Operations
Midwest North Pride
Beloit, WI Operations
#1 in All We Do!
Mike Stahl
Technical Manager
Operations
Midwest North Pride
Frito Lay Beloit Service Area
Region Profile:
• 45% DC
• 55% Bin
TCN DC
Bloomington DC
FVSC
Madison MFSC
DC
● Beloit
• 8 DC’s: TCN, Bloomington, Milwaukee, Omaha,
Madison, FVSC, Des Moines, Davenport
• 202 Bins
• 600MM units Annually
• 44.8MM cases in 2008 (Plan)
• 1118 Vehicles (2nd Largest Fleet)
• 2nd Largest Geography (8 States)
• 85% of potatoes sourced from Wisconsin
Carol Stream DC Northbrook DC
Oak Brook DC
Summit
DC
Davenport DC
Des Moines DC
Omaha DC
Operations
Frito Lay Beloit, WI
The Pre-Eminent Green Company
Midwest North Pride
10
9
Make
Move
8
7
6
5
4
3
2
1
16
17
18
19
20
11
12
13
14
Sell
Support
15
Technology
Practices
PepsiCo Confidential
External
3
Operations
Frito Lay Beloit –
A Pre-Eminent Green Company in Wisconsin
51%
700
36%
4800
4600
4400
1.5
21%
650
4200
kwh / Lb
2
BTU / Lb
Gal / Lb
2.5
Midwest North Pride
4000
3800
3600
600
550
3400
3200
1
'99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09
3000
Water
Tradition of Excellence
'99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09
Natural Gas
500
'99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09
Electricity
•2010 Wisconsin Manufacturer of the Year Award
Grand Sustainability Award
•2010 Business Friend of the Environment Award
•2010 EPA Waste Wise Partner of the Year Award
•2009 Wisconsin Green Tier Acceptance
•2009 Wisconsin DNR Clean Air Award
•2009 Governors Award for GHG Emission Reductions
•2008 – City of Beloit proclaims FL Eco-Friendly
Business
Operations
People Engagement Processes….
Midwest North Pride
Resource Conservation Tracking…gas, water, electrical per pound usage
Daily Performance Reviews/Action Planning on the Frontline……
Operations
Sustainable Processes….
Midwest North Pride
Structured MX Systems
Infrared and Ultrasonic Scanning
Period ________________
1st Shift Powerhouse Walk
Week
Sunday
Monday
Tuesday
Wednesday
Thursday
________________
Friday
Saturday
Team Member Initials:
Boiler Room
Set point or Status
Booster Pumps
Range 80 to 100 PSI
Booster Pumps
Pump A or B
Trace Line Skid
Return Temperature
A
B
A
B
A
B
A
B
A
B
A
B
A
B
Feed Water
Pump A or B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
RO System
Running in Auto
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Water Meter
Usage
1
2
1
2
1
2
1
2
1
2
1
2
1
2
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
A
B
A
B
A
B
A
B
A
B
A
B
A
B
Boiler Running
1 or 2
Boiler 1
usage
Boiler 2
usage
Softeners
Compressed Air
System
Running
Set point or Status
Glycol Pressure
PSI
Glycol Pump
Glycol Incoming
Temperature
< 75
Centac 400, Oil
Temperature
< 114 deg F
Centac 500, Oil
Temperature
< 120 deg F
Site Air Pressure
> 88 psi
Sullair 450, Interstate
Temperature
< 225 deg F
Dryers
range 34-39 deg F
Other Resource Conservation Activities
Quarterly Combustion Checks and Tuning of Ovens and
Heat Exchangers
Weekend Load Optimization ….. Compressor shedding,
boiler turndown, etc.
Operations
Long Range Strategic Planning
Midwest North Pride
Technology Tactics > 150% of Target
2007
2008
2011 - Projected
2010
2009
TC1 Stacks Heat Recovery
Air Compressor WHR
Compressed Air to C. Blower
UVGI Technology in HVAC
PC Stack Heat Recovery Phase I
Adsorption Chiller
Revised SOP in WWT
WWT Optimization
Biomass Boiler Startup
Initiate Air Study
Boiler Economizer
WH to Electricity
Effluent Pump Recycle H2O
Demand Expander
MPC 50 Broach Mx Schedule
High Efficiency Burners Upgrade
Compressed Air Optimization
PC Stack HR Phase II
MPC 50 Broach to dry Starch
Wet Cake Electric Generator
Air Compressor WHR
WWT Blower VFD
BioMass Boiler – In Progress
Power Correction Capacitors
PC50 Stack Heat Recovery Eng.
Nitrogen PSA Generation
Belt Press Upgrade
Bio-Solid Fertilizer
Operations
Waste Heat Recovery Projects…..
GHG Reduction Enabler
Midwest North Pride
3000 MT Scope 1
CO2e Emissions
Operations
Midwest North Pride
Frito Lay Beloit, WI – GHG Emissions
Combining People, Systems and Technology Blended Approach
30
25
20
24% Reduction
7,100 MT CO2e
15
10
5
0
2005
2006
2007
2008
2009
Operations
Beloit “Near Net Zero” Strategy
Biomass Boiler
Midwest North Pride
TC Waste Heat Recovery
PC Waste Heat Recovery
Electrical Kaizens
Beloit MBBR Treatment
Sustainability Leadership
Waste Heat Kaizens
c
Zero Landfill (1st site in FLNA)
LEED Gold
Operations
Midwest North Pride
Frito Lay Beloit – GHG Flight Plan (scope 1)
30
Continued Waste Heat Recovery
and other technologies enable
another 40% GHG emission
reduction from current day
performance…..
25
20
15
Establishes an option for future
zero carbon footprint growth….
10
Beloit remains competitive with
sister plants in Topeka, Kansas and
Frankfort, Indiana…..
5
0
2005
2006
2007
2008
2009
2010
2011
2012
2013
60% GHG Reduction <10 Years
17,800 MT CO2e
Like 3400 vehicles of the road
Operations
Fleet Resource Conservation Initiatives
EPA SmartWay Certified Fleet…..
Gap Farings, Auto Tiring Inflation, etc.
Midwest North Pride
Driver MPG Challenge Contest Every Period
Leveraging Idle Free Technology….Wabasto Heaters
30% Idle Reduction
26,000 Gallons YTD
230 MT CO2e
Operations
Frito Lay Beloit –
A Zero Landfill Leader @ <1%
Midwest North Pride
People, Processes and
Technologies in Place
Continuing the Journey to Zero
Landfill Reduction
140000
120000
Pounds
100000
80000
2008
2009
60000
2010
40000
20000
0
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Months
55% Landfill
Reduction
Sep
Oct
Nov
Dec
Operations
Midwest North Pride
We have goals aligned to our Pre-Eminent Green Vision
75%
Water
% GAL / Lb
80
70
60
40
2007
2017
Electricity
100
1999
2007
2017
50%
Fuel
45%
100
90
80
90
% GAL
% kwh / Lb
50%
90
50
1999
70
60
80
70
50
40
Natural Gas
100
% BTU / Lb
100
90
80
70
60
50
40
30
20
1999
2007
60
2017
PepsiCo Confidential
2004
2007
2017
14