U.S. DEPARTMENT OF THE INTERIOR
Federal Water Pollution Control Administration
                                VOLUME III
                 INDUSTRIAL WASTt PROFILE NO. 9
                                      DAIRIES

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Other publications in the Industrial Waste Profile series
  FWPCA Publication No.  I.W.P.- 1
  FWPCA Publication No. I.W.P.- 2:

  FWPCA Publication No. I.W.P.- 3:
  FWPCA Publication No. I.W.P.- 4:
  FWPCA Publication No. I.W.P.- 5:
  FWPCA Publication No. I.W.P.- 6:

  FWPCA Publication No. I.W.P.- 7:

  FWPCA Publication No. I.W.P.- 8:
  FWPCA Publication No. I.W.P.-10:
Blast Furnace and
 Steel Mills
Motor Vehicles and
 Parts
Paper Mills
Textile Mill Products
Petroleum Refining
Canned and Frozen
 Fruits and Vegetables
Leather Tanning and
 Finishing
Meat Products
Plastics Materials and
 Resins
             FWPCA Publication No. I.W.P.-9

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                    THE COST OF

                    CLEAN WATER
                    Volume III

             Industrial Waste  Profiles
                  No.  9 - Dairies
        U. S.  Department of  the Interior
Federal Water Pollution Control Administration
   For sale by the Superintendent of Documents, U.S. Government Printing Office
               Washington, D.C., 20402 - Price$1.00

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                                PREFACE
The Industrial VJaste Profiles are part of the Aational Requirements and
Cost Estimate Study required by the Federal VJater Pollution Control Act
as amended.  The Act requires a comprehensive analysis of the require-
ment and costs of treating municipal and industrial wastes and other ef-
fluents to attain prescribea water quality standards.

The Industrial V'aste Profiles were established to describe the source
and auantity of pollutants produced by each of the ten industries  stud-
ied.  The profiles were designed to provide industry and government
with information on the costs ana alternatives involved in dealing ef-
fectively with the industrial water pollution prohlen.  They include
descriptions of the costs and effectiveness of alternative methods of
reducing liquid wastes by changina processing methods, by intensifying
use of various treatment methods, and by incrcasina utilization of
wastes in by-products or water reuse in processing.  They also describe
past and projected changes in processing and treatment methods.

The information provided by the profiles cannot possibly reflect the
cost or wflsteload situation for a given plant.  Lowever, it is hoped
that the profiles, by providing a generalized framework for analyzing
individual plant situations, will stimulate industry's efforts to  fine
morn efficient ways to reduce wastes than are cenerally practiced  today.
                                        Conniissioner        0  I
                         Federal w?rt*?r Pollution Control Administration
                                                        IWP 9-2

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INDUSTRIAL   WASTE   PROFILE
            Prepared for F.W.P.C.A.
         FWPCA Contract Number 14-12-102

                  June 30, 1967
Federal Water Pollution Control Administration
                September 1967
                                         IWP 9-3

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                     SCOPE OF MATERIAL COVERED

Industrial Waste Profile IWP-9 Dairies is a qualitative and
quantitative description of wastes and wastewater generated in
the Dairy Industry identified in SIC Code as 202 Dairy Products.

The Industry is examined in its important major subdivisions
identified by SIC Code as followsj

2021  Creamery Butter - Establishments primarily engaged in manu-
      facturing creamery butter.

2022  Cheese, Natural and Processed - Establishments primarily
      engaged in manufacturing all types of natural cheese (except
      cottage cheese-Industry 2026), processed cheese, cheese foods,
      and cheese spreads.

2023  Condensed and Evaporated Milk - Establishments primarilv
      engaged in manufacturing condensed and evaporated milk and
      related products, including ice cream mix and ice milk nix
      made for sale as such and dry milk products.

2024  Ice Cream and Frozen Desserts - Establishments primarily
      engaged in manufacturing ice cream and other frozen desserts.

2026  Fluid Milk - Establishments primarily engaged in processing,
      packaging and distributing fluid milk and cream, cottage
      cheese, and related products.

The Profile is prepared for the Base Year of 1963 which permits
correlation with 1963 Census of Manufacturers data for production
and water use.

The waste and wastewater estimates are developed from actual plant
operating experience, and are correlated with manufacturing pro-
cesses and are augmented with waste reduction and removal cost
estimates.

Projections of waste and wastewater for future years are developed
in detail.
                                                 IWP 9-4

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                  TABLE OF CONTENTS

       INDUSTRIAL WASTE PROFILE IWP-9 - DAIRIES

            (SIC Code 202 - Dairy Products)

Cover Page                                          IWP 9-1

Preface

Title of Report                                     IWP 9-3

Scope of Material Covered                           IWP 9-4

Table of Contents                                   IWP 9-5

Chapter 202  - Dairy Products                       IWP 9-6

Chapter 2021 - Creamery Butter                      IWP 9-9
     Processes and Wastes
     Gross Waste Quantities
     Waste Reduction Processes
     Waste Reduction or Removal Cost Data

Chapter 2022 - Cheese - Natural and Processed       IWP 9-36
     Processes and Wastes
     Gross Waste Quantities
     Waste Reduction Processes
     Waste Reduction or Removal Cost Data

Chapter 2023 - Condensed and Evaporated             IWP 9-65
     Processes and Wastes
     Gross Waste Quantities
     Waste Reduction Processes
     Waste Reduction or Removal Cost Data

Chapter 2024 - Ice Cream and Frozen Desserts        IWP 9-98
     Processes and Wastes
     Gross Waste Quantities
     Waste Reduction Processes
     Waste Reduction or Removal Cost Data

Chapter 2026 - Fluid Milk                           IWP 9-127
     Processes and Wastes
     Gross Waste Quantities
     Waste Reduction Processes
     Waste Reduction or Removal Cost Data

Reference Material                                  IWP 9-159

Summary of Report                                   IWP 9-161

Final Page                                          IWP 9-167


                                                 IWP 9-5

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                      INTRODUCTION
The dairy industry represents a most viable and necessary segment
of our expanding economy.  All members of our society use and
are benefited by the diversified products being manufactured
daily by this industry.  Skim milk, baby formulae, multi-flavored
ice creams and sherbets are examples of only a few of these basic
food products.  The dairy industry no longer follows the simple
producer-consumer concept of former years.  Dairying now encom-
passes a vast network of farmer cooperatives, private businesses,
grocery companies and large nationwide chains, all of which
contribute to the necessary process of bringing dairy products
to market.

Milk production remains a basic adjunct to a nealthy environment.
As is true of most of our industry, technological and scientific
advancements have played an immense role in streamlining the
dairy industry.  Although both milk production and number of
cows have declined over the years, production per cow has been
on the rise.  Such production has increased nationwide from
6,303 Ib. per year in 1957 to 7,561 Ib. in 1963 and 8,513 Ib.
in 1966.  Current industry predictions are that future total
production will increase proportionately with population growth.

In 1963, 16 million cows produced approximately 127 billion Ib.
of milk.  Approximately 125 billion Ib. of this amount was
utilized under five industry product classifications which will
be studied in this profile.  The largest portion, 52 billion Ib.,
has been categorized under the heading of Fluid Milko  This
heading also includes approximately 1% billion Ib. of milk util-
ized in the production of cottage cheese.  The other classifica-
tions are Butter with 34 billion Ib., Cheese with 14.4 billion Ib.,
Ice Cream and Frozen Desserts with 11.9 billion Ib., and
Condensed and Powdered Milk with 10.8 billion Ib.  Each of these
amounts represents the quantity of milk utilized directly under
a heading.  The amounts do not necessarily represent, however,
the total processing under each classification, since certain
"wastes" from one process may serve as the primary raw material
for another process.

The classifications utilized are generally accepted throughout
the dairy industry.  The headings are, therefore, proper in
examining wastes derived from the manufacture of a given dairy
product.
                                     202 - Dairy Industry  IWP  9-6

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The reader should assume that each product discussed is to be
treated separately, exclusive of any by-products which in turn
could be analyzed, e.g. that in the butter process the finished
product is butter alone-~the skim milk and buttermilk which are
by-products of the manufacturing process are for our purposes
considered as wastes.  Historically, this type of waste was an
actual waste to plant sewer, but now the bulk of this material
is utilized for other product manufacture.  In the case of the
butter industry, the skim milk and buttermilk are in very large
part utilized as a raw material in the condensed and evaporated
milk manufacturing industries.  This type of utilization is shown
in the profile as "Utilization as By-product" under "Removal
Methods".

The actual processing facility often consists of two or more
plants.  Butter plants and condenseries are often combined so
that the cream and skim milk portions of the milk may be utilized
in one location.  Similarly, ice cream plants are often combined
with fluid milk and cottage cheese plants for the most efficient
utilization of milk.  To the contrary, cheese plants usually
manufacture cheese only, since whole milk is completely utilized.

Fluid milk plants are generally located near the area of greatest
consumption since transportation costs of the finished product
are greatly increased by the additional xreight of bottles and
cases.

This study relates waste to the amount of finished product
produced rather than to the amount of raw material used, as has
been done in previous studies.  It is intended for the use of
two broad groups:  the dairy products processors and those
other persons directly concerned with wastewater control.
Processing matters are expressed in terms prevailing in the
trade.  In particular, wastes are discussed in Ib. BOD (Bio-
chemical Oxygen Demand), while quantity of wastewater is expressed
in gallons.

As has been mentioned, an actual processing facility often con-
sists of two or more plants.  While this study emphasizes the
isolated product/isolated waste ratio, combination plant data
may be computed by adding the amounts of finished products
produced and comparing this computation with the net amount of
waste quantity derived from the cumulative production processes.
Obtaining combination data is further aided by the fact that the
individual chapters  include lists of waste material which can be
used in subsequent by-product processing.  The reader may evalu-
ate how these materials are utilized and eliminated from the net
waste discharged.
                                     202 - Dairy Industry  IWP 9-7

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The data compiled with regard to the actual plant operations
does not include "shrinkage" (the difference between the
amount of milk measured at the farm as compared with the
amount received in the plant) nor does it include the normal
"overfill" which usually occurs in packaging the finished
product.

Therefore, the reader, in studying the individual chapters,
should keep in mind these points:

       1.  The finished product is the basis of reference.

       2.  The individual profile classifies all materials
           other than the finished product as "waste".

       3.  Certain of the "wastes" of one classification
           t«re the raw materials of another.

       4.  The individual plants are often found in combina-
           tion with other plants to fully utilize the raw
           material in one facility.
                                     202 - Dairy Industry  IWP 9-8

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                     2021 - CREAMERY BUTTER
2021 - Creamery Butter:  Establishments primarily engaged in manufac-
       turing creamery butter.

Butter production has for many years been declining, as a result of
competition from oleorr.argar ine.   Per capita consumption reached a low
in 1966, but total production in the next few years is now expected to
increase in proportion to population growth.

Geographically, over 70% of the butter plants in 1963 were located in
the upper Mississippi Valley  (about 25% in Minnesota).

The manufacturing process of butter may be outlined as follows:
1.  Receipt^;  Raw (unpastourized) milk and cream are received from
the farm in either tank trucks or ten gallon cans.

2-  Storage:  The contents are subsequently pumped to refrigerated
storage tanks.  (A plant may have a refrigerated storage room where
the milk and cream remain before being dumped into storage tanks.)
3.  Separation:  From the storage receptacles, the raw products are
passed through a heater.  The raw milk is warmed to a temperature of
90° F. and then centrifuged.  The cream with a butterfat content of
30% to 40% is separated and stored separately.  (The remaining skim
milk is available for by-product use.)

4.  Cooling:  The cream is cooled in continuous coolers and pumped to
storage.

5.  Storage:  The resultant product is held in tanks under controlled
refrigeration.

6.  Pasteurization:  The raw cream is next pumped to a continuous flow
pasteurizer, where the liquid is pasteurized and cooled.  Small plant
concerns may continue to use the vat type pasteurizer.

7.  Pasteurized Storage:  The cooled product from the pasteurizers is
stored in tanks awaiting utilization further in the process stream.

8.  Churning:  The pasteurized cream is tempered to 45  F. and is
churned.  The buttermilk resulting from the churning process is
drained; the butter granules are washed, drained, rewashed, drained,
standardized to 80% fat with addition of water, salt, color and flavor-
ing, and "worked" to the desired consistency.  The butter portion is
sent to packaging.  The buttermilk portion becomes available for by-
product use or is wasted.
                                   2021 - Creamery Butter  IWP 9-9

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 9-  Packaging:  Butter is placed in various types of packaging
machinery, where the commodity is extruded to the desired shape,
wrapped and packaged.

10.  Cold_Storage:   Butter is placed in cold storage until needed
for customer delivery

^'  Shipping:  Packaged butter is usually placed in refrigerated
vehicles for delivery to customers.

     A flow diagram is included on Page IWP 9-11.
                     Waste and Wastewater
The significant wastes derived from the fundamental butter process
are skim milk from the separation process and buttermilk from the
churning operation.  These waste products may be converted to
valuable by-products through evaporating the moisture and drying
the residue  to a powder form for human consumption or aniraal fesd.
Normally, these wastes are forwarded to condenseries; however, in
the smaller  plants a significant amount of skim milk and buttertiilk
is a "net" waste.  If the skim milk and buttermilk are treated as
wastes, they become a difficult waste problem because of the high
protein content.  The skim milk has a BOD of 7.3% and buttermilk,
6.4%.

Less significant sources of wastes are  (1) the spillage which occurs
in normal processing and packaging operations and (2) the wastes
incurred with cleaning equipment at the end of a day's operation.
Some clear water waste occurs in those plants using water for once-
through cooling  in their refrigeration systems.  This technique  is
often  used in rural plants with their own wells or in areas of
abundant water supply.

No water that comes in contact with butter during the manufacturing
process may  be reused because of the danger of contamination.
                                       2021  - Creamery Butter   IWP  9-10

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                            2021 CREAMERY BUTTER
ALTERNATIVES
FUNDAMENTAL PROCESS
                                                         SIGNIFICANT WASTES
PANS L
p<



1 1 *
CANS f'3






1'
erf
o



I BATCH b 	 	






|j
CONTINUOUS R 	 "








• 'S




K
*•
/






f

\

„
••





,.
V









KJ^l/i^XVb

J 	 ,


0
2 STORAGE TANKS
^L


SEPARATION

"l
4 COOLING
t
5 STORAGE TANKS
i


0 rAoJ.hUKi^Cj
CONTINUOUS
x__ .
7 STORAGE TANKS
I


0
8 CHURN BATCH
1 	 . . 	
9 PACKAGE
T
10 COLD STORAGE
•^

11 SHIP OUT










A. :
.... „ ^ SKIM MILK







K
r COOLING WATER





BUTTERMILK
^ WASH WATER






CLEANING WATER
PRODUCT LOSS Hi
OPERATIONS
                                            2021   CREAMERY  BUTTER     IWP 9~H

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                       RECENT DEVELOPMENTS
The fundamental butter process changed little from 1950 to 1966, and
little change is forecast for 1967 to 1977.  Nevertheless, several
developments of interest have occurred.

The most significant change has been in the number reduction of butter
plants.  Due to economical pressures, many small plants have closed or
have merged.  This trend, which is expected to continue, is depicted
on Page IWP 9-13.

Since 1950, bulk tank trucks have largely replaced the 10-gallon cans
used in Step 1, "Receipt", of the fundamental process.  The trend has
occurred because the use of trucks has virtually eliminated physical
labor, improved sanitation maintenance and reduced the likelihood of
contamination.

Self-cleaning (CIP) separators used in Step 3 of the fundamental
process are now available.  Such machinery reduces the amount of manual
washing required, as well as the reduction of physical labor.

Because of tremendous volume, large plants utilize continuous flow
equipment, as opposed to batch type machinery.  This development has
tended to reduce the percentage of plant loss in operations and, conse-
quently, has helped to minimize wastes.  Greatly improved heating and
refrigeration systems have reduced water needs considerably.

The trend in packaging is to smaller units which better serve the needs
and desires of the consumer.  Automatic packaging continues to replace
manual methods.  Not only is the amount of waste reduced, but new
machinery fills more accurately.

Permanent stainless steel piping systems were introduced in the early
1950's.  Such systems are cleaned in place, as opposed to the daily
take-apart systems formerly accepted.  This type equipment reduces the
quantity of soap required and, therefore, reduces waste.  The fact
that the systems are permanently installed has reduced plant product
losses; also, sanitation and product shelf life has been increased—a
factor which has tended to reduce waste.

Significant changes have occurred in material handling within plants
by the introduction of sophisticated converyors and stacking, grouping
and palletization equipment.  Even though machines have tended to'
increase individual plant wastes through the  enlarged usage of water-
soap lubricants, product loss and waste has been reduced because of
the less likelihood of package damage.
                                   2021 - Creamery Butter  IWP 9-12

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                                      BUTTER - 2021
         Production (Million Lbs.)
1,500
1,000
                    O
                    m
                    a-
                         m
                         vO
         Number  of  Plants
4,000
3,000
2,000

1,000
o
-
-
1
1
,

                     o
                     m
in
in
o
VD
         Prqduct_ion per Plant (Thousand  Lbs.)	
3,000
2,000
1,000




                     o
                     m
in
in
CN
o
vD
o\
                                                       2021 - Creamery Butter   IWP 9-13
    281-032 O - 68 - 2

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The trends- may best be shown in tabular form, which follows.  The
reader should note that these industry changes have occurred over a
span of years.

The process which will become prevalent is identified as P, and that
which is becoming less used as S.
                       TABLE IW? 9 - 14
Estimated Percentage of Plants Employing Process

(b)

(c)

(d)


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                Comparative Waste Control  Problems
 The  subprocesses  (Table  IWP  9-14)  do not require  different  treatment
 from the  fundamental  processes; however, the  choice  of  subprocess  is
 largely determined  by the  total volume  produced.   Large plants  often
 utilize continuous  flow  processes  because  of  greater  productivity  per
 piece of  equipment.   These processes generate less waste per  pound of
 finished  product.

 Skim milk,  buttermilk, product spillage, cleaning water and soaps--all
 constitute  the  significant wastes  for any  type  process  utilized.

 In order  to best  estimate  total industrial waste  and  wastewater, it is
 desirable to identify the  existing levels  of  technology.  The following
 table illustrates  three  technological levels.   The fundamental  process
 steps from  Page IWP 9-9  are  used as reference for the table which  follows.

                         TABLE  IWP  9 - 15
 1.

 2.

 3.


 4.

 5.
     (a)
Older Technology

Receive in cans

Store in cans
Comparative Technology

            (b)
      Typical Technology

      Receive in tank trucks

      Store in tanks
 8.

 9.
Heat, then separate
centrifugally

Cool in batches

Store raw product
in cans

Pasteurize and cool
in batches

Storage in batch
pasteurizers

Churn in batches

Package manually
10.   Store in cold
     storage

11.   Ship out

12.   Take-apart piping

13.   Manual material
     handling
      Heat, then separate
      centrifugally

      Cool continuously

      Cold storage in tanks
      Pasteurize and cool
      in batches

      Pasteurized storage
      in tanks

      Churn in batches

      Package semi-
      automatically

      Inventory in cold
      storage

      Ship out

      Partial CIP piping

      Partial automatic
      material handling
       (c)
Advanced Technology

Receive in tank trucks

Store in tanks

Heat, then separate
centrifugally

Cool continuously

Store raw products
in tanks

Pasteurize and cool
in batches

Pasteurized storage
in tanks

Churn continuously

Package automatically


Inventory in cold
storage

Ship out

CIP piping

Automatic material
handling
                                   2021 -  Creamery Butter  IWP 9-15

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                       Size vs. Technology
In 1963 there were 1,321 butter plants producing 1,419,688,000 Ib. of
butter.  The industry considers a plant producing under one-half million
pounds per year as "small", one-half to three million pounds as
"medium" and over three million pounds as "large".

Waste and wastewater are a function of size as well as technology.  TABLE
IWP 9-16 represents the industry's opinion of the relationship of size
and technology.
                         TABLE IWP 9 - 16

                         Plant Statistics

                               1963

Small     714  54% produce less than 1/2 million pounds per year
Medium    477  36% produce 1/2 to 3 million pounds per year
Large     130  10% produce more than 3 million pounds per year

Total:  1,321  plants produced 1,419,688,000  Ib. in 1963


                               Percentage of  Various Sizes
       Percentage
       Technology             Small       Medium      Large
         Levels            Less than \    % to 3   More than 3

40% Older Technology           94%            4%         2%
55% Typical Technology         30           62          8
 5% Advanced Technology         2             4         94
 The  above relationship provides a basis  for computation  of  overall  plant
 wastes produced when related  to unit waste production  of various  size
 plants utilizing  three technology levels.
                                     2021  -  Creamery Butter   IWP 9-16

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     Gross Waste Quantities Before Treatment or Other Disposal

In plants of advanced technology, waste generated is less than in those
plants less advanced.  Waste and wastewater per pound of finished product
are as follows:

                        TABLE IWP 9 - 17-A

                Waste and Wastewater per Pound of
                        Finished Product
                        Skim &
                       Buttermilk
                       Product
                       Chemicals
                       Pounds BOD   Pounds BOD   Pounds BOD
Older Technology
Typical Technology
Advanced Technology
           1.586
           1.586
           1.586
            .0168
            .0067
            .0034
           .0017
           .0007
           .0003
      Wastewater
       Gallons_

        13.5
         6.5
         4.1
This data represents industry operating experience.  Skim milk and butter-
milk wastes are similar for all levels of technology because the basic
processes are similar; however, the other wastes are affected by plant
size and technology.  Skim milk and buttermilk are largely utilized in
by-product manufacture.
                 Seasonal Waste Production Pattern

Waste quantities tend to be directly proportional to production quantities;
however, wastewater is generated in larger quantities in the warm months,
reflecting increased refrigeration requirements.  The following table illus-
trates this relationship.
                        TABLE IWP 9 - 17-B

Percentage of Yearly Total of Skim, Product, Soap & Chemical and Wastewater

           S-P-S & C   Wastewater                   S-P-S & C   Wastewater
January
February
March
April
May
June
 9.5
 9.7
10.6
10.7
11.0
10.1
 7.5
 8.7
 9.6
10.7
12.0
11.1
July
Augus t
September
October
November
December
7.8
6.4
4.8
5.7
5.9
6.8
9.8
8.4
6.8
5.7
4.9
4.8
This seasonal variation is not expected to change.
                                    2021 - Creamery Butter  IWP 9-17

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The relationship of plant size and technology shown in Table IWP 9-16
permits a comparison of the number of plants in each technology level.
The unit wastes from Table IWP 9-17-A, when applied to the number of
plants, result in Table IWP 9-18.
                         TABLE IWP 9 - 18

          Gross Waste Quantities for Average Size Plants

A.  Older Technology:     These plants process 1,060 Ib. of finished
                          product per day.

                 Significant Wastes - Lb. per Day

              Skim &                       Soap &
            Buttermilk      Product      Chemicals      Wastewater
# Plants    Pounds BOD"    Pounds BOD    Pounds BOD    Gal, per Day

  528          1,681         17.8            1.8         14,400

B-  Typical Technology:   These plants process 3,900 Ib. of finished
                          product per day.

                 Significant Wastes - Lb. per Day

              Skim &                       Soap &
            Buttermilk      Product      Chemicals      Wastewater
# Plants    Pounds BOD*    Pounds BOD    Pounds BOD    Gal, per Day

  727          6,185         26.29           2.6         25,700

C.  Advanced  Technology:  These plants process 17,300  Ib.  of finished
                          product per day.

                 Significant Wastes - Lb. per Day

              Skim &                       Soap &
            Buttermilk      Product      Chemicals      Wastewater
#Plants    Pounds BOD"    Pounds BOD    Pounds BOD     Gal, per Day

    66         27,438         58.32           5.8         72,700
           *The largest  portion of  skim milk and  buttermilk
            is utilized  in by-product  manufacture and  does
            not go to sewer.
                                     2021 - Creamery Butter  IWP 9-18

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                         TABLE IWP 9 - 19-A.

         Gross Waste Quantities Before Treatment or Disposal

The individual plant daf.a (Table IWP 9-18) when multiplied by the number
of plants results in gross waste quantities before treatment, disposal
or utilization in by-product manufacture.

                                Significant Wastes For Year"
Older Technology
Typical Technology
Advanced Technology

     Total

Individual Plant Range
Skim Milk &
Buttermilk
Pounds BOD
(Millions)
508
2,584
1,039
4,131

Product
Pounds BOD
(Millions)
2.94
5.96
1.20
10.10
1" 50%
Soap &
Chemicals
Pounds BOD
(Millions)
.3
.6
.1
1.0
* 50%
Wastewater
Gallons
(Millions)
2,366
5,847
1,496
9,709
1 20%
                         TABLE IWP 9 - 19-B

                  Projected Waste and Wastewater

The relationship among change in total production, plant size and tech-
nology change is shown in the following table:

        1963 and Projected Gross Wastes and Wastewater in Millions*

               1963     1968     1969     1970     1971     1972     1977
Lb. Product
 Manufactured 1,420
1,274    1,290
1,306
1,327    1,348    1,455
Lb. BOD Skim
 Milk and
 Buttermilk   4,131    3,706    3,753    3,799    3,860    3,921    4,233
Lb. BOD Product  10.10     8.97     9.0      9.01     9.06     9.11     9.31
Lb. BOD Soap &
 Chemicals        1.0	._9	._9       .9	.9	._9	._9_
    Subtotal  4,142.10 3,715.87 3,762.9  3,808.91 3,869.96 3,931.01 4,243.21

Gal. Wastewater 9,736    8,473    8,313    8,148    8,006    7,856    6,982

Projections of product manufactured are based upon industry and government
estimates.

       *Table IWP 9-35 shows net wastes which excludes skim milk
        and buttermilk used in by-product manufacture.
                                   2021 - Creamery Butter  IWP 9-19

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                     Waste Reduction Practices

The waste reduction practices utilized in the industry do not vary
greatly.  Skim milk and buttermilk are in large part used in by-product
manufacture.  If not used, these materials become a portion, of the total
plant waste.  (A common sewer piping system can be used for the entire
plant.)  The wastes other than miscellaneous chemicals are of a "biode-
gradable" nature.

Certain processing practices produce varying amounts of wastes.  Table
IWP 9-20 illustrates such relationships.
                         TABLE IWP 9 - 20

                       Processing Practices

The fundamental process used with the "older" technology as the reference
base, described on Pages IWP 9-15 (A).

        Alternate Process    	% Waste Reduction Efficiency

(a)
0)
(c)
(d)
(e)
(f)
(g)
(h)


Plant - Large js . Small
Receive - Tanks vs. Cans
Separator - CIP vs. Manual
Pasteurize - Continuous vs. Batch
Churn - Continuous vs. Batch
Packaging - Automatic vs. Manual
Piping - CIP vs. Take-apart
Material Handling - Automatic vs.
Manual
Product
80
50
-0-
20
20
10
30

15
Soap & Chemical
50
60
50
60
20
15
50

*
Wastewater
54
85
50
60
20
15
40

*
    *Increases wastewater proportionately to lubricant used.

A  large  plant may be created by  the consolidation of several smaller facilities.
The subprocesses (b-h) may be applied to any plant on an individual basis and
are not  dependent on each other; hox^ever, the common practice  is to utilize
continuous  flow and automatic equipment together.

Continuous  flow and automatic equipment tend to have capacity  ratings which
justify  the use thereof  only in  the average to larger size plants.  Continu-
ous churns  are rare even in the  largest of plants because of initial cost
and because very high  production capacities do not permit flexibility of
operation.
                                      2021  -  Creamery Butter   IWP  9-20

-------
                       Treatment Practices

The practice most used in the disposal of skim milk and buttermilk
wastes is by-product manufacture.

Another popular practice utilizes the Management Technique, i.e., the
closest possible supervision of day-to-day operations to eliminate
processing loss — loss due to waste resulting from the initial shrink-
age of the raw material as well as the overfill of the finished package.

In general, most wasce that goes to plant sewers is subsequently
flowed to municipal sewers; to a lesser extent, waste may be discharged
directly into lakes or streams.

The disposal through use of sewage plants represents the least used
treatment practice.

The following table illustrates the effectiveness of the individual
treatment practice.
                         TABLE IWP 9 - 21
                        Treatment Practices
Removal Method                        Normal Removal Efficiency
                                    % of Total Wasteload Removed
                              Skim Milk &            Soap &
                              Buttermilk   Product  Chemicals  Wastewater

 (a)  Ridge and Furrow            95-100     95-100   95-100         4*
 (b)  Spray Irrigation            95-100     95-100   95-100         5*
 (c)  Aerated Lagoon              90-95      90-95    90-95          1*
 (d)  Trickling Filter            90-95      90-95    90-95          0
 (e)  Activated Sludge            90-95      90-95    90-95          0
 (f)  Municipal Sewer              100        100      100           0
 (g)  To Waterways                 100        100      100           0
 (h)  Utilization as Byproduct      85        99.5      NA         99.5
 (I)  Management Technique        50-75      50-75    50-75        10-75

                 NA = Not Applicable

                *Estimated percent of total evaporated to the
                 atmosphere, the remainder going tc waterways.
                                   2021 - Creamery Butter  IWP 9-21

-------
Assuming  optimum conditions,  the removal methods  (supra) could be
employed  in any given plant;  however,  the utilization  of the  ridge
and  furrow, spray  irrigation, and aerated lagoon  type  processes
require significant amounts of  land.   Furthermore,  soil and climate
limit both the physical size  of a treatment  plant as well  as  the
choice of the treatnent process.

The  trickling filter arid activated  sludge processes are relatively
compact;  however,  these types require  greater capital  investment
and  have  higher operating costs than the other methods.

