“Telling Your Sustainability Story” Frito Lay Inc. – Wooster, Ohio
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“Telling Your Sustainability Story”
Frito Lay Inc. – Wooster, Ohio
Frito-Lay North America
• Convenient foods leader
• $14 billion annual sales
• Division of PepsiCo
• 50,000 employees
• Strong presence across U.S. &
Canada
• Headquarters - Plano, TX
• 75+ year history
Broad Portfolio
Wooster Frito-Lay Manufacturing Plant
Overview • Operation for 70 Years (1947)
• Product Lines o 2 - PC Fryers
• Lays, Ruffles
o 2 - Tortilla Chip Fryers • Doritos, Tostitos, Santitas
o 1 – Frito Fryer • Fritos
• Volume o Average Year – 80 MM Pounds Produced
o Full Mix Warehouse -1999
• PepsiCo Center of Excellence Award for ReCON Climate Energy Stage 1
(2015)
• PepsiCo Center of Excellence Award for Environmental Stage 1 (2014)
• Ohio EPA’s Encouraging Environmental Excellence Award in 2013 (Silver
Level)
• Frito Lay Ambassador Award Community Service, Received in 2011 & 2012
• Ohio Environmental Council’s Environmental Achievement Award, Received
Honorable Mention in 2010
• Governor’s Award for Environmental Stewardship 2008
• US EPA Performance Track Site - Accepted into the Program in 2008
• 17 Consecutive Years of “Well-Controlled” Environmental Audit Scores
• Frito Lay Ambassador Award Community Service Runner-Up Award - 2005 &
2006
• Business Award (Recycling & Waste Reduction)
o Stark-Tuscarawas-Wayne Joint Solid Waste Management District - 2005
• Adopt A Highway Involvement – 17 years (Service Award Received - 2016)
• Received Gold Star Status - 2004
Wooster Site Environmental Achievements
Encouraging Environmental Excellence
http://www.youtube.com/watch?v=5bWogzBFqhc
Published on Sep 11, 2014
Ohio EPA Director Craig W. Butler visited Frito-Lay in Wooster, Ohio on
August 20th to recognize the company for its continuing effort in
environmental stewardship. He toured the plant and recognized the
company for being one of the first businesses to earn a silver level
award under Ohio EPA's Encouraging Environmental Excellence (E3)
program.
Corporate Sustainability Performance with Purpose is PepsiCo’s vision
to deliver top-tier financial performance over the long term by integrating
sustainability into our business strategy
• Products
• Planet
• People
Planet Environmental Sustainability means finding innovative
ways to cut costs and minimize our impact on the
environment through energy and water conservation as
well as reduced use of packaging material.
We anticipated the need to take environmental
stewardship to a whole new level at the start of the new
millennium, recognizing that environmental sustainability
was becoming a core component of sustainable
success. We began to put in place the systems,
processes and metrics needed to drive continuous
improvement in energy and water conservation as well
as packaging and waste reduction.
1)Develop a Green Team
2)Training
3) Documentation
4) Plan, Do, Check, Act Cycle
5) Community Involvement
Keys to Sustainability
Developing A
Green Team
• Our Green Team is a Cross Functional Team
oManagement
o Sanitors
o Processing
o Packaging
oMaintenance
o Receiving
• Each Unit Leader is an expert in their program
o Program Ownership is important
Developing A
Green Team
• Continual Improvement o Look for opportunities to
grow your team
o Reward & Recognition
• Competent Program
Owners o Invest in your People
• Training
• Education
• Communication
Pam Carter
Environmental
Coordinator
General
Jorge
Castellanos
EHS Manager Rex Carter
Storm Water
Potable Water
Tracy Houchins
Hazardous
Chemical
Management
Donna Gardner
Sustainability/P2
Jill Mosley
Waste
Management
Sue Suppan
Spill Response
Mark Robinson
Wastewater
Sylvia Staten
Air
Wooster Site Green Team Unit Leaders
Plus Supporting Team
Members across all shifts
Wooster Frito Lay Plant
Training
Facility Awareness Activities o Site Earth Day Celebration
• General Awareness Training
o Eco Hero of the Month
o Frito Scoop (Company Publication)
o Period Regulatory Meetings
o Jumbotron
o Billboards
o Site Reward & Recognition
• Hi5
• Way2Go
Wooster Frito Lay Plant
Training
Focus Group Training o Work Groups with Greater Potential to Impact
the Environment • Sanitation
• Central Lab Technician (Quality)
• Maintenance
• Receiving
• Management
External Training Opportunities o Webinars
o Conferences
Wooster Frito Lay Plant Documentation
EMS Based On ISO 14001 Standards
o Written Policies and Procedures
• Individually Numbered, i.e. EHS-XX-XXX
Integrated PepsiCo, HQ and Site Specific
Requirements
o Program Documentation
• Environmental Filing System
oHard Copy
oElectronic
• Environmental Calendar
omyEHS
Plan o Recognize an opportunity
and plan a change.
