Contents

UK Beet Sugar Industry Sustainability Report 2011 1

The cover photograph ContentsIntroduction was taken at Sir Richard Sutton’s Settled Estates in Lincolnshire during 2010. It features a field margin beside , which has been planted to encourage wildlife (see page 18).

Section Foreword 1. Executive summary 2. Industry developments 3. Innovation and research 4. Agricultural efficiency 5. Reducing inputs 6. Process optimisation 7. Environmental management 8. Biodiversity 9. Climate change 10. Supporting the rural economy

2 UK Beet Sugar Industry Sustainability Report 2011 Foreword 1 Executive 2 Industry 3 Innovation 4 Agricultural 5 Reducing 6 Process 7 Environmental 8 Biodiversity 9 Climate 10 Supporting the summary developments and research efficiency inputs optimisation management change rural economy Foreword

William Martin Gino De Jaegher

The challenges of combating global Increasingly, there is an industry focus upon sharing climate change, reducing environmental best practice, developing new supply chain solutions, embracing a ‘no-waste’ culture and diversification into impacts and increasing the efficiency of new derivative co-products, like bioethanol. food production for a growing population are very real for the British beet sugar Our combined efforts and investment have achieved significant results; crop yields have increased industry. Across Europe, the past five substantially, whilst application rates for fertilisers and years have seen radical reforms, resulting plant protection products have reduced. This increased in the removal of almost 6 million tonnes efficiency has enabled farmers to reduce land use for of sugar production, with the closure sugar beet by some 90,000 hectares. of 60% of the EU’s sugar factories and In our factories we are also making more from less. significant price reduction. Energy consumption per tonne of product has fallen by 25% since 1990 and a diverse range of co-products Against this backdrop, the British beet sugar industry are generated to maximise efficiency; from tomatoes to has invested many millions of pounds into research, animal feed and topsoil to electricity. All these activities development and process efficiency. And it’s heartening to make a positive contribution to the Government’s see that our investment is enabling real progress toward drive for sustainable agriculture and environmental our objectives of protecting the natural environment, protection. reducing greenhouse gas emissions, cutting waste and The UK beet sugar industry is proud of the progress much more, whilst increasing productivity and creating reported in this document. However, we recognise value across the industry. there is much more to do. World population is forecast In the UK, the rate of progress is helped by the close to grow by 2-3 billion in the next 40 years and the level partnership that has developed between beet growers and of knowledge around climate change impacts continues the processor, British Sugar. Together, we are committed to increase. We believe, that as an industry working in to developing our industry sustainably to achieve close partnership, we can look forward to a future of economic, social and environmental improvement. continued innovation and sustainable progress.

William Martin Gino De Jaegher Chairman Managing Director NFU Sugar British Sugar UK

UK Beet Sugar Industry Sustainability Report 2011 3 1 Contents Executive summary

In 2012 the industry will celebrate 100 100 years of UK YEARS production.

As the level of public interest grows Priority areas for the UK beet sugar industry concerning sustainable agriculture, Defra’s 1. Reduce inputs structural reform priorities provide areas of focus for the supply chain: support and The industry monitors and optimises the levels of pesticides and fertiliser applied to the crop. Since 1982: develop British farming; sustainable food production; enhance the environment ■ pesticides application has reduced by 60% and biodiversity to improve quality of life; ■ nitrogen application has reduced by 40% strong and sustainable green economy, ■ phosphate application has reduced by 70% resilient to climate change; enhance rural 2. Protect soil and water resources 1 communities. Sugar beet is grown under the Assured Food Standards protocol In 2010, the NFU combined forces with British Sugar (the which requires adherence to Defra’s ‘Code of Good Agricultural 2 sole UK beet sugar processor) to pioneer a landmark four- Practice’ – designed to protect water, soil and air. year framework agreement which governs contractual ■ Over 95% of the crop is rain-fed: use of irrigation is minimal. arrangements for growing sugar beet in the UK. Working ■ Soil removed during beet harvest has fallen to 6%. together, the industry has introduced a new independently- ■ Less than 0.3% of the crop is re-sown due to wind erosion. generated pricing mechanism and efficiency initiatives designed to respond to the Government’s priorities, whilst 3. Improve agricultural efficiency remaining highly competitive in the international marketplace. UK crop yields are consistently ranked in the EU top quartile. The industry is seeking continuous performance improvement in a number of key areas and provides investment funding ■ UK beet yields have risen to an average of 11 tonnes of sugar totalling £1.8 million each year to investigate solutions per hectare (an increase of 60% in the past 30 years). which raise efficiency and productivity, whilst reducing ■ Net land use for sugar beet has reduced by 90,000 hectares impacts to the environment. Learnings are shared through a since 1981 (48%). comprehensive grower support programme. ■ UK sugar beet travels only 28 miles on average from field In 2012, the UK beet sugar industry will celebrate 100 years to factory. of UK production and this report offers an insight into the partnership activities which contribute to the industry’s resilience and success. Looking to the future, with the four-year framework in place and an effective long-running research and development programme providing valuable intelligence, the industry is well placed to build on commercial success, whilst reaching and exceeding its sustainability 48% targets. reduction in land usage

1 Business Plan 2011-2015, Department for Environment, Food and Rural Affairs, November 2010 2 ‘Protecting our Water Soil and Air– A Code of Good Agricultural Practice for farmers, growers and land managers’, Department for Environment, Food and Rural Affairs

4 UK Beet Sugar Industry Sustainability Report 2011 Foreword 1 Executive 2 Industry 3 Innovation 4 Agricultural 5 Reducing 6 Process 7 Environmental 8 Biodiversity 9 Climate 10 Supporting the summary developments and research efficiency inputs optimisation management change rural economy

100% Only 5% of UK sugar beet 80% the sugar beet travels only 28 60% crop receives miles from field irrigation. to factory. 5% 40% 20%

4. Improve processing efficiency and asset utilisation Today four UK factories process around 7.5 million tonnes of beet annually and produce 2.3 million tonnes of products.

