07 Pepsi Cola Cooler Sustainability With Hydrocarbons Soykan Dirik

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  • The process we used here in Equipment Development is simple: Use research to create a strategy, use strategy to direct your concepts
  • The process we used here in Equipment Development is simple: Use research to create a strategy, use strategy to direct your concepts
  • In 1834, Mr. Jacob Perkins developed the first refrigerator using a heat cycle that undergoes a phase change from a gas to a liquid and back. The refrigerant he used was Ethyl Chloride. Prior to 1930 the two refrigerants most commonly used were ammonia and carbon dioxide. Both were hazardous - ammonia is toxic and carbon dioxides require extremely high pressures (over 1,000 psi) to operate in a refrigeration cycle, and posed great problems to design engineers and operators, and accidents and injuries were common. So because these refrigerants were hazardous, refrigerators were only used in the industry, and the people did not have refrigerators in their houses. During the 1930s the so called “safety refrigerants” were introduced, primarily Chlorofluorocarbons (CFCs) such as FREON 12, and HCFC’s such as R22 and R502. When FREON 12 was discovered it totally took over as the refrigerant of choice. It is an extremely stable, non toxic fluid, and operates at pressures always somewhat higher than atmospheric, so that if any leakage occurred, air would not leak into the system, thus one could recharge without having to apply vacuum. And life was great!!!!! Yet nothing good lasts forever…. In the 1970s scientifics Sherwood Rowland and Mario Molina discovered the disastrous effect of the CFCs and HCFCs on the ozone layer. They discovered that when these refrigerants do ultimately leak and make its way to the ozone layer the ultraviolet radiation breaks up the molecule releasing the highly active chlorine radicals, which help to deplete the ozone layer. In September 1987 many countries signed the Montreal Protocol in which it was established to ban the CFCs from usage on a global scale by the 1990s, followed by the phase out of HCFCs in the early 2000s. The refrigerants introduced to replace the CFC and HCFCs were Hidrofluorocarbons R134a, and R404a. The Montreal Protocol was a big success due to its widespread adoption and implementation, and since its implementation the atmospheric concentrations of the most important chlorofluorocarbons have either leveled or decreased. Mr Kofi Annan said it is perhaps the most succesful international agreement today. And life was great again!!!! Yet nothing good lasts forever. Unfortunately, it was later discovered that while the HFC refrigerants do not damage the ozone layer, they are synthetic greenhouse gases with high Global Warming Potential. Therefore, emission of these refrigerants to the atmosphere contributes to the global warming phenomenon which has been widely reported by the media. In December 1997 the Kyoto Protocol was adopted by 180 countries with the objective of reducing greenhouse gases that cause climate change. The developed countries are required to reduce greenhouse emissions to the levels specified for each of them, by a collective average of 5% below their 1990 levels. The first commitment period ends in 2012. For the EU members their commitment is to reduce 20% of their greenhouse emissions. Today, the refrigeration industry is looking for alternative refrigerants that are as environmentally benign as possible. This means that the new refrigerants must not damage the ozone layer, do not contribute to the Global Warming of our planet, are not toxic, and are safe to use. And if we knew what to do, life would be great again!!!!!