Do o Test the change. Carry out a
small-scale study.
Check o Review the test, analyze the
results and identify what you’ve learned.
Act o Take action based on what you
learned. If the change did not work, go through the cycle again with a different plan. If you were successful, incorporate what you learned from the test into wider changes. Use what you learned to plan new improvements, beginning the cycle again.
Wooster Frito Lay Sustainability Strategy
Wooster Frito Lay Plant Reduction Activities
P2/Sustainability o Analyze Aspects
o Set Objectives & Targets
o Waste Reduction/Inventory
Focus on ReCon o Utility Reduction
• Water
• Natural Gas
• Electric
Elements of Pollution Prevention
Source Reduction
– Prevents Waste Before it is Created
Recycle / Reuse
– Reprocessing a Waste for Other Beneficial Use
– Using a Product Again for its Originally Intended
Purpose
Recover/Treatment
– Physically/Chemically Alter Waste to Lessen its Impact
on the Environment
Disposal
– The Final Release of Waste to the Environment
Zero Landfill Mission
Mission • Zero Landfill Waste for Frito-Lay operations
Program Goals • Reduce Landfill Volume by:
– Reducing/eliminating usage of non-recyclable materials
– Increase effectiveness of recycling
• Increase recycling revenue.
Business Case • Significant Sustainability Statement
• Decrease Waste Expense
• Increase Recycling Revenue
<1% of all
Waste Streams
Go to the
Landfill
Waste Inventory
• We started
tracking our waste
streams in 1999.
• Site visit from
OCAPP to
evaluate
additional
opportunities for
recycling
Wooster Zero Landfill Progress
0
0.5
1
1.5
2
2.5
GOAL
2014
2015
2016
2017
.59%
Started in 2008 with a Dumpster Dive!!
.49%
1.00%
.87%
Waste Recycling Activities
Additional Baler Installed
• Bale Packaging Film,
Seasoning Bags and Shrink
Wrap
Waste Reduction Activities
Energy Efficient High
Powered Hand Dryers
• Replaced Paper Towel
Dispensers (12)
Waste Reduction Activities
New Copiers
o Default Setting is
Double Sided
o Scanning
Capabilities
• Purchase 30%
Recycled Office Paper
Waste Recycling Activities
Feed Waste Recycling o Finished Waste (Dry)
Recycled as Animal Feed
Additive
Waste Recycling Activities
Wet Waste Cake
o Recycled into Animal
Feed Additive
Waste Reuse Activities
Starch Production
o Remove Solids From
Wastewater
o Wastewater effluent
loadings reduced,
saving significant
surcharge costs
Waste Reuse Activities
Centrifuge Installation
o Dewater solids from
clarifier and blend
tank
o TSS removal of at least
85% for a monthly
average
o Wet Waste Cake is
Recycled into Animal
Feed Additive
Waste Reuse Activities
Product ReUse
o Food Bank Donations
Cases of Product are
donated routinely to local
food banks in need
o ~ 25,000 cases of product
donated in 2016
Waste Reuse Activities
Primary Clarifier Installation
o Skimmed Grease Reused for
Electricity Generation
o Reduced TSS/COD discharged to
City POTW
o Partnership with Quasar Energy
Group
Primary Clarifier Installation
Waste Reuse Activities
Beneficial Reuse:
Compost Potato Dirt
o Compost is sent to a
local compost facility
Compost Generation
Waste Reduction
Activities
OLD BATTERY STORAGE
NEW FAST CHARGE
BATTERY STATIONS
Fast Charge Battery
Stations
Reduced number of batteries
per lift, from 3 to 1 on site. Less
chemical reporting and less
waste generated.