The  trend is to connect plants  to municipal  systems wherever  possible
in order  to simplify day-to-day operations and to minimize capital
investment.

The  utilization of skim milk  and buttermilk  in by-product  manufacture
will tend to increase because of increasing  relative value and need
for  these products.

The  management  technique is now being  widely accepted  and  involves
"close supervision  of day-to-day operations,  the utilization of
preventative maintenance techniques, and the use  of inventory control
procedures.

It is estimated that the following  percentages of  industrial  waste
haus  been  or will be discharged  to a municipal sewer:

                1950     1963     1967    1972     1977

                  1      5      10       32      53

The  high  BOD requirements of  butter plant wastes  necessitate  that
the  capacity of a  particular  municipal plant be reviewed prior  to
the  connection  of  a new butter  plant wasteload  to the  system.

Pretreatment  is not usually required because of the characteristics
of  the waste; however,  pretreatment may be required if the municipal
 plant is  of  inadequate  size.
                                     2021 - Creamery Butter  IWP 9-22

-------
The various practices have been utilized in varying degrees.  Plant
location, capital costs, operating costs and problems—all influence
the type adoption.
                       TABLE IWP 9-23

    Rate of Adoption of Waste Treatment Practices Since 1950

The rate of treatment practice adoption is shown in percentages.

                              % of Plants Employing Listed Methods

     Removal Method           1950    1963    1967    1972    1977

(a)  Ridge and Furrow           U*      8      10      15      15
(b)  Spray Irrigation           U       5       5       5       5
(c)  Aerated Lagoon             U       5      10      15      25
(d)  Trickling Filter           U       U       U       U       U
(e)  Activated Sludge           U       U       U       U       U
(f)  Municipal Sewer            U       5      10      32      53
(g)  To Waterways              98      73      58      30      -0-
(h)  Utilization as Byproduct  50      90      95      99     100
(i)  Management Technique      40      50      60      65      70


     *U = Under 1%
                                      2021 - Creamery Butter  IWP 9-23

-------
          Waste Reduction or Removal Cost Information

The butter industry has a rather modest capital investment in sewerage
treatment facilities.

The estimated capital investment in waste removal facilities in 1963
was $380,000 and the estimated annual operating expense was $76,000.

In 1966 the capital investment was estimated to have increased to
$900,000 and the annual operating expense to have increased to
$180,000.
          Comparactive Investment & Operating Expenses

Plant sizes have been classified as small, medium and large and tech-
nology levels have been described as old, typical and advanced.

A comparison of investment costs and operating costs for providing
waste and wastewater removal facilities between plants of different
sizes and technologies for the various subprocesses and removal
methods will provide valuable -data for determining which subprocess
or method offers the most attractive opportunities for use in the future
to implement the Clean Water Restoration Act.

The next several pages include comparison tables.  The tables are based
on investment and operating costs as experienced by industry.  Land has
been estimated at $300 per acre for ridge and furrow, spray irrigation
and aerated lagoon installations.

Capital investment for utilization of skim milk and buttermilk as by-
products does not require condensing or drying equipment as sufficient
capacity exists in the condensing industry to perform this function.
It is only necessary to provide storage and transportation facilities
to move the skim milk and buttermilk to the condensing plant.

The management technique requires no additional capital investment.
Nominal expense is incurred for educational purposes.

Economic life in relation to processing equipment represents current
thinking of industry needs for return on  investment and recognizes
obsolescence.

Economic life in relation to removal methods represents observed useful
life.
                                       2021 - Creamery Butter  IWP 9-24

-------
                           TABLE IWP 9 -  25

                           Comparative Costs

         (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the older technology and of  small
size.  Daily "net" waste quantities from plant to sewer are 53.2 pounds BOD
(tsO'/c) and 12,000 gallons of wastewater (120%).  These quantities are "gross"
to waterways.
                                                                      (Years)
Product  =   1060 Ibs/day           Capital    Annual Operating &      Economic
                                    Costs   Maintenance Expenditure     Life

(a)
(b)
(c)

(d)

(e)

(f)

(g)

00



(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
Subprocess :
Plant - Large vs« Small
Receive - Tanks vs. Cans
Separator - CIP vs.
Manual
Pasteurize - Continuous
vs. Batch
Churn - Continuous vs.
Batch
Packaging - Automatic
vs. Manual
Piping - CIP vs.
Take-apart
Material Handling -
Automatic vs.
Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -15%
5,000
NA

15,000

NA

15,000

12,000


6,000


$ 3,900
11,000
3,200
52,500
35,000
200
-0-
4,500
-0-

$ -20%
-1,000
NA

+2,000

NA

-14,700

+1,800


to


$ +800
+2,200
+600
+10,500
+7,000
+300
-0-
-96,100
-7,500

13
13
NA

13

NA

4

13


13


20
20
20
15
15
*
*
30
*
               NA = Not Applicable             * Permanent

               See Reference Notes on Page IWP 9-8 and IWP 9-24.
                                           2021 - Creamery Butter   IWP 9-25

-------
                           TABLE IWP 9 - 26
                           Comparative Costs

            (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the typical technology and of  small
size.  Daily "net" waste quantities from plant to sewer are 40.3 pounds BOD
(_507.) and 4,700 gallons of wastewater (*207»).  These quantities are "gross"
to waterways.
                                                                      (Years)
Product =  1060 Ibs/day           Capital     Annual Operating &    Economic
 	Costs    Maintenance Expenditure   Life
        Subprocess:

(a)  Plant - Large vs. Small      $  -10%        $   -157o
(b)  Receive - Tanks                  -0-            -0-
        Typical vs.  Advanced
(c)  Separator - CIP vs.               NA             NA
               Manual
(d)  Pasteurize - Continuous       15,000         +2,000
        vs. Batch
(e)  Churn - Continuous vs.            NA             NA
               Batch
(f)  Packaging - Automatic          5,000         -3,000
        Typical vs.  Advanced
(g)  Piping - CIP                   6,000           +900
        Typical vs.  Advanced
(h)  Material Handling -            3,000             1"0
        Typical vs.  Advanced
                       13
                       13

                       NA

                       13

                       NA

                        4

                       13

                       13
        Removal Method:

 (a)  Ridge and Furrow              $  1,600
 (b)  Spray Irrigation                4,400
 (c)  Aerated Lagoon                  2,700
 (d)  Trickling Filter              20,700
 (e)  Activated Sludge              13,800
 (f)  Municipal Sewer                   200
 (g)  To Waterways                      -0-
 (h)  Utilization as Byproduct        4,500
 (i)  Management Technique              -0-
$
    300
    900
    500
  4,200
  2,800
    200
    -0-
-96,100
- 2,800
20
20
20
15
15
 *
 *
30
 *
               NA  = Not Applicable
* Permanent
               See Reference  Notes  on  Page  IWP 9-8 and IWP 9-24.
                                            2021 - Creamery Butter  IWP 9-26

-------
                         TABLE IWP 9 -  27
                         Comparative Costs

           (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the advanced technology and of
small size.  Daily "net" waste quantities fron plant to sewer are 36.6 pounds
BOD (150%) and 2,100 gallons of wastewater  (±20%).
to waterways.
                   These quantities are "gross"
Product B 1,060 Ibs/day
Capital     Annual Operating &
 Costs	Maintenance Expenditure
 (Years)
Economic
  Life
        Subprocess:

(a)  Plant - Large vs. Small     $  -15%
(b)  Receive - Tanks                  AH
(c)  Separator - CIP                  NA
(d)  Pasteurize - Continuous          AH
(e)  Churn - Continuous               NA
(f)  Packaging - Automatic            AH
(g)  Piping - CIP                     AH
(h)  Material Handling                AH
                   -20%
                     NA
                     NA
                     AH
                     NA
                     NA
                     NA
                     NA
   13
   13
   NA
   13
   NA
    4
   13
   NA
        Removal Method:

(a)  Ridge and Furrow            $   780
(b)  Spray Irrigation              1,950
(c)  Aerated Lagoon                2,340
(d)  Trickling Filter             33,800
(e)  Activated Sludge             13,000
(f)  Municipal Sewer                 200
(g)  To Waterways                    -0-
(h)  Utilization as Byproduct      4,500
(i)  Management Technique            -0-
               ?    160
                    390
                    470
                  6,750
                  2,600
                    185
                    -0-
                -96,100
                 -1,200
   20
   20
   20
   15
   15
    *
    *
   30
    *
               NA = Not Applicable
               AH « Already installed
                    by definition
               * Permanent
               See Reference Notes on Page IWP 9-8 and IWP 9-24.
                                                2021 - Creamery Butter   IWP 9-27

-------
                           TABLE IWP 9-28

                           Comparative Costs

            (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the older technology and of medium
size.  Daily "net" waste quantities from plant to sewer are 196 pounds BOD
(t507o) and 44,070 gallons of wastewater (t20%).  These quantities are "gross"
to waterways.
                                                                      (Years)
Product   =    3,900 Ibs/day       Capital     Annual Operating &       Economic
                                  Costs    Maintenance Expenditure     Life

(a)
(b)
(c)

(d)

(e)

(f)

(g)

(h)


(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
Subprocess :
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP vs.
Manua 1
Pasteurize - Continuous
vs . Batch
Churn - Continuous vs.
Batch
Packaging - Automatic
vs . Manual
Piping - CIP vs.
Take-apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -157,
5,000
25,000

18,000

NA

15,000

25,000

15,000


$14,400
40,600
11,800
73,500
49,000
200
-0-
11,400
-0-

$ -20%
-3,500
+1,000

-1,200

NA

-5,300

-3,800
4.
to


$ 2,900
8,100
2,400
14,700
9,800
1,000
-0-
-381,500
-30,000

13
13
13

13

NA

4

13

13


20
20
20
15
15
*
*
30
*
               NA =  Not Applicable              * Permanent

               See Reference Notes  on Page  IWP  9-8 and 9-24.
                                                 2021  - Creamery Butter    IWP  9-28

-------
                          TABLE IWP 9  -29
                          Comparative Costs

            (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the typical technology and  of medium
size.  Daily "net" waste quantities from plant to sewer are  153 pounds BOD
(t507o) and  17,200 gallons of wastewater (t207o).  These quantities are "gross"
to waterways.
                                                                      (Years)
Product   =   3,900 Ibs/day      Capital     Annual Operating &      Economic
	Costs    Maintenance Expenditure     Life
        Subprocess:

(a)  Plant - Large vs. Small     $  -107,
(b)  Receive - Tanks vs. Cans        -0-
        Typical vs. Advanced
(c)  Separator - CIP vs.          25,000
               Manual
(d)  Pasteurize - Continuous      18,000
               vs. Batch
(e)  Churn - Continuous vs.           NA
               Batch
(f)  Packaging - Automatic         5,000
        Typical vs. Advanced
(g)  Piping - CIP                 12,000
        Typical vs. Advanced
(h)  Material Handling -           7,500
        Typical vs. Advanced

        Removal Method:

(a)  Ridge and Furrow            $ 5,600
(b)  Spray Irrigation             16,000
(c)  Aerated Lagoon                9,300
(d)  Trickling Filter             35,000
(e)  Activated Sludge             23,400
(f)  Municipal Sewer                 200
(g)  To Waterways                    -0-
(h)  Utilization as Byproduct     11,400
(i)  Management Technique            -0-
$
     -15%
      -0-

   +1,000

   -1,200

       NA

   -2,200

   -1,900

       +0
   1,100
   3,200
   1,900
   7,000
   4,700
     800
     -0-
-381,500
 -11,700
                       13
                       13

                       13

                       13

                       NA

                        4

                       13

                       13
20
20
20
15
15
 *
 *
30
 *
               NA = Not Applicable              * Permanent

               See Reference Notes on Page IWP 9-8 and IWP 9-24.
                                         2021 - Creamery Butter  IWP 9-29
   287-032 O - 63 - 3

-------
                            TABLE IWP 9 - 30
                            Comparative Costs

           (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the advanced technology and of
medium size.  Daily "net" waste quantities from plant to sewer are 139
pounds BOD (t50%) and 7,800 gallons of wastewater (t20%).  These quantities
are "gross" to waterways.
Product  s    3,900 Ibs/day
Capital     Annual Operating &
 Costs    Maintenance Expenditure
                   (Years)
                  Economic
                    Life
        Subprocess:

 (a)  Plant - Large vs. Small
 (b)  Receive - Tanks
 (c)  Separator - CIP
 (d)  Pasteurize - Continuous
 (e)  Churn - Continuous
 (f)  Packaging - Automatic
 (g)  Piping - CIP
 (h)  Material Handling -
        Automatic
   -157.
     AH

     AH
     NA
     AH
     AH
     AH
-207,
  NA

  NA
  NA
  NA
  NA
  NA
13
13
13
13
NA
 4
13
13
        Removal Method:
(a)

-------
               TABLE  IW?  9-31




               Comparative Costs




(For Providing Waste & Wastewater Removal Facilities)
The plant illustrated is representative of the older technology and of large
size. Daily "net" waste quantities from plant to sewer are 869 pounds BOD
(t50%) and 195,490 gallons of wastewater (t20%). These quantities are "gross"
to waterways .
(Years)
Product = 17,300 Ibs/day Capital Annual Operating & Economic
Costs Maintenance Expenditure Life

(a)
(b)
(c)
(d)

(e)

(f)

(g)

(h)


(a)
(b)
(c)
(d)
<0
(f)
(g)
(h)
(i)
Subprocess :
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - GIF vs. Manual
Pasteurize - Continuous
vs. Batch
Churn - Continuous vs .
Batch
Packaging - Automatic
vs. Manual
Piping - CIP vs. Take-
apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ - 15%
32,000
50,000

35,000
125,000

45,000

35,000

35,000


$ 63,500
180,000
52,000
230,000
152,000
200
-0-
52,000
-0-

$ -20%
-14,400
+ 2,000

-7,200
-23,000

-21,200

-13,100

-25,800


$ 11,400
32,400
9,400
41,500
27,400
4,350
-0-
1,730,000
-134,500

13
13
13

13
13

4

13

13


20
20
20
15
15
*
*
30
*
     NA = Not Applicable               *  Permanent



     See Reference Notes  on Page IWP 9-8 and IWP 9-24.
                               2021  - Creamery Butter  IWP 9-31

-------
                          TABLE IWP 9 -  32

                          Comparative Costs

          (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the typical technology and of large
size.  Daily "net" waste quantities from plant to sewer are 677 pounds BOD
(*50%) and 76,200 gallons of wastewater (j"20%).  These quantities are "gross"
to waterways.
                                                                      (Years)
Product  =    17,300 Ibs/day     Capital    Annual Operating &       Economic
                                  Costs   Maintenance Expenditure	Life

(a)
(b)

(c)

(d)

(e)

(f)

(g)

00


(a)
(b)
(c)
(d)
(e)
(f)
(g)
00
(i)
Subprocessj
Plant - Large vs. Small
Receive - Tanks vs. Cans
Typical vs. Advanced
Separator - CIP vs.
Manual
Pasteurize - Continuous
Typical vs. Advanced
Churn - Continuous vs.
Batch
Packaging - Automatic
Typical vs. Advanced
Piping - CI?
Typical vs. Advanced
Material Handling -
Typical vs. Advanced
Remo va 1 Me t ho d :
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -10%
-0-

50,000

5,000

125,000

15,000

18,000

18,000


$ 24,800
70,000
42,000
108,000
71,500
200
-0-
52,000
-0-

$ -15%
-0-

+2,000

-800

-16,000

-7,100

-6,600

-12,500


$ 4,500
12,600
7,500
19,500
13,000
3,400
-0-
-1,730,000
-53,500

13
13

13

13

13

4

13

13


20
20
20
15
15
*
*
30
*
               NA = Not Applicable             * Permanent

               See Reference Notes on Page IWP 9-8 and IWP 9-24.
                                         2021 - Creamery Butter  IWP 9-32

-------
                          TABLE IWP 9 - 33
                          Comparative Costs
          (For Providing Waste & Wastewater Removal Facilities)
The plant illustrated is representative of the advanced technology and of large
size.  Daily "net" waste quantities from plant to sewer are 615 pounds BOD
(.50%) and 34,600 gallons of wastewater (^20%).  These quantities are "gross"
to waterways.
                                                                      (Years)
Product   =    17,300 Ibs/day    Capital    Annual Operating &        Economic
	Costs   Maintenance Expenditure	 Life
        Subprocess:

(a)  Plant - Large vs. Small    $  -15%
(b)  Receive - Tanks                 AH
(c)  Separator - CIP                 AH
(d)  Pasteurize - Continuous         AH
(e)  Churn - Continuous              AH
(f)  Packaging - Automatic           AH
(g)  Piping - CPI                    AH
(h)  Material Handling -             AH
        Automatic
       -20%
         NA
         NA
         NA
         NA
         NA
         NA
         NA
13
13
13
13
13
 4
13
13
        Removal Method:

(a)  Ridge and Furrow           $11,300
(b)  Spray Irrigation            32,000
(c)  Aerated Lagoon              37,000
(d)  Trickoing Filter            70,000
(e)  Activated Sludge            47,000
(f)  Municipal Sewer                200
(g)  To Waterways                   -0-
(h)  Utilization as Byproduct    52,000
(i)  Management Technique           -0-
$     2,000
      5,800
      6,700
     12,600
      8,500
      3,100
        -0-
 -1,730,000
    -26,500
20
20
20
15
15
 *
 *
30
 *
               NA = Not Applicable
               AH = Already installed
                    by definition
  Permanent
               See Reference Notes on-Page IWP  9-8 and  IWP  9-24.
                                        2021 - Creamery Butter  IWP 9-33

-------
The tables indicate that several subprocesses and removal methods are
particularly attractive in terms of small capital investment and low
annual operating expense.

The utilization of skim milk and buttermilk for byproduct manufacture
eliminates these materials as wastes and in most operations represents
very significant economic gains.  The plant with condensing and drying
equipment always utilizes these materials, the plant without this
equipment generally sells these materials.  In the small plants the
volume of skim milk and buttermilk is such that there is greater diffi-
culty in finding a market than in the larger plants, and consequently
these materials are often dumped to sewers.  The trends toward larger
plants and increasing need for these materials will result in a reduc-
tion of wastes.

The application of Management Technique requires no capital investment
and very little operating expense.  This method results in significant
economy in plant operations, and is a highly desirable practice.

Disposal of remaining waste to municipal sewers requires only nominal
investment and operating cost to the plant and is attractive to the
plant operation.  However, if a municipality establishes a sewage rate
based directly on plant waste loads, then comparative economics deter-
mine whether or not a plant should adopt further waste removal methods.
                Summary of Projected Wasteloads
Year
Waste
Gross Waste
 Generated
                                                 Remova1
                                                    *
 Net Waste
Discharged^
                                     Million
                                             Million
1963   Skim Milk & Buttermilk
          (Lbs.  BOD)
       Product (Lbs.  BOD)
       Soap & Chemical (Lbs.  BOD)
       Water  (Gallons)
                     4,131
                        10.10
                         1.0
                  ST 4,142.10

                     9,736
                                                   85
                                                   15
                                                   15
                          619.6
                            8.6
                    ST    629.1

                 5      9,249
      *Percentage of waste reduced or removed by process changes,
       waste treatment and byproducts utilization
                                  2021 - Creamery Butter  IWP 9-34

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               Summary  of  Projected Wasteloads
Year

1968
1969
1970
1971
1972
1977
Waste

Skim & Buttermilk (Lbs . BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Skim & Buttermilk (Lbs. BOD)
Products (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Skim & Buttermilk (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Skim & Buttermilk (Lbs. BOD)
Products (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Skim & Buttermilk (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Skim ft Buttermilk (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemicals (Lbs. BOD)
ST
Water (Gallons)
Gross Waste
Generated
Million
3,706
8.97
.9
3,715.87
8,473
3,753
9.00
.9
3,762.90
8,313
3,799
9.01
.9
3,808.91
8,148
3,860
9.06
.9
3,869.96
8,006
3,921
9.11
.9
3,931.01
7,856
4,233
9.31
.9
4,243.21
6,982
Removal
*
%
91
30
30
ST
5
92
40
40
ST
5
93
50
50
ST
5
94
60
60
ST
5
95
70
70
ST
5
99.5
99.5
99.5
ST
5
Net Waste
Discharged
Million
333.5
6.28
.6
340.38
8,050
300.2
5.4
.5
306.1
7,897
265.9
4.5
.5
270.9
7,741
231.6
3.6
.4
235.6
7,606
196.1
2.7
,3
199:1
7,463
21.2
.46
.05
21.71
6,633
*Percentage of vaste  reduced  or removed by process changes,
 waste treatment and  by-products utilization
                                   2021 - Creamery Butter   IWP 9-35

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                 2022 - CHEESE,  NATURAL AND PROCESSED
2022 - Cheese, Natural and Processed:  Establishments primarily engaged
       in manufacturing all types of natural cheese (except cottage
       cheese—Industry 2026), processed cheese, cheese foods and cheese
       spreads.

       The cheese industry has grown over the years at a slightly faster
       rate than population growth.   This trend is expected to continue.

       In 1963 over 53% (690)  of all cheese plants were located in
       Wisconsin.  New York possessed the next largest number of plants
       with 85, followed by Illinois with 60, Iowa with 46, Ohio with 34
       and Michigan with 33.

       The manufacturing process of cheese is as follows:

1.  Receipt:  Raw milk and skim milk are received in tank trucks and are
emptied by pumping to storage.

2.  Storage:  The raw (unpasteurized) milk is stored in refrigerated
tanks until ready for further use.

3.  Separation:  For low fat cheese, the raw products are pumped through
a heating device and sent to a centrifugal separator which removes all
or part of the cream from the product.  This cream becomes available for
by-product manufacture.

4.  Pasteurization:  The raw milk is usually pasteurized in a continuous
flow pasteurizer, although in smaller operations batch pasteurizers
continue to be used.

5.  Batch Set-Cooking:  The pasteurized product is normally cooled in
the pasteurizer  to the desired temperature and pumped into cheese vats.
The milk is then innoculated with a culture.  At the end of a controlled
period of time,  the curd which results from bacterial action is drained
and becomes available for either by-product manufacture or is treated as
waste.

6.  Batch Drain-Cut-Salt-Mill Vat:  The curd from the cooking vat is washed
with potable water which completes the rinsing away of whey and serves as
a cooling medium.  This water goes to waste.  At this time salt may be
added, and the curd may be cut or milled.

7.  Press-Hoops:  The curd is pressed (compressed) and placed into hoops,
which are can-shaped molds.

8.  Incubation and Storage:  The  cheese hoops are placed in controlled
environment storage rooms to permit "aging", the incubation period necessary
to complete the  formation of cheese.  This period may be a very short time
or it may be  a matter of months,  the  time depending upon the variety of
cheese being  manufactured.  When  the  cheese is removed from the incubation

                           2022 - Cheese, Natural and Processed   IWP 9-36

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storage a portion may go directly to packaging while the other portion
may be used for processed cheese.

9.  Ingredient Preparation:  In the preparation of processed cheese, the
hoop cheese is ground and placed in vats where stabilizers, flavoring,
and other needed ingredients are added.

10.  Blending:  The ingredients are then blended.

11.  Vat Pasteurization and Cooling:  The blended ingredients are pasteu-
rized, partially cooled, and sent to packaging.

12.  Packaging:  The hoop and processed cheese are conveyed to filling
and packaging machines which shape and place the cheese in characteristic
packages and wrappers.

13.  Cold Storage:  From packaging, the cheese is stored and inventoried
in a cold storage area until needed.

14.  Shipping:  The cheese is removed from cold storage and placed on
refrigerated vehicles for delivery to the consumer.

     A flow diagram is included on Page IWP 9-38.
                                  f^
                                  Cheese,  Natural  and  Processed    IWP  9-37

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                     2022 CHEESE - NATURAL AND PROCESSED
ALTERNATIVES
FUNDAMENTAL PROCESS
SIGNIFICANT WASTE
    CANS
    BATCH
     RECEIVE
    TANK TRUCKS
                             2  STORAGE TANKS
                                 SEPARATION
    PASTEURIZE
    CONTINUOUS
                             |5 SET-COOKING VAT
                             6 DRAIN-CUT-SALT
                                  MILL VAT
                                 PRESS-HOOPS
                             '8   INCUBATION
                                  & STORAGE
                             9   INGREDIENT
                                 PREPARATION
                             10    BLEND
                             111  PASTEURIZE
                                   & COOL
12
PACKAGING
                         NTI
                             13 COLD STORAGE
14
SHIP
                                                  >  SOLD
                                     WHEY
                                     WHEY
                                  WASH-WATER
                                 COOLING WATER
                                                           CLEANING WATER
                                                           PRODUCT LOSS
                                                           IN OPERATIONS
                                2022  CHEESE - NATURAL AND PROCESSED •   IWP 9-38

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                      Waste and Wastewater
The significant waste from the fundamental cheese process is whey.
This waste product may be converted to valuable byproducts through
evaporating the moisture and drying the residue to a powder form
for human consumption or animal feed.

If whey is sent to the plant disposal system, the material becomes a
most difficult waste problem because of the high protein and acidic
content.  Approximately 547. of the solids in the raw material remains
in the whey resulting in a BOD of 3.2%.

To date, whey processing remains a problem to the industry.  Recent
research has shown that mechanical screens are ineffective in separat-
ing whey waste; on a small scale, expensive centrifuging has been
utilized effectively.  Whey contains .9% to 1% albumin which, if
heated and treated with acid, will result in removal of 60% to 70%.
This processing, however, reduces the BOD load by only 20% to 25% and
has proven to be too expensive for normal processing use.  The most
practical utilization of whey has been through the facilities of dry-
ing plants; however, these operate either at the breakeven point or
with only a slight profit.

Less significant sources of wastes are (1) the spillage which occurs
in normal processing and packaging operations and (2) the wastes
incurred with cleaning equipment at the end of a day's operation.
Some clear water waste occurs in those plants using water for once-
through cooling in their refrigeration systems.  This technique is often
used in rural plants with their own wells or in areas of abundant water
supply.

No water that comes in contact with cheese during the manufacturing
process may be reused because of the danger of contamination.
                         2022 - Cheese, Natural and Processed  IWP 9-39

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                       RECENT DEVELOPMENTS
The fundamental cheese process has changed little from 1950 to 1966,
and little change is forecast for 1967 to 1977.  Nevertheless, several
developments of interest have occurred.

The most significant change has been in the number reduction of cheese
plants.  Due to economical pressures, many small plants have closed or
have merged.  This trend, which is expected to continue, is depicted on
Page IWP 9-41.

Since 1950, bulk tank trucks have largely replaced the 10-gallon cans
used in Step 1, "Receipt", of the fundamental process.  The trend has
occurred because the use of trucks has virtually eliminated physical
labor, improved sanitation maintenance and reduced the likelihood of
contamination.

Self-cleaning  (CIP) separators used in Step 3 of the fundamental process
are now available.  Such machinery reduces the amount of manual washing
required, as well as the reduction of physical labor.

Because of tremendous volume, large plants utilize continuous flow
equipment, as  opposed to batch type machinery.  This development has
tended to reduce the percentage of plant loss in operations and,
consequently,  has helped to minimize wastes (other than whey).  Greatly
improved heating and refrigeration systems have reduced water needs
considerably.

The trend in packaging is to smaller units which better serve the needs
and desires of the consumer.  Automatic packaging continues to replace
manual methods.  Not only is the amount of waste reduced, but new
machinery fills more accurately.

Permanent stainless steel piping systems were introduced in the early
1950s.  Such systems are cleaned in place, as opposed to the daily
take-apart systems formerly accepted.  This type equipment reduces the
quantity of soap required and, therefore, reduces waste.  The fact that
the systems are permanently installed has reduced plant product losses;
also, sanitation and product shelf life has been increased--a factor
which has tended to reduce waste.

Significant changes have occurred in material handling within plants
by the  introduction of sophisticated conveyors and stacking, grouping
and palletization equipment.  Even though machines have tended to
increase  individual plant wastes through the enlarged usage of water-
soap  lubricants, product  loss and waste has been reduced because of
the  less  likelihood of package damage.
                          2022  -  Cheese,  Natural  and  Processed   IWP  9-40

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                                    CHEESE - 2022
        Production (Million Lbs.)
2,000
1,500
1,000
3,000
        Number of Plants
2,000
1,000

  800
3,000
2,000
        Production per Plant (Thousand Lbs.)
                   o
                   m
                   o\
m
\o
en
o
i^
Oi
                                     2022 - Cheese,  Natural and Processed  IWP 9-41

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The trends may best be shown in tabular form, which follows.  The reader
should note that the alternative subprocesses and other industry changes
have occurred over a span of years.

The process which will become prevalent is identified as jp, and that which
is becoming less used as J3.

                         TABLE IWP 9 - 42

          Estimated Percentage of Plants Employing Process


                                  1950     1963     1967     1972     1977

(b)  P  Receive in Tank Trucks     -0-       40       50       60       70
     S  Receive in Cans            100       60       50       40       30

(c)  P  Separator (Manual)         100      100       98       96       94
     S  Separator GIF              -0-      -0-        246

(d)  P  Pasteurize Continuously    -0-      -0-        247
     S  Pasteurize Batch           100      100       98       96       93

(e)  P  Batch Set                  100      100       99       98       95
     S  Continuous Set             -0-      -0-        125

(f)  P  Package Automatically       10       35       50       65       75
     S  Package Manually            90       65       50       35       25

(g)  P  CIP Piping                 -0-       20       30       40       60
     S  Take-apart Piping          100       80       70       60       40

(h)  P  Automatic Material Handling 20       50       60       70       75
     S  Manual Material Handling    80       50       40       30       25

     The estimates represent the observations and opinions of people in the
     industry, including processors, material and equipment suppliers and
     manufacturers and industry associations and consultants.
                             2022 - Cheese, Natural and Processed  IWP 9-42

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               Comparative Waste Control Problems
The subprocesses (Table IWP 9-14) do not require different treatment
from the fundamental processes; however, the choice of subprocess is
largely determined by the total volume produced.  Large plants often
utilize continuous flow processes because of greater productivity per
piece of equipment.  These processes generate less waste per pound of
finished product.

