Santa Maria UK’s Nitrogen Generation Project Cuts Carbon Emissions

Food manufacturer cuts 12 tonnes of CO₂ with nitrogen switch

Santa Maria UK has reduced carbon emissions at its Milton Keynes facility by approximately 12 tonnes of CO₂ per year. The change came after the company replaced delivered nitrogen supplies with an on-site nitrogen generation system. The fajita kit and Tex-Mex ingredients producer says the move forms part of a wider decarbonisation programme that includes renewable electricity, energy efficiency upgrades, and carbon offsetting.

For many UK manufacturers, nitrogen is essential for packaging and processing. Traditionally, nitrogen arrives by truck in cylinders or as bulk liquid. This creates transport emissions, handling requirements, and storage risks. On-site generation systems produce nitrogen directly from compressed air. As a result, most delivery-related logistics disappear.

The approach offers clear operational benefits. Routine gas deliveries stop. Storage needs fall. Health and safety risks associated with liquid nitrogen storage reduce. According to industry sources, on-site nitrogen generation can also deliver energy savings and lower operating costs. Pneumatech notes that the method eliminates the need for liquid nitrogen storage, transportation, and associated risks.

Santa Maria’s existing climate commitments and progress

Santa Maria has been working on emissions reductions for several years. The company previously set a target to halve emissions from factories, warehouses and offices by 2020 versus a 2012 baseline. It met that target five years early. Consequently, the company then set a new goal to halve emissions again by 2030 versus 2015 levels.

The strategy relies on three main approaches. First, lower energy consumption across operations. Second, more efficient equipment installations. Third, increased use of renewable electricity. From 2016, Santa Maria has used 100% renewable electricity in its operations in Sweden, Estonia and the UK. The company also climate-offsets remaining emissions through renewable energy projects in India.

This background matters because it shows the nitrogen generation project sits within a structured, ongoing programme. The 12-tonne reduction at Milton Keynes is not an isolated initiative. Instead, it represents one more step in a systematic approach to operational decarbonisation.

How on-site nitrogen generation cuts emissions

The 12-tonne annual CO₂ reduction follows a clear emissions logic. Fewer truck movements mean less transport fuel. Less packaging and handling reduce material waste. Lower energy use in the supply chain cuts indirect emissions. These savings accumulate even though the on-site system itself requires electricity to operate.

On-site nitrogen generation systems typically separate nitrogen from ambient air. Two main technologies dominate: pressure swing adsorption (PSA) and membrane separation. PSA-based systems can deliver high-purity nitrogen on demand. This makes them particularly suitable for food packaging and manufacturing applications where product quality depends on controlled atmospheric conditions.

The technical approach is straightforward. Compressed air enters the system. The technology strips out oxygen and other gases. Pure nitrogen emerges for immediate use in production. The process runs continuously during operating hours. There is no need to schedule deliveries or manage cylinder inventories.

For food manufacturers specifically, this reliability matters. Production schedules depend on consistent nitrogen supply. Any interruption can halt packaging lines. On-site generation removes the risk of supply delays or delivery failures. It also provides better control over nitrogen purity and pressure.

Where facility emissions fit in the wider carbon footprint

Understanding the scale of this reduction requires context. In 2022, Paulig Group commissioned a carbon footprint assessment of Santa Maria Tortilla Original Medium. The RISE study found a footprint of 0.544 kg CO₂e per kg of product from production to market, or 0.513 kg CO₂e per kg excluding market transport.

Importantly, the report showed that factory operations contributed only a minor share of the total footprint. Most emissions came from ingredients, packaging materials, and transport. This pattern is typical for food products. Agricultural inputs and packaging often dominate the carbon profile.

However, this does not diminish the value of facility-level improvements. Operational emissions still matter for several reasons. They sit within direct company control. They affect site running costs. They influence tender decisions for public sector contracts. They contribute to overall corporate carbon accounting under Scope 1 and Scope 2 categories.

Moreover, facility improvements like nitrogen generation can reduce logistics-related impacts beyond the factory gate. Fewer delivery trucks means less fuel consumption across the supply chain. This creates small but measurable reductions in transport emissions that would otherwise appear in Scope 3 calculations.

Key facts about the Santa Maria nitrogen project

• Santa Maria UK’s Milton Keynes site has cut approximately 12 tonnes of CO₂ per year through on-site nitrogen generation.
• The system eliminates the need for delivered nitrogen in cylinders or bulk liquid form, removing associated transport emissions and storage requirements.
• Santa Maria has used 100% renewable electricity in its UK operations since 2016, meaning the on-site generation system runs on clean power.
• On-site nitrogen systems typically use pressure swing adsorption or membrane separation to extract nitrogen from compressed air.
• The company previously met a target to halve facility emissions by 2020 versus 2012, five years ahead of schedule, and has set a new target for 2030.
• A 2022 carbon footprint study found that factory operations contribute a minor share of total product emissions compared to ingredients and packaging.
• Industry sources indicate that on-site nitrogen generation can deliver energy savings, cost reductions, and improved operational control alongside emissions benefits.