  • In 1834, Mr. Jacob Perkins developed the first refrigerator using a heat cycle that undergoes a phase change from a gas to a liquid and back. The refrigerant he used was Ethyl Chloride. Prior to 1930 the two refrigerants most commonly used were ammonia and carbon dioxide. Both were hazardous - ammonia is toxic and carbon dioxides require extremely high pressures (over 1,000 psi) to operate in a refrigeration cycle, and posed great problems to design engineers and operators, and accidents and injuries were common. So because these refrigerants were hazardous, refrigerators were only used in the industry, and the people did not have refrigerators in their houses. During the 1930s the so called “safety refrigerants” were introduced, primarily Chlorofluorocarbons (CFCs) such as FREON 12, and HCFC’s such as R22 and R502. When FREON 12 was discovered it totally took over as the refrigerant of choice. It is an extremely stable, non toxic fluid, and operates at pressures always somewhat higher than atmospheric, so that if any leakage occurred, air would not leak into the system, thus one could recharge without having to apply vacuum. And life was great!!!!! Yet nothing good lasts forever…. In the 1970s scientifics Sherwood Rowland and Mario Molina discovered the disastrous effect of the CFCs and HCFCs on the ozone layer. They discovered that when these refrigerants do ultimately leak and make its way to the ozone layer the ultraviolet radiation breaks up the molecule releasing the highly active chlorine radicals, which help to deplete the ozone layer. In September 1987 many countries signed the Montreal Protocol in which it was established to ban the CFCs from usage on a global scale by the 1990s, followed by the phase out of HCFCs in the early 2000s. The refrigerants introduced to replace the CFC and HCFCs were Hidrofluorocarbons R134a, and R404a. The Montreal Protocol was a big success due to its widespread adoption and implementation, and since its implementation the atmospheric concentrations of the most important chlorofluorocarbons have either leveled or decreased. Mr Kofi Annan said it is perhaps the most succesful international agreement today. And life was great again!!!! Yet nothing good lasts forever. Unfortunately, it was later discovered that while the HFC refrigerants do not damage the ozone layer, they are synthetic greenhouse gases with high Global Warming Potential. Therefore, emission of these refrigerants to the atmosphere contributes to the global warming phenomenon which has been widely reported by the media. In December 1997 the Kyoto Protocol was adopted by 180 countries with the objective of reducing greenhouse gases that cause climate change. The developed countries are required to reduce greenhouse emissions to the levels specified for each of them, by a collective average of 5% below their 1990 levels. The first commitment period ends in 2012. For the EU members their commitment is to reduce 20% of their greenhouse emissions. Today, the refrigeration industry is looking for alternative refrigerants that are as environmentally benign as possible. This means that the new refrigerants must not damage the ozone layer, do not contribute to the Global Warming of our planet, are not toxic, and are safe to use. And if we knew what to do, life would be great again!!!!!
  • 07 Pepsi Cola Cooler Sustainability With Hydrocarbons Soykan Dirik

    1. 1. Cooler Sustainability with Hydrocarbon Refrigeration Soykan Dirik PepsiCo International Marketing Equipment Manager – Europe Division United Nations Enviroment Programme Joint Europe and Central Asia (ECA) and South Asia Network meeting Istanbul, 26 April 2010
    2. 2. AGENDA <ul><li>PepsiCo Performance with Purpose </li></ul><ul><li>Cold Equipment Sustainability Strategy </li></ul><ul><li>Progress to Date </li></ul>
    3. 3. What comes to mind thinking about PepsiCo … 03-05-10 PepsiCo Confidential
    4. 4. PepsiCo has 19 Global mega brands 03-05-10 PepsiCo Confidential
    5. 5. This makes PepsiCo the second largest Food and Beverage company world wide 03-05-10 PepsiCo Confidential Net Revenues ($B) PepsiCo International PepsiCo Americas Foods PepsiCo Americas Beverages 47% 25% 28%
    6. 6. PepsiCo’s responsibility is to continually improve all aspects of the world in which we operate – environmental, social, economic – creating a better tomorrow than today.