■ 25% reduction of energy used to make a tonne of sugar since 1990. ■ Innovative manufacturing processes generate co-products 60% including tomatoes, electricity, animal feed, bioethanol, increase in lime and topsoil. sugar beet yield continues overleaf >

UKUK BeetBeet SugarSugar IndustryIndustry SustainabilitySustainability Report 2011 5 1 Contents

Executive summary continued

Producing Waste to landfill over 50,000 from UK sugar tonnes of 50% beet factories renewable reduction reduced by 50%. fuel. LAND FILL

5. Protect and maintain biodiversity levels ■ Targeting a 10% reduction of all product carbon footprints by 2020. Sown in the spring, sugar beet provides food and shelter for birds and wildlife, and provides a valuable ‘break crop’ in the 7. Reuse or recycle waste arable rotation. The industry embraces a ‘no-waste’ culture, seeking to reduce ■ It supports internationally important populations of stone waste at source or reuse it. curlews and pink-footed geese. ■ Soil removed with the crop is recovered and used in ■ Since 2003 factories have reduced waste to landfill by 50%. productive applications. 8. Support the rural economy 6. Reduce greenhouse gas emissions The UK beet sugar industry remains one of the leading rural Manufacturing sites operate under the UK’s Climate Change employers in the . Agreement scheme and the EU Emissions Trading Scheme, ■ Over 3,000 beet growers based primarily in East Anglia and designed to reduce carbon emissions. the . ■ World’s first sugar industry to certify the carbon footprint of ■ Economic activity associated with the supply chain supports sugar using the new PAS 2050 standard, in partnership with up to 13,000 jobs. the Carbon Trust. ■ Total economic contribution of around £800 million each ■ Using a residual beet sugar syrup, the industry produces year. over 50,000 tonnes of bioethanol each year, with GHG savings of over 70%.

Spring-sown sugar beet supports a wide variety of birdlife.

6 UK Beet Sugar Industry Sustainability Report 2011 2 Industry developments

Supporting Up to the rural 13,000 economy. jobs

Sugar beet yields have been rising faster than those now take on more tonnage and the 2010 transfer scheme has of any other UK arable crop since 1980 and in 2010 successfully redistributed contract tonnage from low yielding the UK industry was ranked as the world’s most producers, contributing to increasing national productivity levels. competitive beet sugar industry by international International relationships sugar economists LMC.3 The industry also ranks alongside cane producers for competitiveness in the The UK beet sugar industry recognizes the importance of international marketplace.4 seeking and sharing best practice internationally. It participates in a number of industry forums, including Comité Européen This has been achieved through prudent investment and des Fabricants de Sucre (CEFS), The International Confederation industry restructuring initiatives to improve productivity and of European Beet Growers (CIBE), Institut International de finance diversification. Today, the UK beet sugar industry makes Recherches Betteravieres (IIRB) and the World Association of Beet a total economic contribution of around £800 million to the UK’s & Cane Growers (WABCG). GDP each year, whilst providing up to 13,000 jobs throughout In 2010, the NFU hosted the 10th WABCG conference in the supply chain. Cambridge, which included a tour of the UK industry’s factory Over 3,000 growers situated in the East of England produce site at and field demonstrations. WABCG is 7,500,000 tonnes of sugar beet each year. On average, the financed and led by farmers, with members from 31 countries, sugar beet travels 28 miles from supplying farms to reach one of representing 5 million cane growers and 650,000 beet growers the UK’s four processing factories at Bury St Edmunds, Cantley, from five continents. Newark and Wissington. The international conference brought farmers, growers, In 2010, a progressive Inter-Professional Agreement, industry leaders and experts together to discuss the issues and developed by the NFU and British Sugar, was introduced to challenges faced by sugar beet and cane growers worldwide. govern contractual arrangements for growing UK sugar beet. The agreement contains a pricing Newark mechanism which covers competing Wissington Cantley commodity margins; Cambridge crop input costs; Bury St Edmunds On average, improvements to the sugar beet travels 28 miles the beet contracting from supplying process; sampling farms to reach one of the UK’s London procedures and a four processing transfer scheme for factories. contract tonnage. 28 miles Historically, contract tonnage could only be transferred when a grower sold land, UK Secretary of State for Defra, Caroline Spelman but since 2001, the system has been significantly reformed addressing the 2010 WABCG conference. to increase industry efficiency. Committed beet growers can

3 LMC International sugar production costs, global benchmarking 2009/2010 report 4 Brazilian Ministry of Agriculture, Livestock and Supply, 2006. USDA Economic Research Service, 2005. European Commission EU sugar production balance sheets 2001/02-2009/10

UK Beet Sugar Industry Sustainability Report 2011 7 3 Contents Innovation and research Over £1.8 million £1.8million is invested each year in research, development and industry education.

