Transcript The European IPPC Bureau Institute for Prospective

Food, drink and milk BREF
Tallinn - 27 and 28 March 2007
Rosemary Campbell
[email protected]
1
BREF scope (Annex 1)
6.4. (b) Treatment and processing intended for the production
of food products from:
-
animal raw materials (other than milk) with a finished
product production capacity greater than 75 tonnes per
day
-
vegetable raw materials with a finished product
production capacity greater than 300 tonnes per day
(average value on a quarterly basis)
6.4. (c) Treatment and processing of milk, the quantity of milk
received being greater than 200 tonnes per day (average
value on an annual basis)
2
BREF scope
• very wide scope
• large number of FDM sectors
• large number of processes
• similar products processed differently
• different products processed similarly
• advantages
• many common environmental issues – also with other BREFs
• many common BAT – also with other BREFs
• learning from sharing - first opportunity at European level
(develop for revision)
• disadvantages
• large document
• amount of information and detail varies between sectors
• difficult to address all the key issues
3
Information submitted/exchanged
• 258 references
• BREF - 638 pages
• some general, some detailed
• BREF outline and guide - structure
• late, even at the final TWG meeting
• data compared where consistent units used
------------------------------------------------------------------• Estonia
4
Key environmental issues
Water consumption/contamination
•drinks manufacture
- in the product
• for processing
• for washing raw materials, product
• for cleaning packaging, equipment, installation
• for transport of product
• from drying of FDM material
- then to the WWTP!
5
Key environmental issues
Energy
• processing
- mechanical/heating/cooling/drying
• maintaining freshness/food safety
- refrigeration, freezing
6
Key environmental issues
Solid waste
• trimmings, peelings
• spills
• leaks
• overflow
• off-specification
• inherent loss
• heat deposited waste
• residues in equipment
7
Other driving forces at FDM installations
• food safety/hygiene
– public health
– shelf life
• quality
– taste
– appearance
– nutrition
• customer preferences/market forces
– regional eating habits of consumers
– downstream industry requirements
8
BREF structure
EXECUTIVE SUMMARY
PREFACE
SCOPE
Chapter 1
GENERAL INFORMATION
Chapter 2
APPLIED PROCESSES AND TECHNIQUES
Chapter 3
CURRENT CONSUMPTION AND EMISSION
LEVELS
Chapter 4
TECHNIQUES TO CONSIDER IN THE
DETERMINATION OF BAT
Chapter 5
BEST AVAILABLE TECHNIQUES
Chapter 6
EMERGING TECHNIQUES
Chapter 7
CONCLUDING REMARKS
Chapter 8
REFERENCES
GLOSSARY
9
How BAT are presented
5.1
General BAT
for whole
FDM sector
5.1.1
Environmental
management
5.1.2
Collaboration
with upstream
and downstream
activities
5.1.3
Equipment and
installation
cleaning
5.1.4
ADDITIONAL BAT
for some
processes and
unit operations
5.1.5
Minimisation of
air emissions
5.1.6
Waste water
treatment
(contains some
sector specific
BAT information)
5.1.7
Accidental
releases
5.1.4.1 - 5.1.4.14
ADDITIONAL BAT for some processes and unit operations where those processes and unit operations are applied
(these processes and unit operations are widely applied in the FDM sector, but not in every sector)
General BAT for whole FDM sector
5.2
ADDITIONAL BAT
for some individual
FDM sectors
Additional BAT for some individual FDM sectors
5.2.2
5.2.3
5.2.1
ADDITIONAL BAT ADDITIONAL BAT
ADDITIONAL BAT
for the
for the fruit and
for the meat
fish and shellfish
vegetable
sector
sector
sector
5.2.4
5.2.9
5.2.5
5.2.6
5.2.7
5.2.8
ADDITIONAL BAT
ADDITIONAL BAT ADDITIONAL BAT ADDITIONAL BAT ADDITIONAL BAT ADDITIONAL BAT
for the vegetable
for the drinks
for the dairy
for the starch
for the sugar
for the coffee
oils and fats
sector
sector
sector
sector
sector
sector
5.2.5.1
5.2.5.2
5.2.5.3
ADDITIONAL BAT ADDITIONAL BAT ADDITIONAL BAT
for milk powder for buttermaking for cheesemaking
5.2.5.4
ADDITIONAL BAT
for ice-cream
manufacturing
5.2.9.1
ADDITIONAL BAT
for brewing
5.2.9.2
ADDITIONAL BAT
for winemaking
BAT for whole FDM sector
Many BAT are concerned with “in-process”
management and operation of FDM processing
involving
• low investment in technology
• require training and supervision
• provide significant protection of the
environment as a whole
11
General BAT for whole FDM sector
General processes and operations
• environmental management system
• training
• design/select equipment
• maintenance
• apply and maintain a methodology to
minimise consumption of water and energy
and the production of waste
12
Apply and maintain a methodology
13
General BAT for whole FDM sector
Apply and maintain a methodology
• obtain management commitment (financial benefit!),
organise and plan
• analyse process steps to identify opportunities for
reduction (mass balance) – possibly use external
benchmarks
• assess objectives (initial)
• identify prevention and minimisation options
• evaluation and feasibility study
• implement prevention and minimisation programme
• monitor by measurement and visual inspection
14
General BAT for whole FDM sector
• landspreading MAY be BAT - consider
–
–
–
–
–
Nitrates Directive (Council Directive 92/46/EEC)
nutritional value to plants
geographic (soil, climatic, hydrologic, may affect food or livestock)
traceability – origin and destination of spread substances
monitoring, e.g. soil and groundwater
• implement a system for monitoring and reviewing consumption
and emission levels for individual processes and at site level
– e.g. emissions to water and air; product and by-product yield
• transport solid FDM materials dry
• segregate outputs to optimise use, re-use, recovery, recycling
and disposal (and minimise waste water contamination)
15
Segregation of outputs
•
•
•
•
•
•
•
16
Achieved environmental benefits
