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As the global spotlight on environmental sustainability intensifies, the food and beverage industry is committed to adopting greener manufacturing practices. Across all facets, from production to packaging, the industry pursues the integration of sustainable energies, affirming a steadfast commitment to a responsible and eco-friendly future. FoodBev explores.

Last year, the EU revised its energy-saving targets within the framework of the ‘Energy Efficiency Directive’. This year marks a heightened target for energy savings, increasing from 0.8% to at least 1.3% for the period 2024-2025 and 1.5% in 2026-2027. So, what is the industry doing to meet these targets?

CFT, a provider of industrial equipment, is committed to addressing these challenges by developing innovative processing and packaging solutions. Sharing insights with FoodBev, a spokesperson for CFT discussed the company’s efforts to reduce energy consumption.

“One notable innovation in CFT’s portfolio is the implementation of mechanical vapour recompression (MVR) technology for evaporation processes,” they said. “MVR technology stands as a paradigm shift in how industries approach evaporation, as it enables the recycling and recompression of vapours, significantly reducing steam consumption compared to traditional methods thanks to the efficient use of electricity.”

They continued: “Depending on the production necessities, MVR evaporators can be installed as stand-alone technologies or coupled with existing traditional evaporators to reduce the overall steam consumption of a plant”.

To enhance the overall efficiency of industrial processes, CFT’s ohmic heating technology for sterilisation works by running an electric current through the product, heating both solids and liquids simultaneously. Unlike other processes, such as microwaves, it is used widely in creating UHT products. It is recognised for its efficiency and gentle approach to heating food, particularly for products containing particles, helping to preserve the integrity and physical characteristics of the product.

He added: “In both cases, the switch from steam to electricity aligns with global efforts to reduce reliance on fossil fuels and mitigate the environmental impact of industrial processes”.

Feeling the heat

While efficient energy systems can yield cost savings and time benefits, for some, the optimal solution for efficiency is to transition entirely to green energy sources.

One stand-out example of green innovation emerged through the partnership between renewable energy company Brenmiller and Tempo, the largest brewery in Israel, owned by Heineken. Brenmiller implemented a complete thermal energy system, replacing the boilers at its site.

Doron Brenmiller, the company’s co-founder and chief business officer, explained: “It functions like a big thermal battery capable of retaining high-temperature heat, storing it for a day, a week or however long is necessary, and subsequently releasing it as heat when needed”.

The company estimates that using thermal energy storage in place of fossil fuel boilers will eliminate the use of approximately 2,000 tons of heavy fuel oil annually and mitigate over 6,200 tons of carbon emissions each year.

Brenmiller continued: “What we observe today is a growing customer preference for eco-friendly solutions, particularly in Europe, where individuals are increasingly reluctant to rely solely on gas. Rather than concentrating on enhancing the efficiency of gas appliances, like light bulbs or boilers, the current emphasis is on presenting alternatives that are not tethered to gas, thereby aligning with the shift towards greener and more sustainable choices.”

Similarly, glass packaging manufacturer Vetropack has pledged to invest in greener and more efficient energy. Last year, the company opened a production facility in Boffalora sopra Ticino, in Milan, Italy, integrating smart technologies and closed-loop systems to maximise the reuse of water in production and to repurpose as much exhaust heat as possible.

The demolition material from a previous paper mill on Vetropack’s site is being recycled in the construction of the new plant. Operating recirculation systems, water used in production and exhaust heat from the blast furnaces are maximally reused, while the latest filter systems play a crucial role in significantly reducing emissions.

Nicolas Lootens, group sustainability manager at Vetropack, told FoodBev: “As part of our ongoing efforts, we have already invested in photovoltaic systems at various locations, including Austria and Croatia. In these regions, we are proud to generate a significant amount of our electricity needs ourselves, through solar power.”

He continued: “For example, at our plant in Kremsmünster, Austria, the first two out of five expansion stages of our photovoltaic system have been successfully implemented, with the initial stage alone producing solar power equivalent to the annual consumption of 400 households. Looking ahead, we have ambitious plans to fully electrify our production processes. Our vision is to transition to 100% renewable energy, contributing to a greener and more sustainable future for glass manufacturing.”

Green lines

In November, KHS unveiled its Double Gate heating concept designed for stretch blow moulding machines. This concept, which features two preforms positioned in front of the radiators and the near-infrared lamps, achieves an energy reduction of around 30-40%. Simultaneously, it contributes to a diminished consumer footprint due to its compact design.

Using efficient near infrared heating technology, KHS cuts energy costs by up to 40% and minimises space. DuoCooling employs two temperature circuits, saving energy and preventing mold condensation. EcoDry, powered by AirbackPlus, slashes condensation, boosts machine hygiene, and streamlines air drying – all while cutting down on costs.

The dynamic duo of EcoDry’s air management system and AirbackPlus works in sync to combat condensation on the base mold, ensuring optimal machine cleanliness and efficiency.

Additionally, the EcoDry process simplifies and can eliminate the requirement for a separate air-drying process in certain climatic conditions, leading to reduced investment and energy costs.

Sustainability, efficiency and the integration of green energy are expected to remain key drivers of innovation within the sector. With available technologies constantly adapting to meet the evolving needs of food and beverage producers, 2024 is expected to witness a surge in innovative applications of green and energy-saving technologies, marking a significant stride towards a more sustainable and eco-conscious future for the sector.