The whey from the cheese manufacturing process, wash water, product
spillage and waste during normal processing, and cleaning water and
soaps represent the significant wastes for all processes and subpro-
cesses .

Whey constitutes by far the largest volume of waste and is high in
protein content as well as acidity.

In order to best estimate total industry waste and wastewater, it is
desirable to identify levels of technology within the industry.  The
following table illustrates three technological levels.  The funda-
mental process steps from Page IWP 9-36 are used as reference for this
table.

                       TABLE IWP 9 - 43
                    Comparative Technology
         (a)
    Older Technology

1.  Receive in cans

2.  Store in cans
                              (b)
                       Typical Technology

                       Receive in tank trucks

                       Store in tanks
    Separation, if     Separate as required;
    required, centri-  heat and separate
    fugally            centrifugally
    Pasteurize in
    batches
                       Pasteurize continu-
                       ously
5.  Set-cooking vat    Set-cooking vat
    manually agitated  equipped with
                       mechanical agitation
                       and pushers

                       Drain, cut, salt,
                       mill vat, curd pumped
                       to this vat from the
                       set-cooking vat

                       Press in hoops, curd
                       conveyed and pressed
                       automatically
6.  Drain, cut, salt
    and mill in the
    set-cooking vat
    Press in hoops
    manually
Advanced Technology

Receive in tank trucks

Store in tanks

Separate as required;
heat and separate
centrifugally

Pasteurize continuously
                                                Set-cooking vat equipped
                                                with mechanical agitators
                                                and pushers
Drain, cut, salt, mill
vat, curd pumped to this
vat from the set-cooking
vat

Press in hoops, curd
conveyed and pressed
automatically
                       2022 - Cheese, Natural and Processed  IWP 9-43

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           (a)
     Older Technology

 8.   Incubate in con-
     trolled environment
 9.  Ingredient prepara-
     tion for processed
     cheese, manual

10.  Blend ingredients
     manually

11.  Pasteurize and
     cool in batches

12.  Package manually
13.  Inventory in cold
     storage

14.  Ship out

15.  Take-apart piping
     and

16.  Manual materials
     handling
       (b)
Typical Technology

Incubation in storage
under controlled
environment

Ingredient prepara-
equipment usually
mechanical

Blend ingredients
mechanically

Vats, batch pasteuri-
zation and cooling

Package in large
part automatically

Inventory in cold
storage

Ship out

CIP piping (partial)
and

Partial automatic
materials handling
       (c)
Advanced Technology

Incubation in storage
under controlled
environment

Ingredient preparation
equipment usually
mechanical

Blend ingredients
mechanically

Vats, batch pasteuriza-
tion and cooling

Package automatically
Inventory in cold stor-
age

Ship out

CIP piping and


Automatic materials
handling
                          2022  -  Cheese, Natural  and Processed  IWP 9-44

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                        Size vs. Technology

In 1963 there were 1,282 cheese plants producing 1,631,817,000 pounds of
cheese.  The industry considers a plant producing under one-half million
pounds per year as "small", one-half to two million pounds as "medium"
and over two million pounds as "large".

Waste and wastewater are a function of size as well as technology.  TABLE
IWP 9-45 represents industry opinion of the relationship of size and
technology.
                         TABLE IWP 9 - 45

                         Plant Statistics

                              1963

Small     483   37% produce less than % million pounds per year
Medium    620   49% produce from \ to 2 million pounds per year
Large     179   14% produce more than 2 million pounds per year

Total:  1,282   plants produced 1,631,817,000 pounds in 1963


                                Percentage of Various Sizes
      Percentage
      Technology               Small       Medium      Large
        Levels              Less than %    \ to 2    More than 2

30% Older Technology            90%          10%         0%
60% Typical Technology           3           85         12
10% Advanced Technology          0           26        102
The relationship provides a basis for computation of overall plant wastes
produced when related to unit waste production of various size plants of
the three technology levels.
                              2022 - Cheese, Natural and Processed  IWP 9-45
   287-032 O - 63 - 4

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       Gross Waste Quantities Before Treatment or Other Disposal

In plants of advanced technology, waste generated is less than in those
less advanced.  Unit waste and wastewater quantities per pound of fin-
ished product arc as follows:
                      TABLE IWP 9 - 46-A

         Waste and Wastewater Quantities per Pound of
                       Finished Product

                                                      Soap &
                      Cream       Whey      Product  Chemicals  Wastewater
                    Pounds BOD Pounds BOD Pounds BOD Pounds BOD  Ga1Ions

Older Technology       .044       .259      .030       .003       23.1
Typical Technology     .037       .258      .012       .001       18.1
Advanced Technology    .036       .253      .0045      .0005      12.9

This data represents industry operating experience.  Whey waste is similar
for all levels of technology because the basic process is similar for all
levels; however, the other wastes are affected to a greater extent by
changes in technology.
               Seasonal Waste Production Pattern

Waste quantities tend to be directly proportional to production quantities;
however, wastewater is used in greater quantities in the warm months,
reflecting increased refrigeration requirements.  The following table
illustrates the relationship.
                      TABLE IWP_ 9 - 46-P

                  Percentage of Yearly Total

         Production   Wastewater               Production   Wastewater

January      7.6          6.2        July          9.3        10.6
February     7.3          7.9        August        8.1         9.2
March        8.9          8.3        September     7.3         8.0
April        9.3          9.1        October       7.1         6.9
May         10.3         10.6        November      6.9         6.5
June        10.5         11.0        December      7.4         6.7

This seasonal variation is not expected to change.
                            2022 - Cheese, Natural and Processed  IWP 9-46

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The relationship of size and technology shown in Table IWP 9-45 permits
estimating the number of plants of each technology level.  The unit
wastes from Table IWP 9-46-A, when applied to the number of plants,
results in Table IWP 9-47.
                       TABLE IWP 9 - 47

       Gross Waste Quantities for Average Size Plants
A.  Older Technology;     These plants process 1,060 Ib. of finished
                          product per day.

               Significant Wastes - Lb. per Day

                                                Soap &
             Cream       Whey       Product    Chemicals    Wastewater
 # Plants  Pounds BOD  Pounds BOD  Pounds BOD  Pounds BOD  Gals, per Day

   513        45.9       269.7        31.2        3.1         2,890
B.  Typical Technology;   These plants process 5,000 Ib. of finished
                          product per day.

               Significant Wastes - Lb. per Day

                                               Soap &
            Cream       Whey       Product    Chemicals    Wastewater
# Plants  Pounds BOD  Pounds BOD  Pounds BOD  Pounds BOD  Gals, per Day

   641       183.5     1280.0        60.0        6.0        10,850
C.  Advanced Technology:  These plants process 13,000 Ib. of finished
                          product per day.

               Significant Wastes - Lb. per Day

                                               Soap &
            Cream       Whey       Product    Chemicals    Wastewater
# Plants  Pounds BOD  Pounds BOD  Pounds BOD  Pounds BOD  Gals. per Day

   128       466.8     3286.0        58.8        5.9        20,120
                            2022 - Cheese, Natural and Processed  IWP 9-47

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                       TABLE IWP 9 - 48A

         Gross Waste Quantities Before Treatment or Disposal

The individual plant data (Table IWP 9-47) when multiplied out by the
number of plants results in gross waste quantities before treatment,
disposal or utilization in byproduct manufacture.

                               Significant Wastes Per Year

                                                     Soap &
                     Cream      Whey      Product   Chemicals  Wastewater
                   Pounds BOD Pounds BOD Pounds BOD Pounds BOD  Gallons
                   (Millions) (Millions) (Millions) (Millions) (Millions)

Older Technology        8.8       51.3       6.0        .6        549
Typical Technology     36.7      256.0      12.0       1.2       2170
Advanced Technology    18.7      131.3       2.4        .3        803

     Total             64.2      428.6      20.4       2.1       3522

Individual Plant
     Range:            _10%      tlO%       ^50%      ^50%
                       TABLE IWP 9 - 48B

                Projected Waste and Waotewater

The relationship among change in total production, plant size and tech-
nology change is shown in the following table:

         1963 and Projected Gross Wastes and Wastewater in Millions

                 1963    1968    1969    1970    1971    1972    1977

Lb. Product
   Manufactured  1,632   1,921   1,945   1,966   2,001   2,032   2,244

Lb. BOD  Cream       64.2    75.6     76.5    77.3    78.7    79.9    88.3
Lb. BOD  Whey       428.6   504.5   510.8   516.3   525.5   533.6   589.3
Lb. BOD  Product     20.4    23.8     23.8    23.9     2.4    24.1    25.3
Lb. BOD  Soap &       2.0     2.4-     2.4     2.4     2.4     2.4     2.5
   Chemicals
         Subtotal   515.2   606.3   613.5   619.9   609.0   640.0   705.4

Gal. Wastewater  3,522   4,022   3,945   3,861   3,800   3,727   3,390
 Projections  of  Product Manufactured  are based  upon  industry  and  government
 estimates.
                             2022  -  Cheese,  Natural  and  Processed   IWP  9-48

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                  Waste Reduction Practices

The waste reduction practices utilized in the industry do not vary
greatly.  Wastes from the various processes and subprocesses are all
similar in nature and thus a common sewer piping system is used for
the entire plant.  The wastes other than miscellaneous chemicals are
of a "biodegradable" nature.

Certain of the processing practices produce varying amounts of wastes,
Table IWP 9-49 illustrates these relationships.
                       TABLE IWP 9 - 49

                     Processing Practices

       Fundamental Process Used as the Reference Base is "Older"
             Technology Described on Pages IWP 9-43

	Alternate Process	% Waste Reduction Efficiency	
	Product   Soap & Chemical   Wastewater

(a)  Plant - Large vs. Small        85           45              45
(b)  Receive - Tanks vs. Cans       50           85              85
(c)  Separator - CIP vs. Manual      0           50               0
(d)  Pasteurize - Continuous vs.
                  Batch             20           60              60
(e)  Set - Continuous vs. Batch      5           30              10
(f)  Packaging - Automatic vs.
                  Manual            10           30              15
(g)  Piping - CIP vs. Take-apart    30           40              40
(h)  Material Handling - Automatic
                  vs. Manual        10            *               *

    *Increases wastewater proportionately to lubricant used.
A large plant may be created by the consolidation of several smaller
facilities.  The other subprocesses (b-g) may be applied to any plant
on an individual basis and are not dependent on each other; however,
the common practice is to utilize continuous flow and automatic equip-
ment together.

Continuous flow and automatic equipment tends to have capacity ratings
that justify the use thereof only in the average to larger size plants,
                            2022 - Cheese, Natural and Processed  IWP 9-49

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                     Treatment Practices

The utilization of whey in byproduct manufacture is the treatment
method being given the greatest amount of attention; however, a rela-
tively small amount is being so used.

Another popular practice utilizes the Management Technique, i.e.,
the closest possible supervision of day-to-day operations to eliminate
processing loss--loss due to waste resulting from the initial shrinkage
of the raw material as well as the overfill of the finished package.

In general, most waste that goes to plant sewers is subsequently flowed
to municipal sewers; to a lesser extent, waste may be discharged
directly into lakes or streams.

The disposal through use of sewage plants represents the least used
treatment practice.

The following table illustrates the effectiveness of the various treat-
ment practices.
                       TABLE IWP 9 - 50
                      Treatment Practices
       Removal efficiency of various treatment methods in
        use in 1963 for a plant of "Typical" technology
Removal Method
 (a)
 (b)
 (c)
 (d)
 (e)
 (f)
 (g)
 (h)
 (i)
Normal Removal Efficiency
 of Total Wasteload Removed
                             Product
      Soap &
     Chemicals
Wastewater
Ridge and Furrow 95-100
Spray Irrigation 95-100
Aerated Lagoon 90-95
Trickling Filter 90-95
Activated Sludge 90-95
Municipal Sewer 100
To Waterways 100
Utilization as Byproduct 99.5
Management Technique 50-75
95-100
95-100
90-95
90-95
90-95
100
100
NA
50-75
4*
5*
1*
0
0
0
0
99.5
10-75
     *Estimated  percent  of  total evaporated  to  the atmosphere.
      The  remainder  goes  to waterways.
                             2022  -  Cheese, Natural  and  Processed   IWP  9-50

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Assuming optimum conditions, the removal methods (supra) could be
employed in any given plant; however, the utilization of the ridge
and furrow, spray irrigation, and aerated lagoon type processes
require significant amounts of land.  Furthermore, soil and climate
limit both the physical size of a treatment plant as well as the
choice of the treatment process.

The trickling filter and activated sludge processes are relatively
compact; however, these types require greater capital investment
and have higher operating costs than the other methods.

The trend is to connect plants to municipal systems wherever possible
in order to simplify day-to-day operations and to minimize capital
investment.

The utilization of whey and cream in byproduct manufacture
will tend to increase because of increasing relative value and need
for these products.

The management technique is now being widely accepted and involves
close supervision of day-to-day operations, the utilization of
preventative maintenance techniques, and the use of inventory control
procedures.

It is estimated that the following percentages of industrial waste
have been or will be discharged to a municipal sewer:

                1950    1963    1967    1972    1977

                  1       5      10      32      53

The high BOD requirements of cheese plant wastes necessitate that the
capacity of a particular municipal plant be reviewed prior to the
connection of a new cheese plant wasteload to the system.

Pretreatment is not usually required because of the characteristics of
the waste; however, pretreatment may be required if the municipal plant
is of inadequate size.
                            2022 - Cheese, Natural and Processed  IWP 9-51

-------
The various practices have been utilized in varying degrees.  Plant
location, capital costs, operating costs and problems--all influence
the type adoption.
                        TABLE IWP 9 - 52

      Rate of Adoption of Waste Treatment Practices Since 1950

The rate of adoption of treatment practice is shown in percentages.

                                  % of Plants Employing Listed Methods

     Removal Method

(a)  Ridge and Furrow
(b)  Spray Irrigation
(c)  Aerated Lagoon
(d)  Trickling Filter
(e)  Activated Sludge
(f)  Municipal Sewer
(g)  To Waterways
(h)  Utilization as Byproduct
(i)  Management Technique
1950
u*
U
U
u
u
u
98
50
40
JL963
8
5
5
U
U
5
73
90
50
1967
10
5
10
U
U
10
58
95
60
1972
15
5
15
U
U
32
30
99
65
1977
15
5
25
U
U
53
0
100
70
    *U = Under 1%
                             2022 - Cheese,  Natural and Processed  IWP 9-52

-------
          Waste Reduction or Removal Cost Information

The cheese industry has a modest capital investment in sewerage treat-
ment facilities, and annual operating and maintenance expenditures.

The estimated capital investment in waste removal facilities in 1963
was $600,000 and the estimated annual operating expense was $120,000.

In 1966 the capital investment was estimated to have increased to
$900,000 and the annual operating expense to have increased to
$180,000.

           Comparative Investment & Operating Expense^

Plant sizes have been determined as small, medium and large and tech-
nology levels described as old, typical and advanced.

A comparison of investment costs and operating costs for providing
waste and wastewater removal facilities between plants of different
sizes and technologies for the various subprocesses and removal
methods will provide valuable data for determining which subprocess
or method offers the most attractive opportunities for use in the future
to implement the Clean Water Restoration Act.

The next several pages include comparison tables.  The tables are based
on investment and operating costs as experienced by industry.  Land has
been estimated at $300 per acre for ridge and furrow, spray irrigation
and aerated lagoon installations.

Capital investment for utilization as byproduct does not necessarily
require condensing or drying equipment as sufficient capacity exists in
condensery; however, the more successful whey plants seem to be
individual facilities.  Animal feed plants are not of the same sanitary
construction as those producing products for human consumption.

The management technique requires no additional capital investment.
Nominal expense is incurred for educational purposes.

Economic life in relation to processing equipment represents current
thinking of industry needs for return on investment and recognizes
obsolescence.

Economic life in relation to removal methods represents observed useful
life.
                            2022 - Cheese, Natural and Processed  IWP 9-53

-------
                           TABLE IWP 9 - 54

                           Comparative Costs

           (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the older technology and of small
size.  Daily "net" waste quantities from plant to sewer are 32 pounds BOD
(±50%) and 1,200 gallons of wastewater (+20%).  These quantities are "gross"
to waterways.
                                                                     (Years)
Product r 800 Ibs/day            Capital     Annual Operating &     Economic
                                  Costs    Maintenance Expenditure    Life

(a)
(b)
(c)

(d)

(e)

(f)

(8)

(h)


(a)
(b)
(c)
(<*)
(e)
(f)
(g)
(h)
(i)
Subprocess ;
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CPI vs.
Manual
Pasteurize - Continuous
vs. Batch
Set - Continuous vs.
Batch
Packaging - Automatic
vs. Manual
Piping - CIP vs. Take-
apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -15%
5,000
25,000

15,000

NA

15,000

12,000

6,000


$ 500
1,300
2,200
6,100
4,100
200
-0-
50,000
-0-

$ -20%
-1,000
+6,000

+2,000

NA

+4,700

+1,000

+0


$ +100
+300
+400
+1,200
+800
+200
-0-
+9,000
-1,000

13
13
NA

13

NA

4

13

13


20
20
20
15
15
*
*
13
*
               NA = Not Applicable
               AH = Already installed
                    by definition
* Permanent
               See Reference Notes on Page IWP 9-8 and IWP 9-53,
                                 2022  -  Cheese  Natural  & Processed   IWP 9-54

-------
            TABLE IWP 9-55
            Comparative Costs
(For Providing Waste
& Wastewater Removal Facilities)
The plant illustrated is representative of the
size. Daily "net" waste quantities from plant
(_507.) and 1,000 gallons of wastewater (1^207.).
to waterways.

Product = 800 Ibs/day


typical technology
to sewer are 15.5
These quantities


Capital Annual Operating &
Costs Maintenance Expenditure
Subprocess^;
(a) Plant - Large vs. Small
(b) Receive - Typical vs.
Advanced
(c) Separator - CIP vs.
Manual
(d) Pasteurize - Continuous
Typical vs. Advanced
(e) Set - Continuous vs.
Batch
(f) Packaging - Automatic
Typical vs. Advanced
(g) Piping - CIP Typical
vs. Advanced
(h) Material Handling -
Typical vs. Advanced
Removal Method:
(a) Ridge and Furrow
(b) Spray Irrigation
(c) Aerated Lagoon
(d) Trickling Filter
(e) Activated Sludge
(f) Municipal Sewer
(g) To Waterways
(h) Utilization as Byproduct
(i) Management Technique

$ -107.
-0-

25,000

4,000

NA

5,000

6,000

3,000


$ 400
1,100
1,100
5,100
3,400
200
-0-
50,000
-0-

$ -15%
-0-

+6,000

+800

NA

-3,000

+500

to


$ +100
+200
+200
+1,000
+700
+100
-0-
+9,000
-400
and of small
pounds BOD
are "gross"

(Years)
Economic
Life

13
13

13

13

NA

4

13

13


20
20
20
15
15
*
*
13
*
NA = Not Applicable              * Permanent




See Reference Notes on Page IWP 9-8 and IWP 9-53.
                  2022  - Cheese Natural & Processed  IWP 9-55

-------
                          TABLE IWP 9 -  56
                          Comparative Costs

           (For Providing Waste & Wastewater Removal Facilities)
The plant illustrated is representative of the advanced technology and of  small
size.  Daily "net" waste quantities from plant to sewer are 8.9 pounds BOD
(*50%) and 500 gallons of wastewater  (^207.).  These quantities are "gross" to
waterways.
                                                                      (Years)
Product = 800 Ibs/day            Capital     Annual Operating &     Economic
	Costs	Maintenance Expenditure	Life	
        Subprocess:

(a)  Plant - Large vs. Small     $  -15%
(b)  Receive - Tanks                  AH
(c)  Separator - CIP vs.              AH
               Manual
(d)  Pasteurize - Continuous          AH
(e)  Set - Continuous                 AH
(f)  Packaging - Automatic            AH
(g)  Piping - CIP                     AH
(h)  Material Handling -              AH
        Automatic
$  -20%
     NA
     NA

     NA
     NA
     NA
     NA
     NA
        Removal Method;

 (a)  Ridge and Furrow            $   200
 (b)  Spray Irrigation                500
 (c)  Aerated Lagoon                  600
 (d)  Trickling Filter              2,500
 (e)  Activated Sludge              1,700
 (f)  Municipal Sewer                 200
 (g)  To Waterways                    -0-
 (h)  Utilization as Byproduct     50,000
 (i)  Management Technique            -0-
$
   •440
  +100
  +100
  +500
  +300
   +50
   -0-
+9,000
  -200
20
20
20
15
15
 *
 *
13
 *
               NA - Not Applicable               * Permanent
               AH = Already Installed
                    by definition
               See Reference Notes  on  Page  IWP 9-8  and  IWP 9-53.
                                  2022  -  Cheese  Natural  & Processed   IWP 9-56

-------
                          TABLE IWP 9 - 57

                          Comparative Costs

           (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the older technology and of medium
size.  Daily "net" waste quantities from plant to sewer are 134 pounds BOD
(1"50%) and 6,500 gallons of wastewater (J20Z).  These quantities are "gross"
to waterways.
                                                                     (Years)
Product = 3,400 Ibs/day          Capital     Annual Operating &     Economic
                                  Costs    Maintenance Expenditure    Life

(a)
(b)
(c)

(d)

(e)

(f)

(g)

00


(a)
(b)
(c)
(d)
(e)
(f)
(8)
(h)
(i)
Subprocess ;
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP vs.
Manual
Pasteurize - Continuous
vs. Batch
Set - Continuous vs.
Batch
Packaging - Automatic
vs. Manual
Piping - CIP vs.
Take-apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -15%
5,000
25,000

18,000

NA

50,000

32,000

38,000


$ 2,400
6,900
9,300
32,800
21,900
200
-0-
90,000
-0-

$ -20%
-3,500
+1,000

-1,200

NA

-9,000

-2,400

-7,000


$ 4500
+1,400
+1,900
+6,600
+4,400
+700
-0-
±0
-3,500

13
13
13

13

NA

4

13

13


20
20
20
15
15
*
*
13
*
               NA = Not Applicable              * Permanent

               See Reference Notes on Page IWP 9-8 and IWP 9-53.
                                 2022 - Cheese Natural & Processed  IWP 9-57

-------
            TABLE IWP 9-58
Comparative Costs
(For Providing Waste
& Wastewater Removal Facilities)
The plant illustrated is representative of the typical technology and
medium size. Daily "net" waste
BOD (+507.) and 4,100 gallons of
"gross" to waterways.

Product = 3,400 Ibs/day

Subprocess :
(a) Plant - Large vs. Small
(b) Receive - Tanks
Typical vs. Advanced
(c) Separator - CIP vs.
Manual
(d) Pasteurize - Continuous
Typical vs. Advanced
(e) Set - Continuous vs.
Batch
(f) Packaging - Automatic
Typical vs. Advanced
(g) Piping - CIP
Typical vs. Advanced
(h) Material Handling -
Typical vs. Advanced
Removal Method:
(a) Ridge and Furrow
(b) Spray Irrigation
(c) Aerated Lagoon
(d) Trickling Filter
(e) Activated Sludge
(f) Municipal Sewer
(g) To Waterways
(h) Utilization as Byproduct
(i) Management Technique
quantities from plant to sewer are 66
wastewater (+20%,). These quantities



of
pounds
are

(Years)
Capital Annual Operating & Economic
Costs Maintenance Expenditure

$ -107. $ -15%
-0- -0-

25,000 +1,000

4,000 -800

NA NA

25,000 -8,100

16,000 +2,900

19,000 -2,800


$ 1,500 $ +300
4,400 +900
4,800 +1,000
20,700 +4,200
13,800 +2,800
200 +300
-0- -0-
90, 000 +0
-0- -1,600
Life

13
13

13

13

NA

4

13

13


20
20
20
15
15
*
*
13
*
NA = Not Applicable              * Permanent




See Reference Notes on Page IWP 9-8 and IWP 9-53.
                  2022 - Cheese Natural & Processed  IWP 9-58

-------
                          TABLE IWP 9 -  59

                          Comparative Costs.

           (For Providing Waste & Wastewater Removal  Facilities)

The plant illustrated is representative of the advanced  technology  and  of
medium size.  Daily "net" waste quantities from plant  to sewer are  37.6
pounds BOD  (+507o) and 2,100 gallons of wastewater  (+207.).  These quantities  are
"gross" to waterways.
                                                                      (Years)
Product = 3,400 Ibs/day          Capital     Annual  Operating &     Economic
                                  Costs    Maintenance Expenditure    Life

(a)
(b)
(c)
(d)
(e)

(f)
(g)
(h)


(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
Subprocess :
Plant - Large vs. Small
Receive - Tanks
Separator - CIP
Pasteurize - Continuous
Set - Continuous vs.
Batch
Packaging - Automatic
Piping - CIP
Material Handling -
Automatic
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -15%
AH
AH
AH
AH

AH
AH
AH


$ 800
2,200
2,600
10,100
6,800
200
-0-
90,000
-0-

$ -207.
NA
NA
NA
NA

NA
NA
NA


$ +200
4500
4500
42,000
41,400
4200
-o_-
10
-1,700

13
13
13
13
NA

4
13
13


20
20
20
15
15
*
*
13
*
               NA = Not Applicable
               AH = Already installed
                    by definition
* Permanent
               See Reference Notes on Page IWP 9-8 and IWP  9-53.
                                 2022 - Cheese Natural & Processed  IWP 9-59

-------
                          TABLE IWP 9 - 60

                          Comparative Costs

            (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the older technology and of large
size.  Daily "net" waste quantities from plant to sewer are 613 pounds BOD
(l507o) and 29,500 gallons of wastewater (1207.).  These quantities are "gross"
to waterways.
                                                                      (Years)
Product = 15,500 Ibs/day         Capital     Annual Operating &       Economic
                           	    Costs	Maintenance Expenditure     Life

(a)
00
(c)

(d)

(e)

(f)

(g)

00


(a)
(b)
(c)
(d)
(e)
(f)
(g)
00
(i)
Subprocess :
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP vs.
Manual
Pasteurize - Continuous
vs. Batch
Set - Continuous vs.
Batch
Packaging - Automatic
vs. Manual
Piping - CIP vs.
Take -apart
Material Handling -
Automatic vs. Manual
Remova 1 Me tho d :
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -15%
32,000
25,000

35,000

**

80,000

75,000

65,000


$ 11,000
31,500
42,300
69,500
46,500
200
-0-
380,000
-0-

$ -207.
+ 4,300
+ 1,000

- 9,900

**

- 22,400

- 6,400

- 8,000


$ +2,000
+5,700
+7,600
+12,500
+8,400
+3,100
-0-
-8,000
-18,200

13
13
13

13

**

4

13

13


20
20
20
15
15
*
*
13
*
               NA = Not Applicable              * Permanent

               **Insufficient Information Available

               See Reference Notes on Page IWP 9-8 and IWP 9-53.
                                 2022  - Cheese Natural & Processed  IWP 9-60

-------
                          TABLE IWP 9 - 61

                          Comparative Costs

            (For Provtding Waste & Wastewater Removal Facilities)
The plant illustrated is representative of the typical technology and of
large size.  Daily "net" waste quantities from plant to sewer are 301 pou
BOD (1507.) and 18,600 gallons of wastewater  (120%).  These quantities are
"gross" to waterways.
Product = 15,500 Ibs/day
Capital    Annual Operating &
 Costs   Maintenance Expenditure
 (Years)
Economic
  Life
        Subprocess:

(a)  Plant - Large vs. Small     $   -10%       $   -15%                13
(b)  Receive - Tanks                  -0-            -0-                13
        Typical vs. Advanced
(c)  Separator - CIP vs.           25,000         +1,000                13
               Manual
(d)  Pasteurize - Continuous        5,000         -1,000                13
        Typical vs. Advanced
(e)  Set - Continuous vs.             **             **                 **
        Batch
(f)  Packaging - Automatic         40,000        -22,200                 4
        Typical vs. Advanced
(g)  Piping - CIP Typical          32,000         -2,100                13
        vs. Advanced
(h)  Material Handling -           35,000         -4,000                13
        Typical vs. Advanced

        Removal Method;

(a)  Ridge and Furrow            $  7,000       $ +1,300                20
(b)  Spray Irrigation              19,800         +3,600                20
(c)  Aerated Lagoon                20,800         +3,800                20
(d)  Trickling Filter              94,000        +16,900                15
(e)  Activated Sludge              62,600        +11,300                15
(f)  Municipal Sewer                  200         +1,500                 *
(g)  To Waterways                     -0-            -0-                 *
(h)  Utilization as Byproduct     330,000         -8,000                13
(i)  Management Technique             -0-         -7,300                 *
               NA = Not Applicable              * Permanent

               ** Insufficient Information Available

               See Reference Notes on Page IWP 9-8 and IWP 9-53.
                                 2022 - Cheese  Natural  & Processed  IWP 9-61

-------
                           TABLE IWP 9-62
                           Comparative Costs

           (For Providing Waste & Wastewater Removal Facilities)
The plant illustrated Is representative of the advanced technology and of
large size.  Daily "net" waste quantities from plant to sewer are 172 pounds
BOD (J50%) and 9,300 gallons of wastewater (120%).  These quantities are
"gross" to waterways.
                                                                     (Years)
Product = 15,500 Ibs/day         Capital     Annual Operating &     Economic
	Costs    Maintenance Expenditure	Life
        Subprocess ;

(a)   Plant - Large vs.  Small
(b)   Receive - Tanks
(c)   Separator - CIP
(d)   Pasteurize - Continuous
(e)   Set - Continuous vs.
               Batch
(f)   Packaging - Automatic
(g)   Piping - CIP
(h)   Material Handling -
        Automatic
-15%
  AH
  AH
  AH
  **

  AH
  AH
  AH
                                                $  -207.
                                                     NA
                                                     NA
                                                     NA
                                                     **

                                                     NA
                                                     NA
                                                     NA
13
13
13
13
**

 4
13
13
        Removal Method;

 (a)  Ridge and Furrow             $  3,500        $  4600
 (b)  Spray Irrigation               9,900        +1,800
 (c)  Aerated Lagoon                11,900        +2,100
 (d)  Trickling Filter              47,000        +8,500
 (e)  Activated Sludge              31,400        +5,600
 (f)  Municipal Sewer                  200          +900
 (g)  To Waterways                     -0-            -0-
 (h)  Utilization as Byproduct     380,000        -8,000
 (i)  Management Technique             -0-        -2,800
                                   20
                                   20
                                   20
                                   15
                                   15
                                    *
                                    *
                                   13
                                    *
               NA = Not Applicable
               AH = Already Installed
                    by definition
           * Permanent
          ** Insufficient Information
             available
                See  Reference Notes  on Page  IWP  9-8  and  IWP 9-53.
                                  2022  -  Cheese Natural  & Processed   IWP  9-62

-------
The tables indicate that several subprocesses and removal methods are
particularly attractive in terms of small capital investment and low
annual operating expense.

