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Sustainable Plant of the Year: Frito-Lay Casa Grande Plant Attains Near Net Zero

Efficiency was built into Frito-Lay’s Casa Grande plant a quarter-century ago, but the snack maker takes the facility’s energy- and water-conservation systems to a new level with near net zero.
Is it feasible for food or beverage production ever to be resource neutral, consuming no more gas, electricity, water and other utilities than what it generates itself?
Perhaps theoretically, but not as a practical matter. Still, placing sustainable manufacturing in the context of assuring resource availability so operational capabilities are maintained, regardless of external disruptions, is intriguing. What would a food plant with net-zero impact look like?
A close proximity sprawls across 283 acres of the Sonoran desert in Arizona. 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. Most of the energy-generation and water-reclamation technology in Casa Grande can be found elsewhere in the Frito-Lay production network, but never before has such a comprehensive infrastructure been created. The result is a plant that pushes the limits of what is possible in energy and water self-sufficiency.
Selection of Casa Grande came after an assessment of Frito-Lay’s 37 US facilities by the US Department of Energy’s National Renewable Energy Laboratory. Abundant real estate, Sunbelt location and middle-of-the-pack production size figured in the choice, but the pick also acknowledged the facility’s pedigree. Built in 1984, Casa Grande was a showcase of energy conservation for its day. Its systems and technologies earned it Food Engineering’s designation as 1985 Plant of the Year.
Efficiency is relative, and the chip

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