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
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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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
(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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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. _ „
LJATFR 1— — '
x
CONTINUOUS "
-ik
S
%
_
k- — r
>w
^
*
K
r
. RC,L.aa.vc.
TANK TRUCKS
1
2 STORAGE TANKS
STORAGE
3 DRY & FROZEN
' r
4 LIQUIFY
i
1
5 ASSEMBLY
1
PASTEURIZE
6 BATCH
7 HOMOGENIZE
1
8f*C\(\\ TMP
1
9 STORAGE TANKS
I
\
CONT. PAGE 2
A COOLING
' WATER
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
-------
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
-------
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
o
m
ON
in
ON
O
\0
ON
in
VO
ON
o
t-»
ON
m
r-%
ON
ON
Number of Plants
3,000
2,000
1,000
500
o
m
ON
m
m
o
vO
ON
in
vO
O
1^
ON
in
r^
ON
1,500
1,000
500
o
in
ON
Production per Plant (Thousand Gallons)
<<
i i-lT*
^-~
X
^^^
X
X
m o m o m r-
>n vo vo ri r~ t-^
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
-------
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
-------
(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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
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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
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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
-------
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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