Mars Petcare Wodonga to power up with renewables

Aligning with its goal of achieving net-zero emissions by 2050, Mars Incorporated has announced that its Wodonga pet food manufacturing facility is set to become the first large-scale steam-based manufacturing site in Australia to deploy a 100% renewable energy solution, for both electricity and process steam, within the next two years.

The $39.3 million Mars Wodonga Solar Thermal Plant will spearhead this transition, including the installation of an 18-megawatt parabolic trough concentrated solar thermal (CST) plant that will provide up to 10 hours of thermal energy storage for cooking pet food. The project, which includes a $17.2 million grant from the Australian Government through The Australian Renewable Energy Agency (ARENA), is claimed to be the first commercial deployment of parabolic trough CST technology in Australia.

The pet food manufacturer will use the parabolic trough technology to harness thermal energy from the sun, discharging a heated water/steam mixture to a steam drum, to be directed to a series of steam accumulator tanks.

Mars Petcare Australia and New Zealand General Manager Craig Sargeant said investing in this technology is a significant step for Mars in Australia and globally.

“Decarbonising site-based process heat, coupled with Mars Australia’s 100% renewable electricity use, is a significant achievement that not only reflects our ongoing commitment to sustainability but also positions our Wodonga facility as a leader in green process heat manufacturing on a national scale,” Sargeant said.

“Investing in renewable energy technologies like CST is critical to decarbonising industrial processes, particularly in sectors that heavily rely on gas for steam-based manufacturing,” Sargeant continued. “CST offers a powerful solution by capturing and storing solar energy, in the form of high temperature heat, for use at any time, making it an ideal fit for our steam-based manufacturing needs.”

The steam accumulator tanks will provide up to 150 MWh steam thermal energy storage system to provide round the clock process heating even when the sun doesn’t shine.

The project will use water as the heat transfer fluid, storage medium and energy carrier to avoid the requirement for heat exchangers and thermal oil systems commonly utilised in CSP plants.

The project also builds on Mars’ implementation of electric thermal energy storage (eTES) technology, which allows the facility to use low-cost, grid-connected renewable electricity during off-peak times to generate and store heat that can produce steam at any time of day or night. This eTES system, supported by CSIRO, provides a cost-effective, renewable alternative to gas.

ARENA CEO Darren Miller said the project aims to prove what the technology can offer Australian businesses.

“We’re excited to be working with Mars Petcare to demonstrate the potential of concentrated solar thermal as a viable option for Australian industry to generate renewable heat, making use of our abundant sunshine to provide the energy required," Miller said.

“With industry currently accounting for around 44% of Australia’s total emissions, we need to look at all renewable energy technology options to generate enough energy to power industry and solve this challenging piece of the puzzle.

“Concentrated solar power has been used for electricity and heat generation for decades overseas, so it’s great to see the renewed interest in it from Mars Petcare in what could be a growing trend for Australian industry in its journey to net zero.”

The promise of concentrated solar thermal as a renewable heat source lies in its smaller land requirements when compared to electric heating backed by solar photovoltaic (PV) and the ability to avoid upgrading power supply infrastructure.

ARENA funding will support Mars to install the 18 MW (thermal) concentrated solar thermal plant to provide industrial process heat to the pet food factory.

“Mars would like to thank the Australian Government for its range of clean energy initiatives and is proud to be partnering with ARENA to develop Australia’s first commercial deployment of Concentrated Solar Thermal at Mars Petcare Wodonga,” Sargeant said.

Set to be completed in 2026, the new plant is designed to halve the facility’s gas use and create approximately 80 jobs in construction.

ARENA has funding available for industrial energy projects through several active programs, including the $400 million Powering the Regions: Industrial Transformation Stream. For more information on existing ARENA projects or to apply for funding, visit ARENA’s funding page.

Image credit: iStock.com/Chalabala