On Stop Food Waste Day, at Powerstar we celebrate the steps our food manufacturing customers are taking to become more sustainable, and the part they play in achieving a net zero, circular food economy.
Food waste is a global problem, with 33% of food produce going to waste every year[1]. As a major proponent of circular living principles, WRAP (the Waste and Resource Action Programme) has a clear focus on future-proof food production and consumption, aiming to halve food waste, reduce water stress, and lower GHG emissions.
72% of global freshwater is used in agriculture[2], with around 30% of global GHGs coming from the food and drink sector[3]. Improvements in manufacturing energy usage, together with changes in consumer behaviour, can have hugely positive impacts for more sustainable food supply.
For food manufacturers, the most pressing concerns include:
- public perceptions – consumers want more ethical, sustainable produce, and they want honestly from suppliers;
- energy security – any downtime in production, especially involving perishable ingredients, can lead to scrappage and wasted produce: food waste, lost profits, and reputational damage;
- unnecessary emissions – for energy-intensive industries such as food production processes, inefficient energy usage means unnecessary spend, as well as excess emissions and energy waste.
Starting the net zero food journey
Last year, IGD commissioned a report, developed by WRAP along with EY, a Net Zero Transition Plan for the UK Food System[4]. In her foreword, Catherine David, Executive Director of Behaviour Change and Business Programmes at WRAP notes,
“On the supply side, the pathway to net zero depends on the rapid decarbonization of electricity, heat, and transport infrastructure, whilst on the demand side, we must ensure that the food we do produce is not wasted and provides people with a healthy, environmentally sustainable diet.”
In her foreword, Sarah Bradbury, Chief Executive at IGD, makes clear the approach needed to meet ambitious targets,
“This is the start of a journey together. In recent years we have seen first-hand the vulnerabilities in the food system and the increasing risks to its resilience, as here in the UK we have seen temperatures reach record highs of 40ºC and some of the wettest months on record last year and this year. It highlights that climate adaptation planning will need to be central to ensuring food security in the future.”
Energy security and its impact on food security
As the UK’s energy supply becomes more electrified, there is increased potential risk of interruptions to local energy supply from the grid. This is of particular concern for food and drink manufacturers, often relying on 24/7 production lines and working with perishable produce.
As transport infrastructure becomes more electrified, decarbonising your operations with investment in EVs can be problematic if you exceed, or come close to exceeding, your existing grid supply. Where this is the case, you may face long and costly delays in approval from the Distribution Network Operator, or you may find that grid constraints are such that your application may be rejected. This can mean that best intentions, such as switching to an EV fleet, can be rendered either too expensive to implement or completely unfeasible, in the current context.
For manufacturers investing in on-site renewable energy assets – largely solar or wind turbines – without efficient energy management technology to make the most of these energy sources, you’re limited to using energy as it is produced or you risk wasting it. However, with modern energy storage – Battery Energy Storage Systems (BESS) – you can store energy as it is generated, and use it when most efficient for your business needs. Equally, if you have BESS with Uninterrupted Power Supply (UPS), then you can protect your production lines in the event of any disruption to grid supply: ensuring that production continues, and supporting food security.
Emission reduction and energy efficiency
At Powerstar, we have vast experience in working with the food and drink sector, both manufacturing and retail. And we celebrate our customers in their ambitions to work towards a net zero, sustainable, food industry. We work with customers to identify the most appropriate energy management technologies for their specific needs and site profiles. And we support them, wherever they are on their decarbonisation journey.
Voltage Optimisation (VO) optimises incoming energy from the grid, to match the voltage required by your equipment – generally, this is 220V in the UK, whereas the grid typically supplies at a higher voltage – around 248V. Stabilising voltage with VO improves efficiency, reducing energy wastage and lower carbon emissions. For food manufacturers, precision machinery and high-energy consumption processes require stable voltage to avoid power disruptions and damage to equipment. Any disruptions to production lines can mean wasted time resetting machinery, and the potential for food waste in scrapping ingredients.
Low-Loss Transformers adjust voltage for on-site power. The UK’s transformer fleet is ageing, with the average unit being more than 60 years old – a significant point of potential failure when design lifespan should be between 20 and 30 years. As with overvoltage, transformer failure can lead to production downtime and, for food manufacturers, unnecessary food waste. High-efficiency transformers can lower operating costs, reduce maintenance demands, and remove unnecessary indirect emissions.
Better energy management in action
Quorn Foods are committed to sustainability, driven by their Supply Chain Sustainability Strategy, and prioritising GHG emissions, water use, waste reduction and responsible sourcing. We identified two incoming supplies where replacement of existing distribution transformers would help cut energy consumption, reduce CO2 emissions, and minimise energy costs. Powerstar’s amorphous core transformers, with integrated voltage optimisation, have reduced consumption on-site by over 10% per annum, which equates to 365 tonnes of carbon emissions and annual cost savings of more than £70,000.
2 Sisters Food Group, Gunstones Bakery, are one of Europe’s leading food manufacturing companies, employing around 23,000 across the UK and Europe. They wanted to reduce energy consumption and CO2 emissions, while futureproofing infrastructure and protecting their manufacturing equipment. With pressure from retailers – their customers – they wanted to reduce energy costs to ensure competitiveness. Powerstar helped to improve their power management with new, low-loss transformers and voltage optimisation. Site resilience has been improved and possible food wastage is avoided by eliminating a potential point of failure. At the same time, only a month after installation, site consumption was shown to have fallen by 119kW per hour, saving over a million kWh over a 12-month period, and lower energy spend by around £61,850 per year.
These are just two of the food manufacturers Powerstar are helping to address energy costs, decarbonisation goals, and minimise food waste by protecting equipment and providing better power resilience. Take a look at more of our case studies to see how we support the food and drink industry – whether manufacturers or retailers – for more sustainable food production and supply, with improved energy management.
Download our White Paper: Decarbonising Food and Drink.
Collaborating across the supply chain: Leveraging smart technologies for efficiency and resilience
[1] https://www.unep.org/topics/chemicals-and-pollution-action/circularity-sectors/food-and-food-waste
[2] https://www.unesco.org/reports/wwdr/en/2024/agriculture?hub=2
[3] https://www.un.org/en/climatechange/science/climate-issues/food
[4] https://prodstorageaccountigd.blob.core.windows.net/prodsiteassets/Assets/Files/0JRQ5QX9V/A-Net-Zero-Transition-Plan-for-the-UK-Food-System-Overview_Nov-2024.pdf
