PB85-216505
Strategics for Water and
Waste Reduction in Dairy
Food Plants
Ohio State Univ., Columbus
Prepared for
Environmental Protection Agency, Cincinnati, OH
Jun 85
U.1 PunntoiM «f Commerce
Mztnut TxtoitJJ Mwimliun Senrice
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PB8f-21<505
EPA/600/2-85/076
June 1985
STRATEGIES FOR WATER AND V7ASTE REDUCTION IN DAIRY FOOD PLANTS
by
W.J. Harper, R.A.H. Delaney,
I.A. Igbeka, M.E. Parkin
The Ohio State University
Colun-.ous, Ohio 43210
and
Schiffermiller, T.E. Ross, R.A. Williams
The Kroger Company
Cincinnati, Ohio 43202
Grant No. R 803374
Project Officer
Kenneth Dostal
Water Engineering Research Laboratory
Cincinnati, Ohio 45268
WATER ENGINEERING RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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TECHNICAL REPORT DATA
(fleae read Inarutnont on the rt>mt before compliant)
t REPORT NO
EPA/600/2-85/n76
3 RECIPIENT'S ACCESSION NO
t TITLE AND SUBTITLE
Strategies For Water and Waste Reduction
in Dairy Food Plants
5 REPORT DATE
June 1985
6 PERFORMING ORGANIZATION CODE
7 AUTMORts'W.J.Harper*, R.A.M. Delaney*. I.A. Igbeka*.
M.E. Parkin*, W.E. Schiffermiller**, I.E. Ross**,
R.A. Williaiis**
a PERFORMING ORGANIZATION REPORT NO
PERFORMING ORGANIZATION NAME AND ADDRESS
10 PROGRAM ELEMENT NO
**
The Ohio State University, Columbus, OH 43210
The Kroger Co., Cincinnit*. OH 45202
11 CONTRACT/GRANT NO
Grant No. R 803374
12 SPONSORING AGENCY NAME AND ADDRESS
Water Engineering Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, OH 45268
13 TVPE OF REPORT AND PERIOD COVERED
Final
14 SPONSORING AGENCV COPE
EPA/600/14
is SUPPLEMENTARY NOTES
Project Officer: Kenneth Dostal (513)684-7502
16 ABSTRACT
A study was undertaken to reduce water and waste discharges in a complex, multi-
product dairy food plant through management control and modifications of equipment and
processes. The objectives were to develop approaches that would be broadly applicable
throughout the dairy industry and to determine the economic and environmental impacts
of the programs instituted.
Detailed studies were made to determine the plant areas contributing major waste
loads and the economic feasibility of reducing these loads. A Management control
program was developed and implemented over a 6-month period. This program included
irajor increases in direct supervision of waste control. A Computer linear program was
applied to the four processing areas to determine economic factors involved in waste-
water discharges and to help select the most economical process and equipment changes
that could be made.
The Study concluded that material reduction can be achieved economically in dairy
food plants that have not previously given attention to this matter.
KEY WURDS ANO DOCUMENT ANALYSIS
DESCRIPTORS
b IDENTIFIERS/OPEN ENDCD ISRMS c COSATI Field/Croup
Inplant Study
Minimize Water Use
Minimize Waste Loads
Food/Dairy/Processing
Water
Wastewater
13B
8 DISTRIBUTION STATEMENT
Release Unlimited
IB SECURITY CLASS iThu Ktportl
Unclassified
21 NO OF PAGES
313
20 SECURITY CLASS iTIntpafri
Unclassified
2: PRICE
EPA Fofm 2220-1 (R»». 4-77) previous IOITION il OBSOLETE
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DISCLAIMER
The information in this document has been funded wholly or
in part by the United States Environmental Protection Agency
inter Grant No. R 803374 to the Kroger Company and The Ohio
State university. It has been subject to tne Agency's peer
and administrative review, and it has been approved for Publica-
tion as an EPA document. Mention of trade names or c°™>ercial
products does not constitute endorsement or recommendation for
use.