The utilization of cream and whey in byproduct manufacture eliminates
these materials as wastes.  Because of its value, cream is always utilized;
however, whey has a low economic value.   The plant with condensing and
drying equipment will utilize whey as a  by-product if there is an econo-
mic market available; otherwise the plant with or without this equipment
tends to send whey to the sewage system.  The trends towards larger plants
and increasing need for these materials  will result in a reduction of
wastes.

The application of Management Technique  requires no capital investment
and very little operating expense.  This method results in significant
economy in plant operations, and is a highly desirable practice.

Disposal of remaining waste to municipal sewers requires only nominal
investment and operating cost to the plant and is attractive to the
plant operation.  However, if a municipality establishes a sewage rate
based directly on plant waste loads, then comparative economics deter-
mine whether or not a plant should adopt further waste removal methods.
                Summary of Projected Wasteloads
Year Waste

1963 Cream (Lbs. BOD)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs.
Water (Gallons)
Gross Waste
Generated
Million
64.2
428.6
20.4
BOD) 2.0
ST 515.2
3,522
Removal
*
7,
99
48
15
15
5
Net Waste
Discharged
Million
.64
222.9
17.0
1.7
ST 242.24
3,346
      *Percentage of waste reduced or removed by process changes,
       waste treatment and byproducts utilization
                             2022 - Cheese,  Natural  and  Processed   IWP  9-63

-------
             Summary of Projected Wasteloads
Year


1968





1969





1970





1971





1972





1977





Waste


Cream (Lbs . BOD)
Whey (Lbs. BOD)
Product (Lbs . BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Cream (Lbs . BOD)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Cream (Lbs . BOD)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Cream (Lbs . BOD)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Cream (Lbs . BOD)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Cream (Lbs. BOD)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Gross Waste
Generated
Million
75.6
504.5
23.8
2.4
606.3
4,022
76.5
510.8
23.8
2.4
613.5
3,945
77.3
516.3
23.9
2.4
619.9
3,861
78.7
525.5
24.0
2.4
630.6
3,800
79.9
533.6
24.1
2.4
640.0
3,727
88.3
589.3
25.3
2.5
705.4
3,390
Remova 1
*
7.
99
53
30
30
ST
5
99
58
40
40
ST
5
99
63
50
50
ST
5
99
68
60
60
ST
5
99
75
70
70

5 ST
99.5
99.5
99.5
99.5
ST
5
Net Waste
Discharged
Million
.76
235.2
16.6
1.7
254.26
3,821
.77
214.5
14.2
1.4
230.87
3,748
.77
191.0
11.9
1.2
204.87
3,668
.78
168.2
9.6
1.0
179.58
3,610
.80
133.4
7.2
.7
142.1
3,541
.44
29.5
.13
.01
30.08
3,221
*Percentage of Waste Reduced or Removed by Process  Changes,
 Waste Treatment and Byproducts Utilization
                        2022 - Cheese,  Natural and  Processed   IWP 9-64

-------
              2023 - CONDENSED AND EVAPORATED MILK

2023 - Condensed and Evaporated Milk:  Establishments primarily engaged
       in manufacturing condensed and evaporated milk and related pro-
       ducts, including ice cream and ice milk mix, and dry milk products.

       Condensed and evaporated milk production has been declining since
       1955 with a marked drop in 1965 and 1966.  The trend is expected
       to continue.

       Total fa-rm milk production has been declining, while fluid milk,
       cheese and ice cream production has increased.  With the exception
       of that portion of condensery production used for ice cream mix
       manufacture, the condensery industry operates by utilizing the
       milk remaining after the requirements of the other segments of
       the industry have been met.

       Geographically, condenseries are located in areas of adequate
       supply.  In 1963 there were 20 states without condenseries and
       five with only one.  There were 64 in Wisconsin, 61 in Minnesota,
       34 in Iowa, and 20 in Michigan.  New York had 38, Pennsylvania 21
       and California 22.  No other state had more than 10.

       The manufacturing process for condensed and evaporated milk may
       be outlined as follows:

1.  Receipt:  Dairy products are normally received in tank trucks and
ten-gallon cans.  The larger volume plants tend to receive in tank trucks
and the smaller plants in cans.  Larger plants may receive a small portion
in cans.  Dairy products normally received include milk as well as skim
milk, whey, and buttermilk, which are byproducts of other processing
operations.  Another significant amount of receipts is in the form of
liquid sugar and liquid corn syrup for use as mix ingredients (although
smaller operations may receive the sugar in bag form).  The liquid in-
gredients are pumped to storage tanks.

2.  Raw (unpasteurized) Product Storage;  Dairy products are stored in
refrigerated tanks prior to utilization.  The sugars and corn syrups are
stored in heated tanks prior to use.

3.  Separation:  From storage a portion of the dairy products is sent
through a heating device and then to a centrifugal separator in which all
of the cream is separated and sent to storage for later use in ice cream
mix manufacture.  The skim milk is sent to pasteurization equipment.

4.  Pasteurization:  The milk is usually pasteurized in a continuous flow
pasteurizer, although smaller plants may continue to use vat-type pasteu-
rizers.  The pasteurized milk is sent to a surge tank to adjust the differ-
ence between flow rates of the pasteurizer and of the evaporator.
                          2023 - Condensed and Evaporated Milk    IWP 9-65

-------
5.  Evaporation (condensing):   Water is evaporated from the milk by heating
the milk with steam in a vacuum chamber.   A vacuum is maintained so that
the boiling point is lowered to a point at which the product is not injured
through excessive heat.   The evaporator is normally a continuous flow unit,
although in smaller operations batch type evaporators may be used.   The
continuous evaporator may have a number of "effects" which permit a signi-
ficant reduction in the amount of steam necessary to produce a given amount
of evaporated milk.  Since the first cost of adding "effects" is significant,
the tendency to have more effects occurs in the larger plants where
greater economies are realized.  Normally 15% of the water is removed and
the evaporated milk will have 25.5% solids compared to the original milk,
12.5% solids.  The evaporated (condensed) milk may be sent to (12)  spray
dryers or may be sent to cooling.

6.  Cooling:  Product from the evaporator is usually cooled in a continuous
cooler, although occasionally batch cooling is used.

7.  Pasteurized Storage:  The cooled evaporated milk is stored in refriger-
ated trucks.

8.  Packaging in Cans:  Automatic machinery is used to fill and seal the
cans.

9.  Sterilize:  The canned milk proceeds to the sterilizer where it is
heated to a high temperature for a short period of time and then cooled to
storage temperature.

10.  Storage;  Packaged product is inventoried in storage until needed for
delivery to customers.

11.  Ship Out;  The finished product is drawn from storage and placed on
vehicles for distribution.

12.  Spray Drying:  That portion of the evaporated milk to be used for
powder is sent to a spray dryer.  The product is pumped with a high pressure
pump into a heated air screen where the remaining moisture is evaporated
and the dry powder is separated.  The spray dryer is a continuous form of
drying under relatively low heat contact with the product.  Some evaporated
milk continues to be dried on roll dryers.

13.  Instantizing:  Powdered milk used by the consumer is usually sent
through an instantizing process prior to packaging.

14.  Packaging Powder:  The powdered milk from the dryer or from the
instantizer is packaged in bags and barrels for bulk users and in retail
type packages for consumer use.  The finished product is sent to Storage
(10).

     In addition to the evaporated milk and powdered milk process described,
there  is the additional fundamental process of mix-making in this type of
establishment.  From Step 3 above, cream is available from refrigerated
storage tanks.  From Step 1, dairy products and sugars.
                          2023 - Condensed and Evaporated Milk   IWP 9-66

-------
15.  Storage of Dry Ingredients:  In addition to the liquid dairy and syrup
ingredients, dry ingredients such as stabilizers, emulsifiers, and choco-
late are needed, as well as water.  The dry ingredients are held 'in storage
prior to use.

16.  Liquify Dry Ingredients;  Prior to use, the ingredients are placed
into solution in a mixing device and then pumped to assembly.

17.  Assembly:  All of the ingredients listed above are assembled in mixing
tanks in the correct proportions needed for the final "mix".

18.  Mix Pasteurization:  The assembled mixes are pasteurized in batch
quantities, although in very large plants a continuous flow pasteurizer
may be used.

19'  H_et Well:  Those mixes that contain excess water are pumped to the
hot well (which is a surge tank) and from there pumped to the evaporator.

20.  Batch Evaporating Pan;  Excess water is removed (as described in 5)
as required by the mix formulation and will be pumped to the homogenizer.

21.  Homogenizer:  Mix from the batch pan or from the continuous pasteurizer
is pumped to the homogenizer, a high pressure pump which breaks up fat
particles within the mix to insure that they stay in suspension in the
finished product.

22.  Cooling:  From the homogenizer the warm mix is sent through a continu-
ous cooler, although in small plants may use a batch-type cooler.

23.  Pasteurized Storage:  The cooled mix is stored in refrigerated tanks
until ready for further use.

24.  Packaging:  Generally, the finished mix is packaged in 10-gallon cans
and to a lesser extent in single service plastic bag and cardboard box
type containers.  Occasionally large volumes of mix are shipped out in
tank truck quantities to the customer.

25.  Cold Storage;  The canned or packaged mix is held in refrigerated
storage as inventory before shipping.

26.  Shipping Out;  The packaged mix is drawn from cold storage and placed
on refrigerated trucks for delivery to the customer.


     A flow diagram is included on Pages IWP 9-69 and IWP 9-70
                        2023 - Condensed and Evaporated Milk    IWP 9-67

-------
                  Waste and Wastewater
The significant waste from the fundamental condensed and evaporated
milk process is the miscellaneous spillage that occurs in normal
processing and packaging operations, and loss that occurs from
cleaning equipment at the end of the day's operation.  Also, the
soaps and chemical cleaning solutions used in daily sanitation
procedures contribute to water waste, and are included in the com-
putations.  Shrinkage in the raw receipts and overfill of the
finished product are not included in later waste quantity computa-
tion.

Significant clear water waste occurs in those plants using water
for once-through cooling in their refrigeration systems and once-
through condensing water in milk evaporators.  The trend is toward
the use of cooling towers which permit the reuse of cooling water.
Wastewater figures shown represent average conditions in 1963.
                             2023  - Condensed and Evaporated Milk  IWP 9-68

-------
                      2023 CONDENSED & EVAPORATED MILK
ALTERNATIVES
                         FUNDAMENTAL PROCESS
SIGNIFICANT WASTE
   [ CANS
                               RECEIVE
                             TANK TRUCKS
                             2  STORAGE TANKS
3
SEPARATION
*
V
CREAM TO j
PAGE 2 j

BATCH
    BATCH
BATCH   ™|f.
  ROLL DRY     if
                                 PASTEURIZE
                                 CONTINUOUS
                             EVAPORATION
                         5   CONTINUOUS
                                   COOLING
                                 CONTINUOUS
                             7  STORAGE TANKS
                                  PACKAGING
                                   IN CANS
                                  STERILIZE
   ENTRAINMENT
  GOOLING WATER
    CONDENSATE







"L
I*











\'














10 STORAGE
1
11 SHIP OUT
I
•1


12 SPRAY DRY


13 INSTANT IZE
^
14 PACKAGE



A






— e















HOT MOIST

TTMTD A TNMPTJT






CLEANING WATER
PRODUCT LOSS
                                                            IN OPERATIONS
                                2023  CONDENSED & EVAPORATED MILK     IWP 9-69
                                                                  PAGE 1 OF 2

-------
ALTERNATIVES
                      2023 CONDENSED - CONT.  - MIX MAKE
FUNDAMENTAL PROCESS
                             15
    STORAGE -DRY
    INGREDIENTS

CONTINUOUS
FROM PAGE 1
MILK
SYRUPS
CREAM
CONDENSED
A
— »
- w
+ r
16 LIQUIFY
^
17 ASSEMBLY
,L
MIX PASTEURIZE
18 BATCH
19
HOT
WELL
                             20
     BATCH PAN
    EVAPORATION
                             21  HOMOGENIZE
25 COLD
STORAGE
26
SHIP
OUT
SIGNIFICANT WASTE
   ENTRAINMENT
   COOLING WATER
    CONDENSATE


BATCH




1 9


1
COOLING
Li CONTINUOUS
4
23 STORAGE TANKS

fc COOLING
f WATER


24 PACKAGING
i
A

CAN WASH
WASTE
                                                            CLEANING WATER
                                                            PRODUCT LOSS
                                                            IN OPERATIONS
                               2023  CONDENSED & EVAPORATED MILK     IWP 9-70
                                                                  PAGE 2 OF 2

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                        RECENT DEVELOPMENTS
The fundamental condensed and evaporated milk processes changed little
from 1950 to 1966, and little change is forecast for 1967 to 1977.
Nevertheless, several developments of interest have occurred.

The most significant change has been in the number reduction of plants.
Due to economical pressures, many small plants have closed or have
merged.  This trend, which is expected to continue, is depicted on
Page IWP 9-73.

Since 1950, bulk tank trucks have largely replaced the 10-gallon cans
used in Step 1, "Receiving", of the fundamental process.  The trend
has occurred because the use of trucks has virtually eliminated physical
labor, improved sanitation maintenance and reduced the likelihood of
contamination.

Self-cleaning (CIP) separators used in Step 3 of the fundamental process
are now available.  Such machinery reduces the amount of manual washing
required, as well as the reduction of physical labor.

Because of tremendous volume, large plants utilize continuous flow
equipment, as opposed to batch type machinery.  This development has
tended to reduce the percentage of plant loss in operations and,
consequently, has helped to minimize wastes.  Greatly improved heating
and refrigeration systems have reduced water needs considerably.

The industry is well along towards conversion from roll to spray drying,
which produces a superior product.

The trend in packaging is to smaller units which better serve the needs
and desires of the consumer.  Automatic packaging continues to replace
manual methods.  Not only is the amount of waste reduced, but new
machinery fills more accurately.

Permanent stainless steel piping systems were introduced in the early
1950"s.  Such systems are cleaned in place, as opposed to the daily
take-apart systems former 1'y accepted.  This type equipment reduces the
quantity of soap required and, therefore, reduces waste.  The fact that
the systems are permanently installed has reduced plant product losses;
also, sanitation and product shelf life has been increased--a factor
which has tended to reduce waste.
                           2023  -  Condensed  and  Evaporated Milk   IWP  9-71

-------
Significant changes have occurred in material handling within plants
by the introduction of sophisticated conveyors and stacking, grouping
and palletization equipment.  Even though machines have tended to
increase individual plant wastes through the enlarged usage of water-
soap lubricants, product loss and waste has been reduced because of
the less likelihood of package damage.

Large quantities of dairy products have been, or will be, replaced
by non-dairy products such as vegetable fat for butterfat and fish
flour for milk powder.
                            2023 - Condensed and Evaporated  Milk  IWP 9-72

-------
           CONDENSED, EVAPORATED, DRY -  2023
       Production /Billion

    o
    m
                o\
o
vO
cr>
500    Number of Plants
                        m
                        r-
400
300
200
                                          IV
                in
                                        m
                                                                     ON
 16



 15



 14



 13



 12



 li



 10
       Production per Plant  (Million  Lbs.)
                m
                m
o
\o
in
\o
o\
o

ON
m
P-
ON
r-.

ON
                     2923 - Condensed and Evaporated Milk    IWP S-73

-------
The trends may best be shown  in  tabular  form, which  follows.   The  reader
should note that the alternative subprocesses and  other  industry changes
have occurred over a span of  years.

The process which will become prevalent  is  identified  as J?,  and  that
which is becoming less used as S_.

                          TABLE  IWP  9  -  74
(b)
(c)
(d)
(e)
(f)
(g)

P
S
P
S
P
S
P
S
P
S
P
S

Estimated Percentage of
Receive in Tank Trucks
Receive in Cans
Pasteurize Continuously
Pasteurize Batch
Spray Dry
Roll Dry
Automatic Packaging
Manual Packaging
CIP Piping
Take-apart Piping
Automatic Material
Handling
Manual Material
Handling
Plants Employing
1950
-0-
100
25
75
50
50
-0-
100
-0-
100
-0-
100
1963
40
60
50
50
75
25
20
80
40
60
50
50
Process
1967
50
50
60
40
85
15
25
75
50
50
60
40
1972
60
40
70
30
90
10
35
65
60
40
70
30
1977
70
30
90
10
95
5
45
55
70
30
80
20
      The estimates  represent the observations and opinions of people in the
      industry.
                               2023 - Condensed and Evaporated Milk  IWP 9-74

-------
                   Comparative Waste Control Problems

The subprocesses (Table IWP 9-74) do not require different treatment from
the fundamental processes; however, the choice of subprocess is largely
determined by the total volume produced.  The continuous flow processes
tend to have less waste per pound of finished product because of the
greater productivity per piece of equipment.

Product spillage and waste during normal processing, and cleaning water
and soaps represent the significant wastes for any type process used.

In order to best estimate total industry waste and wastewater, it is
desirable to identify levels of technology within the industry.  The
following table illustrates three technological levels.  The fundamental
process steps from Page IWP 9-65 are used as reference for the table
which follows.
           (a)
    Older Technology

1.  Receive product in
    10-gallon cans
2.  Store product in
    10-gallon cans

3.  Heat and separate
    centrifugally

4.  Pasteurize in
    batch quantities
5.  Evaporate (condense>
    in batch quantities
  TABLE IWP 9 - 75

Comparative Technology

          (b)
   Typical Technology

   Receive bulk of dairy
   products in tank trucks
   and part of products in
   10-gallon cans

   Products stored in
   tanks

   Heat and separate
   centrifugally

   Pasteurize in a con-
   tinuous unit and pump
   to (5)

   A continuous evaporator
   (condenser) which will
   have one or two effects
6.  Cooling in batch
    quantities

7.  Pasteurized storage
    in 10-gallon cans

8.  Packaging in cans
   Cooling in a continuous
   process

   Pasteurized storage in
   tanks

   Packaging automatically
   in cans
        (c)
Advanced Technology

Receive all products
in tank trucks
Products stored in
refrigerated tanks.

Heat and separate
centrifugally

Pasteurization on a
continuous basis
Evaporation (condens-
ing) on a continuous
basis through a double
or triple effect pan

Cooling in a continu-
ous process

Refrigerated pasteu-
rized storage

Packaging performed
automatically in high-
speed can machinery
                     2023 - Condensed and Evaporated Milk   IWP 9-75

-------
           (a)
     Older Technology

 9.  Sterilization of
     canned products in
     batch equipment

10.  Storage inventoried
     finished product in
     warehouse

11.  Ship out
12.  Drying performed
     on a "drum dryer"

13.  Instantizing not
     used
14.  Packaging powdered
     product manually
15.  Storage of mix
     ingredients in dry
     quantities in bag
     form
16.  Liquify dry ingredi-
     ents manually
17.  Assemble directly
     into  (18)
        (b)
 Typical Technology

Cans sterilized in a
continuous unit
Inventory finished
product in storage
room

Ship out
Drying performed in
a spray type unit

Powder conveyed to
an instantizer and
then conveyed to (14)

Automatic packaging
machinery
Storage of dry ingre-
dients for mix, a
minimum of bag ingre-
dients and as many as
possible in liquid or
syrup form

Liquification of dry
ingredients performed
mechanically

Assembly takes place
in a tank on scales
with ingredients
measured manually
        (c)
 Advanced Technology

Sterilization in a con-
tinuous sterilizer
Finished product
stored in palletized
quantities and (11)

Ship out in pallet
loads

Spray drying utilized
Powder conveyed to an
instantizer and in turn
conveyed to (14)

Automatic packaging
machinery.  Packages
automatically boxed
and automatically
palletized

Storage of mix ingredi-
ents all in liquid form
in tanks
Liquification of dry
ingredients no longer
necessary

Assembly takes place
in programmed automatic
vat-On-weigh scales and
                          2023 - Condensed and Evaporated Milk    IWP 9-76

-------
           (a)
     Older Technology

18.  Batch pasteurizers
19.  Pump to hot well
     and then pumped
     to
         (b)
 Typical Technology

Mix pasteurization
centrifugally  in
batch quantities
which are pumped  to
(19)

A hot well and  from
there pumped to
          (c)
 Advanced Technology

A continuous mix
pasteurizer which pro-
ceeds to  (19)
A hot well and
20.  The batch evaporat-
     ing pan

21.  Homogenize and
     pressure pump

22.  Cool in batch
     quantities

23.  Store pasteurized
     product in 10 gal-
     lon cans, which
     will be the same
     cans for (24)

24.  Packaging
25.  Store packaged cans
     in cold storage
26.  Shipped out
27.  Take-apart piping

28.  Manual material
     handling
The batch evaporating
pan

Homogenization by
pressure pump

Cooling in a continu-
ous cooler

Pasteurized storage
in refrigerated
tanks
Packaging of mix
partially in 10 gal-
lon cans and par-
tially in single
service bag-in-box
containers

Finished product
inventoried in cold
storage

Shipped out
Partial CIP piping

Partial automatic
material handling
A continuous pan
Homogenization by
pressure pump

Cooling in a continu-
ous manner

Pasteurized product
stored in refriger-
ated tanks
Packaging in single
service containers
such as bag-in-box
Inventoried in cold
storage in palletized
quantities

Shipped out in pal-
letized lots

CIP piping

Automatic material
handling
   287-032 O - 68 - 6
                          2023 - Condensed and Evaporated Milk    IWP 9-77

-------
                        Size vs. Technology

In 1963 there were 427 condensed and evaporated milk plants producing
4,970,462,000 Ibs. of condensed and evaporated milk.  The industry con-
siders a plant producing less than five million Ibs. per year as "small",
five to thirty million Ibs. per year as "medium" and over thirty million
Ibs. as "large".

Waste and wastewater are a function of size as well as technology.
TABLE IWP 9-78 represents industry (c) opinion of the relationship of size
and technology.

                         TABLE IWP 9 - 78

                         Plant Statistics

                               1963

Small     231     54.1% produce less than 5 million Ibs. per year
Medium    141     33.1% produce from 5 to 30 million Ibs. per year
Large      55     12.8% produce more than 30 million Ibs. per year

Total:    427 plants produced 4,970,462,000 Ibs. in 1963


                                  Percentage of Various Sizes
     Percentage
     Technology                Small         Medium      Large
       Levels                Less than. %     % to 3     More than 3

15% Older Technology             90%          10%           0%
80% Typical Technology           34%          54%          12%
 5% Advanced Technology           0%          10%          90%
This relationship provides a basis for computation of overall plant wastes
produced when related to unit waste production of various size plants of
the three technology levels.
                              2023 - Condensed and Evaporated Milk   IWP 9-78

-------
      Gross Waste Quantities Before Treatment or Other Disposal

In plants of advanced technology waste generated is less than in those
less advanced.  Waste and wastewater quantities per pound of finished
product are as follows:

                          TABLE IWP 9 - 79A

            Waste and Wastewater Quantities per Pound of
                          Finished Product
Older Technology
Typical Technology
Advanced Technology
 Product
Pounds BOD

  .0062
  .0046
  .0037
                                          Soap &
                                         Chemicals
                                         Pounds BOD
.0006
.0005
.0004
Wastewater
  Gallons

    4.2
    3.5
    3.1
                Seasonal Waste Production Pattern

Waste quantities tend to be directly proportional to production quan-
tities; however, wastewater is used in greater quantities in the warm
months, reflecting increased refrigeration requirements.   The following
table illustrates this relationship.
                         TABLE IWP 9 - 79B
 Percentage of Yearly Total of Product, Soap and Chemical and Wastewater
January
February
March
April
May
June
9.5
9.1
10.2
10.7
12.1
11.2
July
August
September
October
November
December
8.7
6.6
5.0
5.1
5.3
6.5
This pattern is expected to continue since peak production in condenseries
occurs during peak farm milk production periods.
                             2023 - Condensed and Evaporated Milk  IWP 9-79

-------
The relationship of size and technology shown in Table IWP 9-78
permits a. comparison of the number of plants of each technology level.
The unit wastes from Table IWP 9-79A, when applied to the number of
plants, results in Table IWP 9-80.
                        TABLE IWP 9 - 80
A.  Older Technology:     These plants process 7,000 Ib. of finished
                          product per day.

                Significant Wastes - Lb. per Day

                                    Soap &
                 Product           Chemicals          Wastewater
#_Plant£        Pounds BOD        Pounds BOD        Gallons per Day

   64              43.7              4.4               29,376
B.  Typical Technology:   These plants process 37,800 Ib. of finished
                          product per day.

                Significant Wastes - Lb. per Day

                                    Soap &
                 Product           Chemicals          Wastewater
# Plants        Pounds BOD        Pounds BOD        Gallons per Day

  342              173.1             17.3              132,854
C.  Advanced Technology:  These plants process 122,800 Ib. of finished
                          product per day.

                Significant Wastes - Lb. per Day

                                    Soap &
                                   Chemicals          Wastewater
#  Plants        Pounds BOD        Pounds BOD        Gallons per Day
    21             459.7             46                383,693
                         2023 - Condensed and Evaporated Milk  IWP 9-80

-------
                        TABLE IWP 9 - 81-A

         Gross Waste Quantities Before Treatment or Disposal

The individual plant data (Table IWP 9-80) when multiplied by the number
of plants results in gross waste quantities before treatment or disposal.

                                   Significant Wastes Per Year

                              Product    Soap & Chemical  Wastewater
                            Pounds BOD     Pounds BOD      Gallons
                            (Millions)     (Millions)     (Millions)

Older Technology                .874           .09
Typical Technology            18.470          1.85
Advanced Technology            3.016           .31

     Total                    22.36           2.25         17,276

Individual Plant Range:        +507»           +50%          +207.
                       TABLE IWP 9 - 81-B

                 Projected Waste and Wastewater

The relationship between change in total production, plant size and
technology change is shown in the following table:

      1963^ and Projected Gross Wastes and Wastewater in Millions

                  1963    1968    1969    1970    1971    1972     1977

Lb. Product
  Manufactured   4,970   3,971   3,985   3,995   3,959   3,928   3,710

Lb. BOD Product     22.36   17.78   17.75   17.70   17.45    17.23    15.85
Lb. BOD Soap and     2.2     U8     1.8^     1.8     1.7      1^7      l._6
   Chemicals
        Subtotal    24.56   19.58   19.55   19.50   19.15    18.93    17.45

Gal. Wastewater  17,276 13,113  12,467  11,804   11,009  10,241   6,448
Projections of product manufactured are based upon  industry  and  government
estimates.
                         2023 - Condensed and Evaporated Milk   IWP  9-81

-------
                   Waste Reduction Practices

The waste reduction practices utilized in the industry do not vary
greatly.  The various processes are all similar in nature and a
common sewer piping system is used for the entire plant.  The wastes
other than miscellaneous chemicals are of a "biodegradable" nature.

Certain processing practices produce varying amounts of wastes.
Table IWP 9-82 illustrates such relationships.
                       TABLE IWP 9 - 82

                     Processing Practices

The fundamental process used with the "older" technology as the refer-
ence base, described on Page IWP 9-75.

     Alternate Process	% Waste Reduction Efficiency

(a)
(b)
(c)

(d)
(e)

(f)
(g)


Plant - Large vs. Small
Receive - Tanks vs . Cans
Pasteurize - Continuous
vs . Batch
Dry - Spray vs. Roll
Package - Automatic vs .
Manua 1
Piping - CIP vs. Take-apart
Product
73
50

20
10

10
50
Soap & Chemical
26
85

60
70

15
40
Wastewater
26
85

60
80

15
40
Material Handling - Automatic
vs . Manua 1
5
*
*
    *Increases wastewater proportionately to lubricant used.
A  large plant may be created by the consolidation of several smaller
facilities.  The subprocesses  (b-h) may be applied to any plant on an
individual basis and are not dependent of each other; however, the
common practice  is  to utilize  continuous flow and automatic equipment
together.

Continuous flow  and automatic  equipment tends to have capacity ratings
that  justify the use thereof only  in  the average to  larger size plants.
                         2023  -  Condensed  and  Evaporated Milk  IWP 9-82

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                     Treatment Practices

The most prevalent practice is Management Technique, i.e., closest
possible supervision of day-to-day operation to eliminate processing
lossr-loss due to waste resulting from the initial shrinkage of the
raw material as well as the overfill of the finished package.

