Mapping of water losses revealed that 20m3/hr of wastewater are drained from a dairy company. In order to reuse that quantity of wastewater, a technical feasibility study was recommended to the company to understand the water quality, and the required treatment levels for potential reuse.

This company’s steam-condensate circuit was not optimised, where the pressurized condensate was recovered into a vented tank, and then pumped to the water feedtank which is itself vented to the atmosphere to release a large amount of energy (vapour losses). Installation of a flash tank can recovery part of the condensate in the form of low pressure steam, that saves on the boiler consumption.

Manual valves used to shutdown the material dosing system are causing loss of material, and inconsistency of recipie. Installing automatic solenoid valves, with PLC controller will optimise the recipie of products, improving the product quality, and eliminate losses associated to the manual valves.

Records of the oil content in the generated meal of an edible oil company showed excess oil leftover in the meal (rejects) compared to the benchmark value. This was attributed to the old design of the oil extraction rollers, which didn’t deploy differential speed between the two rollers, relying only on pressure to extract oil from seeds.
Differntiting the speed of the two rollers resulted in introducing shear force, in addition to the pressure force, which increased the yield of oil from seeds.

Deodorization of edible oil is done by a stripping process through several steps of steam condensation and vacuum extraction including high consumption of energy and water. For this oil refining plant, the deodorization process amounts to 78% of the total energy consumption and 38% of total water consumption.
Introducing the most recent techniques using dry ice condensing system shall provide a simple, environmentally friendly, cost effective and low temperature way to replace the process vapor used for edible oil deodorization.