The UK beet sugar industry invests over £1.8 million Some of the BBRO’s significant achievements to date each year in research, development and industry include: education. This joint strategy aims to promote Innovation streams Positive outcomes sustainable and environmentally responsible New methods to improve Consistent increase in crop yield practices throughout the supply chain, while helping productivity growers to increase competitiveness and profitability. Crop nutrition Reduced and optimised fertiliser inputs In addition, the industry supports the UK Sugar Disease epidemiology Targeted and efficient use of Bureau which monitors international developments insecticides and fungicides in nutritional science. Crop modelling Improved yield prediction

The British Beet Research Organisation Climate change Reduction in greenhouse gas emissions The industry’s research and development programme is operated by the British Beet Research Organisation (BBRO) In 2011, the BBRO will investigate the effects of climate change and co-funded by both UK beet growers and British Sugar. It on UK sugar beet and seek solutions for a range of issues exists to develop innovative supply chain solutions based upon including: yield improvement; drought resistance and tolerance; independent scientific research. This enables the industry to plant virus mutation; disease prediction and prevention; in-field respond efficiently to market and regulatory changes. Priorities defoliation; and improvements in storage techniques. for the programme are to increase productivity, reduce inputs Research partners for the BBRO include: Broom’s Barn Applied and to maximise the environmental benefits obtained by Crop Sciences, Rothamsted Research, NIAB-TAG, Food and including sugar beet in the arable crop rotation. Objectives Environment Research Agency and ADAS. and targets are revised annually by the BBRO Board, following consultation with its Scientific Advisory Committee. Figure 1: BBRO 5-year research spend by topic area (2010/15)5 Since 2006, the BBRO has allocated over £9.1 million to priority projects. BBRO priorities for the next 5 years are summarised in Figure 1. £1.3m £1.4m Genetic Seed technologies £0.5m Scientists at Broom’s Barn varieties Crop agronomy are dedicated to applied research that has a focus on delivering change in production systems. Investment in research and development by the UK beet sugar industry is a great example of science delivering improvements in agricultural production. Sugar beet yields are increasing at a faster rate than those of other arable crops in the UK – evidence that research £2.6m £2.7m is delivering real solutions to the Grower support Pest / Disease / challenges of increasing yields, Weeds management while protecting the environment. Bill Clark As I see it...1 Director, Broom’s Barn 5 Source: BBRO

8 UK Beet Sugar Industry Sustainability Report 2011 Foreword 1 Executive 2 Industry 3 Innovation 4 Agricultural 5 Reducing 6 Process 7 Environmental 8 Biodiversity 9 Climate 10 Supporting the summary developments and research efficiency inputs optimisation management change rural economy

The industry aims to promote sustainable and environmentally responsible practices throughout the SUPPLY C H A I N supply chain.

Broom’s Barn Research Centre Sharing knowledge The BBRO uses the services of Broom’s After research findings have been Barn Research Centre for a large assessed by the BBRO, they are proportion of its research activity. The translated into shared industry centre was established in 1962, by the improvement targets and communicated British sugar beet industry, to conduct UK to growers via the BBRO Grower Support crop research. Today it forms part of Rothamsted Research, Programme. an internationally recognised centre of excellence for strategic and applied crop research. Broom’s Barn’s facilities include: On-going advisory support, practical plant clinics, laboratories for molecular biology, microbiology and plant training events, publications, SMS texting and on-line services physiology; glasshouses and controlled-environment all ensure that growers and advisers have the latest technical rooms; a 120 hectare experimental farm and specialist information and advice to hand at all times. The industry’s own facilities for field studies. quarterly trade journal, Beet Review, communicates research results and technical innovations to growers and industry stakeholders. It is a popular journal, which is published online and circulated in printed form to a further 6,600 subscribers. In recent years, UK beet growers, hauliers and advisers have turned to the internet for information. The industry has responded by developing web portals which provide 24-hour access to the latest technical crop data and support tools. Some 85% of growers now have internet access in rural areas – this initiative has reduced their paper trail and increased the speed of data Figure 2: BBRO Grower Support Programme transfer throughout the supply chain. A communications team monitors the On-line grower’s guide and advisory tools effectiveness of the Grower Support BBRO Operator training courses Programme. This includes quantitative Programme of and qualitative measures such as research projects, Industry winter meetings on-farm surveys, meeting attendance, knowledge transfer Telephone helpline volume of website downloads and education and stakeholder feedback. This

objectives PROGRAMME Weekly and quarterly bulletins programme is critical to achieving the SMS texts industry’s technical and environmental goals, and helps increase international Regional open days competitiveness. SUPPORT

UK British Area Managers beet Sugar growers Beet Review magazine Decision-maker training days GROWER 50% 50% Plant clinic

UK Beet Sugar Industry Sustainability Report 2011 9 4 Contents Agricultural efficiency Efficiency gains 90,000 have meant hectares 90,000 hectares have been released for alternative uses.

Achieving agricultural efficiency requires an Advanced seed technology integrated approach: monitoring complex Advanced seed priming and coating technology can help interactions between seed, soil, machinery and improve crop performance. labour, in conjunction with the variable influences Since 2007, the British Beet Research Organisation (BBRO) of climate, weather and temperature. The UK beet has worked in partnership with Germains Seed Technology to sugar industry continuously reviews these factors conduct UK field trials of new ‘advanced’ seed products, and to identify opportunities, and develops robust findings have been communicated through the BBRO Grower initiatives to improve performance. Support Programme (see page 9).

Specific efficiency projects have focused on ‘advanced’ seed This research concluded that the ‘advanced’ seed product XBEET technology, harvesting, seed drilling and integrated extension accelerated the rate of seed emergence by up to 7 days. Earlier services. This approach has enabled the UK beet sugar industry seedling establishment reduces the risk of damage to seeds by to accelerate productivity and increase yields faster than any poor weather and pests. The plants also emerge more uniformly, other UK arable crop. Over three decades, UK sugar beet yields providing further efficiencies for growers when applying plant have risen from 7 tonnes to over 11 tonnes of sugar per hectare protection products and during harvest. Trial results demonstrated – a 60% increase. plant population increases of up to 10% and yield increases of up to 7% from ’advanced’ seed, compared to untreated seed. These efficiency gains have meant that some 90,000 hectares have been released for alternative use, providing farmers with Through the BBRO Grower Support Programme, 95% of the UK further economic opportunities. It has reduced the amount of crop has adopted XBEET in just two years, and in 2011 the entire land required to grow the UK sugar beet crop by 48%. seed supply will be treated with the product.

