Whey is one protein rich by-product that is generated from the production of cheese. In a dairy, generated whey was of mild category, thus was not possible to reuse in useful products, and was disposed to the drain. Investigations for mixing it at small quantities for the production of curdeled milk of LFC can lead to utilization of up to 25% of the produced whey
A carbonated drinks facility used diesel fuel to operate its boiler despite it was connected to the natural gas grid. Replacing the boiler’s burner with one that can fire natural gas, and increasing the contracted capacity for natural gas was found as a feasible measure to maintain economic benefits and reduce the pollution load.
A milk and beverage company suffered from repeated power outages, thus relied on diesel generators to maintain production availability. The triggers for the generators were not optimized to recharge after short power outages, leading to occasional cuts, forcing CIP to start. Adjusting the triggers of the generators shall eliminate untimely shutdown of equipment.
Unloading of empty plastic containers from trucks was practiced through manual operations, in which operators drop stacks of 20 containers to the ground. This operation resulted in breakage of the lower container. Switching to forklift rather than manual procedure will result in saving of containers, reducing waste generation.
Floor washing in a dairy was practiced through open end hoses, which operators occassionally leave running instead of closing the taps. Suggested measures include utilization of pressureized cleaners as well as equipping the hoses with spray guns to provide high pressure water suitable for cleaning and to control the water flow.
The packaging material purchased by the company is not according to the ASTM standard, resulting in over consumption for packaging the final proucts. Contacting the suppliers of the packaging material, and incorporating the dimensions satisfying the ASTM shall save over 9% of the packaging cost.
Whey generated at this dairy is not utilized and is discarded to the drain. Separating the fat from the whey, and introducing in to the production of butter or other neich products is a worth investigating alternative, especially that the separator is readily available on site.
Checking the steam network at a carbonated beverage production facility revealed that the steam condensate is not recovered, leading to loss of water and energy. Installing a condensate recovery network is a feasible alternative to conserve natural resources.
It was noted that this dairy and juice company consumes volume of water to rinse the system during the CIP exceeding the benchmarked quantities. Reducing the water quantities over small steps, while monitoring the product quality lead to conservation of water and energy.
Modification to the process in order to have a prewashing stage before the boxes are emptied to the sterilization station saved significantly on water, energy and reduced the pollution load.