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Introduction of water management in food production plant: A Case Study Margarine Production Facility
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The food processing industry consumes relatively high volumes of water for different purposes (production, cleaning, heating and cooling). Beside, wastewater discharged from the production process has high organic load. The industry has huge potential for water conservation and reuse if audited properly.
This paper presents the results of water consumption auditing and identifying water consumption centres in a margarine production line in Serbia. Based on the results of the auditing and performed technological and economic feasibility studies, several measures related to reducing water consumption and increasing water reuse in production process were proposed, implemented and valuated. Implemented the measures the company significantly reduced specific water consumption (from 2.71 m3/t of produced margarine to 0.71 m3/t of produced margarine in two-year period). The study shows that water management activities (as a comprehensive and systematic approach for reducing water consumption, increasing water reuse and reducing wastewater creation) are environmentally and economically feasible in a margarine production company.
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This work aims to evaluate the applicability of electrocoagulation/flotation for the treatment of wastewater from the cleaning processes of the production line of the margarine industry. The electrochemical experiments were performed using plate aluminum electrodes (99% Al). The effects of pH, electrolysis time and current density were studied and discussed. Metal and energy consumption were also evaluated. Obtained results show that the removal of turbidity was up to 99.6% at pH 5.5. The reduction of chemical oxygen demand and total Kjeldahl nitrogen levels can reach 82%–86% and about 78%, respectively, at current densities greater than or equal to 62.5 A/m². The specific consumption of aluminum and energy was about 20.98 g/m3 and 0.156 kWh/m3, respectively when 0.05 A was applied for 15 min. Generally, the effluent treated by electrocoagulation/flotation becomes clear, clean and practically free from any visible pollutant especially when a current intensity of 0.05 A (62.5 A/m²) is applied. Treatment of margarine wastewater by electrocoagulation seems to be a plausible and promising solution because the process is fast, easily operated and leads to a final treated effluent of satisfactory quality.
The pulp and paper industry is confronted with more stringent regulations related to water consumption, wastewater treatment and recycling. The production process and the wastewater treatment process specific conditions are in close connection with the wastewater flows and pollution loads. This study presents an overview of membrane processes in correlation with the particular aspects and emissions of the pulp and paper industry. Issues like membrane configurations, materials and modules, operational parameters and problems are presented with a clear focus on pulp and paper wastewater treatment. The particular issues related to the application of ultrafiltration as an advanced treatment stage are discussed in correlation with the pulp and paper wastewater characteristics and removal efficiencies requirements. In this case, ultrafiltration may be used for either completing the conventional wastewater treatment (and thus achieve a recyclable effluent), or for the closed-loop water systems in the pulp and paper industry. © 2006, Gheorghe Asachi Technical University of Iasi, Romania. All rights reserved.
Since food processing systems consume extensive amounts of water and energy, the food industry has the incentive to reduce water and energy with the goal of developing a zero discharge process that utilizes substantially less water and energy, and generates no waste. The objective of this study is to evaluate water/energy consumption and to propose alternatives that reduce water and energy in the processing of three food products; 1) edible bean, 2) dairy products, and 3) corn masa. Three main approaches were; 1) plant-scale audit data collection to determine energy consumption, 2) laboratory scale experiments to assess product quality changes with a reduction in water and energy usage, and 3) computer-aided simulation to design systems for reduced water and energy consumption and wastewater generation. The results suggest that a zero discharge process is feasible by reducing water and energy. Modifications to the edible bean process reduced water input up to 55% and wastewater generation was decreased up to 91%. In dairy plant, the optimal heat recovery option could economically decrease the boiler fuel requirement by 50 times, and reduce the operating cost to 2.7% of the present cost. The water reuse process in redesigned corn masa process could reduce 90% of wastewater and 55% of water usage compared to the traditional process. The amount of energy required for heating was saved by 70% in the water reuse process. When scaling-up to plant-scale, reusing water could reduce water consumption by 95% and reduce energy requirement by about 80%. (C) by 2011 Published by B.V. Selection and/or peer-review under responsibility of 11th International Congress on Engineering and Food (ICEF 11) Executive Committee.
As energy costs continue to rise, industrial plants (even those of energy nonintensive industries such as furniture industry) need effective way to reduce the amount of energy they consume. Besides, there are a number of economic and environmental reasons why a company should consider environmental management initiatives. This paper provides a detailed guideline for implementing joint energy and environmental management system in wood furniture industrial company. It covers in detail all essential aspects of the system: initial system assessment, organization, policy development, energy and environmental auditing, action plan development, system promotion, checking system performance, and management review.
Proper management of water in the food industry will depend, to a large extent, on economic incentives regulated by legislation. The influence of water cost and wastewater discharge taxes is analyzed, as factors that encourage the implementation of water recycling systems and wastewater treatments within the food industry. Two Spanish taxation models are taken into account: at the national level, the Waste Control Tax; and at the local level, the autonomous Sanitary Tax. The cost reduction obtained in the Waste Control Tax by investing 68,305€ in minimizing water consumption from 193,200m3/year to 142,417m3/year is negligible since it is not a quantitatively elevated tax (from 2262€/year to 1407€/year). With regard to the Sanitary Tax, diversity affects the tax quantity and, consequently, the pressure exerted on the effluent quality in each case. In the Region of Murcia, the sanitary tax reduction was 8885€/year; and in La Rioja, the saving is greater (38,642€/year) given that this tax is considerably higher. Designing more stringent environmental regulation will markedly enhance the development of new technologies for improving wastewater treatment towards the goal of environmentally acceptable discharging and water reuse.