Harvesting performance Figure 3: UK sugar beet crop productivity In only three years, field harvesting losses were halved and root damage significantly reduced, thanks to a programme of systematic 13 - - 190,000 field audits. The industry’s Quality Harvesting 12 - - 180,000 Yield Programme involved independent audit teams up - 170,000 11 - 60% - 160,000 assessing field losses and crop damage during 10 - - 150,000 harvest. The results were collated and shared 9 - - 140,000 confidentially with growers and contractors to Crop - 130,000 improve future performance. Headline results 8 - area down - 120,000 were also shared through industry journals, 7 - 48% - 110,000 including Beet Review.

sugar/ha) Sugar yield (tonnes 6 - - 100,000 (ha) crop Land use for ‘Beet the Best’ yield initiative 1981 1983 1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005 2007 2009 Sugar yield Land use for crop Using innovative methods to promote best practice helps to maintain levels of engagement throughout the supply chain, and 2010 saw the launch of the UK ‘Beet the Best’ yield initiative.

10 UK Beet Sugar Industry Sustainability Report 2011 Foreword 1 Executive 2 Industry 3 Innovation 4 Agricultural 5 Reducing 6 Process 7 Environmental 8 Biodiversity 9 Climate 10 Supporting the summary developments and research efficiency inputs optimisation management change rural economy

The ‘Beet the Best’ Over three yield initiative – an decades, UK sugar innovative method 60% beet yields have yield of promoting best increase risen from 7 tonnes practice. to over 11 tonnes of sugar per hectare. PER HECTARE

Designed as an online competition with its own microsite6, the campaign encourages entrants to produce a ’virtual’ sugar beet crop with maximum yield and profitability. Entry Using seeds categories include beet growers, university or college students, for delivering advanced agronomists and advisers. technologies to the field, we have been able to increase sugar beet Team performance is measured against different stages of crop yields dramatically. Through seed priming we are able to speed up management including preparation, crop protection, harvest and germination, improve uniformity delivery, whilst the site itself provides guidance on how to ‘play’. and enhance yield. Our on-going investment in R&D will ensure that Run in conjunction with the Farmers Weekly publication and seed treatment helps to sustain the Newcastle University, industry experts analyse the performance natural environment by reducing the amount of inputs; such as issues encountered by the entrants and offer up to date advice water, energy and crop protection within Farmers Weekly. Participation in the competition also products. provides Continuous Professional Development points for Paul Mullan relevant entrants upon completion of rounds. As I see it... Managing Director, 2 Germains Seed Technology In April 2011, the competition winners will be awarded a trip to Spain to learn about sugar beet production techniques in the Castilla y León region, whilst sharing their own experiences with local beet growers.

6 www.beetthebest.co.uk

XBEET accelerated the rate of seed emergence by up to 7 days.

UK Beet Sugar Industry Sustainability Report 2011 11 5 Contents Reducing inputs 40% reduction 40% in nitrogen reduction application.

NITROGEN

Plant protection products and fertilisers are used to Herbicides assist crops during the growth phase. They enable The British Beet Research Organisation (BBRO) promotes growers to achieve a higher yield, which in turn targeted herbicide application, without the need for 100% weed reduces the amount of land required to achieve removal. Weeds emerging more than eight weeks after the sugar contract tonnage. beet will not compete with the crop and their seeds survive to Any reduction in provide winter feed for farmland birds. treatment provides The industry has moved to a system of repeated low-dose immediate economic treatments, whilst adopting better product formulation and and environmental application technology. The past 30 years have seen a 50% benefits for growers reduction of active ingredients used on the UK sugar beet crop. and the industry is Recent challenges have included the weed Blackgrass, which continuously seeking has proved resistant to the ‘fop’ and ‘dim’ groups of herbicides. to optimise inputs It has presented a serious problem to UK agriculture, especially through trials, research and innovation. cereal producers. However, the BBRO research programme has identified that the weed can be controlled in sugar beet by Between 1982 and 2008, the UK beet sugar industry achieved herbicides with different modes of action, which in turn benefits a 60% reduction in the use of plant protection products, from the whole arable rotation. 10.4 kg/ha to 3.9 kg/ha. Over a similar period, crop yields have increased by 60%.

Figure 4: Plant protection product use on sugar beet over time7

13 - - 12

12 - Yield up - 10 11 - 60% Use of plant 10 - protection - 8 products down 9 - 60% - 4 8 - - 2 7 - / ha substance active of Kg

sugar/ha) Sugar yield (tonnes 6 - - 0

1981 1983 1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005 2007 2009

Sugar yield Plant protection products Each season before drilling starts, soil samples are taken and analysed.

