future.

“Telling Your Sustainability Story” - Ohio EPAepa.ohio.gov/Portals/0/general...

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