    7. 7. Performance With Purpose Philosophy Is Based On 3 Planks Environmental Sustainability is a priority for Equipment Attract, retain and develop top world-class talent Talent Develop healthy, convenient products for all consumers Human Be responsible stewards of our planet’s resources Environment
    8. 8. Total Environmental Warming Impact 95% 4% 1% <ul><li>Eliminated Hydrofluorcarbons (HFC) as foaming agent </li></ul><ul><li>All factories are compliant- worldwide </li></ul>HFC Free Foam Energy Reduction <ul><li>Compliant for all models with energy standards </li></ul><ul><li>Work with strategic suppliers on latest technology </li></ul><ul><li>Be the industry’s leader and focus on energy reduction </li></ul>Alternative Refrigerants <ul><li>Started field trials of HCs </li></ul><ul><li>and CO 2 in 2006 </li></ul><ul><li>Continue to evaluate both </li></ul><ul><li>options globally </li></ul><ul><li>Build infrastructure in one </li></ul><ul><li>country and expand to </li></ul><ul><li>others </li></ul>Equipment Sustainability Strategy Three strategic initiatives to Reduce green house gas emissions (GHG) Indirect from Electricity Usage Direct from HFC refirigerant in system Direct from HFC in Blowing Agent Leakage
    9. 9. Why Should We Do This <ul><li>Alignment with corporate strategy to reduce GHG (Performance with Purpose) </li></ul><ul><li>Consumers and customers are asking for it </li></ul><ul><li>Equipment contributes considerably to GHG emission </li></ul>3.0 times more electricity used annually All Pepsi Coolers & Venders All Pepsi Plants Combined PepsiCo proactively takes voluntary steps reducing carbon footprint of coolers
    10. 10. 3 2 <ul><li>Efficient System & components </li></ul><ul><li>HC systems design </li></ul><ul><ul><li>R290 </li></ul></ul><ul><ul><li>R600a </li></ul></ul><ul><li>CO 2 system design </li></ul><ul><li>Multi year plan </li></ul><ul><li>Global strategy </li></ul><ul><li>Engage stakeholders </li></ul>Top Level Approach 1 <ul><li>Latest technology </li></ul><ul><li>Analytical tools </li></ul><ul><li>System analysis </li></ul>Research Planning Development
    11. 11. Reducing Energy Through Research & Exploring New Technology <ul><li>Pipeline of Innovative ideas and technologies </li></ul><ul><li>Energy roadmap – System optimization </li></ul><ul><li>Super efficient cooler </li></ul>Energy Reduction Percentage of Energy Reduction Air Curtain - 10 hrs LED Lighting ECM Motor Energy Device Low E-Glass VCC Compressor Expansion Valve Evap. fan Cycling with Compressor Cooler/ vender Mister 25% 30% 20% 20% 12% 10% 5% 2% 10% Energy Roadmap Mathematical Model <ul><li>Optimizing tools using mathematical modeling </li></ul><ul><li>System level approach – smart design </li></ul><ul><li>Compressor consumes over 50% of energy </li></ul><ul><li>Opportunity for better heat exchange design </li></ul>Benefits Measured energy = 5.30 kwh/d Calculated energy= 5.17 Kwh/d 1.44, 28% 0.55, 11% 0.27, 5% 2.92, 56% Compressor Lighting Evaporator Fan Condenser Fan Kwh/d
    12. 12. HC Global Initiative- 2009 and beyond Turkey- HCs Global- HCs <ul><li>Two Systems: </li></ul><ul><li>R600 a </li></ul><ul><li>R290 </li></ul>Establish strategic supplier in each region <ul><li>Leverage learning from Turkey, Expand to Europe </li></ul><ul><li>Expand China - beyond field test </li></ul><ul><ul><li>Plan: place 50,000 coolers by 2013 </li></ul></ul><ul><li>Approve HC models for NA </li></ul><ul><ul><li>Field test unit in US – Jan. 2010 </li></ul></ul><ul><li>Expand HC to new markets – LAR, India…. </li></ul><ul><li>Winter Olympic in Canada – CO 2 vend o rs </li></ul><ul><li>Build infrastructure in Turkey </li></ul><ul><ul><li>Turkey has best model for service </li></ul></ul><ul><li>Build capability for local suppliers </li></ul><ul><li>Incorporate latest technology in design </li></ul><ul><li>Four HCs models approved </li></ul>51% less energy than baseline 29% less energy than baseline 48% less energy than baseline
