As energy costs rise, water becomes scarcer and environmental requirements evolve, food and beverage producers face increasing pressure to improve performance while controlling resource use. More than one third of global greenhouse gas emissions being attributed to food systems1. The challenge is not whether improvement is needed, but how to achieve it without replacing equipment.
When sustainability is discussed, the focus is often on environmental impact. In practice, many sustainability priorities are closely linked to resource use, operating costs and the long-term value of existing assets.
Get more out of your equipment, for longer
Asset lifecycle has a significant impact on both sustainability and operational performance. Firstly, if technology becomes obsolete to the point where a new solution is needed, the older machinery often cannot be reused or repurposed. This is not only a question of resource use, but also of continuing to realise value from assets that are already installed.
“Upgrades contribute to sustainability in terms of the lifecycle of the assets,” explains Manuel Juncal, Senior Product Manager at Tetra Pak. “If the machine is running well and we can update it, we can extend the lifetime and make the most of the equipment. This also reduces future investments as we don’t have to replace the machines, so it’s more economically sustainable. For example, we have machines that are still operational after 30 or 40 years thanks to upgrades that help them better meet today’s needs”
Improving performance through better resource use
While extending the lifecycle of your equipment is a crucial piece of the sustainability puzzle, upgrades can offer a wide range improvements and optimisations across your entire plant, from reducing resource use to optimising water consumption.
“Where a business is based is often the most important factor, as the local conditions create the demands,” says Juncal. “One area could be experiencing high energy prices, for example, where another could be facing water scarcity. Depending on the market, priorities may include energy costs, water availability, sustainability targets or changing regulations.”
Regulations also play an important part in this regard, as they can change production requirements for businesses. Take, for example, the EU Single-Use Plastic directive, which addresses the issue of plastic litter from caps and lids on beverage containers. These containers must now have tethered caps, which meant many producers needed to invest in solutions capable of producing this new kind of package.
Improving resource efficiency can deliver benefits beyond environmental performance. Lower energy consumption, reduced water use and less waste can also contribute to lower operating costs and improved production performance.
How do you decide where to focus?
"Interest in upgrades comes from a range of places: rising utility costs, water scarcity, ageing automation, changing production requirements, sustainability ambitions or regulatory changes," explains Juncal. “It can also be reactive or proactive. We always inform our customers about obsolescence, for example, as they need to be aware, and automation and control systems change fast, so we try to inform the customers of any potential updates far in advance.”
The challenge is rarely identifying available upgrades. It is understanding where improvements can create the greatest value. To do this, the key is often collaborating with the right solution provider that can guide you towards the right solutions, and proactively formulate an upgrade plan that will make a positive impact, quickly, while giving you the performance you need for the long term.
Finding the right opportunity
A proactive approach to upgrades and performance is key to making the most out of any investment, and with so many opportunities it can be a challenge to find the best way forward. That’s where a collaborative approach is essential.
Every customer is different, too. For one customer, a heat pump may be a key upgrade that helps reduce energy consumption and, in turn, carbon emissions. For another, a switch from direct UHT (Ultra High Temperature) to indirect UHT could be the path to improved profitability and sustainability. There is no one upgrade, or set of upgrades, that will work equally well for every business – a tailored, specific approach is necessary.
“Upgrades can expand capability to meet modern needs,” adds Juncal. "It's about understanding where value is being lost today and identifying the improvements that can make the biggest difference tomorrow.”
1. https://openknowledge.fao.org/server/api/core/bitstreams/121cc613-3d0f-431c-b083-cc2031dd8826/content