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Reduced raw material consumption and increased insight through process optimization
Duyvis, part of multinational PepsiCo since 2006, aspired to optimize their production line already for a while; reducing the weekly consumption of sunflower oil and gaining insight in the sunflower oil consumption per production line. With this goal in mind Duyvis found their partner in Orangeworks and Actemium. Jeroen Brans, project manager at Duyvis: "Orangeworks and Actemium where the only companies proposing a turn-key solution. The expertise they offer is very important to us. For example, during the sales phase they already provided better solutions for our goals than we had been able to anticipate ourselves. This solution driven way of working gave a lot of confidence and during the execution of the project Orangeworks and Actemium lived up to the promise.”
Process optimization
Jeroen Brans: "Our daily quality inspections confirmed that the sunflower oil that we disposed of weekly after production, still met the specifications of our production process. This meant we would be able to re-use the oil in our production process, however, our process equipment was not designed to enable re-use of oil. Every week the oil got pumped directly into the waste tank to be collected by trucks for disposal. This way of working resulted in unnecessary transport and waste."
'Winning with Purpose'
Duyvis had 3 tanks for clean oil storage on their premises. Only 2 of those were being used. By connecting the process equipment to the third tank with an additional pipeline, the oil suitable for re-use, can be stored after the weekly production cycle. The stored oil is used in the subsequent production week for refilling the ovens. The oil quality is guaranteed by daily quality inspections. Comparing the result of the quality inspections with the specifications determines whether the oil will be re-used or pumped to the waste tank after all.
By implementing this optimization Duyvis realized a weekly reduction of the amount of new sunflower oil needed and a weekly reduction of sunflower oil to be disposed. And just as important: Duyvis realized the reduction of all the transport needed for the supply and disposal of the oil concerned. This way Duyvis can contribute to the ambitious, global sustainability agenda of PepsiCo with a relatively small intervention. Within PepsiCo this is called 'Winning with Purpose'. It is the Duyvis way of working towards a more sustainable food system.
Koen Swinkels, Project Manager at Orangeworks : “In addition to the system adjustments for this process optimization, we equipped all production lines with flow measurement gauges. The gauges provide accurate data of the oil consumption per production line. "Sam van der Meer, Controls Specialist at Duyvis: "I am enthusiastic about all the data that is logged, it makes me happy”, Sam says laughing. "The available data enables us to control the process more accurately and avoid unpleasant surprises."
Efficient planning and good teamwork
Koen Swinkels: “Initially we assumed that 4 weeks of production downtime would be needed. However, being aware of the importance of production time for our customers, we mutually investigated optimizing the implementation planning right from the start of the project. We found a way to prepare all adjustments during production hours. The time needed for the actual connection of the new line that required a production stop, was decreased significantly in this way. "Jeroen Brans: In our annual production plan we had anticipated a 4 weeks production stop already. By investigating thoroughly what was needed and when the mechanics really needed to carry out work that interfered with the production process, we were able to reduce the production downtime to just 1 week. Success and results like this can only be realized through very good cooperation between all partners involved."
Chris van Dartel, Project Manager at Actemium, the controls partner with whom Orangeworks regularly carries out projects, adds: “The cooperation with the Duyvis production staff was excellent. This was of key importance to establish an efficient and safe way of working for production, people and product". This is fully endorsed by Jeroen Brans: "Safe Delivery is our motto. Our management has a constant focus on work-safety for our own employees and our contractors.”
A good example for other factories
A characteristic of Orangeworks and Actemium is that they have a good collaboration. Together they also provide a back-up plan. Chris: “Suppose that what we had in mind would not work out as planned. Than our backup plan would have ensured that the production process would not be affected. We didn’t need the back-up plan, but it's good to have one in order to be able to guarantee continued production.” Jeroen Brans: “That way our operational reliability was guaranteed. What sticks with me most is the pleasant cooperation we had with all people involved. This has certainly not gone unnoticed at other production facilities of our holding in the Netherlands and abroad."
Knowing more?
If you would like to know which process optimizations Orangeworks and Actemium could realize for you, please contact Actemium Client Manager Michel Dekkers +31(0)6 11 29 34 98 or Orangeworks Account Manager Carla Blekkink +31 (0)412 78 20 00 and view our websites.