11
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FOREWORD
The U.S. Environmental Protection Agency is charged by Con-
gress with protecting the Nation's land, air, and water systems.
under a mandate of national environmental laws, the agency strives
,
£«.SrmUiatC and !m?lement actions leading to a compatible balance
between human activities and the ability of natural systems to
' r11e- e Cl6an Wa
iXE'r -!SrX1V1-e-c ?e Cl6an Water ACt' the Safe Drinking
water Act, and the Toxic Substances Control Act are three of the
major comjressionol laws that provide the framework for restoring
and maintaining the integrity of our Nation's water, for preserv-
ing and enhancing the water we drink, and for protecting the en-
vironment from toxic substances. These laws direct the EPA to
perform research to define our environmental problems, measure
the impacts, and search for solutions.
of EP!^ p^" fleering Research Laboratoiy is that component
of EPA s Research and Development program concerned with prevent-
ing, treating, and managing municipal and industrial wastewater
nantsaf^;^ta^llShing Practices fc° control and remove contami-
storLf ™H J S"l Water Snd t0 Prevent its deterioration during
storaoe and distribution; and assessing the nature and controlla-
Sii,,?0*. ?X1C substance "leases to the air, water, and land from
ea??onC*Uring p"«sses and subsequent product uses. This pubU-
cation is one of the products of that research and provides a
vital communication link between the researcher and the user
community.
The information presented here will help industry airive at
meaningful or achievable solutions to environmental problems by
the sudy of methods for the inplant reduction of wastes through
a management control program. The achievement of these goals
fnn^ff .c?mpjete Dedication on the part of industry management
tSf IJSf J101!"* ^om°tlon ^ industry and government to providn
the needed motivation for success.
Francis T. Mayo, Director
Water Engineering Research
Laboratory
111
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ABSTRACT
A study was undertaken to reduce water and waste discharges
in a complex, multiproduct dairy food plant through management
control and modifications of equipment and processes. The
objectives were to develop approaches that would be broadly
applicable throughout the dairy industry and to determine the
economic and environmental impacts of the programs instituted.
The Kroger Dairy Company at Indianapolis, Indiana, was the
study site. This plant was chosen because it was well engineered,
discharged its wastes to a municipality, was under average manage-
ment control, and had not previously had an extensive waste con-
trol program. As such, it was typical of more than two-thirds
of the diiry plants in this country.
Detailed studies were made to determine the plant areas con-
tributing major waste loads and the economic feasibility of re-
ducing these loads. A management control program was developed
and implemented over a 6-month period. This program included major
increases in direct supervision of waste control. A computer
linear program was applied to the four processing areas to deter-
mine economic factors involved in wastewater discharges and to
help select the most economical process and equipment changes
that could be made.
The study concluded that material reduction can be achieved
economically in dairy food plants that have not previously given
attention to this matter.
This report was submitted in fulfillment of Grant No. R 803374
by The Ohio State University and the Kroge- Company under the
sponsorship cf the U.S. Environmental Protection Agency.
IV
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CONTENTS
Foreword
Abstract iv
Figures vi
Tables viii
Acknowledgments xi
1. Introduction 1
2. Conclusions 9
3. Recommendations 16
4. Facilities and Conduct of the Study 19
5. Development and Evaluation of Analytical
Methods 48
6. Water and Wastewater Characterization 64
7. Departmental Waste Characterization 89
8. Wastewater Characteristics of Unit Processes. . Ill
9. Development and Implementation of Waste
Management Control Program 137
10. Process and Equipment Changes to Reduce Waste
Loads 193
Appendices
A. Glossary 224
B. Record Forms for Water and Waste Control. ... 241
C. Computations and Calculations 264
D. Computer Modeling of Dairy Plant Wastewater . . 269
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FIGURES
<£ Page
1. Floor Plan of Indianapolis Kroger Dairy ...................... 22
2. Drain Plan and Sampling Stations at Indianapolis
Kroger Dai ry .........................................
3. Plan Drawing of Waste Sampling Station at Indianapolis
Kroger Dairy ..................................... ^
4. Plan Drawing of Weirs from Sample Stations #1, #2 and
*3 [[[ 39
5. Standard Curves for Autoanalyzer Analysis of Selected
Carbohydrates .........................................
