Process heat is a major energy demand in New Zealand, and reducing reliance on fossil fuels is key for efficiency and resilience. 

Biomass — renewable organic material such as waste wood or residues — offers a practical low-carbon alternative to coal and natural gas, helping businesses cut emissions while maintaining reliable heat supply. 

We commissioned 4 case studies of businesses that transitioned from coal to biomass, each adopting different technologies and implementation pathways. Download a summary of all 4 case studies, and detailed reports on each project below. 

Transitioning to biomass: lessons learned

We commissioned Aurecon to review 4 biomass boiler projects at Fonterra, Golden Bay Cement, McCain and JS Ewers, in order to share insights with other businesses considering similar investments. Each project took a different approach, using a range of technologies, woody biomass fuels and implementation pathways. 

Despite challenges, projects improved boiler efficiency, lowered carbon and maintenance costs, and strengthened energy resilience. Together, they show that while there is no single pathway, biomass can successfully replace coal across varied industrial settings, delivering both operational and environmental benefits.

Download biomass case studies

These case studies give in-depth detail into the biomass boiler projects at each company.

  • Golden Bay Cement

    Golden Bay Cement has introduced a large-scale biomass fuel system which includes a biomass storage area, hopper, conveyor belt, and screw-feed system designed to fire waste biomass into the precalciner, reducing the volume of coal required for cement production.

    Download case study [PDF 1.1 MB]

     

  • Fonterra Waitoa

    Fonterra’s large-scale 30 MWth bubbling fluidised bed (BFB) biomass boiler can fire a wide range of fuels with higher moisture and ash content, as well as larger particle sizes than conventional grate boilers can manage.   

    Download case study [PDF 2.6 MB]

  • McCain Timaru

    McCain converted its 14 MWth lignite coal boiler to operate on biomass in a travelling grate furnace. The project demonstrates that converting existing coal boilers to biomass can deliver  efficiency and operational gains. 

    Download case study [PDF 1.3 MB]

  • JS Ewers

    JS Ewers depends on process heat for maintaining temperatures inside 12 hectares of greenhouses where they grow vegetables. The company installed two new 4.5 MWth step grate biomass boilers in the main boiler house and converted 5 smaller units (3.3 MWth total), to run on wood pellets. 

    Download case study [PDF 1.8 MB]

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