7 Defra Pesticide Usage Survey

12 UK Beet Sugar Industry Sustainability Report 2011 Foreword 1 Executive 2 Industry 3 Innovation 4 Agricultural 5 Reducing 6 Process 7 Environmental 8 Biodiversity 9 Climate 10 Supporting the summary developments and research efficiency inputs optimisation management change rural economy

50% reduction 90% reduction 50% of active 90% in sugar beet reduction ingredients reduction insecticide. used on ACTIVE INGREDIENTS UK beet. INSECTICIDES

Insecticides Figure 5: Nitrogen usage in sugar beet Advances in seed treatment technology have enabled the majority of insecticide to be applied in micro-doses to the actual sugar beet seed pellet. This treatment provides 170 - localised protection against seedling and foliar pests for up 160 - to 14 weeks. Today almost all UK sugar beet seed is pre- 150 - treated and does not require additional insecticide spray. 140 - This development has led to a 90% reduction in sugar beet 130 - insecticide application since 1990. In turn this has benefited 120 - Nitrogen application those insects which provide biological control of insect 110 - down pests. 100 - 40% 90 -

(kg/ha) application rates Nitrogen 80 - Fertilisers 1972 1976 1980 1984 1988 1992 1996 2000 2004 2008 The nutrient management of soil is a priority for all growers and nitrogen has historically been applied to soil to promote quality and yield. However, fertiliser products are costly and the optimisation of their use is critical to a grower’s productivity, whilst also benefiting the environment. Figure 6: Phosphate and postash usage in sugar beet Since 1980, using results from research and development, the UK beet sugar industry has reduced nitrogen application 180 - rates by 40% and now has the lowest nitrogen usage rate 160 - of any major arable crop in the UK.8 Nitrogen application 140 - rates for the UK’s sugar beet crop now stand at 120 - Use of 93kg N/ha and are optimised for the soil type mix in any potash down particular year. 100 - 54% 80 - Each season before drilling starts, soil samples are taken Use of 60 - phosphate and analysed against industry research data, to provide down each grower with information on soil condition and nutrient 40 - 73% status. Nitrogen requirements can be calculated accordingly 20 -

(kg/ha) application rates Overall 0 - and guidance is available through the BBRO Grower Support

Programme. 1983 1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005 2007 2009

After the harvest, sampling takes place again when beet Potash Phosphate deliveries arrive at the factory. Sample analysis is delivered to each grower, enabling them to adjust applications for the subsequent season. This approach has been used by the industry to promote best practice in crop nutrition and, using similar methods, applications of phosphate have been reduced by 73%, and potash by 54%, since 1983.

8 The British Survey of Fertiliser Practice: ’Fertiliser use on farm crops for the crop year 2007’

UK Beet Sugar Industry Sustainability Report 2011 13 6 Contents Process optimisation PRODUCT For every WASTE tonne of 2kg product, less than 2kg 1 of waste is tonne generated.

In 1980, the UK beet sugar industry manufactured and economic benefits. These can be seen in Figure 7, which one million tonnes of sugar at seventeen factories. outlines the manufacturing process at the industry’s Wissington Today, the processor British Sugar manufactures bio-refinery in Norfolk. more sugar (1.2 million tonnes) at only four factories, Asset utilisation demonstrating what can be achieved by reducing In the past two decades, British Sugar has invested around costs, upgrading workforce skills and increasing £1 billion to improve process efficiency at manufacturing sites, asset utilisation. The company has encouraged installing leading technology in energy efficiency and process creative thinking and innovation to develop a highly optimisation. The industry has also extended the UK processing integrated manufacturing process which maximises season to over 200 days each year, compared to an average 9 efficiency and minimises waste. of about 100 days across the rest of the EU. The factories manage a process of syrup storage in large air conditioned Whilst beet sugar production remains at the heart of factory tanks, converting only a proportion of the crop to crystal sugar operations, each production stage is optimised to capture immediately and storing the remainder as syrup for reprocessing remaining raw materials and convert them into valuable during the summer months. This programme alone adds an co-products. The approach provides significant environmental extra 60 days to the average processing season.

Figure 7: Wissington factory, Norfolk

9 Comite European des Fabricants de Sucre (CEFS) annual sugar statistics, 2009.

14 UK Beet Sugar Industry Sustainability Report 2011 Foreword 1 Executive 2 Industry 3 Innovation 4 Agricultural 5 Reducing 6 Process 7 Environmental 8 Biodiversity 9 Climate 10 Supporting the summary developments and research efficiency inputs optimisation management change rural economy

£1 British Sugar The industry CHP billion has invested plants generate around over 95% of their £1 billion process electricity PROCESS to improve 95% 220,000 and export enough process PROCESS electricity to power EFFICIENCY ELECTRICITY HOMES efficiency. 220,000 homes.

The processor operates robust management systems for business and environment, which revolve around the principle of continuous monitoring, review and improvement. All Cornerways Nursery factories have adopted the following industry-leading standards: benefits from its proximity BRC, ISO 9001, ISO 14001 and OHSAS 18001. to the industry’s Wissington factory, as it’s heated with hot water from the sugar Energy efficiency manufacturing process. We’ve just expanded the size of our The UK beet sugar industry is committed to achieving a 30% glasshouse to 18 hectares, reduction in the amount of energy used to manufacture each due to demand, which means tonne of granulated sugar by 2020 (as measured against a 1990 we’ll be producing 140 million tomatoes this year. baseline). Nigel Bartle Combined Heat and Power (CHP) plants have been installed in Manager of Cornerways Nursery and Chairman of the British all the industry’s manufacturing sites. They are highly efficient, As I see it... Tomato Growers Association extracting up to 80% of the energy contained within fossil 3 fuel – double the amount extracted by a conventional power station. The plants produce high pressure steam, which drives Waste reduction a turbine to generate over 95% of the processor’s electricity Since 2003, the amount of waste sent to landfill from the UK requirements. In addition, the industry exports a further beet sugar industry’s factory sites has been halved. Waste levels 700,000 mega-watt hours of electricity for use in the local are monitored at all processing facilities and annual reporting electricity network – enough to power a town of 220,000 takes place in accordance with good practice and Environment homes. Agency regulations. Waste streams are segregated and recycled wherever possible and in 2009, a total of 2,200 tonnes of Figure 8: Product streams waste were recycled. Currently, for every tonne of product the factories produce, less than 2kg of waste is generated and the Product Distributor / Tonnes per Customer sector processor remains committed to reducing this still further. brand annum (average) Sugar British Sugar 1,200,000 Food, drink and pharmaceutical Water efficiency Silver Spoon manufacturers Retailers and supermarkets Water is used throughout the UK industry’s manufacturing Animal feed Trident 500,000 UK livestock farmers process for cleaning, heat transfer, cooling and crop Topsoil TOPSOIL 170,000 UK landscape and amenity sectors transportation. Over 60% of the water used during processing Soil LimeX 300,000 UK agriculture, civil engineering comes from the sugar beet itself, with the remaining sources conditioner being rivers, boreholes and town mains. Independent water Stones British Sugar 6,000 Civil engineering audits are regularly carried out to review consumption against Tomatoes Cornerways 6,000 Retailers Nursery agreed improvement targets, whilst seeking opportunities for recycling. Water is treated onsite before discharge and quality Betaine British Sugar 11,000 Healthcare and animal feed manufacturers levels are strictly controlled by the Environment Agency. With Raffinate / British Sugar 80,000 Animal feed manufacturers efficient water management processes in place, factories have Vinasse become net exporters of clean recycled water to local water Bioethanol British Sugar 55,000 Fuel suppliers courses. Electricity British Sugar 700,000 MWh Energy suppliers

