Now powered by 100% renewable energy!
In 2019, Turkey Hill collaborated with Brookfield Renewable & Calpine Energy to supply the dairy with 3 megawatts per month of clean, renewable energy from the nearby Safe Harbor and Holtwood dams.
Combined with electricity from the wind turbines of its partner, Frey Farms, the Dairy is powered by 100% sustainable energy sources!
Frey Wind Farm
Turkey Hill partnered with Energy Power Partners and Lancaster County Solid Waste Management Authority to install the first commercial-scale wind energy project in South Central Pennsylvania.
The turbines reduce the dairy’s greenhouse gas emissions by roughly 5,900 tons annually, the equivalent of removing 1,000 cars from the road.
262 feet tall
135 foot-wide blades
Producing 6-7 Million Kwh of electricity
Enough to make 5 million Gallons of ice cream
Green Energy Plant
In 2005, Turkey Hill partnered with Energy Power Partners and LCSWMA to install a Landfill Gas to Energy Plant, taking the Dairy’s waste gases and converting them to electricity and steam used as part of the production and cleaning process.
The Green Plant Saves 150,000 Gallons of Diesel Fuel Annually
Through backhauling and local sourcing, Turkey Hill has worked hard to ensure more economical fuel usage, with fewer trucks coming to or leaving its facilities empty.
In the last three years, Turkey Hill has recycled:
1,248 tons of cardboard
725 tons of plastic
926 tons of metals
35 tons of paper
Equivalent to the weight of 1.5 million cartons of ice cream
Redesigning dairy crates reduced the amount of plastic resin used annually by about 40,000 lbs
We strive to reuse everything we can. Methane gas that’s the by-product of waste-water treatment is used instead of propane to heat equipment, resulting in a reduction of propane usage by about 75,000 gallons annually. That's enough to fuel a backyard gas grill for about 35 summers.
Turkey Hill has pursued energy-saving lighting upgrades for nearly 20 years and is in the process of converting to all LED energy, saving and heat while reducing the energy used for lighting.
Upgrade seals have been added to most loading docks to cut down on heat infiltration and prevent loss of refrigeration.
By reengineering our ice cream cartons and using paper-rimmed carton lids (instead of industry-standard plastic lids), Turkey Hill keeps 210,000 pounds of plastic and 200,000 pounds of paperboard out of landfills each year: a record the company has held since 2002.
Turkey Hill is actively defining and implementing the following green initiatives to drive out waste, reduce packaging, and reduce outputs to the environment.
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
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
- 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
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