*********** *>5y
6. Probability Plots of Daily Water Use and Waste Water
Discharge for the Months of August and May ................. 71
7. Variation Total Water Use for All Days, Processing Days
and Weekends for Base Period ..................... ..... ....... 72
8. Variation in In-Plant Water Use for All Days, Processing Days
and Weekends for Base Period .......................... 73
9. Variation in Waste Water Discharge for All Days, Processing
Days and Weekends for Base Period ......................... ...74
10. Total pH Chart for Kroger Dairy Waste Water .................. 79
11. Hourly Waste Water Discharged for Floor Drains from
Frozen Dessert Operations ................................. 116
12. Hourly COD Discharge of Floor Drains for Frozen Dessert
Operati ons ......................................... 12Q
13. Effect of Tankers Standing Before Unloading on Milk
LOSS [[[ 135
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16. Resources Control Program Computer Summary 177
17. Resources Control Program HTST Performance Report 178
18. Effect of Management Control Program on Waste Water
Volume Coefficient for Total Plant 183
19. Effect of Management Control Program on BOD Coefficient
for Total Plant 184
20. Effect of Management Control on BOD Coefficient for
Total Plant less Whey 185
21. Effect of Management Control Program on Waste Water Volume
Coefficient for Milk Department 186
22. Effect of Management Control Program on BOD Coefficient
for Mi ik Department 187
23. Effect of Manageinent Control Program on Waste Water Volume
Coefficient for Ice Cream Operations 188
24. Effect of Management Control Program on BOD Coefficient
for Ice Cream Operations 189
25. Effect of Management Control Program on Waste Water Volume
Coefficient for Novelty Operation^ 190
26. Effect of Management Control Program on BOD Coefficient
for Novelty Operations 191
VT.1
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TABLES
Number
1. Effect of Refrigerated Storage on Mean COD, BOD Carbohydrates,
Suspended Solids and Standard Plate Count 49
2. Effect of Frozen Storage on COD, BOD, SS and Standard Plate
Count 52
3. Reproducibility aiid Recovery of Added Lipid by Three Procedures
for Fats, Oils and Grease 54
4. Comparison of Lipid Methods 56
5. Effect of Lipid Leval in Dairy Uaste on COD and BOD 58
6. Comparison of Autoar.alyzer and Modified DuBois 61
7. A Comparison of BOD and Organic Compound
Ana 1 ys i s 63
8. Variation in Calculated and Measured Waste Water 66
9. In Plant Water Use 63
10. Standard Deviation for In-Plant Water Use 69
11. Monthly Averages of Waste Characteristics for Total Plant Waste
Water froir Indianapolis Kroger Dairy 76
12. Waste Water Characteristics. Means and Standard Deviations of
Daily and Monthly Averages 77
13. Linear Regression Analysis of Selected Waste Characteristics 81
14. Pounds Discharged Per Day of Selected Wastewater Components 86
15. Selected Waste Water Coefficients in Gallons of Waste Water and
Pounds of Components/100 Pounds BOD Processed 87
16. Departmental Contribution to Mean Daily Wastewater Values for
Total Plant 91
Vlll
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17. Mean Waste Strength of Characteristics of Ice Cream Departmenc
Wastewater [[[ 93
18. Regression Analysis of Selected Wastewater Characteristics for
the Ice Cream Department ............................................. 94
19. Mean Selected Wastewater Characteristics Waste Loads for Ice
Cream Department [[[ ^°
20. Mean Wastewater Coefficient? for Ice Cream Department .............. 97
21. Mean Waste Strength Values for Characteristics of Cottage
Cheese-CIP Department Waste Water .................................. 99
22. Regression Analysis of Selected Characteristics in Cottage
Cheese Department Waste Water ..................................... 101
23. Mean Loads for Cottage Cheese-CIP Department Selected Waste
Water Character! sties ............................................. 102
24. Mean Waste Water Coefficients for Cottage Cheese-CIP Department... 104
25. Mean Waste Strength Values for Characteristics of Milk
Department [[[ 105
26. Regression Analysis of Selected Characteristics in the Waste
Water from the Milk Department .................................... 107
27. Mean Loads for Milk Department Selected Waste Water
Characteristics [[[ 109
28. Coefficients for Selected Characteristics in Milk Department
Waste Water [[[ 110
29. Effect of Fines Removal on BOD of Cottage Cheese Whey ............. 127
30. BOD Losses Based on Market Report Values for Dairy Product
Losses Only [[[
31. COD Cost Accounting for Ice Cream Department
32. Summary of Chemical Oxygen Demand Entering the Ice Cream and
Frozen Novelty Drain Catchment Area, the Losses of Chemical Oxygen
Demand and the Percentages of COD Lost in the Effluent ............ 172
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36. Design Coefficients for Fluid Milk Processing ..................... 197
37. Design Coefficients for Cottage Cheese
Process ing [[[
38. Actual Coefficients for Cottage Cheese Processing in Kroger,
Indianapolis Plant ......................................... •" ....... 1S9
39. Design Coefficients for Ice Cream Processing in the Kroger,
Indianapol is Plant ..................................... " ............ ZJO
