Switching to green energy to power food and drink manufacturing processes is an effective way to reduce a company’s carbon footprint. However, relying entirely on renewable energy can be challenging as there are times of the day when the sun and wind cannot generate enough energy to power manufacturing processes, while at other times, there is a surplus. In addressing this issue, PepsiCo, a major snacks and drinks manufacturer, collaborated with its energy partner Eneco and German start-up Kraftblock to develop a thermal battery that stores excess green energy for later use.
Kraftblock’s innovative technology uses a material capable of storing temperatures up to 1,300˚C. Once heat is transferred from the heat transfer medium, in PepsiCo’s case, from hot air heated by wind energy, to the storage system, it can be used for up to two weeks. At PepsiCo’s Broek op Langedijk production plant in the Netherlands, the stored energy heats thermal oil and cooks PepsiCo crisps.
Off-peak periods allow PepsiCo to source renewable electricity from North Sea windfarms, convert it to hot air, and store the energy in Kraftblock’s iron ‘nuggets’ at 800˚C. Meanwhile, direct electrification powers two electric thermal oil boilers, which can be switched off during the day, and heat is extracted from the storage units in the form of hot air. During peak periods, energy costs are higher, and PepsiCo can use a hot air to thermal oil heat exchanger to supply energy to its production processes.
In replacing natural gas with sustainable electricity, PepsiCo has reduced CO2 emissions by around 50%, with a goal to achieve a 98% reduction. This plant will now become the first fully decarbonised snacks plant within the company’s business worldwide.
Despite the innovative solution, installing new technology at scale is never an easy process. Kraftblock’s batteries must be located relatively close to the thermal oil boiler house on-site, which required rethinking logistics. It also posed challenges regarding operations, given that the Broek op Langedijk site is one of PepsiCo’s top 20 snacks sites. Installation planning had to be carefully developed to sustain production levels during the installation process.
The PepsiCo Positive (pep+) agenda, which aims to reduce greenhouse gas emissions by over 40% by 2030 and achieve net zero emissions by 2040, is in alignment with the company’s decarbonisation project. PepsiCo plans to reach a 75% reduction in GHG emissions by 2030 via innovative technologies like Kraftblock’s thermal battery.
When scouting for new solutions, PepsiCo is conscious of its supply base and works with both established players and start-ups to bring together great ideas. Overall, PepsiCo’s use of Kraftblock’s thermal battery technology has created a sustainable, cost-effective solution to decarbonise the operation of a snacks plant while reducing its carbon footprint.
