Mars Petcare Australia steams ahead with new concentrated solar thermal plant

The facility will use a mix of solar and thermal energy technologies to manufacture pet food.

Mars Petcare Australia is set to be the first large-scale, steam-based manufacturing site in Australia to operate on a 100% renewable energy solution for electricity and process steam. 

Mars Petcare is installing a new Concentrated Solar Thermal (CST) plant at its Petfood Wodonga facility in regional Victoria to power its manufacturing operations. The company is also trialling Electric Thermal Energy Storage (eTES) technology to use renewable power during off-peak times to generate and store heat.

‘Mars Inc has an ambitious global target of 100% net zero carbon by 2050,’ says Caroline Aspiridis, Supply Director, Mars Petcare Australia and New Zealand. ‘We’re looking to be 100% renewable at our Wodonga site by 2026.’

Moving to net zero emissions

Mars Petcare Australia is a subsidiary of Mars Inc., a multinational food manufacturer. Mars Petcare Australia has been operating a manufacturing facility in Wodonga for 5 decades. It is the largest pet food manufacturer in Australia.

Mars Petcare currently uses natural gas to generate heat and produce steam. To meet its net zero goals, it wanted to displace as much natural gas as possible.

In 2019, Mars Petcare approached CSIRO, Australia’s national science agency, to help decarbonise its process heat operations. CSIRO provided technical advice and support to Mars Petcare on cost, risk and integration on a range of renewable heat technologies.

‘We’ve been [Mars’] renewable heat technology partner from day one,’ says Dominic Zaal, CSIRO’s Team Leader on the Mars project. ‘It’s a great example of a company taking a leadership role in the industrial decarbonisation space.’

New Solar Thermal Plant provides thermal energy storage

Central to the project is a A$39.3 million 18 MW Parabolic Trough Concentrated Solar Thermal (CST) plant. It will be the first commercial deployment of parabolic trough CST technology in Australia.

‘When the plant goes live in 2026, it will reduce our natural gas requirements by up to 50%,’ says Aspiridis.

‘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,’ says Craig Sargeant, General Manager of Mars Petcare Australia and New Zealand.

‘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 construction of the plant will create around 80 jobs in the regional community.

Caroline Aspiridis: Mars Inc. have a very ambitious target globally of 100% net zero carbon by 2050 and we're looking to be 100% renewable at our Wodonga site by the end of 2026.

Caroline Aspiridis: We're part of the broader Mars Inc. business which is headquartered in the US and we're responsible for making Australia's largest amount of pet food.

Dominic Zaal: Mars Wodonga site use natural gas to generate heat. They are primarily a steam manufacturer. So most of the heat they require is in the form of steam.

Dominic Zaal: They use around about 140,000 gigajoules of gas and they wanted to understand what they could do to displace as much of that over time.

Caroline Aspiridis: The Mars pet nutrition business within Australia has always seen itself as a pioneer.

Caroline Aspiridis: So in order to meet our 100% renewable targets, the Wodonga site's going to employ three different strategies.

Caroline Aspiridis: The first one is we're currently building a parabolic trough concentrated solar thermal or CST plant, which will be powered by renewable energy to create steam. When we do that it takes away the need for up to 50% of our natural gas requirements at Wodonga.

Caroline Aspiridis: One of them is use of an alternative hydrogen fuel instead of natural gas.

Caroline Aspiridis: And the third one is an ETES technology that takes up to 10 hours of solar thermal energy and it uses that to convert water into steam, which then means we can reduce our carbon footprint.

Dominic Zaal: Back in 2019 we're approached by Mars Wodonga. Mars said we want to do some fundamental change. So we want to break that nexus with gas. They selected the Wodonga site because it's in Australia and what Australia was able to bring to that site was lots of innovation, good companies with good technology, but also energy resources, particularly solar resources, which are the best anywhere in the world.

Dominic Zaal: With the solar thermal and the ETES, they're going to get to 90% gas displacement and associated emissions, which is an absolutely amazing achievement, one of the best in the world and certainly the first of its kind in Australia.

Caroline Aspiridis: Australia is an excellent innovation hub and by pioneering this innovation at Wodonga and with the support of the Australian Government we've been able therefore to test and learn on these innovative technologies and see where they can be applied elsewhere across the globe.

Caroline Aspiridis: We're becoming leaders for the Mars business globally and now Mars Inc. is looking at how they can install CST in other parts of the world where they also have great access to solar thermal and space.

Dominic Zaal: The relationship between the Australian government and industry is critical in this space, particularly as we try to decarbonise. Working with companies like Mars, but also working with the Australian Government and Austrade has been absolutely fundamental to changing this landscape.

Dominic Zaal: A multinational company with multiple sites all around the world use an Australian site to demonstrate Australian technology and to show how that technology can be utilised and broaden out to other countries and other locations, but more importantly for Mars deliver on their significant sustainability objectives and targets.

Dominic Zaal: We're showing what it's like to do business in Australia and attracting an investment locally, but at the same time showing how Australian tech can actually drive innovation globally as well.

Transitioning to green energy

In addition to CST, Mars is trialling the use of Electric Thermal Energy Storage (eTES) technology at the facility, hosting Australia’s first pilot of this system. The eTES system allows Mars to use low-cost, grid-connected renewable electricity during off-peak times to generate and store heat. The stored heat can then produce steam at any time, providing a renewable alternative to gas.

The CST plant and eTES technology is expected to displace Mars Petcare’s natural gas and associated emissions by up to 90%, according to Zaal.

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This is an absolutely amazing achievement – one of the best in the world and certainly the first of its kind in Australia. It shows how Australian tech can drive innovations globally.

Dominic Zaal, CSIRO’s Team Leader on the Mars project


‘Mars is incredibly proud of the fact we have been manufacturing in the Wodonga area for more than 50 years,’ says Sargeant. ‘[Our CST plant] is a major step forward in supporting both regional investment and Australia’s clean energy future.’

Mars is also investigating the use of green hydrogen as an alternative energy source. Mars Petcare Australia has been one of the first businesses to purchase Renewable Gas Guarantee of Origin certificates generated by the new Hydrogen Park Murray Valley facility, which is currently being built in Wodonga. The certificates will match the gas used at the pet food production facility with renewable hydrogen that is then added to the local gas network.

A model for Mars businesses globally

Mars Petcare’s pioneering work in Australia may soon be replicated by other Mars business.

‘We’re becoming leaders for the Mars business globally,’ says Aspiridis. ‘Mars globally is now looking at how they can install CST in other parts of the world where there is access to solar thermal and space.’

Mars received a A$17.2 million grant from the Australian Renewable Energy Agency (ARENA) for the CST project. ARENA has funding available for industrial energy projects through several programs, including the A$400 million Powering the Regions: Industrial Transformation Stream.

‘Australia is an excellent innovation hub,’ says Aspiridis. ‘With the support of the Australian Government, we’ve been able to test and learn on these innovative technologies, and see where they can be applied elsewhere across the globe.’


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