Kraft Coffee Plant Study Exceeds Goals
With more than 500 projects completed with less than one year to payback, Cargill Optimizing Services understands how to decrease costs and increase yields in the food and beverage industry.
Recommendations for energy savings exceeded project expectations of 5-15%. In addition, recommendations for capacity increases were also provided.
Freeze-dried instant coffee from raw beans to final (bulk) product. The process includes: Roasting, evaporation, solids handling, and freeze-drying.
To help meet Kraft’s sustainability and environmental goals and reduce the impact of rising utility costs, economically feasible projects were sought with a target to reduce energy consumption by 5 –15%. The complex, highly integrated Banbury plant has focused on efficiency for a number of years. Identifying capacity improvements is an important secondary goal of the company.
Kraft engaged Cargill Optimizing Services (CPO) to develop recommendations for process improvement. Kraft chose COS based on the organization’s depth and breadth of experience in identifying operational improvements in agri food processes.
COS assigned experienced PhD Chemical Engineers to work closely with Kraft technical and operations experts. The goal was to deliver workable recommendations using a steady state computer model of the instant coffee process. The COS experts created the model using Cargill’s proprietary Agri-food Library.
Once validated by the team as a good representation of the process, the model was used to simulate
the impact of a wide range of potential process modifications. Plant resource requirements for this project were 5-10 hours per week over the 11 week duration.
The Kraft engineering team presented results of the eleven-week project to the Category Engineering Director, the Site Director, and their staffs.
The plant model proved to be very effective in quickly assessing, comparing and adapting a large number of ideas so the best options could be studied in more detail.
Several new and unique ideas were generated which would not have been identified without the plant model.
COS Case Study 002
Client: Kraft Foods,
|Energy Savings Goal||5 - 15%|
|Production Capacity||Improvements Identified|
Cargill Optimizing Services uses a uniquely holistic approach to identify operational efficiencies that others often miss. As an industry leader, we offer high-end engineering talent, a proprietary software library of agrifood unit operations, and over a decade of experience modeling and optimizing complex processes.
With more than 500 projects completed that have less than one year to payback, Cargill Optimizing Services understands how to decrease costs and increase yields in the food and beverage industry.