Harnessing the hidden value of
by-products to capture carbon credits
Bob Carss, Group Environment Manager, VION Food Group Limited
Stephen Woodgate, Chief Executive, Food Chain and Biomass Renewables Association
Presentation Overview
Introduction to Vion
Introduction to Fabra
The by-products sector
Joining forces
Summary
VION Food Group: Profile
• International Food Concern
• € 9.0 billion turnover
• 27,000 employees
• Head Office
• Eindhoven, The Netherlands
• Core activities
• Food
• Ingredients
• Mission
• VION wants to anticipate and
fulfill customer and consumer
needs with high quality and
innovative Food and
Ingredients
• Objective
• VION wants to become a
leader in (selected) Food and
Ingredients market segments
• Credo
• “Passion for Better Food”
VION Locations
VION Food Netherlands VION Food Germany
VION Food International
VION Food UK
VION Ingredients
Profile of VION UK
•
•
•
•
•
•
46 facilities across the UK
14,000 employees (FTE)
70% revenue from retailers
Happy Pigs welfare programme
#1 in Chicken Agriculture
#1 UK meat processor
• #2 in Pork, Chicken and Beef
• #1 in Bacon, Lamb and Sausages
• Cooked Meats
• Turkey
• Pizza
• Other (Agri)
VION Organisational Chart
ZLTO / NCB Ontwikkeling
ZLTO is a Farmers
Union with
approximately
18,000 members
Supervisory Board
VION
Executive Board
FOOD
INGREDIENTS
Fresh pork, beef, poultry, lamb and
convenience products
Ingredients e.g. fat, proteins, gelatin
21,000 employees
6,000 employees
NL
DE
UK
Int.
NL
DE
BE
Int.
Rousselot
Green Energy Park Ecoson
€ 20 million investment in
sustainable energy
Digester
Capacity:
8,000 MWh
36,000 MWh
thermal energy
electricity
Electricity consumption per average
household is ± 3.5 MWh per year
(Source: NIBUD)
Energy
Own use + Rendac
Back to electricity grid
Flotation sludges
Raw material
Digester
Process
Water
WWT-installation
Digestate
Rendac
End products
Application
Development of green electricity
production
Digester input
Sludge trade to 3rd party
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
180.000
160.000
thousand (ton/year)
MWh per year
Electricity production
140.000
120.000
100.000
80.000
60.000
40.000
20.000
2005
2006
2007
2008
2009
2010
2011
2012
2005 2006 2007 2008 2009 2010 2011 2012
• Key for success: Integration with C1 facilities, permits and subsidy programs
• Additional investment in 2011 in 2nd post digester and a fourth motor and
electricity generator
• After these investments Ecoson is the Netherlands Nr 1 in green electricity
production from Biogas
Refinery and Biodiesel
Current capacity:
50.000 MT
De-acidified fat
5 million liters Biodiesel
Animal fat
Refinery
Fatty Acids
CHPs/ steam boilers
Rendac
De-acidified fat
Raw material
Biodiesel
Biodiesel
Truck fleet B100/ B20
installation
Glycerin
Digestation
End products
Application
Process
page 10
VION Summary
• VION are using current engineering technology to use the by-products of
food production for Renewable Energy generation
• Energy Savings/ Efficiencies/ Climate change benefits
• In our UK approach we are looking to utilise such products to replace more
carbon intensive alternatives.
• We hope to move this forward through the work we are undertaking with
FABRA and Harper Adams by validating the carbon footprint aspects of our
products.
Introduction to Fabra
Fabra members collect, process
and utilise more than 2/3rds of the
Animal by-Products [ABP]
originating in UK.
Fabra is committed to maximising
the value of ABP by using the best
technology operated to the highest
standards.
Introduction to Fabra
Introduction to Fabra
Fabra are members of EFPRA
(European Fat Processors and Renderers Association)
Many of the initiatives discussed are part of EFPRA’s ongoing scientific ,
technical and promotional work
Fabra are members of the WRO
( World Renderers Organisation)...
Many of the common themes are adopted by WRO
Stephen Woodgate is a member of the EFPRA Executive Board and is
currently 2nd Vice-President of the WRO
The origin of animal by-products
Live Animals
Slaughter
Fallen Stock
Hide and Skin
Food – meat and edible offal
Animal By-Products
Amounts of Animal By-products
Total amount of UK animal by-products ~ 2.25 million tonnes per annum
Rendering: Simplified Process Flow diagram
Raw material
Sizing
Drying/Cooking
Pressing
Decanting
Cooling
Grinding
Centrifuge
Processed Proteins
“MBM” or “PAP”
Rendered Fat
“Tallow”
Processing Systems in Practice
Category1 Category2
By-Product Processing
[Rendering]
MBM
Rendered
Fat
Category 3
Bio
Fuel
By-Product Processing
[Rendering]
PAP
Rendered
Fat
A carbon footprint “toolkit” for the
rendering industry
Angel Ramirez
Calculating the carbon footprint
Land use
change
Methane
Transpor
t fuel
Crop growing
for feed
production
Fertiliser
Transpor
t fuel
Animal
husbandry
Energy
Energy *
Transpor
t fuel
Animal
Slaughterhouse
Animal
By-product
processing
Energy
Fertiliser
Energy
Additives
Focus
on
By-Products
Rendered
animal
fats *
Processed
animal
protein
Meat and
bone
meal *
The Rendering Process: Boundaries
Summary: Rendering Carbon Footprint (so far)
What we have learned so far from the Rendering industry study*
Products: Rendered Fat
Category 1
Category 3
“Carbon Footprint”
kg CO2 / kg product
- 0.77
0.15
*Preliminary data: Fuel 25% Natural gas:75% rendered fat
Engineering aspects:
Ability to use Renewable fuels in thermal installations
Focus on Energy efficiencies in the process
Ability to develop Carbon Credits and gain ROC’s
Joining the pieces together......
Joint work with Vion and Harper Adams will consider wider perspectives....
From “day old” chick through to use of Poultry PAP in Aquafeeds:
Broiler Poultry Production
Feed Milling
Slaughter
Results of CFP Assessment – Food / Feed
Comparison
Rapeseed Oil
Soybean Oil
Palm Oil
Cat 3 Mixed Fat
Cat 3 Poultry Fat
Foodgrade Fat
0
500
1.000
1.500
2.000
2.500
3.000
Carbon Footprint (kg CO2 eq per tonne)
3.500
4.000
Acknowledgement and
Thank you to Angel Ramirez
Bob Carss
bob.carss@vionfood.com
Stephen Woodgate
swoodgate@fabra.co.uk