When you think of Cadbury, images of delicious chocolate might spring to mind. It’s rare to get a behind the scenes peek into the inner workings of this legendary factory. What’s more, there is a fascinating transformation happening and Enginuity Power Solutions is working closely with Mondeléz International, Cadbury owner, to reduce energy waste, enhance sustainability, and future-proof their production processes. Learn how Cadbury is innovating energy efficiency in food production, reshaping operations, and leading sustainable manufacturing in Australia and beyond.
Cadbury chocolate factory: A Tasmanian treasure
Nestled just outside Hobart, in Claremont, Tasmania, the Cadbury factory has been crafting chocolate for over 100 years. As a beloved staple of the local economy, it represents a deep connection to the community. Producing millions of chocolate products annually, the factory’s energy demands are immense, and optimising this is both a challenge and an opportunity.
Cadbury sustainability goals and challenges overcoming the inefficiencies in energy systems within manufacturing
Cadbury, like all large international brands, aims to meet growing consumer expectations for environmentally responsible practices while maintaining the highest production standards. Modernising energy systems in legacy factories like Cadbury is no small feat. Enginuity Power Solutions were engaged to assess the production facility and recommend ways of reducing costs. Many motors in older systems are often larger than necessary, a safeguard put in place during initial design phases to account for unknowns. This equates to higher energy consumption than is often necessary, inefficient systems waste, increasing operational costs and carbon emissions.
Integration difficulties to overcome in energy efficiency
There are several complexities about this project, these include retrofitting newer, more efficient technologies within existing processes. These issues can not only hinder productivity but also negatively impact environmental and financial goals. It’s Enginuity’s role to overcome these challenges and help Mondeléz achieve their corporate sustainability goals. Enginuity Power Solutions specialises in designing and delivering energy efficiency in food production including energy-efficient systems tailored to client needs. At the Cadbury Tasmanian factory, the Enginuity team brought their expertise and instruments to analyse and ultimately transform the energy usage. These instruments included the Fluke Power and Motor Analysers. These instruments are essential equipment that help Enginuity understand current energy consumption and pinpoint inefficiencies. These instruments help provide real world before and after evidence of energy usage, and ultimately financial savings and the reductions to adverse environmental impact.
What is a Synchronous Reluctance Motor, and why is it central to the solution design?
State-of-the-art modern motors are designed to maximise energy efficiency while offering additional benefits like reduced noise, lower maintenance, and better reliability. Synchronous Reluctance Motors (SynRM) are the centrepiece of the solution offered. The design of the motor upgrades and process improvements are specific to addressing Cadbury’s operational needs, and Enginuity will ensure the new technologies align with existing equipment without disrupting production. According to data from the manufacturer, ABB, the SynRM motors offer up to 40% lower energy losses compared to IE3 motors. These motors are designed with unparalleled energy efficiency. A synchronous reluctance motor (SynRM) is a type of electric motor that works by using the natural resistance of certain materials to magnetic forces to make the motor spin. Unlike other motors that use magnets or electricity running through wires to create movement, a SynRM is simpler and uses fewer parts, making it very efficient, reliable, and great for things like heating, ventilation and air conditioning (HVAC), factory machines, and even electric cars.
What are the overall benefits & real-world impacts of energy efficiency in food production?
Partnering with Enginuity Power Solutions, who have designed this solution has provided Modeléz with tangible advantages, such as:
- Improved Energy Efficiency:
Energy use has been fine-tuned to eliminate waste, saving significant power.
Advanced motors ensure the factory operates at its optimal energy level. - Cost Savings:
Lower energy consumption translates to reduced operational costs.
Savings can be reinvested in innovation, equipment upgrades, or sustainability initiatives. - Enhanced Sustainability:
Reduced carbon footprint aligns with Cadbury’s environmental goals.
Supports broader industry efforts to combat climate change. - Operational Resilience:
Reliable systems mean less downtime and maintenance issues.
Higher system efficiency bolsters production capacity during peak demand periods.
The team at Enginuity Power Solutions, is helping design solutions like this for many other businesses within the food and beverage production sector demonstrating further proof of the advantages of energy efficiency in food production. During a recent performance study the team demonstrated a 42% reduction in energy expenditure for a business in aquaculture and feeds production. Learn more about that story, here.
Why energy efficiency matters for food production
The food manufacturing industry faces mounting pressure to adopt sustainable practices. Energy efficiency in food production isn’t just an environmental necessity—it also makes business sense. According to the Australian Government “Energy use accounts for at least 15% of the total operational costs in a food and beverage manufacturing business.” Furthermore, according to ScienceDirect, the food sector accounts for approximately 30% of global energy consumption and emissions. Reductions in energy consumption within the food production industry have several benefits, including:
- Reducing environmental impacts by lowering carbon emissions.
- Improved cost control. With energy prices on the rise, optimised systems help manage expenses.
- Meeting environmental, social, and governance (ESG) expectations enhances brand reputation and attracts eco-conscious consumers.
- Companies with sustainable practices are more appealing to investors and partners.
Future-proofing Cadbury operations and energy efficiency in food production
Enginuity’s partnership with Mondeléz International isn’t just about meeting today’s demands. It’s about preparing for the future. Adopting cutting-edge technology and leveraging the latest innovations helps keep Cadbury in line with industry trends within energy efficiency in food production and helps to build a scalable model that can be adapted for other operations globally. What’s more, it is helping set a standard for energy efficiency in food manufacturing that others can follow.
The collaboration between Enginuity Power Solutions and Mondeléz International offers valuable insights for professionals seeking to optimise energy usage in their own organisations.
By investing in energy efficiency, companies like Cadbury are leading the way towards a greener, more sustainable future—one that benefits their operations, their customers, and the planet.
Watch our short case study we captured onsite with Managing Director, Tom Green, who helps explain the background about the project.
Enginuity Power Solutions has experience working with organisations in several different markets including within the food and beverage production industry all across Australia. Businesses are looking to find ways of reducing energy expenditure and Enginuity is helping find solutions that provide measurable results.
Whatever sector you operate in, we’d love to help your business achieve your sustainability and energy reduction targets. We’re creating more energy efficiency on food production, and we’re helping achieve similar goals in many other sectors too.
Please get in contact today.