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Energy & Carbon

ELIMINATING BREWERY EMISSIONS

Our Supply Chain Director and senior management team are responsible for the implementation of our improvement roadmap towards a ZERO carbon footprint.

We are always on the lookout for ideas and new ways to reduce energy use, packaging efficiency and carbon emissions at our brewery, which is ISO-certified to 14001:2015 benchmarks.

In 2018, our brewery’s heat energy consumption stood at 23.17 kwh/hl, an improvement from the previous year’s 23.23 kwh/hl. The reduction in energy usage is partly due to improvement in hot insulation, which was mainly on heat supply piping and boiler stations. We will continue this initiative in 2019 with more focus on packaging equipment, including bottle washers and pasteuriser body insulation. This can potentially result in energy savings of between 10 to 15%.

We have also installed energy meters for all levels of production to enable more detailed consumption monitoring, while prioritising on focus areas. Other measures include setting up flue gas online monitoring systems to have better boiler efficiency control, as well as upgrading all steam traps and high temperature water purging system, which were aging and inefficient, to a new system to reduce thermal losses.

Our use of natural gas reduced to 18.86 kwh/hl from 19.40 kwh/hl a year ago, while use of renewable energy in the form of biogas increased to 4.31 kwh/hl versus 3.83 kwh/hl previously. The higher use of biogas is due to our upgrading of the anaerobic-stage settlers and biogas blower system, which reduced gas losses at the reactor and recovered more gas for boiler usage.

We have also reduced electricity use in 2018 due to several measures undertaken:

  • Optimisation of cooling plant condenser by implementing a wet bulb control system to have a more dynamic pressure regulation base on environmental climate.
  • Added inverters to all condenser fans to further improve load regulation base on demand.
  • Continued compressed air leakage audits with regular scheduled inspections and rectification.
  • Replaced one of the old air compressors with a new unit that comes with variable-speed drive control for better load regulation base on demand.

As a result of our efforts, electricity usage at the production facility was reduced to 9.23 kwh/hl in 2018 from 9.38 kwh/hl previously.

We were also able to reduce chemical oxygen demand (COD) in final discharge by almost 50% in 2018, mainly due to improvements and refurbishment of anaerobic settlers.

Our Malaysian operations also saw a reduction in R22 refrigerant usage by 36% to 202.3 kg/CO2 in 2018 thanks to a maintenance strategy that focuses more on preventive maintenance to avoid overly-long running hours and leakages.

We aim to phase out R22 usage completely by 2022. At the same time, more office spaces within our operations now employ centralised air conditioning, which in turn reduces the number of air conditioning units required to cool individual offices.

Reduce, Reuse, Recycle and Rethink (4Rs) programme

As the production and disposal of packaging materials represents the largest component of Carlsberg’s global carbon footprint, our 4Rs programme is aimed to encourage the return of all reusable bottles, kegs and crates from market to brewery via an incentive scheme.

In 2018, we maintained a return rate of 83% for returnable glass bottles (RGBs) – even while the volume of bottles in circulation increased by 11.3%.

This continues our improvement efforts for longer RGB lifecycles via the application of a Kercoat coating on bottles to reduce bottle scuffing and increase bottle reusability and total lifespan. Together with the use to thinner aluminium can walls, these efforts contribute towards reduced carbon emissions while simultaneously reducing material and logistics costs.