Work aimed to identify the effluent is generating areas in a dairy company for purpose of changing concept pollution prevention. methodology consisted measuring volumes and collecting samples effluents production sectors. analysis was conducted by sector, order those which generated excessive amounts effluents. results show that dry products (powdered milk powdered whey) are greatest generators BOD, nitrogen phosphorus, while fluid form (UHT milk, formulated UHT, pasteurized cream) butter produced large quantities oils grease. solids recovery, waste segregation water reuse can be applied with saving potential as much R 11,200) per month only raw materials also environmental gains in pollution prevention.
Industry and commerce use vast amounts of water and in some parts of the world water is becoming a scarce commodity. We shall need to take more care in our future use of water, and this book is a 'best practice' manual for industrial and commercial users world-wide. Based mainly on the Australian experience with water conservation,this is a practical account of measures which can be taken to re-educate industrial and commercial users in the techniques of water saving and re-use. The principles are covered in detail and supported by examples from specific industries and commercial operations. * VERY topical subject * Based on Australian experience * First book to cover this problem for industrial users.
The sustainable use of water resources bring nowadays challenges related to the production and
consumption phases of water intensive related goods such as food and beverages, not only in terms of
technological improvements, but also of management practices considered at the level of the water use
cycle.
This study focuses on the water footprint assessment of one 750 mL bottle of wine produced in
a medium-size wine production plant in Romania, evaluated for a 4-year period with different
precipitation regimes. The assessment is based on the production-chain diagram, presenting the relevant
process stages from the source to the final product, as well as the current emissions and environmental
impacts, considering the existent equipments and actual water related practices. The wine trade-offs
socio-economic potential, and the evaluation of the national water footprint scheme related to Romanian
wine production and consumption were assessed. The findings of this study indicated that almost
99% of the total water footprint is related to the supply-chain water use, out of which 82% green, 3% blue
and 15% grey.
In addition, suggestions of sustainable practices for the winemaking industry have been selected and
briefly discussed based on international relevant cases. Such practices may contribute to savings inwater,
energy, raw materials, diminished emissions and waste generation and a more efficient use of personnel
time, with benefits for the decrease of business costs, the increase of profit and competitiveness. At the
level of the studied Romanian company, due to the current economic and environmental issues, only few
of these practices have been applied for the last three years, e.g.: waste monitoring and treatment, soil,
plant and pest management, waste minimization, water resources efficiency program, integrated
management programmes.
Water is economically cheap, which fails to consider its intrinsic environmental and social value. However, given the uncertain future around the availability of water resources to provide industrial, environmental and social services, water conservation is now of significant concern to industries across the globe. Recently, an extension of water conservation has emerged as zero liquid discharge, whereby no water at all is released from industrial processes, regardless of its quality.
Water auditing is a tool that can be used to identify water conservation strategies, ideally leading to zero liquid discharge. This article discusses a water audit conducted on a sodium cyanide plant, where flows were determined using historical data, proxy data, and known scientific relationships. Water quality throughout the process was defined as contaminated or uncontaminated. From this simple audit, two major water conservation measures were identified and modelled which could reduce inputs and outputs by ~40 %. These were the reuse of rainwater falling throughout the plant’s boundaries instead of demineralised scheme water, and the improvement of the efficiency of one of the cooling towers.
Such a methodology could be easily applied by other industries so as to improve their water conservation. The auditing method may lead to suggestions of conservation techniques for implementation either through retrofitting existing plants or contributing to the design of new ones.
Re-circulating cooling water systems (RCWSs) are widely used to reject waste process heat to the environment, conserve fresh water and reduce thermal pollution relative to once-through systems. Research on RCWS has mostly focused on individual components, cooling tower and heat-exchanger network. Kim and Smith [Kim, J.K. and Smith, R., 2001, Cooling water system design, Chem Eng Sci, 56(12): 3641–3658] developed a grass-root design method of RCWS (KSD). In this paper, the KSD method is expanded and a comprehensive simulation model of RCWS is developed accounting for interaction between cooling tower and heat-exchanger network. Regarding this model, a modern grass-root design method of RCWS, we call it Advanced Pinch Design (APD), based on combined pinch technology and mathematical programming is developed for minimum cost achievement. Having considered cycle water quality through introducing ozone treatment technology, APD methodology is further improved. This technique that we call Enhanced Cooling Water System Design (ECWSD), as the APD supplementary methodology, is provided water and energy conservation, minimum cost and environmental impacts. Related coding in MATLAB version 7.1 is developed for the illustrative example to get optimal values in RCWS design method computations. Finally the results of the introduced grass-root design methodologies, APD and ECWSD, are compared with KSD.