In general, most waste that goes to plant sewers is subsequently
flowed to municipal sewers; to a lesser extent, waste may be dis-
charged directly into lakes or streams.

The disposal through use of sewage plants represents the least used
treatment practice.

The following table illustrates the effectiveness of the individual
treatment practice.
                        TABLE IWP 9 - 83
                      Treatment Practices
Removal Method                         Normal Removal Efficiency
                                      % of Total Wasteload Removed
                              Product	Soap & Chemicals	Wastewater

(a)  Ridge and Furrow         95-100         95-100             4*
(b)  Spray Irrigation         95-100         95-100             5*
(c)  Aerated Lagoon            90-95          90-95             1*
(d)  Trickling Filter          90-95          90-95             0
(e)  Activated Sludge          90-95          90-95             0
(f)  Municipal Sewer            100            100            100
(g)  To Waterways               100            100            100
(h)  Management Technique      50-75          50-75           10-75
                    *Estimated percent of total evaporated to
                     the atmosphere, the remainder going to
                     waterways.
                       2023 - Condensed and Evaporated Milk  IWP 9-83

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Hie processing technology permits any of the listed removal methods
to be used at any time.  Types (a) ridge and furrow; (b) spray irriga-
tion; and (c) aerated lagoon require significant amounts of land, and
the types of soil and climate determine the physical size and year-
round success of each, to a large degree.  In addition, they must be
located at least one-half mile from residential areas because of
possible seasonal odor problems.

Types (d) trickling filter and (e) activated sludge are relatively
compact but require greater capital investment and have higher operat-
ing costs than the other methods.

The trend is to connect plants to municipal systems wherever possible
to simplify day-to-day operations and to minimize capital investment.

Type (h) management technique is improving rapidly and involves close
supervision of day-to-day operations, the utilization of preventative
maintenance techniques, use of inventory control procedures and
exploration of the "Zero Defects" type of thinking.

It is estimated that the following percentage of Industries' Waste will
be discharged to Municipal Sewer:

            1950     1963     1967     1972     1977

              1        5       10       32       53

The discharge of condensed and evaporated milk plant wastes to municipal
systems is feasible.  The high BOD requirements necessitate that the
capacity of a particular municipal plant be reviewed prior to the connec-
tion of a new condensed and evaporated milk plant waste load to the system.

Pretreatrnent is not required because of the characteristics of the waste;
however, pretreatment may be required by the municipality if the municipal
plant is of inadequate size.
                           2023  -  Condensed and Evaporated Milk  IWP 9-84

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The various practices have been utilized in varying degrees.  Plant
location, capital costs, operating costs and problems--all influence
the type adoption.
                       TABLE IWP 9 - 85

    Rate of Adoption of Waste Treatment Practices Since 1950

The rate of treatment practice adoption is shown in percentages.

                              % of Plants Employing Listed Methods

     Removal Method           1950    1963    1967    1972    1977

(a)  Ridge and Furrow           U*      8      10      15       15
(b)  Spray Irrigation           U       5       5       5       5
(c)  Aerated Lagoon             U       5      10      15       25
(d)  Trickling Filter           U       U       U       U       U
(e)  Activated Sludge           U       U       U       U       U
(f)  Municipal Sewer            U       5      10      32       53
(g)  To Waterways              98      73      58      30       0
(h)  Management Technique      40      50      60      65       70


     *U = Under 17.
                        2023 - Condensed and Evaporated Milk  IWP 9-85

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            Waste Reduction or Removal Cost Information
The Condensed and Evaporated Milk Industry has a capital investment in
sewerage treatment facilities,  and also has annual operating and mainte-
nance expenditures in conjunction therewith.

The estimated capital investment in waste removal facilities in 1963
is $1,200,000 and the estimated annual operating expense is $240,000.

By 1°66 the capital investment  is estimated to have increased to
$2,400,000 and the annual operating expense to $480,000.
           Comparative Investment & Operating Expenses

Plant sizes have been determined as Small, Medium and Large and tech-
nology levels described as Old, Typical and Advanced.

A comparison of investment cost and operating cost for providing
waste and wastewater removal facilities between plants of different
sizes and technologies for the various subprocesses and removal methods
will provide valuable data for determining which subprocess or method
offers the most attractive opportunities for use in the future to
implement the Clean Water Restoration Act.

The next several pages include these comparison tables.  The tables
are based on investment costs and operating costs as experienced by
industry.  Land has been estimated at $300 per acre for Ridge and
Furrow, Spray Irrigation and Aerated Lagoon installation.

Management Technique requires no additional capital investment.
Nominal expense is included for educational purposes.

Economic life in relation to processing equipment represents current
thinking on industry needs for return on  investment and recognizes
obsolescence.

Economic life in relation to removal methods represents observed useful
life.
                            2023  -  Condensed  and Evaporated Milk  IWP  9-86

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                          TABLE IWP 9 -  87

                          Comparative Costs

            (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the older technology and of small
6ize.  Daily "net" waste quantities from plant to sewer are 25.9 pounds BOD
(1507.) and 16,000 gallons of wastewater (1"20%) and 65 pounds powder to air.
These quantities are "gross" to waterways.
                                                                      (Years)
Product = 3,800 Ibs/day          Capital     Annual Operating &       Economic
                                  Costs    Maintenance Expenditure     Life

(a)
(b)

-------
           TABLE  IWP 9-88
Comparative Costs
(For Providing Waste
& Wastewater Removal Facilities)
The plant illustrated is representative
of the typical technology
small size. Daily "net" waste quantities from plant to sewer are
pounds BOD (±507.) and 13,300 gallons of
powder to air. These quantities

Product = 3,800 Ibs/day

Subprocess:
(a) Plant - Large vs. Small
(b) Receive - Typical vs.
Advanced
(c) Separator - CIP vs.
Manual
(d) Pasteurize - Typical vs.
Advanced
(e) Spray dry - Typical vs.
Advanced
(f) Packaging - Typical vs.
Advanced
(g) Piping - CIP
Typical vs. Advanced
(h) Material Handling -
Typical vs. Advanced
Removal Method:
(a) Ridge and Furrow
(b) Spray Irrigation
(c) Aerated Lagoon
(d) Trickling Filter
(e) Activated Sludge
(f) Municipal Sewer
(g) 'To Waterways
(h) Management Technique
wastewater (±20%) and 50
and of
19.4
pounds
are "gross" to waterways.

Capital
Costs

$ -10%
-0-


25,000

5,000

44,000

7,500

6,000

6,000

$ 5,000
14,200
1,300
67,500
45,000
200
-0-
-0-

Annual Operating &
Maintenance Expenditure

$ -15%
-0-


+4,000

-800

+1,000

+1,300

+900

-1,200

$ +1,000
+2,800
+300
+13,500
+9,000
+100
-0-
-1,500
(Years)
Economic
Life

13
13


13

13

13

4

13

4

20
20
20
15
15
*
*
*
NA = Not Applicable             * Permanent




See Reference Notes on Page IWP 9-8 and IWP 9-86
                 2023 - Condensed and Evaporated Milk  IWP 9-88

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                          TABLE IWP 9-89

                          Comparative Costs

            (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the advanced technology and of
small size.  Daily "net" waste quantities from plant to sewer are 15.6
pounds BOD (±50%) and 11,800 gallons of wastewater (120%),  and 42 pounds
power to air.  Thpse quantities are "gross" to waterways.
                                                                      (Years)
Product = 3,800 Ibs/day         Capital     Annual Operating &       Economic
                                 Costs    Maintenance Expenditure       Life

(a)
(b)
(c)

(d)

(e)
(f)

(g)

(h)


(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
Subprocess :
Plant - Large vs. Small
Receive - Tanks
Separator - CIP vs.
Manual
Pasteurize - Continuous
vs. Batch
Spray dry - Roll dry
Packaging - Automatic
vs. Manual
Piping - CIP vs.
Take-apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Management Technique

$ -15%
AH
AH

AH

AH
AH

AH

AH


$ 4,400
12,600
1,100
60,000
40,000
200
-0-
-0-

$ -20%
NA
NA

NA

NA
NA

NA

NA


$ +900
+2,500
+200
+12,000
+8,000
+100
-0-
+1,300

13
13
13

13

13
4

13

13


20
20
20
15
15
*
*
*
               NA = Not Applicable
               AH = Already installed
                    by definition
* Permanent
               See Reference Notes on Page IWP 9-8 and IWP 9-86.
                                2023  -  Condensed  and  Evaporated Milk   IWP 9-89

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                         TABLE IWP 9-90

                         Comparative Costs

            (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the older technology and of medium
size.  Daily "net" waste quantities from plant to sewer are 315 pounds BOD
(t50%) and 194,000 gallons of wastewater (t207o), and 736 pounds powder to air.
These quantities are "gross" to waterways.
                                                                      (Years)
Product = 46,200 Ibs/day        Capital     Annual Operating &        Economic
                                          Maintenance Expenditure      Life

(a)
(b)
(c)

(d)

(e)
(f)

(g)

(h)


(a)
(b)
(0
(d)
(e)
(f)
(8)
00
Subprocess :
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP vs.
Manual
Pasteurize - Continuous
vs. Batch
Spread dry - Roll dry
Packaging - Automatic
vs. Manual
Piping - CIP vs . Take-
apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Management Technique

$ -15%
32,000
50,000

35,000

264,000
50,000

35,000

40,000


$ 73,000
207,000
21,800
262,000
174,500
200
-0-
-0-

$ -20%
-14,400
+2,000

-7,200

-23,400
22,000

-13,000

-3,200


$ +14,600
+41,500
+4,400
+52,500
+35,000
+1,600
-0-
-25,900

13
13
13

13

13
4

13

13


20
20
20
15
15
*
*
*
               NA =  Not Applicable             * Permanent

               See Reference Notes  on  Page IWP 9-8  and  IWP  9-86.
                                 2023  -  Condensed  and  Evaporated Milk   IWP  9-90

-------
          TABLE IWP 9-91
Comparative Costs
(For Providing Waste
& Wastewater Removal Facilities)

The plant illustrated is representative of the typical technology and of
medium size. Daily "net" waste
quantities from plant to sewer are
pounds BOD 0^50%) and 162,000 gallons of wastewater (t2070) , and 601
powder to air. These quantities

Product = 46,200 Ibs/day

Subprocess:
(a) Plant - Large vs. Small
(b) Receive - Typical vs.
Advanced
(c) Separator - CIP vs.
Manual
(d) Pasteurize - Typical vs.
Advanced
(e) Spray dry - Typical vs.
Advanced
(f) Packaging •• Automatic
Typical vs. Advanced
(g) Piping - CIP
Typical vs. Advanced
(h) Material Handling -
Typical vs. Advanced
Removal Method:
(a) Ridge and Furrow
(b) Spray Irrigation
(c) Aerated Lagoon
(d) Trickling Filter
(e) Activated Sludge
(f) Municipal Sewer
(g) To Waterways
(h) Management Technique
are "gross" to waterways.

Capital Annual Operating &
Costs Maintenance Expenditure

$ -107, $ -15%
-0- -0-

50,000 +2,000

5,000 -800

90,000 -9,000

25,000 -11,000

17,000 -6,500

20,000 -1,600


$ 61,500 $ +12,300
173,000 +34,600
16,300 +3,300
219,000 +44,000
146,000 +29,200
200 +1,200
-0- -0-
-0- -19,000
236
pounds

(Years)
Economic
Life

13
13

13

13

13

4

13

13


20
20
20
15
15
*
*
*
NA = Not Applicable             * Permanent




See Reference Notes on Page IWP 9-8 and IWP  9-86.
                 2023 -  Condensed  and Evaporated Milk  IWP 9-91

-------
                         TABLE IWP 9 - 92

                         Comparative Costs

           (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the advanced technology and of
medium size.   Daily "net" waste quantities from plant to sewer are 190
pounds BOD (±50%) and 144,000 gallons of wastewater  (±20%), and 509 pounds
powder to air.  These quantities are "gross" to waterways.
                                                                          (Years)
                                                                        Economic
Product - 46,200 Ibs/day
Capital
Annual Operating &
                                  Costs	Maintenance Expenditure
                                         Life

(a)
(b)
(c)

(d)
(e)
(f)
(g)
00

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
Subprocess :
Plant - Large vs. Small
Receive - Tanks
Separator - CIP vs.
Manual
Pasteurize - Continuous
Spray dry
Packaging - Automatic
Piping - CIP
Material Handling
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Management Technique

$ -15%
AH
AH

AH
AH
AH
AH
AH

$ 54,700
154,000
13,100
195,000
130,000
200
-0-
-0-

$ -20%
NA
NA

NA
NA
NA
NA
NA

$+10,900
+30,800
+2,600
+39,000
+26,000
+1,000
-0-
-15,500

13
13
13

13
13
4
13
13

20
20
20
15
15
*
*
*
               NA = Not Applicable
               AH = Already installed
                    by definition
               * Permanent
               See Reference Notes on Page IWP 9-8 and IWP 9-86,
                                 2023 - Condensed and Evaporated Milk  IWP 9-92

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                         TABLE IWP 9 -  93
                         Comparative Costs

           (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the older technology and of large
size.  Daily "net" waste quantities from plant to sewer are 1,556 pounds BOD
(J30%) and 654,000 gallons of wastewater (120%), and 1,556 pounds powder to
air.  These quantities are "gross" to waterways.
                                                                       (Years)
Product = 155,600 Ibs/day        Capital     Annual Operating &       Economic
	Costs    Maintenance Expenditure	Life
        Subprocess:

(a)  Plant - Large vs. Small     $   -157.       $     -207.
(b)  Receive - Tanks vs. Cans      64,000          -28,000
(c)  Separator - CIP vs.           75,000           -2,800
               Manual
(d)  Pasteurize - Continuous       70,000          -15,000
               vs. Batch
(e)  Spray dry - Roll dry         520,000         -223,000
(f)  Packaging - Automatic             NA               NA
               vs. Manual
(g)  Piping - CIP vs.             150,000         -142,000
               Take-apart
(h)  Material Handling -           60,000          -15,200
        Automatic vs. Manual
                                        13
                                        13
                                        13

                                        13

                                        13
                                         4

                                        13

                                        13
        Removal Method;

(a)  Ridge and Furrow
(b)  Spray Irrigation
(c)  Aerated Lagoon
(d)  Trickling Filter
(e)  Activated Sludge
(f)  Municipal Sewer
(g)  To Waterways
(h)  Management Technique
$248,000
 700,000
 107,000
 440,000
 294,000
     200
     -0-
     -0-
$  +44,600
  +126,000
   +19,300
   +79,000
   +53,000
    +8,000
       -0-
   -87,400
20
20
20
15
15
 *
 *
 *
               NA = Not Applicable
               * Permanent
               See Reference Notes on Page IWP 9-8 and IWP 9-86.
                                 2023  -  Condensed and Evaporated Milk  IWP 9-93

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          TABLE IWP 9-94
Comparative Costs
(For Providing Waste
& Wastewater Removal Facilities)
The plant illustrated is representative of the typical technology and
large size. Daily "net" waste
BOD (J50%) and 545,000 gallons
to air. These quantities are

Product = 155,600 Ibs/day

Subprocess ;
(a) Plant - Large vs. Small
(b) Receive - Typical vs.
Advanced
(c) Separator - CIP vs.
Manual
(d) Pasteurize - Continuous
Typical vs. Advanced
(e) Spray dry - Typical vs.
Advanced
(f) Packaging - Automatic
Typical vs. Advanced
(g) Piping - CIP
Typical vs. Advanced
(h) Material Handling -
Typical vs. Advanced
Removal Method:
(a) Ridge and Furrow
(b) Spray Irrigation
(c) Aerated Lagoon
(d) Trickling Filter
(e) Activated Sludge
(f) Municipal Sewer
(g) To Waterways
(h) Management Technique
quantities from plant to sewer are 794
of wastewater (j"207.), and 2,023 pounds
"gross" to waterways.

Capital Annual Operating &
Costs Maintenance Expenditure

$ -10% $ -15%
-0- -0-

75,000 -2,800

10,000 -1,000

100,000 -105,000

50,000 -10,000

30,000 -12,000

25,000 -12,000


$207,000 $ +37,200
584,000 +105,000
55,000 +9,900
368,000 +66,000
245,000 +44,000
200 4,000
-0- -0-
-0- -64,000

of
pounds
powder

(Years)
Economic
Life

13
13

13

13

13

4

13

13


20
20
20
15
15
*
*
*
NA s Not Applicable              * Permanent



See Reference Notes on Page IWP 9-8 and IWP 9-86,
                  2023  -  Condensed  and  Evaporated Milk   IWP 9-94

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                         TABLE IWP 9 - 95

                         Comparative Costs

          (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the advanced technology and of
large size.   Daily "net" waste quantities from plant to sewer are 638 pounds
BOD (J50%) and 483,000 gallons of wastewater  (J20%), and 1,712 pounds powder
to air.  These quantities are "gross" to waterways.
                                                                      (Years)
Product » 155,600 Ibs/day        Capital     Annual Operating &       Economic
	Costs    Maintenance Expenditure	Life

        Subprocess;

(a)  Plant - Large vs. Small     $   -15%       $    -20%               13
(b)  Receive - Tanks                   AH              NA               13
(c)  Separator - CIP                   AH              NA               13
(d)  Pasteurize - Continuous           AH              NA               13
(e)  Churn - Continuous                AH              NA               13
(f)  Packaging - Automatic             AH              NA                4
(g)  Piping - CIP                      AH              NA               13
(h)  Material Handling                 AH              NA               13


        Removal Method;

(a)  Ridge and Furrow            $183,500       $ +33,000               20
(b)  Spray Irrigation             516,000         +93,000               20
(c)  Aerated Lagoon                44,000          +7,900               20
(d)  Trickling Filter             326,000         +58,600               15
(e)  Activated Sludge             217,000         +39,000               15
(f)  Municipal Sewer                  200           3,200                *
(g)  To Waterways                     -0-             -0-                *
(h)  Management Technique             -0-         -52,400                *


               NA = Not Applicable              * Permanent
               AH - Already installed
                    by definition

               See Reference Notes on Page IWP 9-8 and IWP 9-86.
                                 2023 - Condensed and Evaporated Milk  IWP 9-95

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The tables indicate that several subprocesses and removal methods are
particularly attractive in terms of small capital investment and low
annual operating expense.

The application of management technique requires no capital invest-
ment and very little operating expense.  This method results in
significant economy in plant operations, and is a highly desirable
practice.

Disposal of remaining waste to municipal sewers requires only nominal
investment and operating cost to the plant and is attractive to the
plant operation.  However, if a municipality establishes a sewage rate
based directly on plant waste loads, then comparative economics deter-
mine whether or not a plant should adopt further waste removal methods.
                Summary of Projected Wasteloads
Year

1963

Waste

Product (Lb. BOD)
Soap & Chemical (Lb.
Water (Gallons)
Gross Waste
Generated
Million
22.36
BOD) 2 . 2
ST 24.56
17,276
Remova 1
*
%
15
15
ST

Net Waste
Discharged
Million
19.01
1.9
20.91
16,412
       *Percentage of waste reduced or removed by process changes,
        waste  treatment and byproducts utilization

                            2023 - Condensed and Evaporated Milk  IWP 9-96

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             Summary of Projected  Wasteloads
Year

1968
1969
1970
1971
1972
1977
Waste

Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
Water (Gal Ions}
Gross Waste
Generated
Million
17.78
1.8
ST 19.58
13,113
17.75
1.8
ST 19.55
12,467
17.70
1.8
ST 19.50
11,804
17.45
1.7
ST 19.15
11,009
17.23
1.7
ST 18.93
10,241
15.85
1.6
ST 17.45
6,448
Removal
*
%
30
30
ST
5
40
40
ST
5
50
50
ST
5
60
60
ST
5
70
70
5
99.5
99.5
ST
Net Waste
Discharged
Million
12.45
1.2
13.65
12,457
10.65
1.1
11.75
11,844
8.85
.9
9.75
11,214
6.98
.7
7.68
10,458
5.17
.5
5.67
9,729
.079
.008
.087
6,126
*Percentage of Waste Reduced or Removed by Process Changes,
 Waste Treatment and By-Products Utilization
                        2023 - Condensed and Evaporated Milk  IWP 9-97

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                 2024   ICE CREAM AND FROZEN DESSERTS
2024 - Ice Cream and Frozen Desserts:  Establishments primarily engaged
       in manufacturing ice cream and other frozen desserts.

       The ice cream industry has grown steadily over the years and
       this pattern is expected to continue.

       Geographically, the plant locations reflect population patterns.
       There is a trend towards exceptionally large regional plants
       with distributions over wide areas.

1.     Receipt:  The largest volumes of products received are liquid
cream, liquid condensed milk, whole milk, corn syrup and cane sugar
syrup.  These are normally received in tank truck quantities in liquid
form, although in smaller operations cream and condensed milk may be
received in cans, and corn and cane sugars in dry form.

2.  Raw (unpasteurized) Product Storage:  The dairy products are norm-
ally stored in refrigerated tanks and the sugar syrups in heated tanks.

3.  Storage--Dry and Frozen:  Ingredients such as stabilizers, emulsi-
fiers, and chocolate powders, as well as miscellaneous quantities of
sugars are stored in dry form usually in drums and bags.  Cream and
butter are often purchased during the surplus season of the year in the
frozen form and stored frozen.  Similarly, various fruits are stored
frozen in sub-zero rooms.

4.  Liquify;  The dry  and frozen ingredients are normally converted to
liquid solution prior to further use.  This is done in a high speed
blending device in which the dry and frozen ingredients are mixed
thoroughly with water or milk.

5.  Assembly:  The liquified ingredients, as well as the liquid dairy
products and sugar syrups are assembled in batch quantities according
to  formulae.

6.  Mix Pasteurization:  Upon assembly, a given batch of mix is pas-
teurized.  The normal method is in batch quantities, although in
larger plants a continuous pasteurizer may be used.

7.  Homogenization:  After pasteurization is completed, the mix is
homogenized in a high pressure  pump which breaks up fat particles so
that  they will stay  in suspension in the finished product.

8.  Cooling:  The warm mix from the homogenizer  is cooled to 40  or
lower  in a continuous cooler.
                         2024 - Ice Cream and Frozen Desserts  IWP 9-98

-------
 9.  Pasteurized Storage;  The cold pasteurized mix is held in
refrigerated storage tanks until needed in the flavoring and freezing
operations, No. 12 and 13.

10.  Fruit and^ Nut Preparation;  Frozen nuts are drawn from storage
and roasted, and frozen fruits are drawn from storage, defrosted, and
separated into pulp and juice.

11.  Fruit and Nut Storage;  The pulp fruit and the separate juice is
stored in containers under refrigeration for later use in No. 12.

12.  Flavoring;  Mix is drawn from storage tanks, No. 9, into small
mixing vats in which the liquid fruit juices are added for flavoring.
At this time artificial flavors may also be added.

13.  Freezing;  The flavored mixes are pumped to ice cream freezers
which are the industrial type of the familiar frozen custard stand
freezers.  In the freezer the. mix is frozen on the surface of a
refrigerated tube and is scraped off with sharp blades rotating at
high speeds which also whip air into the mix to give it its character-
istics as ice cream.  Freezers are a continuous type device other than
in very small plants in which batch type freezers may be used.

14.  Solids Injection:  The partially frozen ice cream from the freezers
passes through a machine which injects nuts and fruit pulp into the
stream.  This partially frozen ice cream is sent to packaging equipment.

15.  Packaging;  The packaging machinery which is normally automatic,
forms the container, injects a controlled amount of the product, and
seals the package.

16.  Stick Confections;  A special class of packaging-freezing device
is the stick confection unit.  The product from the ice cream freezer,
No. 13, or flavored water base mixes from No. 12, are placed in the
stick confection freezer and frozen, sticks inserted, coatings
applied, and the finished product packaged in a paper bag or wrapper.

17.  Hardening:  The partially frozen ice cream is conveyed in pack-
ages to a "hardening area" in which the product is subjected to low
temperature air circulation and the freezing cycle is completed.  The
hardening area in a larger plant is usually a continuous "tunnel"
device, cycled with the packaging; however, in smaller operations the
product may be stacked in the partially frozen form in racks or on
shelves and hardened in the storage area.
                         2024 - Ice Cream and Frozen Desserts  IWP 9-99

-------
18.  Cold Storage:  The hardened ice cream is held in cold storage
as inventory until ready for shipment.

19.  Ship Out:  The hardened ice cream is drawn from inventory and
placed on refrigerated route trucks for delivery to the consumer.

     A flow diagram is included on Pages IWP 9-101 and 9-102.

     Please note that the numbering system used here is also used
     in comparison tables appearing later.
                    Waste and Wastewater
The significant wastes derived from the fundamental ice cream and
frozen desserts process are (1) the spillage which occurs in normal
processing and packaging operations and (2) the wastes incurred with
cleaning equipment at the end of a day's operation.  Some clear water
waste occurs in those plants using water for once-through cooling in
their refrigeration systems.  This technique is often used in rural
plants with their own wells or in areas of abundant water supply.

No water that comes in contact with ice cream and frozen desserts
during the manufacturing process may be reused because of the
danger of contamination.
                        2024 - Ice Cream and Frozen Desserts  IWP  9-100

-------
ALTERNATIVES
                      2024 ICE CREAM AND FROZEN DESSERTS
FUNDAMENTAL PROCESS
                                                            SIGNIFICANT WASTES
rANS 1. _ „








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CONT. PAGE 2



















A COOLING
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CLEANING WATER

PRODUCT LOSS
IN OPERATIONS
                              2024  ICE CREAM AND FROZEN DESSERTS     IWP 9-101
                                                                  PAGE 1 OF 2

-------
                             2024 ICE CREAM CONT.
ALTERNATIVES
FUNDAMENTAL PROCESS
                                                            SIGNIFICANT WASTES
                             10
    FRUIT & NUT
    PREPARATION
              FROM PAGE 1
              STEP 9	
                             11  FRUIT & NUT
                                   STORAGE
                             12   FLAVORING
    BATCH
>
13
 FREEZING
CONTINUOUS
                             14
      SOLIDS
     INJECTION
                             15   PACKAGING
16
                                    STICK
                                 CONFECTIONS
                             17   HARDENING
18 COLD
STORAGE
19
SHIP
OUT
                                                            CLEANING WATER
                                                            PRODUCT LOSS
                                                            IN OPERATIONS
                                            2024  ICE CREAM CONT.     IWP 9-102
                                                                   PAGE 2 OF 2

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                       RECENT DEVELOPMENTS
The fundamental ice cream and frozen desserts process changed little
from 1950 to 1966, and little change is forecast for 1967 to 1977.
Nevertheless, several developments of interest have occurred.

The most significant change has been in the number reduction of plants.
Due to economical pressures, many small plants have closed or have
merged.  This trend, which is expected to continue, is depicted on Page
IWP 9-105.

Since 1950, bulk tank trucks have largely replaced the 10-gallon cans
used in Step 1, "Receipt", of the fundamental process.  The trend has
occurred because the use of trucks has virtually eliminated physical
labor, improved sanitation maintenance and reduced the likelihood of
contamination.

Equipment has been developed to incorporate dry ingredients into water
or milk, reducing the danger of contamination and labor requirements.

Batches of raw materials are now assembled by the use of load cells or
scales with automatic transfer of the correct amounts of the various
raw ingredients.  This development results in more accuracy in the
composition of the finished product, reduced manual labor requirements,
and improved sanitation.

Because of tremendous volume, large plants utilize continuous flow
equipment, as opposed to batch type machinery.  This development has
tended to reduce the percentage of plant loss in operations and,
consequently, has helped to minimize wastes.  Greatly improved heat-
ing and refrigeration systems have reduced water needs considerably.

Large continuous freezers are rapidly replacing the less efficient
batch freezers.

The trend in packaging is to smaller units which better serve the
needs and desires of the consumer.  Automatic packaging continues to
replace manual methods.  Not only is the amount of waste reduced, but
new machinery fills more accurately.

Devices have been developed which improve the texture of the finished
product by rapid hardening.

Permanent stainless steel piping systems were introduced in the early
1950's.  Such systems are cleaned in place, as opposed to the daily
take-apart systems formerly accepted.  This type equipment reduces the
quantity of soap required and, therefore, reduces waste.  The fact
that the systems are permanently installed has reduced plant product
losses; also, sanitation and product shelf life has been increased—
a factor which has tended to reduce waste.
                         2024 - Ice Cream and Frozen Desserts  IWP 9-103

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Significant changes have occurred in material handling within plants
by the introduction of sophisticated conveyors and stacking, grouping
and palletization equipment.  Even though machines have tended to
increase Individual plant wastes through the enlarged usage of water-
soap lubricants, product loss and waste has been reduced because of
the less likelihood of package damage.
                         2024 - Ice Cream and Frozen Desserts  IWP 9-104

-------
                    ICE CREAM - 2024
1 5QQ  Production (Million Gallons)
1,000
  500
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     ON
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       Number of Plants
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2,000
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Production per Plant (Thousand Gallons)







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m o m o m r-
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ON ON ON ON ON ON
•-1 t-l ,-1 ,_( ^| ^|
                       2024  Ice Cream & Frozen  Desserts  IWP  9-105

-------
The trends may best be shown in tabular form, which follows.  The reader
should note that the alternative subprocesses and other industry changes
have occurred over a span of years.

