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Mitigating the cost of convenience

28 April 2018

Dave Norman explains how it is possible to improve the carbon footprint of the ready-meal production process. 

In 2016 UK consumers collectively spent £3 billion on ready meals, equating to roughly £9 million every day. In the same year the ready-meal market grew by £37 million, clearly demonstrating a growing appetite for pre-prepared meals.

As consumers demand more convenient options and ready meal sales accelerate, retailers and producers must question both the cost-efficiency and environmental impact of ready-meal preparation in light of the findings of a 2017 Unilever study which revealed that one-third of consumers base their purchasing decisions on a brand’s social and environmental responsibility. The study also found that there is an estimated £857 billion opportunity for brands that make their sustainability credentials clear.?

The cost of convenience
There are many areas that need to be considered when looking for reductions in production costs and increases in sustainability. Packaging, for example, would be an obvious area where the carbon footprint could be significantly reduced. However, food grade packing often requires the use of non-recycled plastics to eradicate any chance of cross-contamination and this has a significant impact on the products carbon footprint which is difficult to reduce. With this in mind, every effort must be made to compensate by reducing energy consumption and recycling resources in other areas.

Water, for example, is widely used for energy transfer in food production processes and the water footprint of the ready meal will be a surprise to many. The production of one microwave chicken curry requires approximately 2,500 litres of water. However, there are some ways that ready meal producers can significantly reduce their water usage. ?

Raising the game with steam: Steam heating is the most widely used method for pre-cooking meat, fish, poultry, vegetables, sources and gravies. It provides a quick and effective way to cook components to the point at which they are ready to microwave. Yet this method also involves the sourcing and processing of large quantities of fresh water. If ready meal producers can reduce the amount of make-up water required in this process, they can reduce the cost of operation and the cost to the end consumer while also meeting the growing demand for more sustainable production approaches.

Steam boilers will maintain a constant steam load through a cycle of concentration and this can be analysed and optimised to reduce the volume of water required. Implementing a turn-key pre-treatment plant could drastically reduce both the make-up water required, and the waste water generated which would traditionally have been blown down the drain, creating energy expenditure savings of around 5%, while removing the cost of draining away waste water. ?

Creating cooler energy: Once the meal ingredients have been steam heated to the point at which they are microwave ready, they must be cooled quickly in order to maximise shelf life. This is typically achieved through the use of chillers and cooling towers which also required large amounts of water to operate so are another area where significant savings can be achieved. The quality of make-up water in the cooling towers can be optimised through effective water treatment, but the system must also be analysed for inefficiencies, losses and leaks.

Losses and leaks are not always managed in the food production facilities, but simple analysis can result in a water saving of as much as 33%. Replacing hardware components like fans and recirculation pumps with more energy efficient solutions will allow water to be recirculated at a desired rate rather than a constant. The latter typically results in water returning and overflowing the cooling tower base holding tanks, creating further losses and incurring further costs.?

Energy efficient transport routes: The cost of refrigeration during transportation is significantly higher than the equivalent relative cost of static refrigerated storage. To contend with these costs, many retailers and suppliers make efforts to reduce the time refrigerated goods spend in transport, leading to supermarket chains establishing their own refrigerated distribution depots which again utilise cooling towers to extend the shelf-life of the products by keeping them at optimum temperature.

Reducing the time spent in transit would be a major step in reducing the cost of operation for ready meal producers, suppliers and stockists, but to ensure the process is as sustainable as possible, they must ensure that refrigerated depots, whether directly owned or belonging to a third-party, have undergone the relevant cooling tower optimisation processes.

Maintaining profitability, while striving to meet the conflicting consumer demand for both sustainability and convenience, needn’t be a headache when it comes to producing ready meals. Lowering the water footprint in the heating, cooling and transportation process can be achieved by enlisting a water technology provider that has the experience to design tailored solutions that deliver true return on investment.

Dave Norman is head of marketing at Clearwater Technology.

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