    13. 13. Green Coolers Highlights PEPSI “GREEN” COOLER Green Cooler Energy Saving Device Day/Nignt Mode <ul><li>First Cooler with HC gas in Turkey </li></ul><ul><ul><li>B riefed the suppliers that Pepsi strategically support s HC </li></ul></ul><ul><ul><li>Customer concern s on cooler electricity costs supported transition </li></ul></ul><ul><ul><li>Local s uppliers developed proper equipments for the market needs </li></ul></ul><ul><ul><li>H ad the in - house technical infrastructure to support HC </li></ul></ul><ul><ul><li>PepsiCo Corporate developed Energy saving controller to reduce energy further + 20 % </li></ul></ul><ul><li>First Country switching to HC for 100% of New Coolers </li></ul><ul><ul><li>To retailer : “51% less energy consumption and more environmentally friendly” </li></ul></ul><ul><ul><li>To consumer : “This cooler saves 5 tre e s with i t’s energy saving t echnology” </li></ul></ul>Cooled by HC Refrigerant (R600a) & Equiped with Energy Saving Device All New Coolers G reen as of 2009 and beyond..! The key factor of the successful implementation of the alternative refrigerants in developing countries such as Turkey is that, the proposition brings commercial value to the customer while doing the right thing for the environment
    14. 14. HC vs. CO 2 System <ul><li>HC operate at lower pressure & take less charge </li></ul><ul><li>HC compressor is smaller and more efficient </li></ul><ul><li>COP for HC is higher than R134a </li></ul><ul><li>Operates at 10 times higher pressure </li></ul><ul><li>Performance issue at high ambient </li></ul><ul><li>Estimate system cost (10-25)% > HFC </li></ul>Hydrocarbons (HC) Systems CO 2 System- Carbon Dioxide - R744 <ul><ul><li>Isobutane - R600a </li></ul></ul><ul><ul><ul><li>Widely used in Europe for household refrigeration </li></ul></ul></ul><ul><ul><ul><li>Single door cooler </li></ul></ul></ul><ul><ul><li>Propane - R290 </li></ul></ul><ul><ul><ul><li>Mainly used for low temperature applications </li></ul></ul></ul><ul><ul><ul><li>Double door cooler & open air </li></ul></ul></ul><ul><li>Experimental Stage </li></ul><ul><li>Large coolers and vending machines </li></ul><ul><li>Use when the charge is > 150g </li></ul>PEP Pursuing Duel Strategy Based on Application and Market Regulations – HCs & CO 2
    15. 15. Equipment GHG Emission PepsiCo focused on energy consumption of the coolers which has 95% effect on the environment Hydrocarbon gases are high in energy efficiency and give about 30% energy saving PepsiCo promotes Hydrocarbon gases based on their energy efficiency besides GHG <ul><li>Unit emission reduced </li></ul>By retiring old equipment and implementing new technologies, total emissions will also decrease
    16. 16. Equipment Sustainability Progress to Date……… Alternative Refrigerants Energy Reduction <ul><li>48% energy reduction in 2009 vs. 2004 baseline </li></ul><ul><li>Introduced 48 new efficient coolers in 2009 </li></ul><ul><li>Developed super efficient cooler = 2.2 kwh/d </li></ul><ul><li>863,942 GHG Metric tons saving vs. 2007 </li></ul><ul><li>44% in 2009 vs. 2004 baseline </li></ul><ul><li>Launched Bev Max IV- 30% </li></ul><ul><li>lower energy than E-star </li></ul><ul><li>13073 GHG Metric tons saving </li></ul><ul><li>vs.2007 </li></ul><ul><li>15 HC models approved for bottlers worldwide </li></ul><ul><li>Expanding in Europe & Asia </li></ul><ul><li>Built Turkey as 100% HC </li></ul><ul><li>Design HC model for US market </li></ul><ul><li>Place 35 Units HC in US - FL </li></ul><ul><li>Redesigned & Optimized Beverage Max III CO 2 vending machine to meet E-star requirements </li></ul><ul><li>Placed 30 CO 2 vending machine in strategic location in DC area </li></ul><ul><li>30 CO 2 units in Winter Olympics- Canada </li></ul>Coolers Vending <ul><li>Total of 877,015 metric tons reduction since 2007. On Average 292,338 metric tons/year </li></ul><ul><li>168,000 cars in total or 56000 cars/year </li></ul><ul><li>Total saving 1.8 B Kwh since 2007 </li></ul><ul><li>Increased number of green refrigerant units in the field. Exceeded commitment to R efrigerants N aturally! Group for 2009 </li></ul><ul><ul><li>13 , 321 Units in the field globally </li></ul></ul><ul><ul><li>1 , 372 Units R efrigerants N aturally Commitment </li></ul></ul>Green House Gas Reduction Kwh Turkey 100% “ Green” In 2009 and beyond
    17. 17. Questions?
    18. 18. Backup

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