40 Actual Coefficients for Ice Cream Processing in the Kroger,
Indianapolis Plant ................................................. '01
41. Design Coefficients for Stick Novelty Processing in the Kroger
I ndi anapol is Dai ry ................................................. zoz
42. Actual Coefficient for Siick Novelty Processing at the Kroger
Indianapolis Dairy ................................................. Z03
43. Waste Associated Costs of Fluid Milk Operations Under Design
Condi ti ons ........................... v ........... .' ................. Z0b
44, Waste Associated Costs of Fluid Milk Operations Under Actual
Condi ti ons [[[ zo°
45. Waste Associated Costs of Cottage Cheese Operations under
Desi gn Condi ti ons .................................................. zo'
46. Waste Associated Costs of Cottage Cheese Design under Actual
Condi ti ons
47. Waste Associated Costs of Ice Cream Operations Under Design
Condi ti ons [[[ Z09
48. Waste Associated Costs of Ice Cream Operations Under Actual
Condi ti ons [[[ Z1°
49. Waste Associated Losses for Novelty Operations Under Design
ondi ti ons [[[ 21 1
50. Waste Associated Costs for Novelty Operation Under Actual
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55. Activities 271
56. Raw Products Codes 278
57. Operations, Activities and Process Codes 279
58. Processed Product Codes 28°
59. Description of Vectors for Basic Solution (Columns) 28*
60. Description of Vectors (Rows) for CASESTUD 285
61. Example of Computer Print Out for Novelty Operations 289
XI
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ACKNOWLEDGMENTS
This study was conducted by the Kroger Company of Cincinnati,
Ohio, in collaboration with the Department of Food Science and
Nutrition of The Ohio State University at Columbus, Ohio. Mr.
Ron Rice, Mr. Jack Cornette, and the Board of Directors of the
Kroger Company are acknowledged for their recognition of the
need to study methods Tor the inplant reduction of wastes. The
project directors for this study were Mr. William Shiffermiller
and Mr. Thomas Ross of Kroger, and Dr. W.J. Harper of Ohio State
University.
This study was conducted at the Kroger Dairy in Indianapolis,
Indiana. The support and assistance of the two Plant Managers -
Mr. Harold Wall and Mr. John Morrison - is gratefully acknowledged.
In addition, valuable assistance was received from all of the plant
employees and supervisory personnel, with special thanks to Mr.
Ernie Lippert, Mr. Joseph Salimbene, Mr. Art Rush, Mr. Norman
Clark, and Mr. Eric Perkins.
Technical assistance is acknowledged for analyses conducted
at Ohio State University by Mr. Kevin Brown, Mr. Thomas Laahman,
Mrs. Lee Reichenbach, Mr. Bill Schreiber, Mr. Mark S.nith, and Dr.
C.R. Lee.
The work of Dr. Roy E. Carawan on computer linear programming,
funded by The Ohio State Water Resources Laboratory, was conducted
simultaneously with the study, and the approaches were adapted
to the specific applications required in this study.
Mr. Alfred B. Craig was the project officer for the major
portion of this study, and his suggestions, moral support, and
assistance are gratefully acknowledged.
XII
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SECTION 1
INTRODUCTION
PURPOSE
This investigation was undertaken to develop, implement, and
evaluate strategies for reducing water and waste discharges in a
complex, multiproduct dairy food plant through a combination of
management control and modification of equipment and/or processes,
The purposes were to develop approaches that would be broadly
applicable throughout the dairy industry and to determine the
economic and environmental impacts of the programs instituted.
The results may be used to help reduce wastes at other dairy
food plants.
To make the results as appplicable as possible, a plant was
chosen that was well engineered, discharged its wastes to a
municipality, was under average management control, and had not
been previously engaged in an extensive waste control program.
Such a plant was considered to be typical of more than two-
thirds of the dairy plants in this country.
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The Kroger Dairy at Indianapolis, Indiana, met these criteria.
In addition, it was a large, complex, multishift, multiproduct,
union-labor-operated plant. If this plant could successfully
demonstrate waste reduction through management nontrol and equipment
or process modification, these approaches should be usable across
the industry. The plant was constructed in 1973 and incorporated
the latest in engineering design available at that time, including
computer control of the separation processes and some waste
recovery techniques. Fluid milk products, cultured products,
cottage cheese, ice crear, and frozen novelties were manufactured
under one roof. The plant operated 5 days a week on a three-shift
basis, with some processing going on during all three shifts.
The wastes were discharged to the Indianapolis Municipal Treatment
Plant, which charged for volume and added a surcharge for biologi-
cal ox/gen demand (BOD) and suspended solids (SS) levels in the
wastewater above municipal sewage strength.
The results were evaluated with respect to the extent of
wastewater reduction and its economic impact on the plant.