UK Beet Sugar Industry Sustainability Report 2011 15 7 Contents Environmental management 95% of the crop is rain-fed.

In 2003, the UK beet sugar industry, in partnership with Assured Food Standards, introduced a quality standard for UK sugar beet. The standard offers consumers ‘plough to plate’ quality assurance and is promoted using the Red Tractor mark.

The standard provides a clear statement of the industry’s environmental, safety and production standards. It requires adherence to Defra’s ‘Code of Good Agricultural Practice’10 – designed to protect water, soil and air and has become part of the industry’s contract terms. Key environmental parameters are audited independently such as soil management, crop protection strategy and biodiversity. The standard is reviewed annually by a Technical Advisory Committee which seeks continuous improvement.

Soil conservation Soil can be lost or damaged through erosion, compaction or loss of organic matter, all of which reduce agricultural productivity. To protect soil quality, all UK growers maintain a soil management strategy, which is farm specific. Sugar beet is mainly grown in the East of England where research has shown that wind erosion is negligible.11 Since 1990, only 0.3% of the crop has been re-sown due to wind erosion in any year.12 Water erosion is also uncommon as sugar beet is usually grown on flat land, mitigating risk. On average, only During the beet harvest, some soil adheres to the roots and is around 5% of the beet crop is irrigated during the late summer also delivered to the factory – this is known as ‘soil tare’. when there is a full canopy of foliage. This protects the soil’s The British Beet Research Organisation communicates best surface from the impact of large drops of water. practice on modern harvesting techniques which reduce soil The root structure of sugar beet reaches 1.5 to 2 metres deep, tare, whilst sugar beet is cleaned by growers prior to delivery. making it an efficient scavenger for soil nutrients. As a result, on In addition, the UK industry’s beet contract contains a direct average, less than 30kg/ha of soluble nitrogen is left in the soil commercial incentive for growers to minimise soil tare, with crop at the end of the growing season. Fertiliser application timing payments reduced proportionate to the weight of soil delivered. and rates are carefully controlled and monitored (see page 13). To minimise leaching of more mobile nutrients, like nitrogen, which are poorly retained by the soil, applications are timed to match crop uptake in spring.

10 ‘Protecting our Water Soil and Air – A Code of Good Agricultural Practice for farmers, growers and land managers’, Defra Safeguarding our Soils - A Strategy for England, Defra Soil Protection Review (SPR) 11  Wind Erosion on European Light Soils, http://www2.geog.ucl.ac.uk/weels/ 12 British Sugar agricultural database 13 British Sugar agricultural database 1980-2009 14 Comite European des Fabricants de Sucre survey on beet reception, 2008/09

16 UK Beet Sugar Industry Sustainability Report 2011 Foreword 1 Executive 2 Industry 3 Innovation 4 Agricultural 5 Reducing 6 Process 7 Environmental 8 Biodiversity 9 Climate 10 Supporting the summary developments and research efficiency inputs optimisation management change rural economy

Since 1990, only Soil is recovered 0.3% of the and used in crop has been productive re-sown due to applications. wind erosion in any year. Only 0.3% of crop resown Soil recovery and use

By using these methods, the UK sugar beet soil tare has been Water conservation reduced from 15% to around 6% in the past 25 years13 – one The management and conservation of water resources is of the lowest levels in the EU14. Based on the average UK soil controlled by European legislation including The Groundwater tare, the amount of soil removed from each field is equivalent to Directive, Nitrates Directive and The Water Framework Directive. 0.02% of the available soil in the annual plough layer. This loss Sugar beet can withstand much drier conditions than most other is less than the rate at which topsoil is naturally created, thereby crops without affecting quality or yield significantly. Over 95% ensuring it does not represent a net reduction in soil stocks. of the sugar beet crop is rain-fed and does not require additional Having minimised the soil delivered to processing sites, the irrigation. All farm abstraction licences are controlled by the industry also recovers the incoming soil and conditions over Environment Agency. half of it for resale to the landscape and amenity markets. The remainder is recovered and either returned to agricultural land under the supervision of the Environment Agency, or used for reclamation projects.

Field margins widen the unsprayed boundaries between fields which harbour wildlife. They may be planted with a wild flower mix (pictured), weeds or left empty to support different species of insects, which in turn provides food for nesting birds.

UK Beet Sugar Industry Sustainability Report 2011 17 8 Contents Biodiversity Stone curlews nest between rows of sugar beet.

