Delivering lean manufacturing relies on having the right operational information to be able to identify where efficiencies can be made.
NYB installed state-of-the-art telemetry systems to measure the generation of each co-product and waste stream, continually feeding the data back to a system that can analyse performance and pinpoint areas for improvement. Site managers set tolerances or targets, and the system then analyses what is going on to enable further interventions to cut waste of all types.
This intelligent data collection and management has saved time for managers and operatives, providing real-time insight on waste generation and driving efficiencies in the operations. The telemetry systems have also allowed specific interventions, such as targeting training where it can lead to waste reduction or the installation of new hardware to improve the material efficiency of the bakery’s machines.
Maximising the value in resources was fundamental to NYB’s zero waste journey. To achieve this, it entered into a third party contract with Saltens, who are part of the Duynie Holdings Group, that enables 100% of surplus food product to be converted into a nutritious animal feed. Thousands of tonnes of co-product are now being recovered each year, delivering the following benefits:
- Preventing a resource from becoming waste in the first place
- Maximising the value of surplus food product
- Retaining nutrients in the food chain
- Reducing the need for land to be used to grow crops for animal feed
- Providing a nutritious feed for farm animals
- Recovering significant rebates for the company
Telemetry systems in the co-product line also enable Saltens to achieve ‘just in time’ collections, maximising payload and reducing the overall environmental impact of the solution.
The bakery company has embedded a recycling culture across its two factories by installing multilingual signage, delivering regular training and development for its waste champions, colour-coding bins for source separation and introducing recycling points by the production line to minimise the risk of contamination.
Source separation takes place for 100% of recyclable materials, achieving the highest possible quality for the reprocessor. This helps to strengthen the market for surplus materials and delivers the best rebates for NYB. The factories have a small area for dry mixed recycling, but the remaining materials, including cardboard, polythene, metals, egg waste, food waste and confidential waste, are all collected as individual waste streams for sale to the re-processor market.
This means the business is achieving the best ever rebates for materials that used to be considered waste.
Telemetry systems for constant feedback