Key points
- We're working as the Mars Petcare Wodonga facility's renewable heat technology partner.
- The facility will switch to 100 per cent renewable power solution via a mix of solar and thermal energy technologies and hydrogen.
- This is a first in Australia for a large steam-based food manufacturing site.
After a multi-year collaboration with us, Mars has announced a renewable energy milestone. Mars Petcare facility at Wodonga (Mars Wodonga) in Victoria will become the country’s first large-scale steam-based manufacturing site to operate entirely on renewable energy by 2026.
Dominic Zaal is our Team Leader in this project. He said the groundbreaking initiative showcases what can be achieved between us and industry as Australia works toward its net zero emission targets.
"Since we first spoke with Mars in 2019 about their ambitions to decarbonise their process heat operations, we’ve been on a journey of discovery together," Dominic said.
"We’ve been their renewable heat technology partner from day one. So, it’s very exciting to now see them deliver a completely renewable solution for their operation by 2026.
"It’s another great example of a company taking a leadership role in the industrial decarbonisation space."
Our solar technology research
To underpin Australia’s energy transition, we undertake a wide range of research on a wide range of solutions. These include concentrated solar thermal (CST) and associated thermal energy storage (TES) technologies.
Through our management of the Australian Solar Thermal Research Institute (ASTRI), which Dominic leads, we are working to make thermal technologies more efficient and competitive.
Dr Dietmar Tourbier is our Director of Energy.
"Thermal energy storage is a key component of the work program at ASTRI, which has been funded by the Australian Renewable Energy Agency (ARENA) since 2012," Dietmar said.
"One of CST’s major benefits is its ability to store large amounts of thermal energy cost effectively, sufficient to generate over 15 hours of continuous renewable energy. This heat can be used for overnight steam production or electricity generation.
"We have also been collaborating with industry on electrical thermal energy storage (eTES) systems to displace gas for steam-based manufacturing processes."
This work led to the installation, in mid-2023, of an eTES demonstration system by Graphite Energy at Mars Wodonga that delivered significant savings.
Identifying pathways to decarbonisation
In Australia, industry accounts for 57 per cent of our total annual energy use, with process heat accounting for more than 50 per cent of this energy. At the Mars Wodonga facility, 25 per cent of the site’s energy usage is electricity and 75 per cent is from gas burnt to make process heat.
While all of Mars’ electricity emissions are displaced through grid-connected renewable energy purchases, displacement of the 75 per cent of process heat emissions has been more challenging.
This is where we stepped in. Our breadth and depth of expertise in solar research enabled Dominic and his team to provide technical advice and support to Mars on cost, risk and integration on a range of renewable heat technologies.
Concentrated solar thermal component
The cornerstone of Mars Wodonga’s thermal emission displacement efforts is a $39 million CST project.
With CST, mirrors concentrate sunlight onto a targeted location at high temperatures. The heat is captured, stored and dispatched on demand. This can be in the form of steam to generate electricity via a turbine or used directly for a wide range of industrial process heat applications.
At Mars Wodonga, this involves the installation of an 18-megawatt Parabolic Trough CST plant providing between four and 10 hours of thermal energy storage. The project is jointly funded by Mars and ARENA.
"From the beginning of our discussions, CST was identified as the option that would deliver the highest abatement for Mars Wodonga’s available onsite land," Dominic said.
"Although the upfront costs were high, CST was able to generate more renewable energy per square metre than any other technology."
Electrical thermal energy system component
The project also builds on Mars’ implementation of eTES technology. This allows the facility to utilise 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, which we supported, provides a cost-effective, renewable alternative to gas.
In addition, Mars recently announced another joint initiative whereby the company is working together with Australian Gas Infrastructure Group (AGIG) to purchase Renewable Gas Guarantee of Origin certificates at Hydrogen Park Murray Valley.
This arrangement will displace over 10 per cent of Mars Australia’s total gas consumption, which includes Mars Wodonga.
“For Mars, the CST and eTES systems are complementary renewable heat technologies,” said Craig Sargeant, General Manager, Mars Petcare Australia and New Zealand.
“With the addition of the AGIG hydrogen purchase, and Mars Australia’s existing 100 per cent renewable electricity agreement, the Wodonga facility will deploy a 100 per cent renewable energy solution within two years.”
This is a first in Australia for a large steam-based food manufacturing site.
“Based on this, CSIRO has been able to assist other Mars sites, both domestically and globally, to assess eTES system benefits,” said Craig.
Paving the way for industry transformation
Our long-term collaboration with Mars could catalyse further action on sustainability. Both in Australia’s manufacturing sector, and in north-east Victoria, there are ambitions for a renewable energy hub.
"Mars Wodonga has been open in sharing their experiences with other Australian manufacturers as well," Dominic said.
"That same open-door approach at CSIRO is seeing us actively support other companies take advantage of renewable heat technologies and associated savings demonstrated at Mars Wodonga.
"Our work has been about providing trusted advice and guidance on existing innovative pathways in a technology and supplier agnostic manager. In essence, we are providing assessment and consideration to facilitate improved decision making by companies on their carbon management.
"My team loves doing this work because they know that they’re making a tangible difference for Australian industry and our net zero goals," he said.