The process which will become prevalent is identified as £, and that which
is becoming less used as S^,

                          TABLE IWP 9 - 106

         Estimated Percentage of Plants Employing Process
                                   1950    1963     1967     1972     1977

 (b)  P  Receive in Tank Trucks      -0-      25      30      40       60
     S  Receive in Cans             100      75      70      60       40

 (c)  P  Liquify Manually            100      95      90      85       75
     S  Liquify by Machine          -0-       5      10      15       25

 (d)  P  Assemble Manually           100      98      97      95       90
     S  Assemble Automatically      -0-       2        3        5       10

 (e)  P  Pasteurize Batch            100      98      97      95       90
     S  Pasteurize Continuously     -0-       2        3        5       10

 (f)  P  Freeze Continuously           75      50      65      80       90
     S  Freeze Batch                  25      50      35      20       10

 (g)  P  Automatic Packaging           10      50      65      80       90
     S  Manual Packaging              90      50      35      20       10

 (h)  P  Hardening in Storage        100      99      97      75       50
     S  Hardening in Tunnel         -0-       1        3      25       50

 (i)  P  CIP  Piping                  -0-      20      30      40       60
     S  Take-apart Piping           100      80      70      60       40

 (j)  P  Auto. Material Handling     -0-       2        3        5       10
     S  Manual Material' Handling    100      98      97      95       90
      The estimates  represent  the  observations  and  opinions  of people in
      the industry.
                             2024 -  Ice Cream and Frozen Desserts  IWP 9-106

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               Comparative Waste Control Problems
The subprocesses (Table IWP 9-106) do not require different treatment
from the fundamental processes; however, the choice of subprocess is
largely determined by the total volume produced.  Large plants often
utilize continuous flow processes because of greater productivity per
piece of equipment.  These processes generate less waste per pound of
finished product.

Loss due to viscosity, product spillage, cleaning water and soaps--all
constitute the significant wastes for any type process utilized.

In order to best estimate total industrial waste and wastewater, it is
desirable to identify the existing levels of technology.  The following
table illustrates three technological levels.  The fundamental process
steps from Pages IWP 9-103 and IWP 9-104 are used as reference for the
table which follows.

                      TABLE IWP 9-107
1.
2.
3.
4.
5.
6.
                    Comparative Technology
      00
Older Technology

Receive product in
10-gallon cans
Store all products
in 10-gallon cans

Storage of dry and
frozen products in
bag or unit quanti-
ties
      (b)
Typical Technology

Receive almost all of
product in tank truck
quantities but continu-
ing to receive a small
amount of canned products

Store all products in
refrigerated tanks

Storage of dry and
frozen ingredients,
most products in bag
or unit quantities
except the liquid
sugars and corn syrups
would be utilized
Liquification of     Liquification performed
dry and frozen       in (5)
ingredients manually

Assembly of ingredi- The assembly vat.  Pro-
ents directly into   duct pumped from
(6)                  assembly vat into (6)
        (c)
Advanced Technology

Receive all products
in tank truck quanti-
ties and (2)
Store in tanks
Storage of dry and
frozen ingredients
at an absolute mini-
mum.  Almost all
products stored in
tank quantities
                          Liquification performed
                          in an automatic machine
Batch type mix
pasteurizers
Batch pasteurizers
Assembly takes place in
a programmed automatic
vat on weigh scales and
pumped to (6)

Continuous mix
pasteurizers
                         2024 - Ice Cream and Frozen Desserts  IWP 9-107

-------
           (a)
     Older Technology

 7.   Homogenize in a
     high speed pressure
     pump

 8.   Cool in batch
     quantities
 9.   Store pasteurized
     products in 10-
     gallon cans

10.   Fruit and nut prepa-
     ration manually and
     product stores in
     (11)

11.   10-gallon cans or
     unit quantities
       (b)
Typical Technology

Homogenization in a
high pressure pump
continuously

Cooling performed in
a continuous manner
with ammonia D.X.
Pasteurized product
stored in refrigerated
tanks

Fruit an^ nut prepara-
tion performed with
machine assistance
Stored in 10-gallon
cans or unit quantities
        (c)
Advanced Technology

Homogenization in a
continuous high
pressure pump

Cooling with regenera-
tion in a continuous
manner, and product
pumped to (9)

Refrigerated storage
tanks
Fruit and nut prepara-
tion essentially manual
with semi-automatic
machine assistance

Fruit juices stored
in tanks and pumped,
and nuts stored in
wheeled containers
12.  Flavoring performed
     in 10-gallon cans
     or in
13.  Batch freezers
Flavoring performed
in small mixing vats
adjacent to  (13)
The automatic continu-
ous freezers
Flavoring performed in
either large pasteurized
storage vats (9) or in
small mixing vats
adjacent to (13)

The continuous auto-
matic ice cream
freezers
14.  Solids injected
     directly into
     barrel of batch
     freezers
Solids injected by
machine
Sol?'ds injected by
machine
15.  Packaging performed
     by hand
16.  Stick confections
     made on manual
     devices
Packaging in some
automatic machinery
and some still performed
by hand

Stick confections
made in small size
semi-automatic
machinery and hand
packaged
Packaging in all auto-
matic machinery
Stick confections
made and packaged on
all automatic machinery
                           2024 - Ice Cream and Frozen Desserts  IWP 9-108

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           (a)
     Older Technology

17.  Hardening performed
     by stacking product
     on shelves or in wire
     baskets in the open
     storage room in the
     same place that (18)
     is held

18.  Inventory is held
19.  Ship out
20.  Take-apart piping

21.  Manual materials
     handling
        (b)
Typical Technology

Hardening takes place
in the same area as
inventory storage (18)
Inventory performed by
placing product in
wire baskets or on
shelves in this area

Ship out
Partial CIP piping

Partial automatic
materials handling
         (c)
Advanced Technology

Hardening performed
in an automatic
"freezing tunnel" and
product conveyed to
(18)
Cold storage where
it is handled in a
palletized manner
Product shipped out in
pallet loads or some
other form of unit load
quantities

CIP piping

Automatic materials
handling
                          2024 Ice Cream and Frozen Desserts     IWP 9-109
    237-032 O - 68 - 8

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                         Size vs. Technology

In 1963 there were 2,512 ice cream plants producing 1,052,986,000 gallons
of ice cream.  The industry considers a plant producing under 50,000
gallons per year as "small", 50,000 to one million gallons as "medium",
and over one million gallons as "large".

Waste and wastewater are a function of size as well as technology.  TABLE
IWP 9-110 represents industry (C) opinion of the relationship of size and
technology.

                           TABLE IWP 9-110

                           Plant Statistics
Small    1,269
Medium     992
Large      251
                1963

50% produce less than 50,000 gallons per year
40% produce 50,000 to 1,000,000 gallons per year
10% produce more than 1,000,000 gallons per year
Total    2,512   plants produced 1,052,986,000 gallons in 1963

Overall industry average:  419,200 gallons per year
      Percentage
      Technology
        LeveIs

46% Older Technology
607. Typical Technology
 4% Advanced Technology
                                 Percentage of Various Sizes
               Sma11       Med ium
           Less than .05  .05 to 1
                98%
                11
                 0
 2%
77
 0
 This relationship provides a basis for conputation of overall plant wastes
 produced when related to unit waste production of various size plants of
 the three  technology levels.
                               2024  -  Ice Cream and  Frozen Desserts   IWP  9-110

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      Gross Waste Quantities Before Treatment or Other Disposal

In plants of advanced technology, waste generated is less than in those
plants less advanced.  Waste and wastewater per pound of finished pro-
duct are as follows:

                      TABLE IWP 9 - 111-A

        Waste and Wastewater Quantities per Gallon Product

                        Product      Soap & Chemicals    Wastewater
Older Technology
Typical Technology
Advanced Technology
     	Soap & Chemicals	
    Pounds BOD       Pounds BOD        Gallons

     .0073             .0007            12.0
     .0032             .0003             8.0
     .0015             .0002             6.2
This data represents industry operating experience.  Ice Cream wastes
are similar for all levels of technology because the basic process is
similar for all levels.

               Seasonal Waste Production Pattern

Waste quantities tend to be directly proportional to production quantities;
however, wastewater is used in greater quantities in the warm months,
reflecting increased refrigeration requirements.  The following table
illustrates this relationship.

                      TABLE IWP 9 - 111-B
                   Percentage of Yearly Total
January
February
March
April
May
June
July
Augus t
September
October
November
December
Product

  5.9
  6.0
  7.5
  8.7
  9.8
 10.6
 11.8
 11.2
  8.5
  8.0
  6.3
  5.7
Soap & Chemical

     4.5
     4.6
     6.5
     9.3
    11.0
    12.5
    14.2
    13.8
     9.1
     6.8
     4.8
     4.5
Wastewater

   4.5
   4.6
   6.5
   9.3
  11.0
  12.5
  14.2
  13.8
   9.1
   6.8
   4.8
   4.5
This seasonal variation is not expected to change.  One may note that
summer month production is almost twice that of winter months.  Summer
sales are even greater, since some items such as pops ides can be stored
for several months.
                          2024 - Ice Cream and Frozen Desserts  IWP 9-111

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The relationship of plant size and technology shown in Table IWP 9-110
permits a comparison of the number of plants of each technology level.
The unit wastes from Table IWP 9-111-A when applied to the number of
plants results in Table IWP 9-112.

                      TABLE IWP 9 - 112

         Gross Waste Quantities for Average Size Plants

A.  Older Technology;    These plants process 240 gallons of finished
                         product per day.

             Significant Wastes_- Lb. BOD per Day

                                    Soap &               Wastewater
# Plants          Product          Chemicals            Gal, per Day

 1,156              8.76             0.88                 3,009
B.  Typical Technology:  These plants process 1,700 gallons of finished
                         product per day.

               Significant Wastes - Lb. BOD per Day

                                    Soap &              Wastewater
# Plants          Product          Chemicals           Gal, per Day

 1,256             27.3              2.7                13,141
C.  Advanced Technology:  These plants process 9,700 gallons of finished
                          product per day.

               Significant Wastes - Lb. BOD per Day

                                    Soap &              Wastewater
# Plants          Product          Chemicals           Gal, per Day

   100             70.8              7.1                62,733
                            2024 - Ice Cream and Frozen Desserts  IWP 9-112

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                        TABLE IWP 9 - 113-A

        Gross Waste Quantities Before Treatment or Disposal

The individual plant data (Table IWP 9-112) when multiplied by the number
of plants results in gross waste quantities before treatment or disposal,

                              Significant Wastes Per Year
Product
Pounds BOD
(Millions)
3,212
10,804
2,336
16,352
t 50%
TABLE IWP 9 -
Soap &
Chemicals
Pounds BOD
(Millions)
.32
1.08
.23
1.63
t 50%
113-B
Wastewater
Gallons
(Millions)
1,083
4,290
1.958
7,331
t 20%

Older Technology
Typical Technology
Advanced Technology

     Total

Individual Plant Range
                  Projected Waste and Wastewater

The relationship between change in total production, plant size and tech-
nology changes is shown in the following table:
        1963 and Projected Gross Wastes and Wastewater in Millions

                     1963    1968    1969    1970    1971    1972
                                                  1977
Gal. Product Mfg.  1,053   1,153   1,167   1,182   1,200   1,219   1,317
Lb. BOD Product
Lb. BOD Soap and
   Chemicals
      Subtotal

Gal. Wastewater
   16.35   17.71   17.75   17.79
    1.6     1.8     1.8     1.8
17.87   17.97   18.40
 1.8     1.8     1.8
   17.95   19.51   19.55   19.59   19.67   19.77   20.20

7,331   7,786   7,637   7,488   7,351   7,214   6,418
Projections of product manufactured are based upon industry and government
estimates.
                           2024 - Ice Cream and Frozen Desserts  IWP 9-113

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                  Waj>te^ Reduction Practices

The vaste reduction practices utilized in the industry do not vary
greatly.  A common sewer piping system can be used for the entf.re
plant.  The wastes other than miscellaneous chemicals are of a
"biodegradable" nature.

Certain processing practices produce varying amounts of wastes.  Table
IWP 9-114 illustrates such relationships.
                      TABLE IHj? 9 - 114

                     Processing Practices

The fundamental process used with the "older" technology as the refer-
ence base, described on Page IWP 9-107  (A).

	Alternate Process	 % Waste Reduction Efficiency
	Product  Soap & Chemical  Wastewater

(a)  Plant - Large vs. Small            80         50              48
(b)  Receive - Tanks vs. Cans           65         80              85
(c)  Liquify - Automatic vs. Manual     12          5               5
(d)  Assemble - Automatic  vs. Manual     7          *               *
(e)  Pasteurize - Continuous vs. Batch  10         40              60
(f)  Freeze - Continuous vs. Batch      10         10              10
(g)  Package - Automatic vs. Manual     10          *               *
(h)  Hardening - Storage vs. Tunnel     25          0               0
(i)  Piping - CIP vs. Take-apart        25         50              50
(j)  Material Handling - Automatic vs.
                         Manual          5         **              **

   *Adds wastewater  as extra equipment  must be  cleaned.
  **Adds wastewater  proportional to lubricant used.


A large plant may be created by the consolidation of several  smaller
facilities.  The subprocesses  (b-h) may be applied to  any plant on an
individual basis and are not dependent  on each  other;  however, the com-
mon  practice is to utilize continuous  flow and  automatic equipment
together.

Continuous flow and  automatic  equipment tend  to have capacity ratings
which  justify  the use  thereof  only  in the average to larger  size  plants.
Continuous churns are  rare even  in  the  largest  of plants because  of
 initial  cost and because  very  high  production capacities do  not permit
 flexibility  of  operation.
                             2024 - Ice Cream and Frozen Desserts  IWP 9-114

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                     Treatment Practices

The most prevalent practice is Management Technique, i.e., closest
possible supervision of day-to-day operation to eliminate processing
loss—loss due to waste resulting from the initial shrinkage of the
raw material as well as overfill of the finished package.

Most waste that goes to sewers is sent to municipal sewer and, to a
lesser extent, is sent directly to water courses.

Company owned treatment plants represent the least used treatment
practice.

The following table illustrates effectiveness of the various treatment
practices as observed in the industry.
                      TABLE PfP 9 - 115

                     Treatment Practices

                                     Normal Removal Efficiency
Removal Method                      % of Total Wasteload Removed
                                Product   Soap & Chemicals   Wastewater

(a)  Ridge and Furrow            95-100       95-100             4*
(b)  Spray Irrigation            95-100       95-100             5*
(c)  Aerated Lagoon               90-95        90-95             1*
(d)  Trickling Filter             90-95        90-95             0
(e)  Activated Sludge             90-95        90-95             0
(f)  Municipal Sewer               100          100              0
(g)  To Waterways                  100          100              0
(h)  Utilization as Byproduct     99.5           NA             99.5
(i)  Management Technique         50-75        50-75            10-75

    *Estimated percent of total evaporated to the atmosphere; the
     remainder goes to waterways.
                       2024 - Ice Cream and Frozen Desserts  IWP 9-115

-------
Assuming optimum conditions, the removal methods (supra) could be
employed in any given plant; however, the utilization of the ridge
and furrow, spray irrigation, and aerated lagoon type processes
require significant amounts of land.  Furthermore, soil and climate
limit both the physical size of a treatment plant as well as the
choice of the treatment process.

The trickling filter and activated sludge processes are relatively
compact; however, these types require greater capital investment
and have higher operating costs than the other methods.

The trend is to connect plants to municipal systems wherever possible
in order to simplify day-to-day operations and to minimize capital
investment.

The management technique is now being widely accepted and involves
close supervision of day-to-day operations, the utilization of
preventative maintenance techniques, and the use of inventory control
procedures.

It is estimated that the following percentages of industrial waste
have been or will be discharged to a municipal sewer:

               1950    1963    1967    1972    1977

                50      70      80      90      98

The high BOD requirements of  icecream and frozen desserts plant wastes
necessitate that the capacity of a particular municipal plant be
reviewed prior to the connection of a new plant wasteload to the
system.

Pretreatment is not usually required because of the characteristics
of the waste; however, pretreatment may be required if the municipal
plant is of inadequate size.
                              2024  -  Ice Cream and  Frozen Desserts   IWP  9-116

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The various practices have been utilized in varying degrees.  Plant
location, capital costs, operating costs and problems—all influence
the type adoption.
                      TABLE IWP 9 - 117

    Rate of Adoption of Waste Treatment Practices Since 1950

The rate of adoption of treatment practice is shown in percentages.

                               % of Plants Employing Listed Methods

     Removal Method            1950    1963    1967    1972    J.977

(a)  Ridge and Furrow            U*      U       U       U       U
(b)  Spray Irrigation            U       U       U       U       U
(c)  Aerated Lagoon              U       U       U       U       U
(d)  Trickling Filter            U       U       U       U       U
(e)  Activated Sludge            U       U       U       U       U
(f)  Municipal Sewer            70      75      80      90      98
(g)  To Waterways               26      21      16       6       0
(h)  Utilization as Byproduct    U       U       U       U       U
(i)  Management Technique       40      55      65      75      85

    *U = Under 17,
                            2024 - Ice Cream and Frozen Desserts  IWP 9-117

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             Waste Reduction or Removal Cost Information

The ice cream industry has a capital investment in sewerage treatment
facilities, and also has annual operating and maintenance expendi-
tures in conjunction therewith.

The estimated capital investment in waste removal facilities in 1963
is $750,000 and the estimated annual operating expense if $150,000.

By 1966 the capital investment is estimated to have increased to
$1,000,000 and the annual operating expense to $200,000.
            Comparative Investment and 'Operating Expense

Plant sizes have been determined as small, medium and large and tech-
nology  levels described as old, typical and advanced.

A comparison of  investment cost and operating cost for providing
waste and wastewater removal  facilities between plants of different
sizes and technologies for the various subprocesses and removal
methods will provide valuable data for determining which subprocess
or method offers the most attractive opportunities for use in the
future  to implement the Clean Water Restoration Act.

The  next several pages include these comparison tables.  The tables
are  based on investment costs and operating costs as experienced by
industry.  Land  has been estimated at $300 per acre for the ridge and
furrow, spray  irrigation and  aerated lagoon installation.

Management technique requires no additional capital investment.
Nominal expense  is  included for educational purposes.

Economic life  in relation to  processing equipment represents current
thinking on  industry needs for return on  investment and recognizes
obsolescence.

Economic  life  in relation to  removal methods represents observed useful
 life.

There  are no small  plants of  typical or advanced  technology.
                         2024 - Ice Cream and Frozen Desserts   IWP 9-118

-------
                         TABLE IWP 9 -119
                         Comparative Costs

          (For Providing Waste & Wastewater Removal Facilities)
Daily "net" waste quantities from plant to sewer are  .35 pounds BOD
                                       These quantities are "gross"
The plant illustrated is representative of the older technology and of  small
size.
(+50%) and 560 gallons of wastewater  (1207.).
to waterways.
                                                                       (Years)
Product = 47 gals /day            Capital     Annual Operating &      Economic
                                  Costs    Maintenance Expenditure      Life

(a)
(b)
(c)
(d)
(e)

(f)

(g)

00

(i)
(j)

Subprocess ;
Plant - Large vs. Small
Receive - Tanks vs. Cans
Liquify - Auto vs. Manual
Assemble - Auto vs. Manual
Pasteurize - Continuous
vs. Batch
Freeze - Continuous vs.
Batch
Packaging - Automatic
vs. Manual
Hardening - Storage vs.
Tunnel
Piping - CIP vs. Take-apart
Material Handling -
Automatic vs. Manual

$ -20%
5,000
6,000
NA
9,500

13,000

NA

NA

5,500
NA


$ -257.
+1,500
+1,800
NA
+2,000

+3,400

NA

NA

+1,200
NA


13
13
13
13
13

13

4

13

13
13

        Removal Method:

(a)  Ridge and Furrow
(b)  Spray Irrigation
(c)  Aerated Lagoon
(d)  Trickling Filter
(e)  Activated Sludge
(f)  Municipal Sewer
(g)  To Waterways
(h)  Management Technique
                              300
                              600
                              500
                               NA
                               NA
                              200
                              -0-
                              -0-
+100
+150
+150
  NA
  NA
+100
 -0-
+450
20
20
20
NA
NA
 *
 *
               NA = Not Applicable
                                         * Permanent
               See Reference Notes on Page IWP  9-8  and  IWP  9-118.
                                2024 - Ice Cream and Frozen Desserts  IWP 9-119

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                         TABLE IWP 9 -120

                         Comparative Costs

          (For Providing Waste & Wastewater Removal Facilities)
The- plant illustrated is representative of the older technology and of medium
size.  Daily "net" waste quantities from plant to sewer are 6.3 pounds BOD
(J507.) and 11,000 gallons of wastewater (t20%).  These quantities are "gross"
to waterways.
                                                                      (Years)
Product = 890 gals/day           Capital     Annual Operating &      Economic
                                  Costs    Maintenance Expenditure     Life

(a)
(b)
(c)
(d)
(e)

(f)

(g)

00

(i)

0)


(a)
(b)
(c)
(d)
(e)
(f)
(g)
00
Subprocess ;
Plant - Large vs. Small
Receive - Tanks vs. Cans
Liquify - Auto vs. Manual
Assemble - Auto vs. Manual
Pasteurize - Continuous
vs. Batch
Freeze - Continuous vs.
Batch
Packaging - Automatic
vs. Manual
Hardening - Storage vs.
Tunnel
Piping - CIP vs.
Take -apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Management Technique

$ -157.
5,000
5,000
25,000
14,000

32,000

62,000

30,000

12,000

8,000


$ 4,200
11,800
500
56,000
37,200
200
-0-
-0-

$ -20%
-0-
-600
-2,200
+1,600

-3,800

-2,400

4600

-6,400

-2,000


$ 4600
4-2,400
4100
411,200
47,500
4-200
-0-
-500

13
13
13
13
13

13

4

13

13

13


20
20
20
15
15
*
*
*
               NA = Not Applicable              * Permanent

               See Reference Notes on Page IWP 9-8 and IWP 9-118.
                                  2024 - Ice Cream and Frozen Desserts  IWP 9-120

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                         TABLE IWP 9 -121

                         Comparative Costs

           (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the typical technology and of
medium size.  Daily "net" waste quantities from plant to sewer are 2.9 pounds
BOD (.507.) and 6,400 gallons of wastewater
to waterways.
(120%).
These quantities are "gross"

                   (Years)
Product = 890 gals /day

(a)
(b)

(c)
(d)
(e)

(f)

(g)

(h)

(i)

(J)


(a)
(b)
(c)
(d)
(e)
(f)
(g)
(b)
Subprocess ;
Plant - Large vs. Small
Receive - Typical vs.
Advanced
Liquify - Auto vs. Manual
Assemble - Auto vs. Manual
Pasteurize - Continuous
vs. Batch
Freeze - Continuous vs.
Typical vs. Advanced
Packaging - Automatic
Typical vs. Advanced
Hardening - Storage vs.
Tunnel
Piping - CIP
Typical vs. Advanced
Material Handling -
Typical vs. Advanced
Removal Me thod :
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Management Technique
Capital Annual Operating & Economic
Costs Maintenance Expenditure Life

$ -10%
-0-

5,000
25,000
14,000

7,500

25,000

30,000

6,000

4,000


$ 2,400
6,900
500
32,400
21,600
200
-0-
-0-

$ -15%
-0-

-200
+1,400
+2,200

-600

-3,400

+1,800

-3,200

-1,000


$ +500
+1,400
+100
+6,500
+4,300
-0-
+200
-200

13
13

13
13
13

13

4

13

13

13


20
20
20
15
15
*
*
*
               NA = Not Applicable              * Permanent

               See Reference Notes on Page IWP 9-8 and IWP 9-118.
                                 2024  -  Ice  Cream and Frozen Desserts  IWP 9-121

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                         TABLE IWP 9 -122
                         Comparative Costs

          (For Providing Waste & Wastewater Removal  Facilities)

The plant illustrated is representative of the advanced  technology  and  of
medium size.  Daily "net" waste quantities from plant  to  sewer  are  1.4  pounds
BOD (150%) and 5,500 gallons of wastewater (1207.).
to waterways.
                   These quantities are "gross"
Product = 890 gals/day
Capital     Annual Operating &
 Costs	Maintenance Expenditure
 (Years)
Economic
  Life
        Subprocess;

 (a)  Plant - Large vs. Small      $   -15%
 (b)  Receive - Tanks                  AH
 (c)  Liquify - Auto vs. Manual        AH
 (d)  Assemble - Auto vs. Manual       AH
 (e)  Pasteurize - Continuous
 (f)  Freeze - Continuous              AH
 (g)  Packaging - Automatic            AH
 (h)  Hardening - Storage vs.          AH
               Tunnel
 (i)  Piping - CIP                     AH
 (j)  Material Handling                AH
                   -20%
                     NA
                     NA
                     NA

                     NA
                     NA
                     NA

                     NA
                     NA
  13
  13
  13
  13

  13
   4
  13

  13
  13
        Removal Method;

 (a)   Ridge  and Furrow
 (b)   Spray  Irrigation
 (c)   Aerated  Lagoon
 (d)   Trickling Filter
 (e)   Activated Sludge
 (f)   Municipal Sewer
 (g)   To Waterways
 (h)   Management Technique
2,100
5,900
500
27,900
18,600
200
-0-
-0-
$ +400
+1,200
+100
+5,600
+3,700
+200
-0-
-100
                                         20
                                         20
                                         20
                                         15
                                         15
                                          *
                                          *
                                          *
                NA = Not  Applicable              * Permanent
                AH = Already installed
                     by definition
                See  Reference Notes on Page  IWP 9-8 and IWP 9-118.
                                  2024 - Ice Cream and Frozen Desserts  IWP 9-122

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                         TABLE IWP 9 - 123

                         Comparative Costs

         (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the typical technology and of
large size.  Daily "net" waste quantities from plant to sewer are 31.1
pounds BOD (1"50%) and 78,000 gallons of wastewater (1"207.).  These quantities
are "gross" to waterways.
Product = 9,700 gals /day

(a)
(b)
(c)
(d)
(e)

(f)

(g)

(h)

(i)

0)


(a)
(b)
(c)
(d)
(e)
(f)
(g)
00
Subprocess ;
Plant - Large vs. Small
Receive - Tanks vs. Cans
Liquify - Auto vs. Manual
Assemble - Auto vs. Manual
Pasteurize - Continuous
vs. Batch
Freeze - Continuous
Typical vs. Advanced
Packaging - Automatic
Typical vs. Advanced
Hardening - Storage vs.
Tunnel
Piping - CIP vs.
Take -apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Management Technique
(Years)
Capital Annual Operating & Economic
Costs Maintenance Expenditure Life

$ -15%
5,000
7,000
25,000
25,000

10,000

50,000

65,000

55,000

15,000


$ 29,600
83,500
2,200
126,000
84,000
200
-0-
-0-

$ -207.
-6,300
-700
-9,700
-400

-100

-10,800

5,300

-5,700

-200


$ 45,300
+15,000
+400
22,700
+15,100
+300
-0-
-4,100

13
13
13
13
13

13

4

13

13

13


20
20
20
15
15
*
*
*
               NA - Not Applicable              * Permanent

               There are no large plants of typical technology.

                See  Reference Notes  on  Page  IWP  9-8  and  IWP 9-118.


                                 2024 - Ice  Cream and Frozen Desserts  IWP 9-123

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                         TABLE IWP 9 -124
                         Comparative Costs

         (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative o'f the advanced  technology  and  of
large size.  Daily "net" waste quantities from plant to  sewer are 14.6
pounds BOD (150%) and 60,140 gallons of wastewater (1"20%).   These quantities
are "gross" to waterways.
Product = 9,700 gals/day
Capital    Annual Operating &
 Costs    Maintenance Expenditure
                     (Years)
                     Economic
                      Life
        Subprocess:

(a)  Plant - Large vs. Small     $
(b)  Receive - Tanks
(c)  Liquify - Auto vs. Manual
(d)  Assemble - Auto vs. Manual
(e)  Pasteurize - Continuous
(f)  Freeze - Continuous
(g)  Packaging - Automatic
(h)  Hardening - Storage vs. Tunnel
(i)  Piping - CIP
(j)  Material Handling -
        Automatic
    -20%
      AH
      AH
      AH
      AH
      AH
      AH
      AH
      AH
      AH
     -257.
       NA
       NA
       NA
       NA
       NA
       NA
       NA
       NA
       NA
13
13
13
13
13
13
13
13
13
13
        Removal Method;

 (a)  Ridge and Furrow
 (b)  Spray Irrigation
 (c)  Aerated Lagoon
 (d)  Trickling Filter
 (e)  Activated Sludge
 (f)  Municipal Sewer
 (g)  To Waterways
 (h)  Management Technique
$ 22,800
  64,000
   1,000
 169,000
 112,500
     200
     -0-
     -0-
$  44,100
  +11,500
     +200
  +30,400
  +20,200
     +700
      -0-
   -1,600
20
20
20
15
15
 *
               NA * Not Applicable               * Permanent
               AH = Already  installed
                    by definition

               See Reference Notes  on Page  IWP  9-8 and  IWP  9-118,
                                  2024 - Ice  Cream and Frozen Desserts  IWP 9-124

-------
The tables indicate that several subprocesses and removal methods are
particularly attractive in terms of small capital investment and, low
annual operating expense.

The application of Management Technique requires no capital investment
and very little in operating expense.  The method results in significant
economy in plant operations, and is a highly desirable technique.