Why small process changes matter for industrial decarbonisation

This example illustrates how manufacturers can reduce emissions without redesigning entire product lines. The nitrogen switch addresses operational emissions directly. It improves how a utility gas is supplied. Consequently, it reduces transport-related impacts.

The approach fits within a wider UK industrial decarbonisation trend. According to the Climate Change Committee, UK emissions in 2023 stood at around half the 1990 level. However, future reductions will increasingly depend on electrification, efficiency measures, and low-carbon energy systems. The committee emphasises that achieving net zero by 2050 requires sustained action across all sectors.

For UK SMEs, the Santa Maria example offers useful lessons. First, emissions reductions often come from multiple small changes rather than single large projects. Second, process improvements can deliver both carbon savings and operational benefits. Third, facility-level changes work best when combined with broader commitments like renewable electricity purchasing.

The financial case matters too. On-site nitrogen generation can reduce operating costs by eliminating delivery charges and cylinder rental fees. Meanwhile, the system provides better supply reliability. These commercial benefits make the investment easier to justify alongside carbon considerations.

Additionally, facility emissions increasingly appear in tender criteria and supply chain requirements. Public sector buyers routinely ask for carbon reporting. Large corporate customers set expectations for supplier emissions. Demonstrating measurable reductions helps manufacturers compete for contracts and maintain customer relationships.

Practical considerations for other food manufacturers

Food manufacturers considering similar changes should evaluate several factors. First, assess current nitrogen consumption volumes and delivery frequencies. Higher usage makes on-site generation more economically attractive. Second, review available space and utilities infrastructure. The systems require compressed air supply and electrical connections.

Third, consider nitrogen purity requirements. Different applications need different purity levels. Modified atmosphere packaging might require 99.5% purity or higher. Other processes may work with lower specifications. The required purity affects system design and capital costs.

Fourth, calculate the payback period including both cost savings and carbon value. In addition to eliminating delivery charges, consider how emissions reductions support carbon reporting obligations for public sector suppliers. Many manufacturers now need to demonstrate progress toward science-based targets or net zero commitments.

Fifth, ensure the project aligns with wider environmental management systems. On-site nitrogen generation works best as part of a structured approach to resource efficiency. It should complement other measures like energy monitoring, waste reduction, and renewable electricity procurement.

Finally, document the emissions benefits properly. Calculate baseline emissions from delivered nitrogen including transport impacts. Measure electricity consumption of the new system. Account for the carbon intensity of grid electricity or, as in Santa Maria’s case, the zero emissions from renewable power contracts. This documentation supports ESG compliance reporting and carbon reduction verification.

How this connects to broader net zero requirements

The nitrogen generation project demonstrates the kind of incremental change that many businesses need to make. Achieving net zero requires action across all emission sources. Facility operations represent one category where manufacturers have direct control.

For businesses working toward net zero, every tonne of CO₂ saved contributes to the overall target. A 12-tonne annual reduction may seem modest compared to total company emissions. Nevertheless, it represents permanent progress that compounds over time. Over ten years, this single change saves 120 tonnes of CO₂.

Moreover, the approach shows how operational improvements can support compliance with emerging requirements. Procurement Policy Note 06/21 requires suppliers bidding for large government contracts to publish carbon reduction plans. These plans must demonstrate concrete actions and measurable outcomes. Projects like on-site nitrogen generation provide clear evidence of progress.

Similarly, the growing expectation for Scope 3 emissions reporting means businesses need to address indirect impacts. While the nitrogen switch primarily affects Scope 1 and Scope 2 emissions, it also reduces transport emissions in the supply chain. These indirect benefits strengthen the overall carbon profile.

Understanding these connections helps businesses prioritise investments. Changes that deliver multiple benefits deserve attention. On-site nitrogen generation cuts emissions, reduces costs, improves operational control, and supports compliance requirements. This combination makes the business case stronger than carbon savings alone.

Where to find guidance and support

Manufacturers exploring similar projects can access several sources of technical and regulatory guidance. The Department for Energy Security and Net Zero provides information on industrial energy efficiency and decarbonisation support schemes. These resources help businesses understand available grants and technical assistance programmes.

The Carbon Trust offers sector-specific advice on emissions reduction opportunities for food and drink manufacturers. Their resources include carbon footprinting tools and guidance on operational efficiency measures. Meanwhile, the Institute of Environmental Management and Assessment provides professional standards and training for environmental practitioners working on industrial decarbonisation projects.

For businesses needing to understand carbon accounting requirements, UK greenhouse gas emissions statistics from the Department for Energy Security and Net Zero offer official emissions factors and calculation methodologies. These ensure that emissions reductions are measured consistently and reported accurately.

Food manufacturers should also consult industry-specific resources. The Food and Drink Federation publishes guidance on environmental reporting and sustainability standards relevant to the sector. Additionally, businesses preparing carbon reduction plans for public procurement should review the detailed requirements published by the Cabinet Office.