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We are working with managers from the Ginsters factory in Cornwall to develop a learning history of their environmental management practices over the past 10 years.
Ginsters, part of the large and privately owned Samworth Brothers Group, have been making Cornish pasties and other savouries for over 40 years and currently produce over 3.5m products per week. With nearly 1000 staff on-site they are the largest private employer in Cornwall, and they take their community responsibilities and local reputation very seriously. Their contribution to local sustainability was officially recognised when they won the “Best Large Company” and “Overall Winner” in the Cornwall Sustainability Awards 2006.Â
Through the Learning History approach, we are helping Ginsters to notice, understand and learn about the factors which have come together to enable their proactive approach to carbon reduction.  In particular, we will be telling the story of Ginsters’ approach to resource efficiency and waste management. We will attempt to show how changes in government legislation were the initial drivers for change (particularly the new IPCC†regulations in 2004) but how these ‘external’ factors have given way to more self-sustaining or ‘internal’ drivers, as the business benefits of sustainable practice have become more apparent, and a group of environmental ‘champions’ has emerged. The Lowcarbonworks team are working with a number of theories which might help explain some of the contextual factors which Ginsters have faced .
An important turning point in Ginsters’ environmental history was their decision to support a new Anaerobic Digestion plant at Holsworthy, North Devon, in 2003.  The £7.8m plant was originally conceived by a group of local farmers as a cost-effective solution to their farmyard waste, and was one of the first of its kind in the UK. The plant takes a mixture of farmyard slurry and local food waste and converts it into biogas* which is then sold back to electricity generating companies as green energy. The remaining by-product (or digestate) is spread back on the land as a nutrient-rich, natural fertiliser. The biogas plant encountered significant technological, management and financial difficulties in 2005, which resulted in it being sold to a London based waste management company, so it is no longer in community ownership. Another recent development is that from June 2008 the plant has stopped taking farmyard slurry from local farmers, and only accepts food waste from local manufacturers and municipal food waste collection schemes. This type of waste contains higher energy levels and has the potential for greater biogas production. The new owners are hoping that this will enable them to make a profit for the first time since the plant opened. Ginsters continue to send 20 tonnes of food waste to the plant every week, which would otherwise go to the landfill, and the green energy produced by the plant has the potential to power about 1000 homes. Â
Despite the huge potential for anaerobic digesters to provide green energy, and the fact that thousands are being used in mainland Europe (particularly in Germany and Austria) only about 12 generators in the UK are currently being used to produce energy, and this is mainly to power farms. There is currently a lot of interest in the press and government circles about the potential for such ‘Waste to Energy’ technologies, but there seems to be little understanding about all the complex factors which have to come together to make this finely-tuned technology actually work, and also the potential social, legal and political barriers which can stand in its way. By writing this Learning History we are hoping to achieve 2 important aims:
1. To enable Ginsters to learn from their own experience of working with this new technology and apply that learning to any future investment in low carbon technologies.
2. To disseminate the learning more widely, both within and outside the food industry, to help others understand the economic, organisational and political issues that might need attending to, in order to make this new technology a success.
We are currently in the process of conducting interviews with key people from within Ginsters, and also a number of external people who were involved at the conception of the biogas plant, and the current owner. We will then construct and share the Learning History with the Ginsters team before disseminating it more widely. Â
†Integrated Pollution Prevention and Control (IPCC) regulations came into affect in 2004 and apply to all food manufacturers who produce more than 75 tonnes of product a day. All companies in this category must get a permit from the Environment Agency in order to conduct their business.
* Biogas produced by AD consists of mainly methane and carbon dioxide. The Biogas can be
used to generate electricity and heat (CHP). It can also be converted to a vehicle fuel.
Biogas is a renewable energy source. It displaces fossil fuels and therefore helps to reduce
additions of carbon dioxide to the atmosphere. It does produce carbon dioxide when burnt
but this comes from the natural atmospheric carbon cycle, so it doesn’t add to the stock of
green house gases that lead to climate change.