Date Published: 06/2013

Bickford's is a privately owned and managed Australian beverage manufacturer. Today, it holds 62% of the market share in premium adult cordials, but this is only part of its story. The company has grown to encompass 16 brand portfolios and more than 120 products.

Bickford's Lime Juice Cordial is perhaps its best-known product and much more than a household name. In 2005, the product joined places and services of significance on the BankSA Heritage Icon List, an acknowledgement of excellence and Australian ingenuity.

Bickford's has a robust export business, including Southeast Asia, China, Hong Kong and the UAE. It is a major supplier to Australia's three major supermarket chains, including private-label products. As well as these larger outlets, there is a strong presence in cafés, restaurants, pubs and clubs, and the route market, which includes petrol stations and convenience stores.

Culture of Sustainability

The values that were important to the company's founders in 1839, integrity and quality, remain central today. Bickford's has since expanded these values to include workplace sustainability. The manufacturer has maintained an Environment Committee since 2006. In 2012, industry body Food SA recognised Bickford's efforts through the Food SA Sustainability Award and Best Practice Award.

Sustainability Initiatives Previously Undertaken

Before engaging Pangolin fdor a comprehensive energy audit, Bickford's had already implemented a range of efficiency initiatives. The company reduced electricity consumption through the installation of skylights and C-Bus systems, the latter allowing automated control of lighting.

Other energy-saving measures included:

• Installing variable speed drives (VSDs) to improve line control.
• Upgrading the reverse osmosis (RO) plant to reduce energy-intensive water treatment.
• Installing a night compressor to better align operating loads and capacity.
• Introducing laser-guided vehicles to reduce transport waste and recharge during off-peak hours.
• Eliminating air leaks in the factory using six air meters installed on site.

The company also reduced the environmental footprint of its vehicle fleet by transitioning to four-cylinder, diesel and hybrid vehicles. As a result, Bickford's reduced its water consumption by 26%, equivalent to 24 megalitres (ML) per year. In 2010, the company also saved $19,000 in compressor operating costs.

Finding Greater Efficiency Opportunities

As a participant in South Australia's Business Sustainability Alliance (BSA) Energy Efficiency Program, Bickford's sought advice from energy efficiency specialists. Pangolin Associates' audit team met the experience and accreditation requirements for a Level 2 energy audit, which complies with the Australian and New Zealand Standard for Energy Audits (AS/NZS 3598:2000).

Pangolin's Energy Audit and Associated Services:

• Established an energy baseline.
• Prioritised opportunities for Clean Technology Investment Program (CTIP) funding.
• Identified cost-saving efficiency opportunities.
• Calculated return on investment (ROI) for implementation.

If fully implemented, the identified benefits are extensive:

• Expected annual energy savings of 35.2%.
• Cost savings of more than $320,000.
• Energy use reductions of 5,467.7 GJ, including electricity savings of 529.9 MWh.
• Carbon emissions reductions of 1,341.1 tCO₂-e.

Grant Outcome

Through Pangolin's recommendations, Bickford's received a Clean Technology Investment Program (CTIP) grant of $72,500. This will fund a voltage optimisation project to further reduce the manufacturer's energy load. Pangolin's trusted partner, Energywise, will undertake this work.

Future Initiatives from the Energy Audit

New sustainability initiatives are on the agenda. In addition to voltage optimisation, Bickford's is investigating solar photovoltaic (PV) arrays and LED replacements for security and perimeter lighting. LED lighting upgrades and solar PV were identified and recommended as part of Pangolin's audit report.

Business Sustainability Alliance (BSA) Energy Efficiency Funding

Bickford's Australia and several other Pangolin clients in South Australia have received BSA Energy Efficiency funding. This assisted them in undertaking energy audits and training. BSA is an initiative of the Department for Manufacturing, Innovation, Trade, Resources and Energy, SA Water, Zero Waste SA and the Environment Protection Authority.

Knowledge Sharing

We now have several clients who have received BSA Energy Efficiency funding. Where appropriate, and where organisations are not direct competitors, we have successfully connected clients to facilitate knowledge sharing.