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FOOD, DRINK AND MILK INDUSTRIES
GESTION AMBIENTAL (5º Ingeniería Química)
GRUPO 1 Isabel Cebrián Renedo Jesús Pérez
Baraja Mario Sainz Martín Juan David Tejerina
Gutiérrrez
Universidad de Valladolid
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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• Milk Composition
• 87 water
• Protein
• Fat
• Lactose
• Calcium
• Phosphorus
• Iron
• Vitamins
• Milk Origen Cows, goats and sheep.
• Milk Products milk, ice - cream, cheese,
  yoghurt, butter and whey.
• Processing milk the objective is to extend shelf
  life and eliminate the risk of pathogens. Heat
  treatment is the most common processing technique
  and pasteurisation destroys the most heat
  resistant pathogen, M. tuberculosis.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• TREATMENT
• Reception ? Milk is received at the dairy and
  transferred to bulk storage.
• Centrifugation ? Used to separate mixtures of two
  or more phases, one of which is a continuous
  phase.
• Homogenisation ? Reduce the size of fat globules
  so that they stay evenly divided in the milk,
  thereby preventing the fat separating and the
  cream rising. The whole milk, is pressed under
  high pressure 200 to 300 bar, through a small
  orifice.
• Heat treated? Controlled heating process used to
  eliminate microorganism and stops bacterial and
  enzyme activity . Use to prevent loss of quality
  in food products.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• TREATMENT
• 4) Heat treated?Various time/temperature
  combinations can be applied
• Pasteurisation
• High temperature short time (HTST) pasteurisation
  uses a temperature of 72 to 75 C for 15 to 240
  seconds.
• Low temperature long time (LTLT) pasteurisation
  uses a temperature of 65 C for 30 minutes.
• Sterilisation This can be achieved by dry heat,
  filtration, irradiation or by chemical methods.
• The product is canned or bottled and then
  heat-treated in a steriliser with steam or hot
  water.
• Conditions heat treatment of over 100 C
  applied for a period long enough to lead to a
  stable product shelf-life.
• UHT treatment Very short heat treatment at
  temperatures of 135 to 150 ºC for only a few
  seconds. This results in a sterilised product
  with minimal heat damage to the product
  properties.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information
TREATMENT
Process Diagram
Table- Different tipes of heat treatment process
and the operation conditions
Obtention of different dairy products
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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• PRODUCTS BUTTER
• Butter is an emulsion of water in oil and
• its composition is
• - Fat 80
• - Moisture 16
• - Salt 2
• - Milk SNF 2
• The process steps apply are
• Butter is produced from cream which is
  centrifugally separated from pasteurised milk ?an
  emulsion of oil in water is transformed to
  butter.
• Ageing ? Cream is rapidly chilled and held at
  that temperature for a set period
• Churning ? agitates the cream to partially break
  down the oil in the water emulsion until fat
  globules bind together to produce butter grains.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• PRODUCTS CHEESE
• Cheese is a concentrate of the milk
  constituents,mainly fat, casein and insoluble
  salts, together with water.
• The process steps apply are
• Production of a coagulum through the action of
  rennet and/or lactic acid.
• Separation of the resulting curds from the whey.
• Manipulation of the curds to produce the desired
  characteristics of the cheese.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
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• PRODUCTS YOGHURT
• The main ingredients milk, concentrated milk and
  stabilisers.
• The main steps are
• The fat and non-fat solids content of the milk is
  first increased by the addition of milk powders.
• 2) The milk is homogenised at a temperature of
  55 ºC and heat treated at 80 to 90 ºC for 30
  minutes in a batch process.

• 3) The heat treated milk is cooled to around 40
  to 43 ºC and seeded with two starter organisms
  Streptococcus salivarius and Lactobacillus
  delbrueckii. Fermentation takes around 4 hours.
• 4) The product is cooled to 15 20 ºC, using
  either tank cooling coils or tubular or plate
  heat-exchangers.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• PRODUCTS ICE-CREAM
• Main ingredients fat, non-fat milk solids,
  sugars, stabilisers, emulsifiers
• Process steps apply are
• The ingredients are blended, heated to around 70
  to 75 ºC and homogenised.
• The mixture is pasteurised by heating to 80 85
  ºC for 2 to 15 seconds before cooling.
• Continuous freezers are used to rapidly freeze
  the ice-cream down to around -6 ºC.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
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• WATER CONSUMPTION
• Water has many different uses
• For cooling and cleaning.
• For washing.
• As a raw material, especially for the drinks
  industry.
• For cooking, dissolving and transportation.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
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• EMISSIONS WASTE WATER
• Waste water from dairy sectors contain high
  concentrations of fats and oils and vary from pH
  3,5 to pH 11.
• Sources of waste water
• Washing.
• Cleaning of installations, process lines,
  equipment and process areas.
• Blowdown from steam boilers.
• Freezer defrost water.
• Storm-water.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• EMISSIONS AIR EMISSIONS
• Air emissions can be divided into ducted,
  diffuse and fugitive emissions.
• Diffuse and fugitive emissions can be prevented
  and/or mininised, but only ducted emissions can
  be treated.
• Sources of ducted emissions in the FDM sector
• Process emissions.
• Waste gases from purge.
• Gases from units providing energy (boilers,
  turbines, engines).
• Discharges of safety relief devices.
• Air pollutants from FDM processes
• Dust.
• VOCs.
• Odour odour units per cubic metre (OU/m3).
• Refrigerants containing ammonia and halogen.
• Products of combustion (CO2, NOx, SO2).

