case study
Greening up the cutting, slicing,
grating and packing process
Known primarily in the uK for its butter brand, Kerrygold has recently built a state-of-the-art
processing facility that incorporates a variety of green technologies.
I
t’s not often you find a futuristic Kerrygold managing director, Carl Ravenhall, practice elements from other fresh food
plant based in an historic northern who has been running the company since industries, that it says has set a new global
English town, but that’s exactly what 2005. “The project began in March 2006 with benchmark in food hygiene standards for
Kerrygold’s new processing facility is. a feasibility study and I’m happy to report it cheese packing. These include high- and low-
Using a variety of green has been completed on time and on budget.” care areas, greater air filtration and increased
technologies such as sun pipes, photo- The factory operates approximately 20 temperature control.
voltaic panels and inverter driven motors production lines that incorporate cutting, So far, the factory has reduced its carbon
on pumps and fans, the plant - situated slicing, grating, and packing, but it has the footprint by 15%, but Ravenhall believes
in Leek, Staffordshire - is an example of capacity for several more if demand surges. this is only the beginning. “The new build
a growing global business trend towards At £30 million, the project was a is the most efficient and environmentally
environmentalism and reducing one’s carbon significant investment, but Ravenhall friendly cheese packing facility in the UK
footprint. . says it was worth it, as many of the green and Europe,” he says. “And as such, we
Although it is known primarily for its technologies used in the building are already are capable of reducing our impact on the
butter brand, the Kerrygold Company’s main providing cost savings to the business. environment - our carbon footprint - a great
business in the UK is the cutting and packing “The factory is a significant improvement deal more. We’ve made a commitment to
of cheese for many high street grocery on the old plant, providing tangible review our sustainable energy practices on
retailers, and the new facility was built operational and commercial efficiencies,” an ongoing basis, in line with our company
specifically for this purpose. The company is adds Ravenhall. “The factory has been ethos of continual improvement.”
owned by the Irish Dairy Board, and owes its built taking into account its impact on the The company also encourages its
name to Irish businessman and former rugby environment, which has not only helped us employees to be more environmentally
union player, Sir Anthony O’Reilly, who is meet the growing demand from customers friendly, and runs a ‘cycle to work’ scheme
credited with coming up with the Kerrygold and suppliers to be more environmentally that subsidises bikes and helmets.
brand name in 1962. conscious, but it has also allowed us to be “The business is encouraging our staff to
Although the presence of the company more cost effective as a business.” leave the car at home and ride to the factory,
in Leek can be dated back to 1922, the All throughout the building process, making our community greener,” says
factory has been operational only since last Kerrygold was keen to maximise waste Ravenhall. “We realise that having a state-
November, when the first few production reduction and environmental preservation and of-the-art facility is only half of the equation.
lines were moved over from the old plant. so decided to make full use of old factory site We need to promote an environmentally
According to Kerrygold, the decision materials. All the concrete from the old plant friendly attitude in our employees so that
to build a state-of-the-art environmentally and other ancillary buildings was crushed, we make full use of the technologies on
friendly facility to replace the old one was graded and re-used as structural fill. This offer, which will help us reduce our carbon
not taken lightly by the management. re-use of materials meant that newly quarried footprint even more.”
“We had been considering an upgrade to material was not needed. The factory is now completely operational
the existing facility for a long time,” says The factory has also incorporated best and will officially open in May 2009.
50 SuStainable SolutionS april 2009
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