Disposal of remaining waste to municipal sewers requires only nominal
investment and operating cost to the plant and is attractive to the
plant operation.  However, if a municipality establishes a sewage rate
based directly on plant waste loads, then comparative economics deter-
mine whether or not a plant should adopt further waste removal methods.
               Summary of Projected Wasteloads
Year

1963

Waste

Product (Lbs. BOD)
Soap & Chemical (Lbs .
Water (Gallons)
Gross Waste
Generated
Million
16.35
BOD) 1.6
ST 17.95
7,331
Removal
*
7.
75
75
ST
5
Net Waste
Discharged
Million
4.09
.4
4.49
6,964
      *Percentage of waste reduced or removed by process changes,
       waste treatment and byproducts utilization
                         2024 - Ice Cream and Frozen Desserts  IWP 9-125
   237-032 O - 68 - 9

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             Summary of Projected  Wasteloads
Year

1968
1969
1970
1971
1972
1977
Waste Gross Waste
Generated

Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water Gallons)
Million
17.71
1.8
19.51
7,786
17.75
1.8
19.55
7,637
17.79
1.8
19.59
7,488
17.87
1.8
19.67
7,351
17.97
1.8
19.77
7,214
18.40
1.8
20.20
6,418
Removal Net Waste
* Discharged
%
82
82
5
85
85
5
88
88
5
90
90
5
92
92
5
99.5
99.5
5
Million
3.19
.3
ST 3.49
7,397
2.66
.3
ST 2.96
7,255
2.13
.2
ST 2.33
7,114
1.79
.2
ST 1.99
6,983
1.44
.1
ST 1.54
6,853
.092
.01
ST .102
6,097
*Percentage of Waste Reduc.ed or Removed by Process Changes,
 Waste Treatment and Byproducts Utilization
                       2024 - Ice Cream and Frozen Desserts  IWP 9-126

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                          2026   FLUID MILK
2026 - Fluid Milk;  Establishments primarily engaged in processing
       (pasteurizing, homogenizing, vitaminizing, bottling) and
       distributing fluid milk and cream and related products, includ-
       ing cottage cheese.

       The fluid milk industry has grown steadily over the years and
       this trend is expected to continue.

       Geographically, population patterns govern plant locations.
       There is a trend towards exceptionally large regional plants
       with distributions over wide areas.

       The manufacturing process for fluid milk may be outlined as
       follows:

1.     Receipt;  Raw milk is received in tank truck quantities, although
a few smaller plants continue to receive milk in 10-gallon cans.

2.     Raw Milk Storage:  Raw milk is pumped from receiving to refrig-
erated storage tanks until needed.  Milk from raw milk storage proceeds
to No. 11, the byproducts department, or to clarification.

3.     Clarification;  Raw milk is clarified (strained) in a centrifugal
device although in smaller plants mechanical filters may be used.

4.     Pasteur ization;  The clarified milk is usually pasteurized in a
continuous flow pasteurizer, although batch type units may be used in
smaller plants.

5.     Homogenization;  The pasteurized product is homogenized in a
pressure pump which breaks up the butterfat particles to keep them in
suspension.

6.     Deodorization:  The homogenized milk is usually subjected to a
vacuum steam injection treatment to remove off-odors and off-flavors.
Where the flavors and odors are not serious, the use of steam may be
eliminated and only a vacuum treatment used.  In some areas the milk
supply is of such quality that milk "grading" can be done during receiv-
ing so that deodorization is not necessary.

7.     Pasteurized Storage:  The pasteurized product is cooled after
leaving the previous treatments and is sent to storage tanks and held
until needed in packaging.

8.     Packaging:  Milk is packaged or bottled on automatic machines in
a number of different type containers, including"glass bottles, paper
cartons, plastic bottles, and plastic bags in cardboard box units.  In
the packaging operation, the packages are usually placed in wire or plas-
tic cases and conveyed to a refrigerated cold storage area.
                                       2026 - Fluid Milk  IWP 9-127

-------
 9.  Cold Storage;  The packaged product is held in cold storage until
needed for shipping.

10.  Ship Out:  The packaged product is drawn from cold storage and
placed into refrigerated trucks for delivery.

     Returning to the raw milk storage, we can proceed with the funda-
     mental process for byproducts.

11.  Separation;  The raw milk is separated into cream and skim milk
in a centrifugal device and the two products sent to refrigerated
storage.

12.  Cream Storage:  Cream is normally stored in refrigerated tanks,
but occasionally may be stored in cans.

13.  Blending:  Cream is blended with whole milk and miscellaneous
additives placed in the cream at this time to make the various grades
of cream for bottling.

14.  Pasteurization:  The blended products are generally pasteurized
in batch quantities, although in larger plants a continuous pasteur-
izer may be used, such as in No. 4.

15.  Homogenization:  The pasteurized product is homogenized as in
No. 5.

16.  Cooling;  The homogenized product is cooled in batches, although
in larger plants this may be a continuous process.

17.  Skim Milk:  Skim milk from the separation process, No. 11, is
stored in refrigerated tanks and is used as follows:

     A portion is returned to the raw milk storage tanks to standard-
     ize the product to a controlled percentage of butterfat.

     A portion is sent to pasteurization, No. 4, and continues
     through Steps  5, 6, and 7, to packaging, No. 8.

     Skim milk is used also in other products, as follows:

18.  Cultured Products:  Skim milk is processed into buttermilk and
yogurt in batch type processors and sent to packaging, No. 8.

19.  Skim for Cheese;  Skim milk is drawn from storage tank (16) and
pasteurized as in No. 5, and sent to cottage cheese vats.
                                      2026 - Fluid Milk  IWP 9-128

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20.  Cottage Cheese Vat;  The pasteurized product is cooled in
pasteurizers to the desired "setting" temperature and pumped into
cheese vats.  In the cheese vats the skim milk is innoculated with
a bacterial "culture".  At the end of a controlled period of time,
the curd resulting from the setting is cut into small pieces and cooked
in the vat.  At the end of the cooking period, the whey is drained off
and becomes available for byproduct manufacture or is sent to waste.
The curd from the set-cooking vat is washed with potable water to
complete the removal of whey and to perform a cooling function.  This
water goes to waste.  In large plants, the washing and draining may
occur in a separate piece of machinery.

21.  Cheese Dressing;  Cream dressing is made under byproducts Steps
13 through 15, and pumped to the cheese and blended.  In small plants
the curd and dressings are mixed in cans and stored until packaged.

22.  Packaging;  The completed cheese is pumped to packaging where it
is placed in containers and sent to (9) cold storage.

     A flow diagram is included on Page IWP 9-131.
                     Waste and Wastewater
The significant waste from the fundamental fluid milk process is whey.
This waste product may be converted to valuable byproducts through
evaporating the moisture and drying the residue to a powder form for
human consumption or animal feed.

If whey is sent to the plant disposal system, the material becomes
a most difficult waste problem because of the high protein and acidic
content.  Approximately 54% of the solids in the raw material remains
in the whey resulting in a BOD of 3.2%.

To date, whey processing remains a problem to the industry.  Recent
research has shown that mechanical screens are ineffective in
separating whey waste; on a small scale, expensive centrifuging
has been utilized effectively.  Whey contains .9% to 1% albumin which,
if heated and treated with acid, will result in removal of 60% to
70%.  This processing, however, reduces the BOD load by only 20% to
25% and has proven to be too expensive for normal processing use.
The most practical utilization of whey has been through the facilities
of drying plants; however, these operate either at the breakeven
point or with only a slight profit.
                                      2026 - Fluid Milk  IWP 9-129

-------
Less significant sources of wastes are (1) the spillage which occurs
in normal processing and packaging operations and (2) the wastes
incurred with cleaning equipment at the end of a day's operation.
Some clear water waste occurs in those plants using water for once-
through cooling in their refrigeration systems.  This technique is
often used in rural plants with their own wells or in areas of
abundant water supply.

No water that comes in contact with the product during the manufactur-
ing process may be reused because of the danger of contamination.
                                        2026  -  Fluid Milk   IWP  9-130

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                               2026 FLUID MILK
ALTERNATIVES
FUNDAMENTAL PROCESS
SIGNIFICANT WASTE
                                   RECEIVE
                                 TANK TRUCK
                             2  STORAGE TANKS
                                   CLARIFY
                                 PASTEURIZE
                                 CONTINUOUS
                              1
                             5   HOMOGENIZE
                             6   DE-ODORIZE
                             7  STORAGE TANKS
                             8    PACKAGING
                             9  COLD STORAGE
                             10   SHIP OUT
                                    ENTRAINMENT
                                    COOLING WATER
                                    CONDENSATE
                                    BOTTLE
                                 WASHER WASTE
                                                            CLEANING WATER
                                                            PRODUCT  LOSS
                                                            IN  OPERATIONS
                                                 2026  FLUID MILK     IWP 9-131
                                                                   PAGE I OF 2

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ALTERNATIVES
2026 FLUID MILK CONT.

  FUNDAMENTAL PROCESS

 *(
  11  SEPARATION
                                CREAM STORAGE
                             12   IN TANKS
                             13     BLEND
                             14
      PASTEURIZE
         BATCH
                             15  HOMOGENIZE
                                COOLING BATCH
                                SKIM STORAGE
                             17     TANKS
                                  CULTURED
                                  PRODUCTS
                             19
       SKIM FOR
        CHEESE
                            $20
        COTTAGE
      CHEESE VAT
                                   CHEESE
                             21   DRESSING
                              22    PACKAGING
SIGNIFICANT WASTES
      WHEY
   WASH-WATER
                               CLEANING WATER
                                                          PRODUCT LOSS
                                                          IN OPERATIONS
                                                               PAGE 2 OF 2
                                         2026  FLUID MILK CONT.      IWP 9-132

-------
                       RECENT DEVELOPMENTS

The fundamental fluid milk process has changed little from 1950 to 1966
and little change is forecast for 1967 to 1977.  Nevertheless, several
developments of interest have occurred.

The most significant change has been in the number reduction of plants.
Due to economical pressures, many small plants have closed or have
merged.  This trend, which is expected to continue, is depicted on
Page IWP 9-135.

Since 1950, bulk tank trucks have largely replaced the 10-gallon cans
used in Step 1, "Receipt", of the fundamental process.  The trend has
occurred because the use of trucks has virtually eliminated physical
labor, improved sanitation maintenance and reduced the likelihood of
contamination.

Self-cleaning (CIP) separators used in Step 3 of the fundamental process
are now available.  Such machinery reduces the amount of manual washing
required, as well as the reduction of physical labor.

Because of tremendous volume, large plants utilize continuous flow
equipment, as opposed to batch type machinery.  This development has
tended to reduce the percentage of plant loss in operations and, conse-
quently, has helped to minimize wastes.  Greatly improved heating and
refrigeration systems have reduced water needs considerably.

In the early 1950's, vacuum deodorizing equipment became available and
is now used in many areas to eliminate feed, onion and other off-flavors.
This equipment has tended to increase plant product losses.

The trend in packaging is to smaller units which better serve the needs
and desires of the consumer.  Automatic packaging continues to replace
manual methods.  Not only is the amount of waste reduced, but new mach-
inery fills more accurately.

The processing of certain cultured products is the only significant
process change to occur since 1950.  In the processing of sour cream,
the use of chemical means as opposed to biological cultures is used in
a small way and reduces the time of the process, but does not change
the amount of waste.

Research work is underway to develop continuous setting methods.  How-
ever, commercial production does not appear imminent.

Hot pack sour cream and cottage cheese is now in use in a small way.
In this process the packages are filled with the product prior to
culture growth.  The growth takes place in the package, and thus elimi-
nates this step in the batch process, thus theoretically reducing waste.
The actual plants utilizing this method are experiencing increased
waste during the technological development of machinery.
                                       2026 - Fluid Milk  IWP 9-133

-------
Permanent stainless steel piping systems were introduced in the
early 1950's.  Such systems are cleaned in place, as opposed to the
daily take-apart systems formerly accepted.  This type equipment
reduces the quantity of soap required and, therefore, reduces waste.
The fact that the systems are permanently installed has reduced plant
product losses; also, sanitation and product shelf life has been
increased—a factor which has tended to reduce waste.

Significant changes have occurred in material handling within plants
by the introduction of sophisticated conveyors and stacking, grouping
and palletization equipment.  Even though machines have tended to
increase individual plant wastes through the enlarged usage of water-
soap lubricants, product loss and waste has been reduced because of
the less likelihood of package damage.

A  large amount of dairy product manufacture has been replaced by non-
dairy products especially  in coffee creamers in which vegetable fat is
substituted  for butterfat.
                                       2026  - Fluid Milk   IWP  9-134

-------
                          FLUID MILK  -  2026
70
60
50
oc
5
Production (Billion Lbs.)
1
j
i






- -
^-—~


/



^
------ - --
'
^'
. . -
x'


m o  o m vo vo i~- r- i^-
• in ON ON ON ON ON ON
\ ON r-1 r-l i-l 1-1 i-l «-l
        Number  of  Plants
8,000
5,000
2,000
     oo
          o
          m
              m
              m
o
vo
                                               m
                         in
                         r»
                         ON
   30
Production per  Plant (Million Lbs.)
   20
                                                             7*
                                                                  X
                                                                          X
                                                                            X
   10
                                                          X

     oo
     •*
     O>
  O
  m
  ON
o
vO
in
vo
ON
o

ON
                                 2026 - Fluid  Milk  IWP 9 - 135

-------
The trends may best be shown in tabular form, which follows.  The reader
should note that the alternative subprocesses and other industry changes
have occurred over a span of years.

The process which will become prevalent is identified as P, and that
which is becoming less used as S.
                         TABLE IWP 9 - 136
                                                             1972    1977

                                                               70      90
                                                               30      10

                                                               92      85
                                                                8      15

                                                               70      90
                                                               30      10

                                                               20      25
                                                               80      75

                                                               90      92
                                                               10       B

                                                               96      90
                                                                4      10

                                                               98      95
                                                                2       5

                                                               97      93
                                                                3       7

                                                               60      95
                                                               40       5

                                                               65      85
                                                               35      15

     The estimates represent the observations and opinions of people in
     the industry.
    *Almost all plants have conveyors of some type.  This heading  indicated
     utilization  of  casers, stackers, palletization devices,  etc.

                                                2026 -  Fluid Milk  IWP 9-136
Estimated Percentage of Plants Employing Process
1950
(b)
(c)

(e)
(f)
(g)
(h)
(i)
(j)
(k)*
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
P
S
Receive in Tank Trucks
Receive in Cans
Centrifuge Manually
Clean-in-Place
Pasteurize Continuously
Pasteurize Batch
Deodorizer Installed
Not Installed
Package Automatically
Package Manually
Sour Cream - Biologically
Sour Cream - Chemically
Batch Set Cottage Cheese
Continuous Set Cottage Cheese
Cold Pack Cultured Products
Hot Pack Cultured Products
Welded Piping
Take-Apart Piping
Automatic Material Handling
Manual Material Handling
-0-
100
100
-0-
30
70
-0-
100
70
30
100
-0-
100
-0-
100
-0-
-0-
100
-0-
100
1963
50
50
100
-0-
50
50
10
90
80
20
100
-0-
100
-0-
100
-0-
20
80
60
40
1967
60
40
99
1
60
40
15
85
85
15
98
2
100
-0-
99
1
40
60
50
50

-------
               Comparative Waste Control Problems

The subprocesses (Table IWP 9-136) do not require different type treat-
ment from the fundamental processes; however, the choice of subprocesses
is largely determined by the total volume produced.  The continuous flow
processes tend to have less waste per pound of finished product because
of the greater productivity per piece of equipment.

The whey from cottage cheese manufacture, product spillage and waste
during normal processing, and cleaning water and soaps represent the
significant wastes for all processes and subprocesses.

In order to best estimate total industry waste and wastewater, it is
desirable to identify levels of technology within the industry.  The
following table illustrates three technological levels.  The fundamental
process steps from Page IWP 9-127 are used as reference for the table
which follows.

                      TABLE IWP 9 - 137
                    Comparative Technology
         (a)
    Older Technology

1.  Receive products
    in 10-gallon cans
2.  Store in refrig-
    erated tanks

3.  Clarify, using
    strainers
                         Typical Technology

                         Receive almost all
                         products in tank trucks,
                         although a certain
                         amount in 10-gallon cans

                         Store in refrigerated
                         tanks

                         Clarify in a centrifugal
                         device
4.  Pasteurize in batch  Pasteurize in a continu-
    quantities

5.  Homogenize in a
    continuous pres-
    sure pump

6.  Deodorization not
    used
ous manner

Homogenize in a continu-
ous pressure pump


Deodorize in steam
vacuum equipment
7.  Pasteurized storage  Pasteurized refriger-
    in surge tanks, and  ated storage tanks
    (8)
                                  (c)
                           Advanced Technology

                           Receive all products
                           in tank truck quan-
                           tities
Store in refrigerated
tanks

Clarify in a centrifugal
device

Pasteurize in a continu-
ous manner

Homogenization in a
continuous pressure
                                                    Deodorize in steam
                                                    vacuum equipment

                                                    Pasteurized refrigerated
                                                    storage tanks
8.  Packaging in small   Package in automatic
    commercial size      machinery, place con-
    automatic or semi-   tainers into cases
    automatic machinery  manually and stack
                         manually on slow speed
                         lines and automatically
                         on high speed lines
                                              2026 - Fluid Milk  IWP 9-137
                                                    All packaging takes place
                                                    on fully automatic mach-
                                                    inery and finished pack-
                                                    ages placed in cases
                                                    automatically, stacked
                                                    automatically and

-------
           (a)
    Older Technology

 9.  Product sent to cold
     storage and handled
     in case quantitie s
10.  Ship out in cases
     handled on an indivi-
     dual basis or stacks
                                  (b)
                         Typical Technology

                        Cold storage,  where
                        product is inventoried
                        in stack quantities
                        Shipped out in stack
                        quantities
                                   (c)
                           Advanced Technology

                          Product sent to cold
                          storage where stacked
                          cases are handled in
                          unit or pallet quantities,
                          are then

                          Shipped out in unit or
                          pallet quantities
     BYPRODUCTS:

11.  Separation for by-
     products occurs in a
     centrifugal device

12.  Cream stored in 10-
     gallon cans

13.  Blending of various
     creams takes place in
     small vats, usually
     the same vat as (14)

14.  Batch pasteurization
15.
16.
17.
Homogenization on a
continuous pressure
pump

Cooling in batch
quantities
                        Separation for by-
                        products performed in
                        a centrifugal device

                        Cream sent to refrig-
                        erated storage tanks

                        Blending takes place
                        in refrigerated storage
                        tanks
Pasteurization of by-
products would occur
in a smaller plant in
batch quantities and
in a large plant on a
continuous pasteurizer

Homogenization in a
continuous pressure
pump

Cooling in a continuous
manner and then product
pumped to pasteurized
surges (7) for packaging
Separation in the
advanced plant will
take place in a separa-
tor located within the
pasteurizer (4),  so
arranged that the milk
blends, and skim milks
come out of the pasteu-
rizer in two streams
already completely pasteu-
rized and homogenized at
the correct fat content
to be sent directly to
(7), pasteurized storage
tanks, and then to pack-
aging.  The skim milk out
of the advanced pasteurizer
would be sent to (18)
Skim milk for the       Skim milk from the sepa-
separation process      rator is normally sent
may be stored in 10-    directly to storage tanks
gallon cans in a small  for later use
plant and in small vats
in larger plants
                                     2026  - Fluid Milk  IWP 9 - 138

-------
           (a)
     Older Technology

CULTURED PRODUCTS:

18.  Cultured products in
     small plants made in
     10-galIon cans and the
     larger plant in batch
     quantities

19.  Skim for cheese would
     be pumped directly from
     the batch pasteurizer to
     (20), the cottage cheese
     vat

20.  Setting, cooking,
     draining whey and wash-
     ing of curds would all
     take place in cottage
     cheese vat, which would
     be a manual type
21.  Cheese dressing would
     be made in a batch
     processor and mixed
     with the cheese in
     100# cans, stored
     until cream is absorbed
     by the curd and is
     ready for packaging

22.  Product transferred by
     hand to semi-automatic
     machinery or filled by
     hand and finished
     product sent to (9),
     cold storage
23.  Take-apart piping
       (b)
Typical Technology
For cultured products
skim milk is pumped
directly to the batch-
type processors
Skim for cottage cheese
would be pumped directly
to the cottage cheese
vat from continuous
pasteurizer

Cottage cheese vat is
equipped with mechani-
cal agitation and push-
ers; however, curd cut-
ting, cooking and whey
draining and washing
would normally occur in
this vat, as will (21)
Application of cheese
dressing
Products from the
cheese vats will be
pumped to semi-
automatic packaging
machinery where it is
manually cased and sent
to (9), cold storage
Partial CIP piping
24.  Manual material handling  Partial automatic
                               material handling
       (c)
Advanced Technology
Skim milk out of
advanced pasteurizer is
sent to the cultured
products batch proces-
sors, or (19)

The cottage cheese vats
at the correct tempera-
ture for innoculation
Product will be set, cut
and cooked in cottage
cheese vat; however, the
mixture of curd whey
will be pumped to a
separate draining device
which will also have
provision for washing
and will be located on
a weighing device so
that cheese dressing
may be applied

Cheese dressing may be
applied in known weight
quantities and mixed
mechanically at this
point.  The finished
product will be pumped
to (22)
Automatic packaging
machinery from which
it will be packed
automatically and
sent in conveyor quan-
tities or pallet quan-
tities to cold storage
(19)

CIP piping

Automatic material
handling
                                             2026 - Fluid Milk  IWP 9-139

-------
                        S ize vs. Technology

la 1963 there were 4,619 fluid milk plants producing 52,200,000,000 Ibs.
of milk and 829,500,000 Ibs. of creamed cottage cheese.  The industry
considers a plant producing less than 2 million Ibs. per year as "small",
from 2 to 20 million Ibs. as "medium" and more than 20 million Ibs. as
"large".

Waste and wastewater are a function of size as well as technology.  TABLE
IWP 9-140 represents industry  (C) opinion of the relationship of size and
technology.

                         TABLE IWP 9 - 140

                         Plant Statistics

                               1963

Small     2,671   57.8% produce less than 2 million pounds per year
Medium    1,448   31.4% produce from 2 to 20 million pounds per year
Large       500   10..870 produce more than 20 million pounds per year

Total:    4,619   plants produced 52,200,000,000 Ibs. of milk and
                  829,500,000  Ibs. of creamed cottage cheese in 1963
                                  Percentage of Various Sizes
       Percentage
       Technology
        Levels

207. Older  Technology
707, Typical  Technology
107, Advanced Technology
  Small
Less than 2

   98%
   51
    0
Med ium
2 to 20

   2%
  42
   1
   Large
More than 20

    0%
    7
   99
 This  relationship provides  a  basis  for  computation  of  overall  plant wastes
 produced when related  to  unit waste production  of various  size plants  of
 the three technology levels.
                                                2026 -  Fluid  Milk  IWP 9-140

-------
      Gross Waste Quant it i.tes. Before Treatment or. Other Disposal

Industry (C) has observed that in plants of advanced technology waste
production is less than in those less advanced.  Unit waste and wastewater
quantities per pound of finished product are as follows:

                        TABLE IWP 9 - 141-A

           Waste and Wastewater Quantities per Pound of
                         Finished Product
2026 - Fluid Milk:
   A.  Fluid Milk
Older Technology
Typical Technology
Advanced Technology

   B.  Cottage Cheese
                                    Product
                                    Soap &
                                   Chemicals
                                   Pounds BOD   Pounds BOD
Older Technology
Typical Technology
Advanced Technology
           Whey
         Pounds BOD

           .128
           .128
           .128
                        .0026
                        ,0010
                        .0005
                                    Product
                        .0003
                        .0001
                        .0001

                       Soap &
                      Chemicals
                                   Pounds BOD   Pounds BOD
           .012
           .008
           .002
          .0012
          .0008
          .0002
                     Wastewater
                      Gallons

                        5.0
                        3.5
                        2.0
      Wastewater
       Ga1Ions

        53.2
        48.4
        35.1
This data represents industry operating experience.  Whey is similar for
all levels of technology because the basic process is similar for all
levels; however, the other wastes are affected by plant size and tech-
nology.

                   geasonal Waste Production Pattern

Waste quantities tend to be directly proportional to production quantities;
however, wastewater is used in greater quantities in the warm months,
reflecting increased refrigeration requirements.  The following table illus-
trates the relationship.

                          TABLE IWP_ 9 - 141-B

Percentage of Yearly Totg^l o_f Whey^ Product, Soap & Chemical and Wastewater

           W-P-S & C   Wastewater                   W-P-S & C   Wastewater
January
February
March
April
May
June
 7.7
 7.9
10.1
 8.9
 8.9
 8.8
7.4
7.6
8.2
8.0
8.8
9.6
July
August
September
October
November •
December
8.6
8.3
8.3
7.8
7.5
7.2
9.7
9.6
8.6
7.6
7.5
7.4
                                               2026 - Fluid Milk  IWP 9-141

-------
Cottage cheese consumption is historically greatest during the Lenten
season.  This peaking will tend to reduce due to the lifting of certain
religious restrictions on the Catholic population.

Milk consumption tends to drop during the summer months;  however, produc-
tion of fruit drinks increases during these months so that total plant
volume tends to increase.  Also milk production tends to  be much heavier
towards the end of the week to accommodate the end-of-week consumer
shopping pattern.  These patterns are expected to continue.
                                               2026  -  Fluid Milk  IWP  9-142

-------
The relationship of plant size and technology shown in Table IWP 9-140
permits a comparison of the number of plants in each technology level.
The unit wastes from Table IWP 9-141-A when applied to the number of
plants results in Table IWP 9-143.
                        TABLE IWP 9 - 143

          Gross Waste Quantities for Average Size Plants

A.  Older Technology:     These plants process 6,000 Ib. of milk and
                          96 Ib. of creamed cottage cheese per day.
                 Significant Wastes - Lb. per Day

                                             Soap &
               Whey          Product       Chemicals       Wastewater
# Plants     Pounds BOD     Pounds BOD     Pounds BOD     Gal, per Day

    924        12.28           15.99          1.6            4,220
B.  Typical Technology;   These plants process 34,500 Ib. of milk and
                          560 Ib. of creamed cottage cheese per day.
                 Significant Wastes - Lb. per Day

                                            Soap &
              Whey           Product       Chemicals       Wastewater
# Plants     Pounds BOD     Pounds BOD     Pounds BOD     Gal, per Day

  3,464        71.68           44.59          4.5            17,745
C.  Advanced Technology;  These plants process 183,600 Ib. of milk and
                          3,000 Ib. of creamed cottage cheese per day.
                 Significant Wastes - Lb. per Day

                                            Soap &
               Whey          Product       Chemicals       Wastewater
  Plants     Pounds BOD     Pounds BOD     Pounds BOD     Gal, per Day

    231       384             112.5          11.2            55,515
                                   2026 - Fluid Milk  IWP 9-143

-------
                       TABLE IWP 9 - 144-A

          Gross Waste Quantities Before Treatment or Disposal

The individual plant data (Table IWP 9-143) when multiplied by the number
of plants results in gross waste quantities before treatment, disposal
or utilization in byproduct manufacture.

                               Significant Wastes Per Year

                                                   Soap &
                          Whey        Product     Chemicals    Wastewater
                        Pounds BOD   Pounds BOD   Pounds BOD    Gallons
                                                      .46
                                                     4.82
                                                      .81

                                                     6.09

                                                      50%

Older Technology
Typical Technology
Advanced Technology
Total
Individual Plant Range

(Millions)
3.55
77.47
27.68
108.70
t 50%
TABLE IWP 9 -
(Millions)
4.61
48.18
8.10
60.89
t 50%
144-B
21,980

 1" 20%
                  Projected Waste and Wastewater

The relationship among change in total production, plant size and tech-
nology change is shown in the following table:

      1963 and Projected Gross Wastes and Wastewater in Millions

                   1963    1968    1969    1970    1971    1972    1977

Lb. Product Mfd. 52,200  58,658  59,363  60,117  61,074  62,031  66,990

Lb. BOD Whey        108.7   121.2   121.7   122.3   123.3   124.3   129.0
Lb. BOD Product      60.88   67.88   68.18   68.42   69.07   69.62   72.25
Lb. BOD Soap &        6.1     6.8     6.8     6.8__    6.9     7.0     7.2
   Chemicals
      Subtotal      175.68  195.88  196.68  197.52  199.27  200.92  208.45

Gal. Wastewater  21,982  24,207  23,998  23,796  23,661  23,509  22,567


Projections of product manufactured are based upon industry and government
estimates.
                                        2026  - Fluid Milk   IWP  9-144

-------
                    Waste Reduction Practices

The waste reduction practices utilized in the industry do not vary
greatly.  Wastes from the various processes and subprocesses are all
similar in nature and thus a common sewer piping system is used for the
entire plant.  The wastes other than miscellaneous chemicals are of a
"biodegradable" nature.

Certain processing methods produce varying amounts of wastes.  Table IWP-
145 illustrates these relationships.


                        TABLE IWP 9 - 145

                       Processing Practices

The fundamental process used with the "older" technology as the reference
base, described on Page IWP 9-137.

	Alternate Process	_^  % Waste Reduction Efficiency	
                                          Product  Soap & Chemical  Wastewater
(a)
(b)
(c)

-------
                       Treatment Practices

The utilization of whey for byproduct manufacture is the treatment method
being given the greatest amount of attention; however, a relatively small
amount is being so used.

The most prevalent practice is Management Technique, i.e., that closest
possible supervision of day-to-day operation to eliminate processing loss—
loss due to waste resulting from the initial shrinkage of the raw material
as well as the overfill of the finished package.

In general, most waste that goes to plant sewers is subsequently flowed
to municipal sewers; to a lesser extent, waste may be discharged
directly into lakes or streams.

The disposal through use of sewage plants represents the least used treat-
ment practice.

The following table illustrates the effectiveness of the individual treat-
ment practices.

