Alpro, a leading European producer of plant-based foods, has successfully reduced its operational costs by 25% through the strategic application of operational research techniques. This achievement marks a significant transformation in Alpro’s energy management and production planning processes.
Faced with the challenge of synchronising fluctuating energy demand with production schedules amidst volatile electricity markets, Alpro’s large-scale factories and energy-intensive operations required a sophisticated solution. The company utilises a combination of boilers, generators, and solar panels, supplemented by external electricity market purchases where prices are often unpredictable. This complexity, compounded by maintenance schedules, necessitated an intricate optimisation approach.
Alpro collaborated with GAMS Software to create a decision-support system that consolidates energy generation, market dynamics, factory loads, and operational constraints into a unified framework. The solution employs two bespoke optimisation models delivered via a web-based interface, which also facilitates conditional bidding in the day-ahead electricity market.
The first model automates bidding decisions by analysing spot price forecasts, solar energy projections, factory demand, and maintenance schedules to determine optimal energy buying or selling times. The second model optimises the load of each energy-generating asset in 15-minute intervals, ensuring efficient resource utilisation and maximisation of renewable energy from Alpro’s solar installations.
Since adopting this system, Alpro reports that energy management processes have become three times faster, allowing employees to manage energy assets more efficiently. This advancement not only reduces costs but also enhances Alpro’s competitiveness in the electricity market and aligns with its sustainability objectives.
At the EURO 2025 conference, Alpro underscored the significance of collaboration between operational teams and technical experts, iterative development with continuous feedback, and fostering a strong culture of automation acceptance.
Read our in-depth write-up of Alpro’s success story with GAMS Software at IN Food.
