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.
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.
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.
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.
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. Joe Kilburg, Plant Manager
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.
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. Sarah Fersdahl, Environmental Engineer
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.
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. Damian Long, Technology Manager
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.
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. Katariina Rasinmaki, Senior VP Operations, Health & Biosciences
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.
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.
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.
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.
350 tons a month of cake shavings have been upcycled for agricultural use.
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.
The new steam generation facility can save up to 20,000 MT of CO2 a year.
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.
says Damien 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.”
says Sarah Fersdahl
In 2020, Cedar Rapids was hit by one of the most powerful windstorms in U.S. history; 70% of its trees were destroyed.
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.
See how our biotech manufacturing site is applying innovative sustainability practices to be a valuable contributor to the community.