                        TABLE IWP 9-146

                       Treatment Practices
                                     Normal Removal Efficiency
Removal Method                     7» of Total Wasteload Removed
                             Whey &       Soap &
                             Product	Chemicals	Wastewater

 (a)  Ridge and Furrow         95-100       95-100            4 *
 (b)  Spray Irrigation         95-100       95-100            5 *
 (c)  Aerated Lagoon           90-95        90-95             1
 (d)  Trickling Filter         90-95        90-95            -0-
 (e)  Activated Sludge         90-95        90-95            -0-
 (f)  Municipal Sewer            100           100             -0-
 (g)  To Waterways               100           100             -0-
 (h)  Utilization as Byproduct 99.5           NA             99.5
 (i)  Management Technique       -0-           40             40


    *Estimated percent  of  total evaporated to the atmosphere,
     the  remainder going to waterways.

     NA = Not Applicable
                                         2026  -  Fluid Milk   IWP  9-146

-------
Assuming optimum conditions, the removal methods (supra) could be
employed in any given plant; however, the utilization of the ridge
and furrow, spray irrigation, and aerated lagoon type processes
require significant amounts of land.  Furthermore, soil and climate
limit both the physical size of a treatment plant as well as the
choice of the treatment process.

The trickling filter and activated sludge processes are relatively
compact; however, these types require greater capital investment
and have higher operating costs than the other methods.

The trend is to connect plants to municipal systems wherever possible
in order to simplify day-to-day operations and to minimize capital
investment.

The utilization of whey in byproduct manufacture will tend to increase
because of increasing relative value and need for these products.

The management technique is now being widely accepted and involves
close supervision of day-to-day operations, the utilization of
preventative maintenance techniques, and the use of inventory control
procedures.

It is estimated that the following percentages of industrial waste
have been or will be discharged to a municipal sewer:

                 1950    1963    1967    1972    1977

                  50      70      80      90      98

The discharge of fluid milk plant wastes to municipal systems is
entirely feasible.  The high BOD requirements necessitate that the
capacity of a particular municipal plant be reviewed prior to the
connection of a new fluid milk plant waste load to the system.

Pretreatment is not required because of the characteristics of the
waste; however, pretreatment may be required if the municipal plant
is of inadequate size.
                                      2026 - Fluid Milk  IWP 9-147

-------
The various practices have been utilized in varying degrees.  Plant
location, capital costs, operating costs and problems--a11 influence
the type adoption.
                         TABLE IWP 9 - 147

    Rate of Adoption of Waste Treatment Practices Since 1950

The rate of treatment practice adoption is shown in percentages.

                              % of Plants Employing Listed Methods

     Removal Method           1950    1963    1967    1972    1977

(a)  Ridge and Furrow          U*       U       U       U       U
(b)  Spray Irrigation          U        U       U       U       U
(c)  Aerated Lagoon            U        U       U       U       U
(d)  Trickling Filter          U        U       U       U       U
(e)  Activated Sludge          U        U       U       U       U
(f)  Municipal Sewer          50       70      80      90      98
(g)  To Waterways             26       21      16       6      -0-
(h)  Utilization of Whey as
        Byproduct             10       30      40      70     100
(i)  Management Technique     40       55      65      75      80


    *U = Under 1%
                                        2026  - Fluid Milk   IWP  9-148

-------
           Waste Reduction or Removal Cost Information

The milk industry has a capital investment in sewerage treatment
facilities, and also has annual operating and maintenance expenditures
in conjunction therewith.  Both are rather modest considering the size
of the industry.

The estimated capital investment in waste removal facilities in 1963
was $2,000,000 and the estimated annual operating expense was $400,000.

By 1966 the capital investment was estimated to have increased to
$2,600,000 and the annual operating expense to have increased to
$520,000.
           Comparative Investment & Operating Expenses

Plant sizes have been determined as small, medium and large and tech-
nology levels described as old, typical and advanced.

A comparison of investment cost and operating cost for providing waste
and wastewater removal facilities between plants of different sizes
and technologies for the various subprocesses and removal methods will
provide valuable data for determining which subprocess or method offers
the most attractive opportunities for use in the future to implement
the Clean Water Restoration Act.

The next several pages include these comparison tables.  The tables are
based on investment costs and operating costs as experienced by the
industry.  Land has been estimated at $300 per acre for ridge and
furrow, spray irrigation and aerated lagoon installation.

Management technique requires no additional capital investment.  Nominal
expense is included for educational purposes.

Economic life in relation to processing equipment represents current
thinking on industry needs for return on investment and recognizes
obsolescence.

Economic life in relation to removal methods represents observed useful
life.
                                        2026 - Fluid Milk  IWP 9-149

-------
                         TABLE IW? 9 - 150
                         Comparative Costs

          (For Providing Waste & Wastewater Removal Facilities)
Daily "net" waste quantities from plant to sewer are 257 pounds BOD
                                         These quantities are "gross"
The plant illustrated is representative of the older technology and of small
size.
       and 4,900 gallons of wastewater (±20%).
to waterways.
                                                                     (Years)
Product « Milk     Ibs. 5,300    Capital     Annual Operating &     Economic
          Cottage Cheese   85 _ Costs    Maintenance Expenditure    Li f e

(a)
(b)
(c)
(d)
(e)

(f)

(g)

CO

(i)

(J)

00


(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(D
Subprocess ;
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP vs. Manual
Deodorize vs. Not
Pasteurize - Continuous vs.
Batch
Packaging - Automatic
Older vs. Typical
Culture - Chemical vs.
Biological
Cheese Set - Continuous
vs. Batch
Pack Culture Products -
Hot vs. Cold
Piping - CIP vs.
Take-apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -15%
5,000
25,000
7,000

10,000

8,000

-0-

NA

10,000

12,000

8,000

$ 1,500
4,200
14,200
19,900
13,300
200
-0-
20,000
-0-

$ -207.
-900
46,000
+2,300

-600

-800

-400

NA

+2,000

-1,900

to

$ +300
+800
+2,800
+4,000
+2,700
+1,300
-0-
+4,000
-1,100

13
13
13
13

13

4

NA

NA

13

13

13

20
20
20
15
15
*
*
13
*
               NA * Not Applicable              * Permanent

               See Reference Notes on Page IWP 9-8 and IW? 9-149.
                                                 2026 - Fluid Milk  IWP 9-150

-------
                TABLE IWP 9 - 151

                Comparative Costs

(For  Providing Waste  & Wastewater  Removal Facilities)
The plant illustrated is representative of the typical technology and of small
size. Daily "net" waste quantities from plant to sewer are 68 pounds BOD (150%)
and 2,700 gallons of wastewater (j"207.). These quantities are "gross" to water-
ways.
(Years)
Product • Milk Ibs. 5,300 Capital Annual Operating & Economic
Cottage Cheese 85 Costs Maintenance Expenditure Life

(a)
C>)
(c)

(d)
(e)
(f)
(g)

(h)

(i)

(J)

00


(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
Subprocess :
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP Vs.
Manual
Deodorize vs. Not
Pasteurize - Continuous
Packaging
Culture - Chemical vs.
Biological
Cheese Set - Continuous
vs. Batch
Pack Culture Products -
Hot vs. Cold
Piping - CIP
Typical vs. Advanced
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -107.
5,000
25,000

7,000
AH
AH
-0-

NA

10,000

6,000

8,000


$ 800
2,300
3,700
11,000
7,300
200
-0-
20,000
-0-

$ -157.
-200
+6,000

+2,300
NA
NA
-400

NA

+2,000

-900

+0


$ +200
+500
+800
+2,200
+1,500
+300
-0-
+4,000
-200

13
13
13

13
13
4
NA

NA

13

13

13


20
20
20
15
15
*
*
13
*
     NA =  Not Applicable
* Permanent
     AH  - Already  installed
          by definition
     See Reference Notes on Page IWP 9-8 and IWP 9-149,
     There  are  no  small  plants  of  advanced  technology.
                                       2026 - Fluid Milk  IWP 9-151

-------
                         TABLE IWP 9 - 152

                         Comparative Costs

          (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the older technology and of medium
size.  Daily "net" waste quantities from plant to sewer are 1,912 pounds BOD
(i50%) and 36,500 gallons of wastewater (1207.).  These quantities are "gross"
to waterways.
                                                                      (Years)
Product - Milk     Ibs. 39,500   Capital     Annual Operating &      Economic
          Cottage Cheese   630	Costs    Maintenance Expenditure	Life

(a)
(b)
(c)
(d)
(e)

(f)

(g)

CO

(1)

(j)
00


(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
Subprocess :
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP vs. Manual
Deodorize vs. Not
Pasteurize - Continuous
vs. Batch
Packaging - Automatic
Older vs. Typical
Culture - Chemical vs.
Biological
Cheese Set - Continuous
vs. Batch
Pack Culture Products -
Hot vs. Cold
Piping - CIP vs. Take -apart
Material Handling -
Automatic vs. Manual
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -15%
10,000
25,000
10,000
15,000

34,000

-0-

NA

25,000

38,000

45,000

$ 10,900
31,500
105,000
69,000
46,000
200
-0-
40,000
-0-

$ -20%
-6,400
+4,000
+8,000
-3,300

-6,300

-800

NA

-3,000

-6,600

11,800

$ +2,200
+6,300
+21,000
+13,800
+9,200
+9,600
-0-
+4,000
-11,000

13
13
13
13
13

4

NA

NA

13

13

13

20
20
20
15
15
*
*
13
*
               NA = Not Applicable              * Permanent

               See Reference Notes on Page IWP 9-8 and IWP 9-149.
                                                2026 - Fluid Milk   IWP 9-152

-------
                         TABLE IWP 9 - 153

                         Comparative Costs

         (For Providing Waste & Wastewater Removal Facilities)
The plant illustrated is representative of the typical technology and of
medium size.
BOD (i50%) and 19,600 gallons of wastewater  (+207.).
to waterways.
                                                                         (Years)
                                                                       Economic
              Daily "net" waste quantities from plant to sewer are 502 pounds
                                                     These quantities are "gross"
Product = Milk
Ibs. 39,500   Capital
Annual Operating &
          Cottage Cheese   630	Costs    Maintenance Expenditure
               NA = Not Applicable              * Permanent

               See Reference Notes  on Page IWP  9-8  and  IWP 9-149,
                                                                         Life

00
(b)
(c)

(d)

(e)

(f)

(g)

(h)

(i)

(j)

00


(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
Subprocess :
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP vs.
Manual
Deodorize - Typical vs.
Advanced
Pasteurize - Continuous
Typical vs. Advanced
Packaging - Automatic
Typical vs. Advanced
Culture - Chemical vs.
Biological
Cheese Set - Continuous
vs. Batch
Pack Culture Products -
Hot vs. Cold
Piping - CIP vs.
Take-apart
Material Handling -
Typical vs . Advanced
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -107,
10,000
25,000

10,000

5,000

24,000

-0-

NA

25,000

19,000

25,000


$ 5,900
16,700
27,600
79,500
53,000
200
-0-
40,000
-0-

$ -157.
-2,400
•44,000

46,000

-300

-3,100

-800

NA

-3,000

-2,500

-4,700


$ +1,200
+3,300
+5,500
+15,900
+10,600
+2,500
-0-
+6,000
-4,000

13
13
13

13

13

4

NA

NA

13

13

13


20
20
20
15
15
*
*
13
*
                                                2026 - Fluid  Milk  IWP 9-153

-------
                         TABLE IWP 9 - 154
                         Comparative Costs

          (For Providing Waste & Wastewater Removal Facilities)
The plant illustrated is representative of the advanced technology  and of
medium size.  Daily "net" waste quantities from plant to sewer  are  271 pounds
BOD (1507.) and 15,300 gallons of wastewater  (±207.).  These quantities are
"gross" to waterways.
Product = Milk     Ibs. 39,500
	Cottage Cheese   630
Capital     Annual Operating &
 Costs    Maintenance Expenditure
 (Years)
Economic
  Life
        Subprocess:
(a)
(b)
(<0

-------
                         TABLE IWP 9 - 155

                         Comparative Costs

         (For Providing Waste & Wastewater Removal Facilities)

The plant illustrated is representative of the typical technology and of
large size.  Daily "net" waste quantities from plant to sewer are 2,439 pounds
BOD (1507.) and 95,300 gallons of wastewater  (±207.).  These quantities arc
"gross" to waterways.
                                                                         (Years)
Product s Milk     Ibs. 191,000  Capital     Annual Operating &        Economic
          Cottage Cheese  3,100   Costs    Maintenance Expenditure       Life

(a)
(b)
(c)

(d)
(e)

(f)

(g)

00

(i)

(j)

00


(a)
(b)
(c)
(d)
(e)
(f)
(g)
CO
(i)
Subprocess :
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP vs.
Manual
Deodorize vs. Not
Pasteurize - Continuous
Typical vs. Advanced
Packaging - Automatic
Typical vs. Advanced
Culture - Chemical vs.
Biological
Cheese Set - Continuous
vs. Batch
Pack Culture Products -
Hot vs. Cold
Piping - CIP vs.
Take -apart
Material Handling -
Typical vs. Advanced
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique

$ -107.
32,000
25,000

15,000
5,000

48,000

-0-

NA

60,000

95,000

28,000


$ 28,600
81,000
134,000
103,000
68,500
200
-0-
90,000
-0-

$ -157.
-9,400
+3,000

+23,000
-800

-3,700

-3,200

NA

-7,000

-22,300

-5,300


$ +5,200
+14,600
+24,100
+18,500
+12,300
+12,200
-0-
±0
29,600

13
13
13

13
13

4

NA

NA

13

13

13


20
20
20
15
15
*
*
13
*
               NA s Not Applicable              * Permanent
               See Reference Notes on Page IWP 9-8 and IWP 9-149.
               There are no large plants of older technology.
                                                2026 - Fluid Milk  IWP 9-155

-------
                         TABLE IWP 9 - 156
                         Comparative Costs

          (For Providing Waste & Uastetfater Removal Facilities)

The plant illustrated is representative of the advanced technology and of
large size.  Daily "net" waste quantities from plant to sewer are 1,317
pounds BOD (1507.) and 74,200 gallons of wastewater (120%).  These quantities
are "gross" to waterways.
Product * Milk     Ibs. 191,000  Capital
	Cottage Cheese  3,100   Costs
  Annual Operating &
Maintenance Expenditure
 (Years)
Economic
  Life
        Subprocess;
(a)
(b)
(c)
(d)
(e)
(0
(g)
(h)
(i)

(J)
00


(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(1)
Plant - Large vs. Small
Receive - Tanks vs. Cans
Separator - CIP
Deodorize vs. Not
Pasteurize - Continuous
Packaging - Automatic
Culture - Chemical Set
Cheese Set - Continuous
Pack Culture Products -
Hot Pack
Piping - CIP
Material Handling -
Automatic
Removal Method:
Ridge and Furrow
Spray Irrigation
Aerated Lagoon
Trickling Filter
Activated Sludge
Municipal Sewer
To Waterways
Utilization as Byproduct
Management Technique
$ -107.
AH
AH
AH
AH
AH
AH
NA
AH

AH
AH


$22,200
63,000
72,000
97,000
64,500
200
-0-
90,000
-0-
                                                      -157.
                                                       NA
                                                       NA
                                                       NA
                                                       NA
                                                       NA
                                                       NA
                                                       NA
                                                       NA

                                                       NA
                                                       NA
                                                $  44,000
                                                  +11,400
                                                  +13,000
                                                  +17,500
                                                  +11,600
                                                   +6,600
                                                  -14,600
                              13
                              13
                              13
                              13
                              13
                               4
                              NA
                              NA
                              13

                              13
                              13
                              20
                              20
                              20
                              15
                              15
                               *
                               *
                              13
               NA = Not Applicable              * Permanent
               AH = Already installed
                    by definition

               See Reference Notes on Page IWP 9-8 and IWP 9-149.
                                                2026 - Fluid Milk   IWP  9-156

-------
The tables indicate that several subprocesses and removal methods are
particularly attractive in terms of small capital investment and low
annual operating expense.

The utilization of whey in byproduct manufacture eliminates this mate-
rial as a waste.  The plant with condensing and drying equipment will
utilize whey as a byproduct _if there is a market available; otherwise
the plant with or without this equipment tends to send whey to the
sewage system.

The application of management technique requires no capital investment
and very little operating expense, and results in significant economy
in plant operations, and is a highly desirable practice.

Disposal of remaining waste to municipal sewers requires only nominal
investment and operating cost at the plant and is attractive to the
plant operation.  However, if a municipality establishes a sewage rate
charge based directly on plant waste loads, then comparative economics
determine whether or not the plant should adopt further waste removal
methods.
                 Summary of Projected Wasteloads
Year


1963



Waste


Whey (Lb. BOD)
Product (Lb. BOD)
Soap & Chemical (Lb .

Gross Waste
Generated
Million
108.7
60.88
BOD) 6.1
ST 175.68
Remova 1
*
%
80
80
80
ST
Net Waste
Discharged
Million
21.74
12.18
1.2
35.12
       Water (Gallons)              21,982                   20,883
      *?ercentage of waste reduced or removed by process changes,
       waste treatment and byproducts utilization.
                                       2026 - Fluid Milk  IWP 9-157

-------
           Summary of Projected Wasteloads
Year

1968
1969
1970
1971
1972
1977
Waste Gross "Waste
Generated

Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Whey (Lbs. BOD)
Product (Lbs. BOD)
Soap & Chemical (Lbs. BOD)
ST
Water (Gallons)
Million
121.2
67.88
6.8
195.88
24,207
121.7
68.18
6.8
196.68
23,998
122.3
68.42
6.8
197.52
23,796
123.3
69.07
6.9
199.27
23,661
124.3
69.62
7.0
200.92
23,509
129.0
72.25
7.2
208.45
22,567
Removal
*
%
87
87
87
ST
5
89
89
89
ST
5
91
91
91
ST
5
93
93
93
ST
5
95
95
95
ST
5
99.5
99.5
99.5
ST
5
Net Waste
Discharged
Million
15.76
8.82
.9
25.48
22,997
13.39
7.50
.7
21.59
22,798
11.01
6.16
.6
17.77
22,606
8.63
4.83
.5
13.96
22,478
6.22
3.48
.3
10.00
22,334
.65
.036
.004
.690
21,439
*Percentage of Waste Reduced or Removed by Process Changes,  Waste
 Treatment and Byproducts Utilization
                                         2026 - Fluid Milk  IWP  9-158

-------
                    REFERENCE SOURCES
A.  Federal and State

    1.  Department of Agriculture
           Dr. A. C. Manchester
           Mr. A. G. Mathis

    2.  Bureau of Census

    3.  State of Wisconsin, Department of Natural Resources
           Mr. Theodore Wisniewski

B.  Associations and Committees

    1.  Dairy Industry Waste Committee

    2.  Dairy and Food Industries Supply Association, Inc.

           Mr. Fred C. Messemer
           Mrs. G'Schwend

    3.  Evaporated Milk Association
           Mr. Fred Greiner

C.  Industry

    1.  Mr. A. G. Larsen
        The Great Atlantic & Pacific Tea Co.
        New York, New York

    2.  Mr. Orville Karhl
        Beatrice Foods
        Chicago, Illinois

    3.  Dr. H. Howard
        Borden Company
        New York, New York

    4.  Mr. H. S. Christiansen
        Carnation Company
        Los Angeles, California

    5.  Mr. J. E. Crowley
        Crowley's Milk Company
        Binghampton, New York

    6.  Mr. G. A. Houran
        Delaval Separator Company
        Poughkeepsie, New York
                                     Reference Sources - IWP 9-159

-------
     7.   Mr.  Joseph Maldari
         Foremost  Dairies,  Inc.
         San  Francisco,  California

     8.   Mr.  Tetherow
         Knudsen Creamery of California
         Los  Angeles, California

     9.   Michigan  Milk Producers  Association
         Detroit,  Michigan

    10.   Mr.  J.  W. Rugaber
         Pet  Milk  Company
         St.  Louis, Missouri

    11.   Mr.  L.  J. Fox
         Safeway Stores, Inc.
         Oakland,  California

    12.   Dr.  Gordon Harding
         Mr.  Frank McKee
         National  Dairies Research  Laboratory
         Glenview, Illinois

    13.   Mr.  Kenneth Burke
         Sealtest  Dairies, Southern Division
         Charlotte, North Carolina

    14.   Mr.  R.  B. Barrett
         Klenzade  Products
         Beloit, Wisconsin

    15.   Land-0-Lakes Creameries, Inc.
         Minneapolis, Minnesota

         and  many  individual companies

D.  Publications and Books

     1.   Industrial Waste Guide  - Dairy Industry
         Waste Committee Publication

     2.   Sewerage  and Sewerage Treatment - Wiley

         and  many  trade  journal  articles

E.  Johnson Associates International
         reported  operational experience from more than 155
         processing facilities (approximately 350 plants as
         described in the Profile).
                                     Reference Sources - IWP 9-160

-------
        INDUSTRIAL WASTE PROFILE - DAIRIES SIC 202
                         SUMMARY
               SCOPE OF MATERIAL COVERED
Industrial Waste Profile IWP-9 Dairies is a qualitative
and quantitative description of wastes and wastewater
generated in the Dairy Industry identified in SIC Code
as 202 Dairy Products.

The Industry is examined in its important major subdivi-
sions identified by SIC Code as follows:

2021  Creamery Butter - Establishments primarily engaged in
      manufacturing creamery butter.

2022  Cheese, Natural and Processed - Establishments pri-
      marily engaged in manufacturing all types of natural
      cheese (except cottage cheese - Industry 2026), pro-
      cessed cheese, cheese foods, and cheese spreads.

2023  Condensed and Evaporated Milk - Establishments pri-
      marily engaged in manufacturing condensed and evaporated
      milk and related products, including ice cream mix
      and ice milk mix made for sale as such and dry milk
      products.

2024  Ice Cream and Frozen Desserts - Establishments pri-
      marily engaged in manufacturing ice cream and other
      frozen desserts.

2026  Fluid Milk - Establishments primarily engaged in pro-
      cessing, packaging and distributing fluid milk and
      cream, cottage cheese, and related products.

The Profile is prepared for the Base Year of 1963 which
permits correlation with 1963 Census of Manufacturers data
for production and water use.

The waste and wastewater estimates are developed from actual
plant operating experience, are correlated with manufacturing
processes and are augmented by waste reduction and removal
cost estimates.

Projections of waste and wastewater for future years are
developed in detail.
                   Summary - 202  Dairy Industry  IWP 9-161

-------
Government statistics show that total milk production has declined
steadily since 1964, but the U. S. Department of Agriculture prognos-
ticates that production is at or near the minimum and will tend to
increase in the future in proportion to population growth.

The number of processing plants has decreased more rapidly than pro-
duction; production per plant, however, has increased rapidly.  This
trend will continue because the cost per unit of product in the larger
technologically advanced plants is significantly less than in the
smaller less advanced plants.

Waste and wastewater production per pound of product is lower in a
large plant than in a small plant, and is also lower in a technologi-
cally advanced plant than in one  less advanced.

Dairy wastes are similar in all of the five processing groups.  The
most significant wastes include:  product loss in the process stream,
water, soap and chemicals used in sanitation procedures, cooling water,
skim milk and buttermilk from butter manufacture and cream and whey
from cheese manufacture.

Product loss during processing can never be reduced to zero; however,
the industry finds that large technologically advanced plants have
process stream product waste of 1/2%, compared to a waste of 1 to
1-1/2% in the typical plant, and  to 2-1/2% waste in the small plants
of older technology.  This reduction in waste represents a consider-
able financial saving and is a contributing factor in the trend towards
the consolidation and building of large plants (labor costs being the
primary factor).  Plant management technique has as much to do with
process stream loss reduction as  does plant size or technology.  One
should note that this resultant waste is in addition to the "shrinkage"
in receipts of raw product and "loss" due to overfill, which when com-
bined with process waste comprise the plant "loss".

 "Water, soap and chemicals used for sanitation represent waste and
wastewater volume.that  is proportionately less for large technologically
advanced plants than for small, less advanced plants.  Most soaps now
used are of the "biodegradable" type which decompose readily during
sewage treatment.  Advancing  technology in sanitation has resulted in
the use of welded stainless  steel lines, "cleaned in place" (CIP) pro-
duct piping systems, and automation of many processes which greatly
improve total plant sanitation.   These in turn improve product, shelf
life and reduce waste.  The  design and operation of the sanitation
systems has much to do  with  the quantities of wastes produced, which
                              Summary  -  202   Dairy Industry   IWP 9-162

-------
if not properly operated, can actually .result in increased wastes
in technologically advanced plants.  The trend, however, is toward
the reduction in the amount of soap and chemicals used.

Cooling water waste is created by cooling products in processing
equipment or by use in the refrigeration systems.  The availability
and cost of cooling water determines whether a "once-through" usage
is employed as opposed to recirculation through cooling towers and
evaporative condensers.  The latter reduce water requirements by 95%.
As water becomes scarce or expensive, the use of recirculation equip-
ment will increase.

Skim milk and buttermilk from butter manufacture and cream and whey
from cheese manufacture are wastes which can be utilized in by-product
manufacture.  The great bulk of the skim milk and buttermilk from butter
manufacture is currently used in the manufacture of condensed and powdered
products.  As butter plants increase in size, the individual plant out-
put of these products grows in volume and becomes more economical to
use in by-product manufacture.  Cream from the cheese manufacturing
process is always utilized because of the great value of this product.
On the other hand, whey does not have great commercial value.  Some uses
for whey have been developed, but the greatest incentive toward whey
utilization has been the penalties imposed on industry when untreated
whey is sent to waterways.

Whey comprises the largest sewerage load (BOD) that is not economically
subject to reduction in volume through utilization in by-product manu-
facture.  There are relatively few whey drying plants.  The plants which
are operating are doing so at a "breakeven point" or at a slight profit.
If whey becomes more valuable because milk production increases at a
slower rate than consumption, then whey processing plants will tend to
become more profitable; however, until products derived from whey increase
in value, the municipal incentives and penalties will determine how whey
is utilized.
                             Summary - 202  Dairy Industry  IWP 9-163

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Past and projected industry aggregate wastes prior to reduction through
utilization in by-product manufacture are as follows:

                       Waste Before Reduction
Total Milk Production
    Pounds

Product (Lb. BOD)
Soap & Chemical
   (Lb. BOD)
Cream, Skim & BM
   (Lb. BOD)
Whey (Lb. BOD

Total Theoretical Load
   (Lb. BOD)

Wastewater  (Gallons)
    (In Millions)

   1963         1968


125,000    122,200

    130.09     136.14

     13.0       13.6
  4,195.2
    537.3
3,781.6
  625.7
  4,875.59   4,557.04

 59,847     57,601
                                                   1972
                         1977
           127,200     133,700

               138.03      141.10
   13.8

4,000.9
  657.9
   14.1

4,321.3
  718.3
             4,810.63    5,194.80

            52,547      45,805
The wastes that are not reduced as previously described, are sent to
waterways.
Product (Lb. BOD)
Soap & Chemical
    (Lb. BOD)
Cream, Skim & BM
    (Lb. BOD)
Whey (Lb. BOD)

Total Sewerage Load

Total Wastewater
   (Gallons)
                        Net Waste to Waterways
                             (In Millions)
                            1963
     931.8
               1968
  637.4
             1972
  35,971    31,725
 358.5
           27,586
           1977
60.9
6.1
620.2
244.6
47.4
4.7
334.3
251.0
20.0
2.0
196.9
139.6
8.0
.82
21.6
31.1
 61.52
          22,077
                               Summary - 202  Dairy Industry   IWP 9-164

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These net wastes must be treated to eliminate water pollution.  The
wastes may be treated biologically in standard sewage treatment
plants.  Dairy wastes have a high sewage (BOD) demand in relation to
volume, but are generally low in suspended solids.

Special attention has been given to treatment of cheese whey because
of small amount of cheese curd carried by the whey as well as the large
volume involved.

Most dairy plants are not large enough in size to justify the cost of
an industrial plant treatment system as this may represent an excessively
large capital investment compared to total investment in plant (10 to
20%).

The proper operation of a treatment plant requires qualified technical
personnel, thus causing the individual plant treatment system to be
high in operating cost.

It is preferable to discharge dairy plant wastes to municipal systems
where possible.  In rural areas, lagoons can be used for large plant
waste treatment and ridge and furrow and irrigation systems for waste
from smaller plants.

Treatment plants become necessary only when municipal incentives and
penalties are established.

The following table summarizes the information developed in the
individual chapters.
                            Summary - 202  Dairy Industry   IWP 9-165

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                                1963      1968      1972      1977

Total Milk Production            125.0     122.2     127.2    133.7
   (Billion Lb.)
Total No. of Plants           10,142     7,600     6,350     4,861

Technological Advance:
  (1) % increase in
      plant size                 --         45.8      83.9    161.6
  (2) 7<, plants becoming
      technologically
      advanced                   --         56        94       100
  (3) % process waste
      reduced by advance         —          5         9        14

Utilization of Waste  in By-product Manufacture:
  (1) 7. skim milk  from
      butter manufacture          85        91        95        99.5
  (2) 7» buttermilk from
      butter manufacture          85        91        95        99.5
  (3) 7. cream from
      cheese manufacture          99        99        99        99.5
  (4) 7, whey from
      cheese manufacture          48        53        75        99.5

Estimated Development of  Sewage Treatment Practices:
  (1) Plants in municipalities
      (a) % to municipal
          sewer                   98        98        98        99
      (b) % to plant  operated
          systems                  2221
  (2) Rural plants
      (a) 7« to ridge  and
          furrow                   8        11        22        33
      (b) 7o to spray
          irrigation               4         5         8        11
      (c) 70 to aerated
          lagoons                  8        11        22        56
      (d) 7o to waterways
          untreated               80        73        48         0

Net  Waste to Waterways:
    (Million Lb. BOD)             931.8    637.4    358.5     61.52

Total Wastewater:
  (Million Gallons)           35,971    31,725    27,586   22,077
                                Summary 202 - Dairy Industry  IWP 9-166


                                      U. S. GOVERNMENT PRINTING OFFICE 1963 O - 287-032

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