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					Toronto Region Sustainability Program
     Pollution Prevention Case Study

Food Processing
Company Overview                                                 Summary of Findings

The following describes a food processor in the Greater          The facility consumed approximately 100,200 tonnes of
Toronto Region that manufactures avours for the food and         water per year at an estimated annual cost of about
beverage industries. Operations at the facility include six      $158,000. Due to excessive Biochemical Oxygen Demand
main processes: aseptic cooking line, open cooking line,         (BOD) in the wastewater, the facility reportedly paid a sewer
liquid compounding, cleaning and sanitation, quality             surcharge of approximately $120,000 per year. This BOD
assurance/quality control (QA/QC), and building services.        results from discharge of product and ingredient materials
                                                                 containing high sugar content.
P2 Assessment Process
                                                                 The two aseptic cooking lines or workcentres accounted for
Through the Toronto Region Sustainability Program (TRSP),        approximately 385 tonnes per year, or 73 percent of the
this avour manufacturer retained the services of an              total product and retain loss. It was therefore imperative
environmental consulting rm to complete a Pollution              that P2 measures rst target opportunities for prevention
Prevention (P2) assessment of its facility. The key driver for   and reduction of product losses from the aseptic lines.
participation was a high level of organic loadings to sewer
resulting in annual sewer surcharge of $120,000. The             A number of options were identi ed to reduce the BOD
company management was also interested in reducing               loading from the aseptic cooking lines, including removal of
costs and business risks, and optimizing processes for a new     pipe bottlenecks, a product di erentiation sensor, and line
facility.                                                        con guration optimization. Together, these options have
                                                                 the potential to reduce BOD loading and process wastes by
The P2 Assessment process involved an onsite P2 training         approximately 350 tonnes annually.
seminar for facility sta , in-plant study work, and an
engineering assessment of alternatives. The consultant           Improved sample collection and disposal procedures in
provided the company with a detailed P2 Assessment               QA/QC can further reduce BOD loading and process wastes
Report, which summarized the ndings of the assessment            by 15 tonnes annually.
along with recommendations on P2 options for key
processes.                                                       It was found that kettle cleaning, boiler make-up water, and
                                                                 cooling kettles in the aseptic cooking lines account for
                                                                 about 90 percent of the annual water consumption.
                                                                 Opportunities for reductions in water consumption include
                                                                 the use of more e cient spray nozzles for kettle cleaning,
                                                                 the collection and return of steam condensate, and the use
                                                                 of closed loop cooling to cool aseptic mixing kettles. These
                                                                 options have the potential to reduce water consumption by
                                                                 approximately 32,000 tonnes annually and greenhouse
                                                                 gases by 500 tonnes annually.
                 P2 Solutions, Environmental Results and Related Cost Savings
The table below summarizes P2 projects being undertaken by the food processor from the list of P2 recommendations outlined in the
assessment report. When implementation is complete, the P2 measures are projected to reduce annually:

       • 362 tonnes process wastes              • 31,958 tonnes water            • 495 tonnes greenhouse gases

With annual savings of $430,000 and an overall payback of 6 months.

        Process                      P2 Solutions                Environmental Reductions                      Cost Savings & Payback

Aseptic Cooking Line         Remove pipe bottlenecks and       86 tonnes/yr process wastes                    $80 K annual savings
                             recover wasted products           (20 tonnes BOD and 66 tonnes                   Payback immediate
Targeted Pollutants/Waste:                                     product losses)
Process Wastes, BOD
                             Product di erentiation sensor     158 tonnes/yr process wastes                   $122 K annual savings
                                                               (79 tonnes BOD and 79 tonnes                   Payback of 1.5 years
                                                               product losses)

                             Optimize line con guration        100 tonnes/yr process wastes                   $60 K annual savings
                                                               (76 tonnes BOD and 24 tonnes                   Payback immediate
                                                               product losses)                                (new site design)

Quality Assurance /          Sample disposal procedures        10 tonnes/yr process wastes (BOD)              $3.9 K annual savings
Quality Control                                                                                               Payback of 7 months

Targeted Pollutants/Waste:   Sample collection methods         5 tonnes/yr process wastes                     $4.7 K annual savings
Process Wastes, BOD                                            (1 tonne BOD and 4 tonnes product              Payback of 7 months
                                                               losses)

Building Services            Cooling tower/closed loop         20,131 tonnes/yr water consumption             $31.8 K annual savings
                             cooling                                                                          Payback of 7 months
Targeted Pollutants/Waste:
Water and Energy             Boiler condensate return          11,827 tonnes/yr water consumption             $127 K annual savings
Consumption                                                    and 495 tonnes/yr GHGs                         Payback short-term

                             Energy e ciency measures          To be investigated longer term

Open Cooking Line            Cooking line loss recovery        70% recovery of product losses
Targeted Pollutants/Waste:
Process Wastes, BOD

Liquid Compounding           Product reformulation             VOC reduction
Targeted Pollutants/Waste:
                                                                                                                           Options to be
VOCs
                                                                                                                           investigated
Cleaning and Sanitizing      Recover tote retain and           Water consumption reduction
                             segregate initial kettle rinse
Targeted Pollutants/Waste:
Water Consumption            More e cient nozzles for
                             kettle rinsing




                                                                           For more information, please contact:
                                                                           Fred Granek, Vice President, Sustainability, OCETA
Program delivered by:                                                      2070 Hadwen Rd, Unit 201A, Mississauga, ON L5K 2C9
                                                                           Tel: 905 822 4133 x224, email: fgranek@oceta.on.ca
                                                                           Web site: www.TRSP.ca