Results were also evaluated with regard to the reduced environmen-
tal impact of dairy food plant wastes.
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OBJECTIVES
The project was divided into three phases: (1) de-
termination of a baseline for water use, wastewater discharge and
waste characterization, (2) development, implementation, and
evaluation of methods for management control and (3)
determination of economically feasible changes in unit processes
and/or equipment for further waste reduction in the plant and
implementation of feasible changes.
The specific objectives for Ehase 1 were:
1. To construct sampling stations for
monitoring the waste from individual
departments.
2. To determine a mass balance for water and product
through the plant.
3. To determine the volume and composition of the
waste being discharged from the plant.
4. To establish the waste components that were inter-
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dependently and independently related.
5. To determine specifically whether the relationships
between COD (chemical oxygen demand), BOD, and SS
were constant enough for the total plant wastewater
to use COD as a predictive measure of BOD and SS.
6. To determine the amount of preventable and
unavoidable water and organic discharges from the
plant and from each department. (The unavoidable
waste is that associated with the design of the
plant processes and can not be reduced without
making physical changes.)
7. To compare lossej measured from production re-
cords with those measured in the wastewater and
to determine the reasons for previously reported
underestimates of losses by the use of production
records.
8. To determine the major factors involved in the
loss of water and organic material.
9. To determine water and waste coefficients for
najor unit operations.
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The specific objectives for Phase 2 were:
1. To develop a comprehensive management waste
control program for reducing at least 75% of
the preventable water and organic waste load.
2. To use a computer system to monitor water,
wastewater recovery systems and product proces-
sing as a managment tool in t!~" • jntrol program.
3. To implement the control program, evaluate its
effectiveness, and make modifications to optimize
the program.
4. To prepare a waste control management handbook for
the dairy industry as a separate document.
The specific objectives for Phase 3 were:
1. To investigate the specific changes in unit
processes or equipment that would
significantly reduce losses of water
or ingredients.
2. To adapt a computer linear analysis system for model-
ing the waste-related costs of milk products,
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cottage cheese, ice cream and frozen novelties
and thereby determine the economics of
changing the unit process or the equipment
or both to reduce waste loads.
3. To apply the LP model to the proposed project
changes and select those that would recover the cost
of the changes within an 18 month period.
4- To implement the process and/or equipment
changes for reducing water or wasce loads
and to evaluate the actual versus the predicted
effectiveness.
BACKGROUND
As regulations on the effluents from municipal water
treatment plants become more restrictive, major contributors
of organic matter, such as dairy plants, will face
considerable pressure to reduce their loads, increase
pretreatment, and/or provide full secondary treatment. User
charges for nunicipal treatment will become a major economic
facto; requiring good management control of fluid wastes in dairy
food plants.
Historically, dairy plants that have not been subjected to
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prior pressure as point dischargers of wastewater or as
overloaders of the municipal system have given little attention to
water or organic was'.e loads, buch plants' waste loads have
generally included about 50% preventable wastes under average
management control. Tne investigators considered that a majority
of the plants located in large cities would fall under chis
category, including the dairy at Indianapolis. Kith the
continuing trend for further consolidation of the dairy industry,
ttiuse large plants probably contribute about 50% to 60% of the total
organic waste load contributed by the dairy industry.
Tlie Kroger Dairy at Indianapolis is typical of the
large dairy plants that have been built over the past decade and
that process more than 1 million Ib of milk a day an-J generate
organic waste lodds equal to those of a city of more thar 50,000.
Nost of thes« plants jnrt those built in the future will be
located near a municipal waste treatment facility that can
effectively treat the compatible wastowaters generated by
dairy product processing. Such plants will be major contributors
of organic waste loa-.lj. Reduction of these waste loads may have a
'.ignif ic-ant impact on the efficiency of the municipal treatment
works in many instances, tho-jgh the degree of impact will vary
in different locations.
Custrvations made before the plant was chosen for study
indicated that (1) large, preventable losses occurred, (2) the
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plant was not achieving water or waste control in keeping with
its engineering design capability, (3) the management was
concerned about waste control, (4) the city sewer charges were
relatively low and thus made sewer costs basically invisible as
an economic cost, and (4) the plant provide'' a challenge for
developing an effective control program.
At the time this study was initiated, the Kroger dairy
received up to 1.5 million Ib of milk per day and discharged
approximately 500,000 gal of wastewater per day with an
average BOD load of 10,000 to 12,000 Ib. The amounts of
BOD and water (wastewater coefficients) per 100 Ib of BOD
processed were 6.3 Ib of BOD and 37C gal of wastewater,
respectively. (These data were based on a preliminary survey of
time composite samples over 1 week within 6 months of the
opening of the plant.)
