Case study

All steamed up about chocolate at Cadbury Claremont

Financial Dividends Annual cost savings – $36,000 Payback period – 3 years

Environmental Dividends Water savings – 8,640 kilolitres per year Coal savings – 390 tonnes per year Greenhouse gas emissions avoided – 790 tonnes of CO2 per year Coal ash reduction – 97 tonnes per year At the Claremont crumb plant, milk and sugar are combined and dried into a crumbly mixture which is later combined with cocoa to make milk chocolate. The eco-efficiency team implemented a strategy to improve the use of steam and water at the plant. In early 2008, the team engineered the capture of high pressure steam used in drying the milk and sugar mixture. The steam is then re-used in the plant’s hot air dryer, and then transferred to the boiler as preheated feed water for further steam production. This process has added significantly to pre-heated boiler feed water volumes collected from other areas in the factory. Significant environmental and cost benefits are associated with this project.

Continuously improving manufacturing efficiency is an objective of production sites all around the world. Cadbury P/L is familiar with the challenge. Recent efforts have focused on the crumb plant at the company’s chocolate factory near Hobart. Cadbury’s eco-efficiency team regularly identifies opportunities to improve efficiency and sustainability at the site, as the company prepares for a low carbon future.

Environment. Health and Safety Manager).640 kilolitres. Other examples of resource efficiency initiatives by the company include: . Capital expenditure on the project for the low pressure and flash steam vessels. Right: The new low pressure steam condensate vessel. The Tasmanian facility employs about 850 people and produces around 45. With expected savings of about $36. However. coal ash reduced by 97 tonnes. The company’s commitment to environmental sustainability is reflected in their policy.The change to operations will save coal and water used to produce steam. “We are looking at all opportunities to reduce our carbon and water footprint. and condensate return steam driven pump. look after the health and safety interests of our employees. Cadbury’s involvement in CleanBiz’s training and support program provided a good opportunity to focus closely on the crumb plant. We believe that such an approach will generate and sustain significant environmental. Participating in the ‘Global Reporting Initiative’ shows the company’s willingness to monitor and report on the aspects of their business that impact on the environment. and potable water use reduced by at least 8. and Clinton Luckock (Environmental Specialist). platforms.using Australian invented starch based biodegradable chocolate trays. social and financial benefits.Luckock@cadbury. and become a more sustainable business. and seek opportunities to improve the local environment in the communities in which we operate. and has pledged a 50% reduction of net absolute carbon emissions by 2020. The Claremont factory is one of many sites that manufacture the company’s confectionary products. associated pipe work.000 per year. Cadbury Claremont Factory Contact Cadbury Pty Ltd Clinton Luckock ph: (03) 6249 0111 Clinton. high pressure flash steam vessel.000.collecting cooling water used in the crumb plant (about 6. scaffolding. Each year it is estimated coal use will be reduced by about 390 tonnes. the company recognises that resource efficiency is not just about projects. Health and Safety Manager. Ken Holmes (Environment. at the current cost of energy production. in part “We minimise our impact on the environment around the world. which reads. The company is also conducting a “purple goes green” environmental campaign. and installation was $112. but about a systems approach that is based on continual improvement. The Tasmanian Government’s CleanBiz grant scheme contributed $35. . Cover page images . from left Marcus Bealey (Technical Specialist). Greenhouse gas emissions will also be reduced by about 790 tonnes per annum. Profile of the business The chocolate making facility was established in Tasmania in 1921.000 KL/yr) and re-using it on the adjacent Claremont golf course. Cadbury Pty Ltd is the second largest confectionary manufacturer in the world.com 100 Cadbury Road. projected pay back on the investment (including the grant) was three years. This helps ensure our long term future in Tasmania. Above: Greatly reduced steam discharge at the crumb plant (also the discharge point was moved) – the remaining discharge is a work in progress.Left: Cadbury’s registered trademark. Centre: Cadbury personnel near recent plant modifications. Less greenhouse gas emissions and coal ash waste (ash left over from burning coal) will be produced. condensate pump.000 tonnes of chocolate per year. Above: Steam discharge at the crumb plant prior to the CleanBiz project. Claremont Tasmania . contributing to our objective of long term sustainability”.000 to the project. Subsequent energy price increases brought the pay back period to less than two years.” Ken Holmes.