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• EMISSIONS LOSS OF MATERIALS
• Exceed weight/volume specification
• Very important to accurately quantity the amount
  of overfill.
• Spillage
• Indicates poor equipment design, poor
  maintenance or poor operation.
• Leakage of liquid/overflow
• Leakage of liquid product from pipe joints and
  overflow from tanks.
• Product defects/returned product
• Products not meeting the required specification.
  Includes over-produced fresh products.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• EMISSIONS LOSS OF MATERIALS
• Inherent loss
• Loss of materials and waste which is unavoidable
  by design of process equipment.
• Retained material
• Liquid products or ingredients cannot freely
  drain to the next stage
• in the process.
• Heat deposited waste
• Deposition of the product onto the heat-exchange
  surface, plates
• or tubes.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
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• CONSUMPTION OF ENERGY
• The FDM sector depends on energy
• For processing.
• Storage.
• To maintain freshness.
• To ensure food safety.
• Process heating uses approximately 29 of the
  total energy used in the FDM sector.
• Process cooling and refrigeration accounts for
  about 16 of the total energy used.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• GENERAL TECHNIQUES FOR THE FDM SECTOR
• Environmental management tools.
• Optimise operation by providing training.
• Equipment design and installation design
  considerations.
• Maintenance.
• Methodology for preventing and minimising the
  consumption of water and energy and the
  produccion of waste.
• Production management techniques.
• Process control techniques.
• Selection of materials.
• Cleaning.
• Techniques for minimising air emissions.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
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• ENVIRONMENTAL MANAGEMENT TOOLS
• The best environmental performance is usually
  achieved by the installation of the best
  technology and its operation in the most
  effective and efficient manner.
• OPTIMISE OPERATION BY PROVIDING TRAINING
• Achieved environmental benefits
• Reduced consumption and emission levels and
  reduced risks of accidents throughout the
  installation.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• EQUIPMENT DESIGN
• Design equipment to minimise consumption and
  emission levels.
• Design pipework to minimise noise emissions.
• Sound insulation of equipment.
• Position equipment to direct noise away from
  neighbours.
• MAINTENANCE
• Achieved environmental benefits
• Reduced consumption of energy, water and
  substances, and reduced emissions to air, water
  and land.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• WATER POLLUTION CONTROL
• reducing the volume of the waste water generated
• reducing the strength of the waste water
  generated
• decreasing the concentration of certain
  pollutants
• recycling or re-using water
• waste water treatment
• ENERGY CONSUMPTION CONTROL
• efficient energy management
• process optimisation and innovation

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• PRODUCTION MANAGEMENT TECHNIQUES
• Achieved environmental benefits
• Reduced consumption of water, energy and
  chemicals and generation of waste water and
  waste.
• Minimise storage times for perishable materials.
• Segregation of outputs, to optimise use, re-use,
  recovery, recycling and disposal (and minimise
  water use and waste water contamination).
• Minimise heating and cooling times.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Emerging Techniques
General Information
Techniques determ BAT
BAT

• WHY END OF PIPE WASTE WATER TREATMENT IS
  REQUIRED?
• BECAUSE
• Waste water volume in a well managed installation
  is reported to be about 1 2 L/kg of milk
  processed.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Emerging Techniques
General Information
Techniques determ BAT
BAT

• WASTE WATER TREATMENT TECHNIQUES APPLIED
• PRIMARY TREATMENTS OR PRETREATMENTS

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WASTE WATER TREATMENT TECHNIQUES
APPLIEDSECONDARY TREATMENTS
FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Emerging Techniques
General Information
Techniques determ BAT
BAT

• ANAEROBIC PROCESSES

• AEROBIC PROCESSES

Advantages and disadvantages of anaerobic waste
water treatment compared to aerobic treatment
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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Emerging Techniques
General Information
Techniques determ BAT
BAT

• TECHNIQUES APPLICABLE IN SOME INDIVIDUAL SECTORS
  MILK
• SEGREGATION OF OUTPUTS ? MINIMASE WASTE WATER
  CONTAMINATION
• DRY CLEANING
• PARTIAL HOMOGENISATION
• CONTINUOUS PASTEURISERS
• REGENERATIVE HEAT EXCHANGE IN A PASTEURISATION
  PROCESS
• FILTRATION AND CLARIFICATION
• RECIRCULATION OF PASTEURISERS

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
BAT
Emerging Techniques
General Information
Techniques determ BAT

