In this French fry factory, waste is not done

Published: 2025-04-30 09:08:21 ET LW

Published on 05/23/2025 at 09:01

Without water and energy, it is difficult to make frozen fries. But that doesn't mean the production process can't be more sustainable. Lamb Weston, one of the world's largest producers of frozen potato products, recently opened a new factory in Kruiningen, Zeeland, where everything is aimed at reusing water and heat as much as possible. The result: a particularly sustainable fries.

It starts with the raw material, the potato. The new factory has advanced sorting facilities to determine which specimens lend themselves best to making fries or another potato product. That means: less cutting loss and therefore less waste.

Halving water use

The cut fries then go through several production stages, where the water is cleverly used for multiple processes. Water cascading, in other words. And that leads to a halving of water use for this sub-process.

Residual heat for the neighbors

And then, of course, there is energy consumption. Most of the energy is used to create steam, needed to heat the oven to 180 degrees. Thanks to a smart heating system, Lamb Weston is able to utilize residual heat and exchange heat and cold in the new plant. For example, heat from the steam peeler is reused by linking it to process steps that need just this temperature. And the low-grade heat that remains at the very end of the production process? That goes to the neighbor, Wiskerke Onions, which needs a temperature of thirty degrees to dry onions.

Already ready for hydrogen

Solar panels on the roof, energy-efficient installations and an office space with energy label A+++; all this also fits well with Lamb Weston's sustainable mission. And yes, the boiler still runs on natural gas, but is technically suitable for switching to hydrogen. So if that becomes a possibility in the future, it won't require a new boiler.

Mindset

"It is difficult to look far into the future and predict what the role of hydrogen will be in the future, but we want to keep our options open in that regard. In addition, it is a nice idea that we have the possibility to switch at any given moment," says Wouter Smit, vp supply chain. When asked why the focus is so clearly on sustainability, he does not have to think long. "Sustainability is in our DNA. We are a value-driven organization in which, among other things, integrity is central. For us, that means not only acting honestly and transparently, but also caring for the society and environment in which we operate."

Developing strategy

Many companies struggle with making their production processes more sustainable. Often they begin in good spirits, but motivation quickly drops when it becomes apparent what is involved. "It only works if you really do it from a clear conviction and you also develop a strategy for it," Smit points out. "That's why we always look first at which issues we can really influence. Only then do we outline our plans."

Flagship

A practical approach, in other words. And with that approach they have already come a long way. "In terms of sustainability, we are way ahead of our other factories with this factory. That means there are still plenty of opportunities in those other factories to significantly reduce water and energy consumption as well. In that respect, this new plant in Kruiningen is a flagship in Lamb Weston's global production network."

Booster

"The advantage of a new plant is that at such a time you have the opportunity to redesign the production processes and purchase the necessary equipment to do so," adds Mariska van Dalen. As director sustainability by design, she is a booster at Lamb Weston who ensures that the ambitions in making the plants more sustainable are actually realized.

No whim

"Our focus on sustainability is not a whim," Van Dalen emphasizes. "It is an ongoing program. Sustainability is an integral part of our company's vision. That's not always easy, because although investments in sustainability can yield long-term cost savings, it doesn't always manage to make the business case. At such times, it is nice to have a management team that not only looks at the money needed for an investment, but also at the broader picture and the importance of sustainable operations for the future.

A great example of this is Lamb Weston's sustainable step at the end of 2024 with the introduction of packaging in the retail segment that consists of 60 percent bio-circular plastic based on used frying oil.

Discussion topic during job applications

For the new plant, of course, new employees had to be recruited. And that with the current tight labor market. But those new colleagues were found relatively quickly. Thanks also to the company's sustainable image.

Van Dalen clearly notices this during the job applications. "Whether it's a vacancy for an executive or a plant operator: we clearly notice during job interviews that candidates have read our sustainability report. And it doesn't make much difference whether they are young or old: they all indicate that they find this an important and attractive aspect. So in that respect, our focus on sustainability helps us as well."