The UK sugar beet crop supports a wide variety of Rotational benefits birdlife, which is drawn to the spring-sown crop for During a typical arable rotation, sugar beet is grown one year food, shelter and nesting sites. The crop retains an in every four. It acts as a ‘break crop’, which helps to break the open vegetative structure, with areas of bare soil cycle of disease, reducing crop protection inputs and assisting until early summer. It attracts nesting birds like the biodiversity levels. skylark, lapwing and one of Britain’s rarest birds, Over 90% of the UK beet crop is preceded by a winter cereal17, the stone curlew, which is highlighted as a priority which means the land remains undisturbed between the species in the UK Biodiversity Action Plan. cereal harvest in August and March/April when sugar beet is sown. The cereal stubble also provides feeding and foraging The RSPB confirms that UK sugar beet production supports opportunities for farmland birds and mammals. “internationally important populations of pink-footed geese and nationally important populations of stone curlews”, and is “associated with a uniquely high wildlife conservation benefit.”15 Communicating research findings After the sugar beet harvest from September to February, birds The UK beet sugar industry promotes targeted herbicide are attracted to remaining beet tops for food. Species include application, as many weeds do not compete with the crop and the pink-footed goose, skylark, golden plover, lapwing, pied instead improve biodiversity levels by attracting insects, birdlife wagtail, meadow pipit and various breeds of swan. In fact, and mammals. Most recently, the industry commissioned during autumn and winter, more than a quarter of the world’s research from the British Trust for Ornithology and Broom’s population of pink-footed geese feed and forage on sugar beet Barn Research Centre to investigate the potential for beet, cereal tops and stubble in eastern England.16 stubbles and cultivated and uncultivated cereals to provide food for birds. Assessments included weed biomass, weed seeds and invertebrates. In one season, weeds and invertebrates were also monitored in sugar beet at four sites. The survey data has been shared with growers in the industry’s Beet Review publication.

It’s all about the insects really, if your planting provides them with food and habitat, then birds and wildlife will follow. At Sutton Estates, we sow field margins around our crops, which include sugar beet. They feature wild flower mixes, nectar pollen mixes A handful of Knapweed seed heads and we provide wild bird cover in from a field margin, where they field corners, all of which plays a part in increasing wildlife such as have been planted to provide nectar barn owls and grey partridges. and pollen for bumble bees and Chris Dowse butterflies. Estate Manager, Sir Richard As I see it... Sutton’s Settled Estates

15 4 RSPB evidence submitted to the DEFRA select committee, March 2004 16 Gill, J.A.; Watkinson, R.A. & Sutherland, W.J. (1996) The impact of sugar beet farming practice on wintering In 2010, Chris Dowse was named one of the RSPB’s Agri-Environment pink-footed geese (Anser brachyrhynchus) populations. Biological Conservation 16, 95-100 17 British Sugar Annual Crop Survey Heroes of the year.

18 UK Beet Sugar Industry Sustainability Report 2011 Foreword 1 Executive 2 Industry 3 Innovation 4 Agricultural 5 Reducing 6 Process 7 Environmental 8 Biodiversity 9 Climate 10 Supporting the summary developments and research efficiency inputs optimisation management change rural economy

Sugar beet More than 1/4 of the provides an ideal world’s pink-footed breeding ground geese feed and for grey forage on sugar beet partridges. in eastern England.

“Healthy bird As a spring sown crop the open canopy provides populations signify precious habitat for ground- nesting species of high conservation concern, such as a healthy state lapwing, skylark and yellow wagtail. After harvest, the crop aftermath is a valuable source of the plants and of winter food for migrant birds, such as pink-footed invertebrates on goose, redwing and fieldfare. Dr Ian Henderson Senior Research Ecologist As I see it... British Trust for Ornithology which they feed.” 5

Defra 2010, Wild Bird Indicators for the English Regions

UK Beet Sugar Industry Sustainability Report 2011 19 9 Contents Climate change Sugar beet is an efficient converter of CO2.

To understand the risks associated with climate change, the UK beet sugar industry has commissioned research through the British Beet If we are to meet an 80% reduction in emissions Research Organisation (BBRO) to inform mitigation by 2050 innovative businesses have a key role to play. The work and adaptation strategies. that British Sugar has done to pilot the PAS 2050 standard has been Sugar beet is an efficient converter of CO2, removing up to 35 invaluable in helping to deliver a UK 18 standard for the measurement of tonnes of CO2 from the atmosphere per hectare each year. the greenhouse gas emissions from With average temperatures set to increase by 1.8% by 2050, goods and services. We hope this beet yields in England are predicted to rise by 34% due to work will enable businesses around warmer springs, and by a further 8% as a result of increased the world to look beyond their direct operational emissions and make 19 CO2 concentrations in the atmosphere. their supply chains more carbon and cost efficient. Looking to the future, insufficient moisture during the summer Tom Delay As I see it... Chief Executive, Carbon Trust months would limit the beet crop, and the BBRO is therefore 6 sponsoring research to improve drought tolerance in sugar beet. The industry will continue to monitor scientific developments in The PAS 2050 was developed by BSI British Standards and is sponsored climate change so that it can effectively plan for the future. by the Carbon Trust and Defra.

Measuring our carbon footprint In 2008, the UK beet sugar industry worked in partnership with the Carbon Trust and the British Standards Institute, to assist the development of a new UK standard for measuring carbon footprint. It is called ‘PAS 2050’ and measures the full life cycle of a product from plough to plate. The process took six months to complete for all British Sugar’s products and the UK beet sugar industry became the first in the world to certify the carbon footprint of granulated sugar using the new standard. Findings from the carbon footprint project demonstrated that 38% of the overall emissions associated with sugar beet occur at the farming stage through fuel, fertilisers and soil emissions, which has underlined the importance of the industry’s research and development programme. The carbon footprint of granulated sugar currently stands at 0.6g CO2 per gram of product and the industry has targeted a 10% reduction by 2020.