reduced water consumption
reduced volume of waste water
reduced waste water contamination
reduced energy consumption (to heat water, for
WWTP)
reduced waste and can dispose of appropriately
increased recovery/recycling of materials
reduced use of detergents
General BAT for whole FDM sector
Collaboration with upstream and downstream activities
• minimise storage times
• manage on-site vehicle movements
• selection of less harmful materials, e.g. cease use of
pesticides ahead of supply
• supply fresh, but not over-ripe raw materials
• high quality fish
17
General BAT for whole FDM sector
Equipment and installation cleaning
• remove raw material residues asap after
processing
• provide and use catch-pots
• optimise the use of dry cleaning
18
Dry cleaning
•
•
•
•
•
•
•
19
Achieved environmental benefits
reduced water consumption
reduced volume of waste water
reduced waste water contamination
reduced energy consumption (to heat water,
for WWTP)
reduced solid waste
increased recovery/recycling of materials
reduced use of detergents
General BAT for whole FDM sector
Equipment and installation cleaning
• pre-soak before wet cleaning
• manage the use of water, energy and
detergent
• operate CIP optimally - measure
turbidity, conductivity or pH automatically dose chemicals
• minimise the use of EDTA
20
General BAT for whole FDM sector
Additional BAT for some unit operations
– freezing and refrigeration
• avoid keeping aircon and refrigerated
areas colder than necessary
• minimise transmission and ventilation
losses from cooled rooms and coldstores
21
General BAT for whole FDM sector
Additional BAT for some unit operations
– compressed air systems
• review the pressure level and reduce it
if possible
• optimise the air inlet temperature
• fit silencers at air inlets and exhausts,
to reduce noise levels
22
General BAT for whole FDM sector
Additional BAT for some unit operations
– steam systems
• maximise condensate return
• avoid losses of flash steam from condensate
return
• isolate unused pipework
• improve steam trapping
• repair steam leaks
• minimise boiler blowdown
23
General BAT for whole FDM sector
Waste water treatment
• waste water arises from water consumption
during processing and cleaning and from the
drying of FDM materials.
• apply process-integrated BAT to minimise
consumption and contamination of water
• apply end-of-pipe treatment waste water
treatment techniques
24
General BAT for whole FDM sector
Waste water treatment
• BAT not concluded on whether it is better to
treat waste water from FDM installations
on-site or off-site, except some primary on-site
techniques, i.e.
– apply an initial screening of solids
– remove fat using a fat trap, if the waste
water contains animal or vegetable FOG
25
Waste water treatment - BATAELs
TWG supported BATAELs for whole diverse
FDM sector
– no sector-specific BATAELs
– some sector-specific evidence of low
achievable levels available
– no lower level concluded for COD, BOD5,
oil and grease or total nitrogen (low levels
achievable at some installations)
26
Waste water treatment - BATAELs
Parameter
Concentration
(mg/l)
BOD5
<25
COD
<125
TSS
<50
pH
6–9
Oil and grease
<10
Total nitrogen
<10
Total phosphorus
0.4 – 5
Better levels of BOD5 and COD can be obtained. It is not always
possible or cost effective to achieve the total nitrogen and phosphorus
levels shown, in view of local conditions.
SPLIT VIEW
27
Additional BAT for meat and poultry
• thaw meat in air
• avoid using flake ice, by mixing chilled and
frozen raw materials
• dose spices and other solid ingredients from a
bulk container, not plastic bags
• stop water flow to sausage fillers during
production breaks
28
Additional BAT for the fruit and vegetable sector
E.g.
• where storage of fruit and vegetables and byproducts cannot be avoided, minimise
storage time and, subject to weather, store
outdoors in clean covered area
• after blanching fruit and vegetables, pass
through cold water before freezing
• optimise the re-use of water, whilst
maintaining hygiene
29
Additional BAT for dairies
E.g.
• replace batch pasteurisers with continuous
ones
• maximise the recovery of diluted, but
otherwise uncontaminated, product from CIP
initial rinses, HTST start-up, shut-down and
change-over and from the rinsing of other
equipment and pipework
30
BAT - dairies
BATACLs and BATAELs for
• market milk
• milk powder production
• ice-cream
addressing
• energy consumption
• water consumption
• waste water volume
31
BAT – dairies
BATACLs and BATAELs – ranges
• indicative of levels achievable by in-process BAT
• energy consumption levels vary due to, e.g. production volumes
• warm climates may use more energy for cooling and vice versa
• water consumption and waste water emission levels vary due
to, e.g. various product portfolios, batch sizes and cleaning
• waste water emission levels may be lower than water
consumption levels if dairies measure intake of cooling water,
often from their own wells, but then discharge it unmeasured
• warm climates - water may be lost due to evaporation
32
Additional BAT for drinks manufacturing
E.g.
• if CO2 is used in the installation, use CO2
which is either recovered from the
fermentation process or as a by-product of
another process, to avoid the production of
CO2 directly derived from fossil fuels
especially for use in the installation
• recover yeast after fermentation
33
Recommendations for future work
•
•
•
•
olive oil extraction – more information
NOx from coffee roasting (techniques/levels)
EDTA – avoiding use – existing information!
exploration of wider applicabilities of
techniques
• economic data, including payback times
34
Suggested topics for future R&D projects
• composition and harmfulness of odours
• reducing NOx emissions from coffee roasting
• EDTA – avoiding use
• reverse osmosis – economic and cross-media
effects
35