Kwh reduction in charging batteries
Waste Reuse Activities
Carton Re-Use Program
• Re-Use KD’s vs. New
• 93.7 % Used KD’s in 2016
Waste Recycling Activities
Carton Recycling
• Recycling vs. Landfill
Wooster Frito-Lay Plant Resource Conservation
• Focus On Reduction of Utilities
oNatural Gas
oWater
o Electricity
0
500
1000
1500
2000
2500
3000
3500
4000
4500
2004 2014 2015 2016 2017
Natural Gas (BTU/lb of
Product Produced)
Natural Gas Usage
Since 2004
Reduced by
15%
Natural Gas Reduction Activities
PC Heat Exchanger
Replacement (2)
Old Heat Exchanger
New Heat
Exchanger
Natural Gas Reduction Activities
PC Heat Exchanger
Stack Heat Recovery
• Reclaimed Heat is
used to dry starch
Before
After
Natural Gas Reduction Activities
Annual Burner Tuning
• Energy Efficiency
0
0.5
1
1.5
2
2.5
3
3.5
2004 2014 2015 2016 2017
Water (Gal/Lb of
Product Produced)
Water Usage Since 2004
Reduced By
35%
Water Reduction Activities
Replaced Clean In
Place High Pressure
Nozzles
o From 8010 Style to
8002 Style
• Replaced 400+
Nozzles
• Energy Cost
Savings/Yr
Water Reduction Activities
Installed Low Flow
Bathroom Fixtures
• Sensor Exposed
Flushometer for Water
Closets, Battery-
powered 1.6 gpf
• Sensor Activated
Faucets Water-
efficient flow rate of
0.5 gpm
Water is reused to clean
potatoes in the Flume
Area. This system,
designed by our
employees, allows dirt particles to separate and
water to be reused for
potato washing. The solids
are removed and composted which reduces
TSS/COD discharged in our
wastewater to the City of Wooster.
The dry cleaning method is encouraged by Frito-Lay.
Use a broom to clean-up instead of spraying product down the drain
Water Reduction Activities
PC Flume Recycle Water
Water Reduction Activities
Water Leak Elimination
• Weekly Water Leak
Audits Conducted By
Maintenance
• Different Department
each week
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
2004 2014 2015 2016 2017
Electric (Kwh/lb of
Product Produced)
Electric Usage
Since 2004
Reduced by
21%
Electric Reduction Activities
Packaging Automation
• Energy Cost Savings/Yr
Vacuum Pump
Before
After
Electric Reduction Activities
Electric Upgrades
o Switch Gear
Replacement
o Transformer Reduction From Two Units to One
• Energy Cost Savings/Yr
Increase Reliability,
Reduce Power
Outages/Shutdowns
Vacuum Pump
Electric Reduction Activities
Energy Star Rated Reflective Roofing
• Kwh Reduction
Electric Reduction Activities
Stober Gearbox
Replacements
o Energy Efficient
Electric Reduction Activities
Install LED Lighting
o Entire Facility
• Auto Sensors
o Energy Cost Savings
• Waste Reduction
OLD
NEW
Electric Reduction Activities
Install LED Lighting
o Parking Lots
• (HID to LED)
• Light Sensors
• Energy Cost Savings
• Waste Reduction
Electric Reduction Activities
Rapid Roll Doors in
Packaging
• HVAC Air remains in
the Packaging
Department
• Keeps Electrical
Equipment Cooled
Properly
~ Energy Efficiency
Electric Reduction Activities
FL710 Conversion to Water
Cooling
o Old system used
compressed air
o Current system re-
routes water going to
PC Washboxes and
Corn Duck Ponds to
pass by the FL710
units, cooling them in
the process
Vacuum Pump
• Education o EDC’s Earth Fest
o Ohio OEC Lobby Day
o OARDC Scarlet, Gray & Green Fest
o Local School Presentations
• Hands On o Adopt A Highway Litter Pick-
Up
o Hiking Trail Clean-up (TWC)
o Burning River Fest in Cleveland
• Meetings o Wooster Area Safety
Council o Northern Ohio Chapter Air
& Waste Management
Wooster Site Green Team Community Service
Thank you for the opportunity to
share our Sustainability Story!
Questions??
Working together to move beyond compliance to
enhance and preserve our Environment for the future.
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