18 Goudriaan, J. & van Laar, H.H. (1994) Modelling potential crop growth processes. Kluwer Academic Publishers, Dordrecht, Netherlands www.ipcc.ch/pdf/assessment-report 19 Vulnerability of UK Agriculture to Extreme Events: 2008. http://randd.defra.gov.uk/Document.aspx

20 UK Beet Sugar Industry Sustainability Report 2011 Foreword 1 Executive 2 Industry 3 Innovation 4 Agricultural 5 Reducing 6 Process 7 Environmental 8 Biodiversity 9 Climate 10 Supporting the summary developments and research efficiency inputs optimisation management change rural economy

Carbon GREENHOUSE Over a full ...the industry’s 10% footprint life-cycle fuel qualifies reduction 10% bioethanol gave for the highest reduction a greenhouse score for any UK by 2020. gas gas saving of biofuels reported 70% Carbon 70% relative to to the RFA. footprint petrol...

Responding to climate change Supplying renewable energy Four percent of the industry’s carbon footprint is attributed The UK beet sugar industry is committed to supporting the to sugar beet transportation. The industry is minimising food Renewable Energy Directive, which requires 15% of UK energy miles by incentivising efficient growers that are local to factories to be supplied from renewable sources by 2020. In response to increase their contract tonnage. As a result, despite the to this challenge, British Sugar opened the UK’s first bioethanol UK industry’s rationalisation (including factory closures), the plant in 2007 at its Wissington processing site. The plant average beet transport distance from farm to factory remains produces 55,000 tonnes each year of bioethanol from sugar only 28 miles. beet feedstock. The industry recently commissioned independent transport In line with current UK legislation, the plant’s performance is consultants, WSP Development & Transportation and Transport reported to the Renewable Fuels Agency (RFA). In 2008/09,

& Travel Research Ltd, to undertake a sugar beet transport the bioethanol resulted in a greenhouse gas saving (CO2 efficiency study, with funding from the East of England equivalent) of over 70% relative to petrol, measured on a full Development Agency and the East Midlands Development life-cycle basis. The industry’s fuel qualifies for the highest Agency. Following a trial, the industry is currently implementing score for any UK biofuels reported to the RFA. recommendations to improve efficiency levels. .

Wissington bioethanol plant produces 55,000 tonnes of bioethanol each year from sugar beet feedstock.

UK Beet Sugar Industry Sustainability Report 2011 21 10 Contents

Supporting the rural Each year the £800 UK beet sugar million industry makes economy a total economic contribution of £800 million. ECONOMY

Each year, the UK beet sugar industry makes a total economic contribution of around £800 million. The local economy benefits from a substantial Our college has worked in partnership with proportion of this financial output in the form of the industry’s Wissington site for crop payments, capital investment, maintenance over 10 years to train engineering apprentices. The four-year expenditure, raw material and energy payments, programme is full-time and it employment salaries and contractors’ fees. differs to many apprentice schemes because the first year is spent entirely at the college where students The economic activity associated with the supply chain supports will learn machining, welding and up to 13,000 jobs, making the industry one of the leading rural electrical skills. In fact, the industry’s employers in the East of England. These jobs are highly-skilled award-winning approach has set a precedent within the region and with earnings above national averages for the food sector. other businesses have followed suit, Each manufacturing site forecasts requirements for skills and providing important investment in the local economy and its young a thriving graduate, year-placement and apprentice scheme people. encourages the ongoing development of new talent. Shân Woodley Work-based Learning Training Advisor College of West Anglia, Engaging with younger growers As I see it...7 King’s Lynn In February 2011, the sector launched a new training and development initiative for younger farmers and industry members. The programme comes in response to public data highlighting a steady increase in the average age of UK farmers, ■ a comprehensive tour of British Sugar’s Wissington factory set against a reported lack of engagement in agriculture from and bio-refinery to see the processes first hand and the younger generation. Whilst this is not specific to the UK understand the company’s approach to processing efficiency beet sugar sector, it is an issue that the industry recognises and ■ meetings in Brussels with European industry bodies including the new Sugar Industry Programme (SIP) has been designed CIBE and CEFS, a visit to the European Parliament including to engage participants in the wider context of the industry – discussions with MEPs and a trip to seed manufacturers its policy framework, research priorities and manufacturing Complementing these visits, a range of skills training is also processes. offered, providing additional value to participants. This year, 15 younger growers and Area Managers are The programme concludes with a visit to NFU Headquarters in participating in a range of away-days, including: Warwickshire which will also serve as an opportunity to share ■ a visit to Westminster to meet with politicians, NFU policy reflections and views amongst the group. The industry’s Beet advisors and senior industry economists Review magazine and farming press will follow the initiative’s ■ a briefing session at Broom’s Barn with industry science progress, which provides another example of a co-ordinated experts industry, committed to a sustainable future.

22 UK Beet Sugar Industry Sustainability Report 2011 I was very proud of my achievement and “ Pictured are this helped push me on to do more and participants in the progress further in my second year, where industry’s engineering apprentice scheme, I achieved a double distinction in my Btec about to leave on an outward bound course National Certificate course and was awarded to develop teamwork skills and encourage a a distinction in every subject. passion to excel. ” Ed Haylock, Apprentice Engineer A winner of the College of West Anglia’s Engineering Apprentice of the Year

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UKUK BeetBeet SugarSugar IndustryIndustry SustainabilitySustainability Report 2011 23 Contents

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