Embracing rail for sustainable logistics

By Niall McCarthy, Rail Development and Delivery Manager at Nestlé UK and Ireland

To achieve these goals, we have implemented various logistics plans, including route optimisation and transitioning to low-emission fuels. One key development in our sustainable logistics strategy is maximising the capacity of our vehicles by filling them more efficiently. This means fewer vehicles on the road, resulting in reduced traffic congestion, lower fuel consumption and, ultimately, lower carbon emissions.  

But we knew we could achieve more through exploring alternative transportation options, so we recognised the potential environmental benefits of rail transportation. According to the Rail Delivery Group, it has been highlighted that a single freight train has the capacity to replace up to 76 heavy goods vehicles on the road. Evidence suggests that transporting one tonne of products via rail results in 76% less emissions compared to a diesel road journey1.  

INVESTIGATING OPTIONS 

However, we questioned whether a rail container existed that could facilitate a larger capacity. After discussions with the rail industry, it became apparent that no suitable container was available, which led Nestlé to embark on finding a solution. In the beginning, the project seemed largely aspirational. The vision of the project was to bring the innovation and efficiency we’d seen achieved on road transport to an even more sustainable transport option.  

The idea was to create a specially designed freight container capable of accommodating double-stacked pallets. Nestlé could then maximise the container’s capacity, allowing for the transportation of up to double the number of products compared to conventional rail containers.  

Nestlé partnered with Bootle Containers and Marine Container Test Services to design and build the container. Trials were carried out in partnership with Network Rail, Forth Ports, W H Malcolm Group and Direct Rail Services to contribute to the success of its development and cover safety precautions. 

NEW CHALLENGES NEED NEW SOLUTIONS 

One challenge Nestlé had to overcome was that our Hams Hall Distribution Centre was unsuitable for rear door loading of containers, therefore we currently load curtain-sided trailers. As a company that manufactures and distributes a wide range of products, including confectionery, water, cereal and pet food, Nestlé UK and Ireland naturally transports large quantities. We needed to find a solution that facilitated double-stacked pallets which was both rail compatible and curtain sided.  

That’s where our bespoke unit comes in. We fitted a roof-raising mechanism to the container, which provides a few extra centimetres of height. This allowed us to smoothly load double-stacked pallets onto the container and then lower the roof just enough to fit comfortably on the UK railway’s shared access network.  

Sally Wright, Head of Logistics for Nestlé UK and Ireland, had the honour of unveiling the developmental rail container to the public at the 2022 Multimodal exhibition in Birmingham. She spoke about her ambition to develop the future transport strategy for Nestlé and established the profound impact this project could have on reducing the number of trucks that Nestlé puts on the roads.  

SIGNIFICANT MILESTONES 

It was in August 2022 when I joined the Nestlé team in a new role, Rail Development and Delivery Manager. The role’s creation stemmed from this ambition to grow Nestlé’s rail presence, with a focus on achieving a cleaner and more sustainable logistics network. It became my responsibility to carry through the roof-raising rail container’s journey.  

In August 2023, Nestlé achieved a significant milestone by completing the first groundbreaking trial. We delivered the first-of-its-kind container from Hams Hall Distribution Centre, in North Warwickshire, to the Tesco Thurrock distribution centre. The container was double stacked with a range of Nestlé Purina pet food products, including Felix and Gourmet pouches.  

The trial was a success, though we see it as just the beginning. We view this as a valuable opportunity for further innovation and development, recognising that there are still adjustments to be made, feedback to be gathered and training to be done. Our objective is to ensure that the rail container meets both our own and our customers’ needs. 

CONTINUAL INNOVATION 

Looking ahead, Nestlé is dedicated to refining the rail container itself, to integrate it into our overall distribution strategy. By leveraging the potential of rail transportation, we envisage a distribution approach that is aligned with our commitment to sustainability. This shift towards rail transportation presents exciting possibilities for transporting more of Nestlé’s well-known brands, from cereals to confectionery, across the country in a way that contributes to a greener distribution strategy.  

In addition to our commitment to rail transportation, Nestlé is actively pursuing other routes to embrace sustainable logistics practices. Nestlé has made significant progress in transitioning its fleet of trucks to low emission alternatives. We have switched 75% of our owned truck fleet from diesel to Bio-LNG fuel, a renewable liquified gas derived from waste. 

Nestlé food and drink is now delivered around the UK and Ireland by trucks which emit up to 95% less carbon. This has been a complex undertaking, requiring careful planning and collaboration within our delivery network. However, we are actively working with our haulage partners to transition our fleet from diesel to alternative fuels, to achieve cleaner road transport.  

Moreover, Nestlé is actively exploring the integration of yard shunters which use alternative fuels to diesel to streamline the movement of goods on our sites. By replacing traditional diesel shunters with those which use alternative fuels, we aim to reduce our carbon footprint across our full transport network. 

We are currently in the process of trialling options to determine the final solution to yard shunter alternatives, to ensure operational efficiency and availability across our operational sites. Nestlé has already implemented one electric shunter vehicle at its cereals site in Bromborough, effectively facilitating the transportation of raw materials, packaging and finished goods.  

Through these combined efforts, including the rail container development, the transition to low emission trucks and the adoption of alternative fuelled yard shunters, Nestlé is transforming its logistics operations. By continuously innovating, we hope consumers can enjoy their favourite Nestlé products with the knowledge that they are being transported more sustainably and, ultimately, contributing to a greener future for all. 

Published On: 07/12/2023 12:30:00

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