The Frey family has been on the Turkey Hill farm since 1817. Over the years, we've seen many things change in our surrounding community. To do our part in ensuring that future generations can also enjoy our little part of Lancaster County, and the rest of the world, we've taken some added steps.
Turkey Hill is actively defining and implementing the following green initiatives to drive out waste, reduce packaging, and reduce outputs to the environment.
Hydroelectric Renewable Energy
- A collaboration between Brookfield Renewable - Safe Harbor Dam and Turkey Hill Dairy.
- Both Safe Harbor plant and Turkey Hill Dairy started operating in 1931.
- Safe Harbor plant will provide 3 megawatts of clean, reliable energy.
- Electricity sold to Turkey Hill Dairy through Calpine Energy Solutions by way of a local electric substation hub.
- Safe Harbor Dam is known for its fish lift and playing an active role in the restoration of the American Shad.
- This agreement allows Turkey Hill to be 100% renewable energy GREEN company.
The Frey Farm Wind Turbine
Since 2011, two wind turbines have been partially powering the Dairy's annual electricity needs.
- Partnership between the LCSWMA, PPL, and Turkey Hill Dairy
- 3.2 megawatt, two turbine wind generating facility
- Each General Electric turbine is 262 feet high and each blade is 135 feet in length
- Output from the wind project will be delivered directly to Turkey Hill for use in its manufacturing facility
- During times of low demand, excess power will be delivered to the grid
- Wind facility will provide up to 6.2 million kWh annually
- Will provide energy diversification, and reduced electrical costs
- Reduces greenhouse gas emissions by about 5,900 tons per year
- Replaced nearly all T-12 fluorescent lights with higher efficiency T-8 lights and nearly all metal halides & high pressure sodium fixtures
- 530 fixtures converted to energy-saving T-5 fluorescents (ice cream and fluid production areas and refrigerated and freezer warehouses)
- Replaced 400-watt high pressure sodium lights with 200-watt energy efficient induction lights
- As existing lights fail, Turkey Hill will replace them with induction or LED lamps
- Reduced annual operating costs, extended lamp life cycles, lower maintenance costs, and reduced heat load in warehouses
Landfill Gas (Green Energy Plant)
- Partnership between the LCSWMA, PPL Renewable Energy, and Turkey Hill Dairy
- 3.2 megawatt methane gas-to-electricity facility
- Generated electricity sold to the grid
- Heat from large engines used to produce steam piped directly to dairy to make hot water for processes: pasteurization, cleaning, case washing, etc
- Steam supplies up to 75% of dairy's manufacturing demand
- Reduced use of diesel fuel by an estimated 150,000 gallons per year
- Less fuel consumption, reduced energy costs, capital avoidance, less air emissions
- U.S. EPA Landfill Methane Outreach Program's 2006 Project of the Year
Wastewater Treatment Plant Bio-Gas
- Project involves collecting and burning methane gas generated from Turkey Hill's anaerobic wastewater treatment facility
- Turkey Hill was able to reduce its use of propane gas by nearly 85 percent or the equivalent of more than 120,000 gallons of propane per year.
Wastewater Treatment UV Equipment
- Project involved installing UV equipment to replace chlorine gas as a disinfection chemical
- Sulfur dioxide gas used to counteract the chlorine prior to discharge was also eliminated
- Note: Chlorine gas is a hazardous chemical and its replacement by UV disinfection improved worker safety, reduced toxic chemical reporting, and eliminated the formation of chloramines in our effluent discharge
- Turkey Hill maintains an active recycling program Major waste streams: cardboard, HDPE and LDPE plastics, ferrous and non-ferrous metals, paper products, food-grade waste
- Minor waste streams: fluorescent lamps and ballast, batteries, and waste oil
- Past three years, Turkey Hill has recycled the following volumes of major items:
- Cardboard:902 tons
- Plastics: 305 tons
- Metals: 130 tons
- Paper: 135 tons
- Food-Grade: 720,000 gallons
Ice Cream Waste Reduction
- Implementation of allergen program made it necessary to eliminate traditional methods for reworking ice cream mix waste created during production
- In 2007, Turkey Hill invested in systems to capture and safely reclaim waste from production
- Resulted in a one third reduction of ice cream mix waste (which had previously been discarded)
- Eliminated the use of additional commodities to replace the waste
- Also eliminated the transportation of heavy liquid to a disposal location.
Reduced Resin Content of Half Gallon Decanters
- Worked with suppliers to upgrade dairy crate design
- Changed lattice structure on crate: able to maintain and exceed edge crush and top load strength characteristics
- Removed .2 pounds of HDPE resin from the dairy crates — amounts to 40,000 pounds of resin on an annual basis.
- Use of Dairy crates — reduce single use packaging material
Reduced Resin Content of Half Gallon Decanters
- Turkey Hill invested significant capital into filling, labeling, and handling equipment
- Allows us to fill and handle a redesigned half gallon bottle
- New half gallon bottle has 22 grams less of HDPE resin than previous container — an annual quantity of 1,424,500 pounds
Reduced Plastic Fruit Pails
- Reducing number of single use plastic pails used in facility
- With the help of our suppliers — transitioned many of our fruit ingredients from a plastic 30 lb pail to a reusable 2500 lb tote system
- Reusable totes are backhauled from facility when ingredients are delivered
- The totes are cleaned and sanitized by vendor before refill
- Utilizing 45,000 fewer pails (135,000 pounds of plastic) per year than in 2008
Paper Ice Cream Lids
- Dairy Industry standard: use Ice Cream lids with plastic rims
- Most filling and conveying equipment — designed to run plastic specifically
- 2002: Turkey Hill made decision to switch all our plastic rimmed lids to paper
- Ice cream lines were reengineered to allow paper lids
- We save 210,000 pounds of plastic per year
- Turkey Hill has an on-going commitment to use paper-rimmed lids (even though we could save money by using plastic rims)
Paper Ice Cream Cartons
- Turkey Hill tested and introduced a paper carton
- Weighed 5.5% less than our previous carton
- Note: Even though paper is a renewable resource, it still often ends up being discarded into landfills
- By removing plastic from our cartons we have reduced our annual paperboard requirements by 200,000 pounds
- Turkey Hill Distribution Department is committed to reducing the number of miles spent on the road with empty trailers
- Partnered with our suppliers to backhaul
- Ingredients and packaging are hauled to the plant during return trips from deliveries to our customers
Local Sourcing and Vendor Consolidation
- Actively working to source raw materials and packaging from local suppliers
- Reduces number of miles that trucks drive to our facility to drop off products
- Also working to consolidate our vendor list
- Reduced total number of deliveries to plant
- Ensures that delivery trucks are full when shipped to us
Adoption of LEAN Processing Principles
- In the process of training and certifying its associates in LEAN manufacturing principles
- LEAN principles are focused on identifying and driving all waste out of our systems
- Turkey Hill teams use LEAN process to analyze and implement changes in areas of the company
- Goal: through companywide continuous improvement, we will find more ways to increase sustainability of our business and products
- Installed under-leveler seals to eliminate "white space" and energy saving lighting at all incoming and outgoing docks
- Dock seals were installed on twenty dock doors to prevent loss of refrigeration
- Twenty-eight docks were converted from standard 150-watt floodlights to 16-watt energy-efficient LED lights
- Reduced cost for cooling and lighting and less maintenance due to increased lamp life