olam food ingredients turns cocoa shells into power to fuel factory
Two circular biomass boilers have entered operation at olam food ingredients’ (ofi’s) cocoa processing factories in the Netherlands and Germany, reducing greenhouse gas emissions.
The boilers use cocoa shells, a by-product of the production process, as fuel to generate steam, which in turn powers the crafting of cocoa ingredients from ofi’s premium brand, deZaan, at its factories in Koog aan de Zaan, Netherlands, and in Mannheim, Germany – where it believes it will be the first cocoa shell boiler of its kind in the country.
The boiler at Koog aan de Zaan was partly funded by a subsidy from the Netherlands Enterprise Agency (RVO) and took over four years from concept to completion. It will reduce natural gas usage and CO2 emissions at the facility by 50%. In 2022 alone, ofi used 8,000 tons of residual cocoa shells to generate green energy equivalent to using 3.4 million cubic meters of natural gas, helping cut absolute CO2 emissions at the facility by 23%. This is the equivalent of warming over 3,0001 Dutch houses per year.
The second boiler at ofi’s factory in Mannheim has been developed through a joint venture with energy company MVV. It has the potential to provide up to 90% of the steam needed to power the facility, saving approximately 8,000 tons of CO2 annually. The new roll-out adds to the circular biomass shell boilers used in ofi cocoa factories in Brazil, Côte d’Ivoire, Indonesia, and Singapore.
This latest move forms part of ofi’s ambition for sustainable cocoa, Cocoa Compass, which sets ambitious goals – including a 30% reduction in natural capital costs2 by 2030. In 2021, ofi reduced these costs in its global cocoa processing operations by 11% per metric ton of product output, partly thanks to its network of biomass shell boilers and other initiatives such as green electricity and solar panels.