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SECTION 2
CONCLUSIONS
The study of the Kroger U;iiry at Indianapolis, InrJianj
nas led to the conclusion that material reduction can be achieved
economically in dair^ food plants that have not previously given
attention to this area. The conclusions have been divided into
tnrc-e categories: (a) those relating to the composition of dairy
fooo p .nt wastes, (b) those relating to reduction of preventable
wastes, and (c) those relating to process and/or equipment
modification to reduce unavoidable waste levels.
DAIRY PLANT WASTE COMPOSITION
1. The following waste parameters were interrelated: COD,
BOD, SS, volatile suspended solids VSS), total solids (TS),
protein, fat, carbohydrates, and photohorus. Sodium, calcium,
and chloride varied independently of the other components.
These results are expected where the related organic components
are all derived from ingredient losses; Na and Cl would also
be contributed by cleaning and sanitizing solutions, and
calcium chloride would be discharged in large quantities
from the freezing of stick novelties.
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2. About 95% ot the organic matter in the waste from the
Kroner dairy plant was derived from food ingredients, and the
remainder v>as derived from acid cleaniroi compounds.
3. Ihe bOD/COD ratio for the total plant waste at the
Kroger dairy was fount] to be 0.46 + 0.06. This suggests that
for a given plant, where there is no change in the
Cleaned-in-Place (CIP) system or in the relative amounts of
different products processed, the BOD/COD ratio remains
relatively constant. Therefore, either BOD or COD can be used to
estimate the other once the relationship has bc-en established for
a particular process.
4. Tnc composition and waste coefficients for the Kroger
dairy were typical of those ootained for dairy plants that had no
previous record of extensive study.
5. The EPA-recognized metuods for determining fats, oils,
and grease in municipal wastes were not reliable for determining
them in dairy food plant wastos. Acid hydrolysis before extrac-
tion was essential for providing a reproducible, routine method
to determine fats, oils, ar.cl groaso. The fat recovery by this
method was 37% + 3%.
f,. The standard Tcchnicon method for determining carbo-
hydrates in fluid wastes was not reliable for dairy wastes, since
10
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it failed to measure more than 80% of the lactose in the
samples. A modified procedure was developed that gave more than 90%
recovery of sucrose, lactose, glucose and fructose, which are all
found in dairy plant wastes.
7. Because of the short time require' for analysis, COD
was the preferred method for estimating loss and product yield
for wastewater analysis. COD analyses of products and
ingredients increase the accuracy of this approach. This involved
COD analysis of the wastewater, COD analysis of all ingredients, and
calculation of pounds of COD processed by multiplying the amount
of each ingredient used by the pounds of COD per pound of
ingredients and summing the total pounds of COD processed: % loss
= (pounds COD in wastev/ater/pound «f COD processed) * 100.
8. Determination of losses by COD and/or BOD analysis of
the wastewater was more accurate than that obtained from
production figures, since the latter were frequently based on
reference to established standards and production goals that were
not reflected in actual practice.
MANAGEMENT CONTROL OF '.JATEF AND WASTE DISCHARGES
1. Approximately one-third of the water and one-half of
the orr^nic load wasted in the Kroger dairy were found to be
11
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preventable wastes subject to reduction through managment
control.
2. Tlie computer installed for monitoring production,
water, and wastewater was of limited value because of inability of
project personnel to program it. The cost of software
revision was not economical.
3. Raw waste must be transformed into an economic impact
format (such as dollars of loss/day) for management to fully
understand the situation.
4. Data interpretation is a major problem in developing
•nanagament understanding. The data generated by waste analysis
required extensive calculations to put it in a form that
management could readily understand and act on. The basic
problem was that the output was in a form thr.t was too techni-
cal for management use. A cheaper alternative to speeding up
calculations by buying more software for the computer installed
in the plant was to obtain a low-cost micro-computer that could
be programmed in basic to calculate and format reports
specifically for management.
5. This and other studies show that plant management does
not have an adequate background in waste and waste co.-.trol to be
able to develop an effective control program without specialized
assistance.
12
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6. The control management procedure that included
education and daily evaluation was effective in reducing water
and wastes to about the level predicted. A waste control manager
with no other duties was the best approach.
7. The management control handbook that resulted from
this investigation should be of value in assisting management to
develop a control program. This handbook should also
apply to other areas of tl>e food field.
