In this series,
A Tale of Two Cities: Scaling Sustainability, we’ll get an inside glimpse into the innovative manufacturing practices at two very different IFF facilities, showing how sustainability is not a one-size-fits-all endeavor. We’ll explore how each location uniquely adapts its sustainability strategy to integrate with its local community, environment, available natural resources and regulatory framework.
From their proactive waste diversion programs to innovative water conservation initiatives, each site exemplifies how industry can indeed contribute to restorative ecosystems and lead the way for a more sustainable future.
Sustainable Growth in the Heart of the Corn Belt: IFF's Cedar Rapids Journey
In the Midwest’s fertile heartland, the Cedar Rapids, Iowa, biotech manufacturing plant is committed to advancing best practices in sustainable growth that bolster the community and local farmers — and create jobs — while reducing its environmental impact.
A specialist in producing enzymes for the home and personal care industry, the site has grown by 10% in recent years while helping to advance IFF’s overarching sustainability goals, including reducing Scope 2 greenhouse gas (GHG) emissions by 50% from their 2021 levels by the year 2030.
As global companies race to meet ambitious emission targets, the Cedar Rapids site is an example of incremental progress on the ground today.
From upcycling waste streams to improving energy efficiency, the team applies consistent discipline to look for areas of improvement. And on the path to net zero, they’re showing how small, deliberate actions can add up to substantial collective impact.
Discover how IFF is playing a critical role in addressing the climate crisis. ↗️
“Focusing on sustainability has always been a return on investment. And we will continue to challenge the paradigms. What might not have worked last year could work in the next year or so.”
One key to the plant’s success is the Green Team, a cross-functional group of employees who take ownership of the site’s environmental goals. Serving as the eyes and ears of the facility, they identify sustainability opportunities unique to their location and work together to make them a reality.
FROM FARM TO BIOTECH
Strategically located in Iowa’s Corn Belt, the Cedar Rapids site makes use of a sugar byproduct from corn processing to fuel its fermentation. This contributes to a circular economy where agricultural waste is kept out of landfills and is repurposed and recycled back into the production cycle.
Being close to where their feedstock is generated helps cut carbon emissions by eliminating the need for long-haul trucking to transport these materials.
And recently, the Cedar Rapids team has introduced a new set of programs that redirect the waste from their enzyme production processes for use by local farmers to replenish their soil.
“The agricultural raw materials used for fermentation don’t get completely consumed in our process, and have inherent value. They come from the earth and we’re putting them back into the earth.”
The site has two different waste streams that are reused by local farmers.
Biomass
A liquid byproduct from enzyme production that traditionally was sent to wastewater treatment plants, this material has been recognized by the Iowa Department of Agriculture and Land Stewardship as a soil conditioner that can be reused by farmers.
Impact
2.8 million gallons of liquid biomass a month are diverted to farmers to use as a soil conditioner that can enable less use of traditional fertilizer.
This results in an approximately 10% reduction in the site’s wastewater that would otherwise be sent to the city’s wastewater treatment plant and eventually the Cedar River.
Cake shavings
Diatomaceous earth, a powdery natural substance used as a filter aid in the enzyme production process, becomes a valuable byproduct post-filtration. It can be repurposed as a farming product to add moisture and nutrients back into the soil.
Impact
350 tons a month of cake shavings have been upcycled for agricultural use.
This represents 80% of this specific waste stream’s being kept out of local landfills.
Stepwise efficiency upgrades
The Cedar Rapids team is continually seeking novel ways to improve energy efficiency across the plant’s operations. In the past several years, they’ve installed over 300 variable frequency drives on the site motors, which enables team members to adjust the speed and power of their equipment based on real-time demand. This yields significant savings, especially with energy-intensive equipment like the agitator mixers used in the fermentation process. They’ve also switched to energy-efficient LED lights throughout the facility — resulting in approximately 490,000 kW/hr of energy savings.
The key to implementing many of these upgrades is to take an incremental approach while considering the end-to-end production system, says Damian Long, Technology Manager. In the agitator mixer upgrade, for example, they gradually reduced the agitation setpoint by 5% in each subsequent fermentation until they begin to encounter mass/heat transfer limitations.
“We have a formal approach to take smaller steps in these changes to mitigate any impact on the production performance or the quality of the final products.”
Looking to the future, they’re working on an investment proposal for a hybrid-electric boiler for steam production that would cut their use of fossil fuels. The electro-boiler can be heated by surplus renewable solar and wind energy from the grid. And since steam generation is such a critical part of many of their production processes, there’s significant potential for carbon-emission reductions with this new boiler.
Cold-water-wash challenge
The R&D and manufacturing teams also invest and collaborate to update their enzyme strains to yield more product with less inputs. For example, one of their new enzymes used in cold-water laundry detergents has undergone several rounds of strain and process improvements, resulting in a significant increase in yield.
“We work closely with R&D to develop new products that save energy for our customers. However, with new process and strain improvements on current products, customers can get the same amount of product with less of a carbon footprint. In turn, this has a positive impact on the footprint of their end products.”
says Long.
Building on the site’s commitment to environmental stewardship, the team recently put its enzyme innovations into practice, inviting employees and their families to participate in a “Cold Water Wash Challenge”.
“Throughout the three-month program, employees used a leading laundry detergent (containing their new enzyme) at a cold setting and tracked their energy savings. Everyone was interested and proud that the products they work on add value to our society and environment,”
says Fersdahl.
Removing Roadblocks
In 2020, Cedar Rapids was hit by one of the most powerful windstorms in U.S. history; 70% of its trees were destroyed.
In a program led by the Green Team, the site partnered with the city on a three-year initiative to donate and replant thousands of trees, targeting low-income areas most in need. And as part of this community program, employees received education on tree planting and land stewardship.
In a program led by the Green Team, the site partnered with the city on a three-year initiative to donate and replant thousands of trees, targeting low-income areas most in need. And as part of this community program, employees received education on tree planting and land stewardship.
In a program led by the Green Team, the site partnered with the city on a three-year initiative to donate and replant thousands of trees, targeting low-income areas most in need. And as part of this community program, employees received education on tree planting and land stewardship.
In a program led by the Green Team, the site partnered with the city on a three-year initiative to donate and replant thousands of trees, targeting low-income areas most in need. And as part of this community program, employees received education on tree planting and land stewardship.
“It’s been one of the most popular community service events. And we get to see our local impact with new trees growing in the city’s parks and neighborhoods.”
says Fersdahl.
The Green Team continues to drive the facility’s sustainable efforts through an approach that empowers and engages employees to develop on-the-ground solutions. After initiating the waste diversion (cake shavings) program, they’re leading plans to find new homes for the site’s other waste streams, getting them closer to their zero-waste-to-landfill certification.
“We love getting input from our Green Team, because they have the knowledge and expertise to help see our plans to a conclusion,” says Fersdahl. “And as we continue on this journey, their mix of idea generation and removing roadblocks will propel us forward.”
The Cedar Rapids site showcases IFF’s commitment to leveraging science and creativity to do more good for people and the planet.
“Sustainability is truly embedded in everything we do. Through collaborative efforts and a steadfast commitment to sustainability, Cedar Rapids exemplifies how IFF is helping to build a more sustainable and equitable world.”
In case you missed Part 1:
Visit IFF’s Hanko, Finland, biotech manufacturing site to see how they’re applying innovative sustainability practices to be a valuable contributor to the community.
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