How is innovation helping companies achieve sustainable manufacturing?
The need for manufacturing companies to make the transition to sustainable and resilient operations is becoming increasingly urgent. Public concern on issues from emissions to waste to water is growing. Regulation is tightening. Implementation of strategies and new production methods cannot be delayed.
How is this being achieved in practice and what role can innovation play in the process? This was the focus of a seminar led by Royal HaskoningDHV entitled Innovation to Achieve Sustainable Manufacturing. We were joined by leaders from a wide range of global manufacturers in sectors which included food and beverages, animal nutrition, pharmaceuticals, industrial products and more. Through keynote presentations, break-out sessions and discussions among attendees, perspectives were shared which highlighted similarities and differences in experiences and approach.
Innovation in action at Battolyser and Chemelot
Two keynote speeches provided inspiring examples of innovative approaches in action. Maarten van Heel, Head of Projects and Engineering at Battolyser Systems, described his company’s novel integrated battery electrolyser system. Its built-in flexibility means it can store electricity and produce green hydrogen. This makes the hydrogen more affordable and contributes to the security of grid supply. When renewable electricity is available and prices are low, the Battolyser charges like a normal battery. Once it is fully charged, it becomes an electrolyser to produce green hydrogen. When renewable energy is not available (and the market price is high), the Battolyser sells the stored electricity to the grid.
Maarten was followed by Lianne van Oord, Programme Manager for Process Innovation at Brightsite – a public-private partnership between Sitech Services, TNO (Netherlands Organisation for Applied Scientific Research), Maastricht University and Brightlands Chemelot Campus.Lianne described the approach Brightsite takes to support Chemelot in reaching the climate goals. Potential transition pathways are modeled and compared. To enable transition, innovative technologies like plasma technology and recycling technologies, are further developed in consortia. Alongside the reduction of CO2 emissions, reduction of emissions via water and reduction of water usage is high on the list of objectives and requires implementation of innovative technologies.
Successful innovation for sustainability requires a systematic approach and cooperation:
- Take the whole system into account and determine priorities;
- Don’t tie yourself to a single technology – innovations are constantly opening up new opportunities and you need to be able to switch to the best option;
- Innovate together and be aware of the political environment – transition requires flexibility and clear communications between stakeholders on what is required for success.
How to achieve a successful transition and where to start?
Two parallel break-out sessions enabled delegates to share practical experiences, ask questions and look at best practices.
One session explored How to Achieve a Successful Transformation Towards Net Zero Manufacturing. We described how our experience at Royal HaskoningDHV shows that many manufacturing corporations are reaching the point in their decarbonisation journey where they need to start scaling up. The subsequent move from pilot phase to a fully deployed global programme is proving a complex challenge and the question ‘where to start?’ was a concern shared by many of our participants. This prompted much discussion and enabled attendees to take away valuable insights and ideas. There was widespread agreement in the importance of getting the basics right – start by ensuring the plant is operating at optimal efficiency.
The second break-out session focused on How to develop a carbon neutral energy system, addressing the need to balance costs, security of supply and sustainability. To illustrate this, we presented a case study on developing a carbon neutral energy system for malt production in Africa. The process involved identifying local energy sources and evaluating technologies to define potential scenarios. The business cases are based on technical feasibility and outcomes obtained from energy modelling. In this case, a solar system for thermal and electrical generation, combined with storage, has the lowest Total Cost of Ownership. Also, it meets the energy supply reliability requirements and is carbon neutral when biodiesel is used for back-up.
Key takeaways from the seminar
Discussions were open and wide-ranging which enabled attendees to pick up valuable information relevant to their own particular challenges. In addition, four general points were highlighted:
- Optimise existing buildings and installations as a first step.
- Sustainable operations are easier to achieve if annual energy costs are approximately the same or lower than those using conventional energy generation methods. Where costs are potentially higher, the strength of the ambition and commitment to innovative approaches can help secure success
- The indirect benefits of sustainable operations - such as improved reputation - are important. These need to be quantified and included in the business case.
- The biggest challenge to carbon neutrality for companies operating in the Netherlands is grid congestion. If this is an issue and there is limited space for PV panels, extra attention should be paid to innovation in electricity supply.
- Innovation through collaboration and partnerships based on an ecosystem model can prove successful in enabling change.
Interested as manufacturer in attending future events? Scan the QR code or click here to register.
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