8. Plant operators are Motivated more by social and
environmental goals than by economic considerations. The op-
erator, in the Kroger dairy developed interest in the control
program, and about 10% were highly motivated as long as th.'* was
visible interest on the part of their immediate supervisors.
9. A detailed analysis of the water use, production
scheduling, plant preventive maintenance, equipment operation,
and waste loads - by department and unit process is essential
to understanding how to structure a waste control program
and establish realistic goals.
10. ihe management control program can be an effective way
of reducing wastes and will uor. than pay for the costs involved.
13
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11. Control of preventable wastes is a management
function. Effective control requires the full-time effort of at
least one individual who has no other responsibilities and
who answers directly to the general manager.
12. The LP computer models developed for this study are
applicable to any dairy plant that has adequate information on
water and waste coefficients. The program was useful in
delineating the factors associated with economic losses that
were waste -related, showing the difference between design and
actual losses. Loss-associated costs were for incredientSj.wa-
ter, wastewater, surcharges for BOD and 55, packaging materials,
labor associated with lost product,and energy associated with
lost product.
EQUIPMENT AND/OR PROCESS CHANGES
1. The LP computer program provided a basis for
determining the projected effect of process and/or equipment
changes and was used in making final decisions about the changes
that were economi:ally feasible.
2. Process and equipment changes in the Kroger Dairy
results in a Savings of 100,000 gal per day (20%) and a
reduction of 1000 ib of BOD (10%) per day.
14
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3. The elimination of whey was not considered
economically feasible at this time. The cost of discharging whey
to the municipal treatment plant was 40 C/lb of dry curd.
More detailed information is needed to determine the economic
feasibility of converting whey to baker's yeast.
15
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SECTION 3
RECOMMENDATIONS
Recommendations based on this study are divided into
thos- specifically pertaining to the Kroger Dairy's future
operations and those that apply to the dairy industry at large.
KROGER DAIRY RECOMMENDATIONS
1. Continue the management waste control program using a
single individual who has no other responsibilities and who
reports r'lrectly to the plant manager.
2. Institute a daily loss/cost analysis program of the
wastes from the ice cream and from the total plant operations,
using COD determinations.
3. Modify the current computer system to:
a. exclude production data,
b. include counters from milk and ice cream
fillers.
c. include stick counters and package counters
for the four-stick novelty machines.
1C
-------
d. include mathematical calculations to convert
raw data into usable form.
4. Improve maintenance capability to ensure that the
preventive maintenance program is actually carried out as
scheduled and includes those items specifically related to waste
control.
5. Conduct further study to determine process
and/or equipment changes that would further reduce cost and
recover the cost of the changes in 3 to 5 years.
6. Conduct further study to determine the
technological and economic cost of achieving zero discharge in
this plant.
INDUSTF1YWIDE RECOMMENDATIONS
1. The management waste control program instituted at
the Kroger Dairy should be used by other dairy plants as a
viable means of reducing waste loads.
2. The LP program used for this study should he
made available fo.: general dairy food plant use.
3. Each dairy plant should institute a
17
-------
waste monitoring program using COD as the basic analytical
method to monitor wastes and plant yields.
4. All dairy plants should institute an
evaluation of the potential changes in process and/or equipment
that would achieve further reductions in waste loads.
18
-------
SECTION 4
FACILITIES AND METHODS OF STUDY:
Thir sect.on discusses the Indianapolis Kroaer dairy
plant in detail to provide an understanding of the subsequent
findings and alterations KaOe in process equipment, a description
of the sewer drain system and provisions tor ..onitorin, flow and
sampling; and a description of the analytical methods that »r.
utilised.
DESCRIPTION OF DAIRY PLANT
The Kroger Dairy at Indianapolis, Indiana was utilized
Eor this investigation. The plant, which was constructed in
1973, is a multi-product plant producing fluid .ilk products,
cottage cheese and frozen desserts. A typical day-s production
would be:
. Fluid milk received 1,500,000 Ib
- Fluid milk r-roduots 1,200,000 Ib
- cottage cheese- 19'°n° lb
-------
Ice Cream
Novelties
90,000 Ib
56,000 Ib
Wastewater volume
Waste as BOD
Waste as SS
650,000 gal
10,000 Ib
4,000 Ib
The products manufactured in this plant are as follows:
Fluid milk products:
-3.25% homogenized milk
-Lo Fac milk, 0.5%
-Fortified skimmilk
-Egg nog
-Half & Half
-Cheese skimmilk
-Sour Cream
-Fruit yoghurt
-Orange drink
-Orange juice
-2.0% milk
-Chocolate drink, 2%
-Imitation chocolate
-Buttermilk
-Coffee cream
-Cheese dressing
-Imitation sour cream
-Old Fashioned yoghurt
-Lemon drink
-Crape drink
Cottage cheese;
-dry curd
-creamed cottage
cheese
20
-------
Ice Cream products:
-10% fat ice cream -12% fat ice cream
-Ice milk -Ice Cream Sandwich
-Sherbet
Frozen Novelties:
-Ice pops -Ice cream bars
-Ice milk bars -Fudge bars
-Specialty bars -Root beer floats
The fluid products are produced in a variety of package
sizes and the frozen deserts are in a variety of different
flavors. Altogether, the plant produces over 124 different
packages of products.
