Waste prevention in drinks manufacture

27th March 2015

The British Beer and Pub Association (BBPA) and British Soft Drinks Association (BSDA) worked in collaboration with Britvic Soft Drinks and Carlsberg (UK) to reduce the amount of product waste in the brewing and soft drinks industries, ‘Project Shandy’.

The companies saved £293K on two sites, and further savings are expected as waste prevention solutions are adopted on other sites.
WRAP have published two case studies detailing how savings were achieved, and a checklist with scores of waste prevention opportunities.

Checklist of waste prevention measures in drinks manufacture


WRAP, together with the BBPA and BSDA, have prepared a checklist of useful waste prevention measures proven to reduce waste and increase profitability. We hope that the measures are already standard practice in your company, but there may be some new ideas that are worth evaluating. Use the true cost of waste formula in cost benefit analyses to calculate a realistic payback.

  • General considerations
  • Ingredients
  • Preparation
  • Cleaning
  • Filling & Sealing
  • Conveying
  • Packaging
  • Palletising
  • Pallet Displays

“The BBPA was pleased to be involved in Project Shandy. We hope that the Case Studies and Industry Guidance will help brewers and soft drink manufacturers reduce waste and increase profits.”

David Sheen - Director,
BBPA Environmental Ltd


 Green Bottles

Guidance and Checklist
Guidance and checklist for waste prevention in brewing and soft drinks manufacture

In addition to case studies from Carlsberg and Britvic, the Project Shandy team have put together a short note to:

  • Help drinks companies take action to reduce waste in the most effective way;
  • Signpost to further, more detailed guidance; and
  • Provide checklists of how to address the most common waste hotspots in drink manufacture.

  

Britvic Case Study
Case Study: Reducing syrup waste in soft drinks manufacture saves £117,000 a year

Britvic was part of ‘Project Shandy’ which involved measuring waste arising and identifying hotspots for action. For Britvic, the key focus was reducing syrup waste.

As a result of waste reduction workshops at Britvic, the company identified that improvements in operator awareness could lead to significant savings in ingredient waste, in particular syrup. By improving Standard Operating Procedures and providing support to operators in the syrup preparation area to achieve ‘Right First Time’, Britvic achieved the following savings:

  • 156 tonnes of syrup saved from effluent per year (780m3 waste product equivalent)
  • £117,000 per year due to reduction in syrup waste
  • £1,400 per year water and effluent cost savings.

  

Carlsberg Case Study
Carlsberg UK implements a series of measures to reduce waste

One of the key findings from Project Shandy for Carlsberg was the detailed understanding of waste product from filling and packing lines. This involved identifying the points on the lines where filled products were being rejected or falling off, measuring the frequency of rejects or falls at these points and quantifying the loss to the business incurred.

The Carlsberg team in Northampton determined a simple solution to prevent product falling off the line resulting in the following benefits:

  • 28% reduction in can falls, leading to
  • 475 tonnes product waste to sewer prevented per year
  • £175,000 savings per year