Baking&Snack - December 2011 - 82

HEAT RECOVERY

Frito’s Plant Nears Net Zero
Frito-Lay North America’s Casa Grande, AZ, facility has reached “near net zero,” or as far “off the grid” as possible, by running primarily on renewable energy sources and recycled water while producing almost no landfill waste. The nearly 188,000-sq-ft snack manufacturing plant generates two-thirds of all energy used from renewable sources and works toward reducing greenhouse gases by 50%, relying on 75% recycled water and dropping its natural gas usage by 80%. A water recovery and reuse system combines membrane bio reactor (MBR) and lowpressure reverse osmosis (LPRO) technologies to recycle and purify 50 to 75% of the plant’s wastewater. Five solar photovoltaic (PV) systems, installed throughout the property, produce nearly 10 million kilowatt-hours of electrical power. The newly installed 60,000 lb-perhour biomass boiler, which uses wood and agricultural waste as its combustion energy source, will produce the steam necessary for the plant and reduce natural gas usage by more than 80%, according to the company. The Casa Grande facility also sends less than 1% of its overall waste to a landfill through recycling and using food waste for cattle feed. ▶ Frito-Lay’s Casa Grande plant employs some of the most innovative green technologies in the world to reuse energy, recycle water and eliminate nearly all landfill waste.
FRITO-LAY NORTH AMERICA

foot of fuel per pound of finished product formula. This can be reported as a monetary savings and a conservation of natural resources, which makes the big customers very happy.” Scott Houtz, AMT’s president, said heat recovery is just common sense. “When you look up to the roof of a bakery and see these heat plumes, you just think, ‘What a waste of energy,’” he noted. In addition to providing heat to bakery equipment, the system can preheat cold outside air to warm the bakery during winter months. “Sometimes it’s a little tough to swallow that you are burning gas inefficiently to heat air when you can do it basically for free,” Mr. Widman said. The glycol tanks and other main parts of the system can be installed outside of the bakery and are tolerant enough to operate in either extreme heat or cold, according to Mr. Houtz. The actual heat exchanger

Hang up your gloves.
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BAKING & SNACK / December 2011

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Baking&Snack - December 2011

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