Frito-Lay Casa Grande Gallery
Frito-Lay Casa Grande was chosen as Food Engineering's 2011Sustainable Plant of the Year.Part learning lab, part sustainability showcase, the Frito-Lay facility in Casa Grande is the focus of the snack food manufacturer’s ambitious goal of creating a blueprint for sustained production in a resource-strapped tomorrow.
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Albert DeCima pulls a sample of SunChips as they emerge from the fryer. Casa Grande became the seventh plant in the Frito-Lay network to produce the chips when the new line was completed last year. Source: Reed Rahn.
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Mark Duran Sr. is the only operator for nine SunChips packaging lines on his shift. The high-speed lines feature robotic case packers and palletizers. Source: Reed Rahn.
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Considerably larger than a gas-fired unit, the plant’s biomass boiler generates up to 60,000 lbs. of steam an hour, the same as the boiler it replaces but using wood scraps and agricultural waste. Source: Frito-Lay.
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Considerably larger than a gas-fired unit, the plant’s biomass boiler generates up to 60,000 lbs. of steam an hour, the same as the boiler it replaces but using wood scraps and agricultural waste. Source: Frito-Lay.
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A membrane bioreactor helps the facility treat and reuse half the water coming into the plant, and the addition of low-pressure reverse osmosis technology is expected to boost recovery to 75 percent. Source: Frito-Lay.
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Employee engagement is a key element of near net zero. Presentations on the bottom-line costs of waste help raise awareness and get workers involved in improved efficiency programs.
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Ten parabolic mirrors concentrate sunlight and use the energy to power Stirling engines that generate electricity through the compression and expansion of helium gas. Source: Reed Rahn.