Unilever Kenya has partnered with Lean Energy Solutions to replace fossil-fuel steam generation with a biomass Steam-as-a-Service model, cutting steam costs by 25% and avoiding 2,400 tonnes of CO2 emissions a year, at zero upfront capital cost.
Industrial steam is the backbone of manufacturing — powering heating, processing, cleaning, and production across global supply chains. Yet for decades, steam generation has remained one of the hardest industrial challenges to decarbonize, with most factories relying on fossil-fuel-fired boilers running on Heavy Fuel Oil (HFO) or diesel. Unilever Kenya, one of the country's largest FMCG manufacturers, faced this exact challenge: how to reduce emissions, improve cost efficiency, and future-proof its steam operations without compromising reliability or safety.
The Challenge: Fossil-Fuel Dependence and Rising Costs
Prior to Lean Energy's intervention, Unilever's factory depended heavily on furnace oil boilers to meet its steam demand for critical heating applications across its operations — consuming approximately 50,000 litres of furnace oil per month, or 600,000 litres annually. This reliance created three major challenges: high and volatile fuel costs, significant carbon emissions, and a growing operational and maintenance burden.
The Lean Energy Solution: Steam-as-a-Service
Lean Energy partnered with Unilever to deliver Steam-as-a-Service — fully replacing fossil-fuel steam generation with clean, sustainable biomass-powered steam, delivered with zero upfront capital investment. Under a Build, Own, Operate (BOO) model, Lean Energy designed the steam solution, financed the full project, installed and commissioned the boiler system, and now operates and maintains the plant daily, supplying steam reliably under a long-term service agreement.
World-Class Industrial Boiler Operations
Lean Energy installed a fully automatic 2 tonnes-per-hour (2 TPH) biomass-fired boiler, built to meet the highest safety and operational standards. The system runs on 100% waste-based biomass — crushed maize cobs, wood waste from manufacturing industries, and processed wood chips from waste streams — supplied end-to-end by Lean Energy under a dedicated fuel supply contract.
Results and Impact
The transition has delivered immediate, measurable impact. Unilever has achieved a 25% reduction in the cost of steam. Lean Energy supplies 2,400 tonnes of biomass annually, avoiding approximately 2,400 tonnes of CO2 emissions every year. Each tonne of biomass used generates 12 man-days of employment — translating to roughly 28,800 man-days of employment created annually across the biomass value chain, from agricultural waste collection through processing and transport. Each tonne of biomass also saves approximately $150 in foreign exchange by displacing imported fuel, equal to $360,000 saved in foreign exchange every year.
Decarbonizing the Steam That Powers Industry
Lean Energy is delivering Industrial Steam Decarbonization as a Service — helping manufacturers cut costs, reduce emissions, and lead the transition to sustainable industry in Africa.
Lean Energy Team
Energy Specialist, Lean Energy Solutions Kenya