• TECHNIQUES APPLICABLE IN SOME INDIVIDUAL SECTORS
  CHEESE
• USING ULTRAFILTRATION (UF) FOR PROTEIN.
• STANDARDISATION OF CHEESE MILK.
• REDUCTION OF FAT CHEESE FINES IN WHEY.
• MINIMISE THE PRODUCTION OF ACID WHEY.
• RECOVERY AND USE OF WHEY.
• RECOVERY OF SALT WHEY BY EVAPORATION.
• USE OF HEAT FROM WARM WHEY FOR PREHEATING CHEESE
  MILK.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• GENERAL BAT APPLICABLE TO ALL FOOD, DRINK AND
  MILK INDUSTRIAL OPERATIONS
• Employees aware of the environmental
  aspects/responsibilities.
• Design/select equipment, which optimises
  consumption and emission levels.
• Control noise emissions (designing, selecting,
  operating and maintaining equipment enclosing
  noisy equipment).
• Apply and maintain a methodology for preventing
  and minimising
• Consumption of water and energy
• Production of waste
• Promote use, re-use, recovery, recycling and
  disposal .

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• BAT FOR DAIRIES
• 1) PARTIALLY HOMOGENISE MILK
• Energy savings (? homogeniser)
• 2) REPLACE BATCH PASTEURISERS WITH CONTINUOUS
  ONES
• HHST HTST ? ? Energy consumption
• 3) REDUCE THE REQUIRED FREQUENCY OF CLEANING OF
  CENTRIFUGAL SEPARATORS
• Improving the preliminary milk filtration and
  clarification processes ? ? Water consumption
• 4) USE REGENERATIVE HEAT EXCHANGE IN
  PASTEURISATION
• Energy savings (90)

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• BAT FOR DAIRIES
• 5) USE JUST-IN-TIME COMPONENT FILLING
• Two lines
• ? losses minimise water production
• 6) MAXIMISE THE RECOVERY OF DILUTED PRODUCT
• Pipelines filled with water before start-up
• Water is then pushed out by the product through a
  drain valve
• Conductivity transmitters and using optical
  sensors
• 7) USE SEVERAL SMALL CIP SYSTEMS
• Instead of a centralised CIP system
• Alkaline solution (fat, proteins) Acid (mineral)
• No acid ? ? water and energy consumption

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
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Techniques determ BAT
BAT
Emerging Techniques
General Information

• BAT FOR THE PRODUCTION OF MARKET MILK
• 1) Consumption and emission levels associated
  with the production of market milk from 1 litre
  of received milk.

• BAT FOR MILK POWDER PRODUCTION
• TO PRODUCED POWDERED MILK USE
• Multi-effect evaporators
• Optimising vapour recompression
• APPLY AN EARLY FIRE ALARM
• 3. Consumption and emission levels associated
  with the production of market milk from 1 litre
  of received milk.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• BAT FOR BUTTERMAKING
• REMOVE RESIDUAL BUTTER FROM PIPEWORK USING
  COMPRESSED AIR
• It can be used to gain access to parts of
  equipment where other equipments cannot
  physically pass and any risk of contamination
  from introducing cleaning tools or equipment can
  be avoided.
• RINSE THE CREAM HEATER WITH SKIMMED MILK BEFORE
  CLEANING IT

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• BAT FOR CHEESEMAKING
• USE THE HEAT FROM WARM WHEY FOR PREHEATING CHEESE
  MILK.
• MAXIMISE WHEY RECOVERY AND USE
• 90 milk ? Whey
• Sweet/Salty whey ? by-products/ animal feed/
  babies feed
• 3. REDUCE FAT AND CHEESE FINES IN WHEY AND
  SCREEN LIQUID STREAMS TO COLLECT FINES.
• MINIMISE THE OCCURRENCE OF ACID WHEY.
• 5. TO PRODUCE WHEY POWDER USE MULTI-EFFECT
  EVAPORATORS.

• BAT FOR ICE-CREAM MANUFACTURING
• 1) Consumption and emission levels associated
  with the production of market milk from 1 litre
  of received milk.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
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Techniques determ BAT
BAT
Emerging Techniques
General Information

• Use of UV/OZONE in absorption for odour abatement
• Ozone use as an oxidant, its reactivity in
  gaseous phase is lower than in liquid phase.
• Description Pack bed system and a liquid recycle
  system.
• Step 1- Ozone is bubled into the absorber.
• Step 2- Ozonated water is passed through UV
  lamps.
• Step 3- Ozone produces hydroxyl radicals.
• Step 4- Dissolved organic compounds are oxidised.
• Enviromental Benefits reduced odour emissions.
• Aplicability not too hot and humid airflows.

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FOOD, DRINK AND MILK INDUSTRIES
Process and Techniques
Emissions
Techniques determ BAT
BAT
Emerging Techniques
General Information

• THANK YOU FOR YOUR
• ATTENTION
• GRUPO 1
• Isabel Cebrián Renedo
• Jesús Pérez Baraja
• Mario Sainz Martín
• Juan David Tejerina Gutiérrrez