We’re always trying to make our facility as efficient as possible and eliminate waste. We have continuous targets for our team that we try to beat week after week. We were tracking waste before this work with Anthesis, but it wasn’t as detailed. This work allowed us to rethink our priorities and refocus our energy.”James Oliphant – Operations Lead Righteous Gelato
Righteous Gelato is a small-batch gelato company with factory operations based in Calgary, Canada. The organisation’s mission is to enrich people’s lives, one tiny spoonful at a time. Righteous Gelato use honest ingredients and nothing artificial.
The purpose of the project was to prevent and reduce food loss and waste at the Righteous Gelato manufacturing facility in Calgary, Canada as part of the Walmart Foundation funded Food Loss & Waste Prevention & Implementation Program.
Anthesis’ partner, Enviro-Stewards, conducted an on-site waste prevention assessment utilising our award-winning Food Loss + Waste Toolkit at the Righteous Gelato manufacturing facility. We measured the savings achieved from our previous Food Loss + Waste assessment, and re-engaged the team on opportunities not implemented or new solutions found.
Three opportunities were quantified to ensure as much gelato as possible was not wasted from the production line:
Opportunity 1 | 600kg/year in Fruit Savings
Sometimes the holding tanks filled with gelato are not properly emptied, resulting in wasted gelato at the bottom of the tank. In order to maximise the gelato quantities, the floor has been sloped and the tanks pulled and tilted forward to permit them to drain more effectively. This costs next to nothing to install and saves $6,500 of gelato a year.
Opportunity 2 | 7,750 kg/year in Milk Savings
Milk is pumped from the milk tote to the tanks in a pipe. Residual milk is often left in the pipes, and so to save ~35L of milk a day – we suggested the milk in the pipes be pushed forward with water to remove the excess milk in the line. This allows for 35 extra litres of milk a day to be turned into gelato.
Opportunity 3 | 9,200 kg/year in Gelato Savings
Gelato is pumped through stainless steel piping from the holding tanks to the freezing unit, leaving residual gelato in the pipes. We estimated this was ~9,200 kg of gelato a year left in the pipes. We recommended a pigging system to use air and water to push out the remaining gelato – allowing it to be packaged and utilised.
Large capital investment isn’t the only way to embed sustainability into your operations. Although Righteous Gelato didn’t install a pigging system, they maintained its sustainable agenda everywhere in its facilities that was feasible. The organisation partnered with Second Harvest, Canada’s largest food rescue organisation, to donate surplus food that would otherwise go to waste to a network of local non-profit organisations serving people in need. Righteous Gelato is now focusing its food loss and waste prevention and reduction efforts on the right priorities, and will use these recommendations to inform the design of its new facility.