PepsiCo aimed to reduce emissions below regulatory limits by replacing its 25 MW gas-fired boiler with a sustainable thermal energy storage system. 

The project had some challenges: managing costs, navigating a complex permitting process, and pioneering the integration of thermal storage into the plant. Defining the scope strategically and ensuring financial feasibility were key to its success. 

We provided full engineering, design, and permitting services for the transition to a green thermal energy system, including new power infrastructure, process integration, and construction support. 

The Volt Project is the first of its kind in the Netherlands—a pioneering pilot for PepsiCo, Eneco, and Kraftblock in using green thermal energy at an industrial scale.  

By repurposing waste heat, the system will power production with renewable energy, cutting 98% of CO₂ emissions and saving thousands of tons annually. Despite financial and regulatory challenges, Arup’s expertise in industrial decarbonisation ensured that the project remained viable.  

With the project delivered, this innovative approach has set a new standard for sustainable manufacturing, demonstrating how food production can transition to net zero while maintaining operations.

Engineering and design services 

Arup provided engineering and design services to support PepsiCo’s transition to a green thermal energy system. We designed the new potato intake building and starch collection canopy, ensuring permitting compliance. Our civil engineers developed cable routing for the new power infrastructure and coordinated with PepsiCo’s process consultant.

Structural design covered foundations, superstructures, and a pipe bridge for thermal oil transport. Our engineers integrated Kraftblock’s thermal storage system, while HVAC and ventilation solutions improved plant efficiency. Electrical engineers designed lighting, fire safety, and power infrastructure.

We also managed permitting, procurement, and contractor selection. Our team assessed demolition impacts and supervised construction to integrate new infrastructure with plant operations, reducing the project timeline from 70 to 28 weeks.