Description of Plant Operations:
A d iagratnatic description of the plant and equipment
layout is presented in figure 1. Specific equipment is described
by number and letter in this figure. Specific descriptions of
21
-------
BOOO
nnnnfinnn
j—; so n a a
|aaaa
IOODO
Figure 1. Floor PTan of Indianapolis Kroger Dairy
-------
the various areas numbered in the figure are as follows:
1. Haw milk receiving:
The four-bay receiving room permits the unloading of four
6,000 gal tankers at one time. The total raw milk pumping
capacity is 400 gal a minute or 200,000 Ib an hour which
matches the plant's High Temperature Short Time (HTST)
capabilities. Incoming tankers are weighed on a 70 ft ground
scale just before entering the room. In addition to raw -nilk, the
central receiving area accepts corn and cane syrup, cane sugar,
bulk chocolate coating, condensed milk, cream and bulk cleaning
solutions. Each bay has its own CIP system for washing the
trucks. All rinses and washings are discharged to the sewer.
2. Haw Milk storage tanks:
The plant is equipped with (2-A) five, 30,000 gal Mueller
and one 25,000 gal Cherry Burrell raw product cold walJ silo
storage tanks, providing a total capacity of 17b,000 gal
(1, 505, 000 pounds) .
3. Fluid milk processing:
Total rated capacity is 190,000 Ib per hour.
Equipment includes (3-A) 89,000 Ib por hour Crepaco (modified
22
-------
to 50,000 pounds per hour to provide processing or. special products
and decrease processing time), with homogenizer; (3-B) 55,000 Ib
per hour A.P.V. HTST with a Gaulin homogenizer. Two SAMM-25006
Westfalia 55,000 Ib per hour CIP Separators are tied into the
50,000 Ib. units and a 27,000 Ib. per hour Westfalia CIP
Separator (Model LAMM-12006) is tied into the third 50,000 Ib
per hour unit; (3-D) The control panel directs all fluid product
processing; (3-ii) Batching area for by products; and (3-F)
Mueller square tanks.
4. Pasteurized storage tanks:
Tne plant has six, 10,000 gal Crepaco pasteurized
storage tanks that are cleaned and sar.itized with a Klenzade
single pass CIP unit.
5. Milk filling room:
At the beginning of the project, the filling room was
equipped with (5-A) Cherry Burrcll G-60 gal. paper filler; ( 5-B)
a Kemy gal plastic filler; (5-C &5-D) Ex-Cell-0 TP half-gal
fillers; (5-E) and a NNL aseptic Ex-Cell-0 unit for by-products.
The room is air filtered with a laminar air filter system.
6. Milk and milk casing:
24
-------
This area has five milk lines and one cheese, yoghurt and
sour cream line for automatic casing and stacking.
7. Culture room:
The room is equipped with one, 1,000 gal. Mueller and
two, 1,500 gal. cone bottom Cherry Burrell vats for yoghurt and
sour cream. The room also has three 600 gal. all purpose flat
bottom round processors for culture or cultured products.
8. Cheese filling room:
The filling room is air filtered and has an Auto Pak
choose filler and two Akra Pack fillers for yog.iurt and sour
cream.
9. Ccttage cheese room:
Six 30,000 pound «ind two 15,000 pound Damrow cheese vats
are used for cottage cheese production. The room has one 3,000
gal., three-compartnent Cherry burrell cheese dressing tank.
Three 9,000 gal. Cherry Burrell rectangular tanks store skim milk
for choebe making. Two other tanks are used to store chilled
water, which is used to wash the cottage cheese.
10. Case return area:
25
-------
The case return area is equipped with Conveyor Speciality
unstackers and case washers. The in-floor conveyors do not
require lubrication.
11. Milk cooler:
The cooler holds about 50,COO cases, withan in-floor,
double loop conveyor that allows continuous circulation of cases
until they are placed in inventory. A milk recovery tank is
located in the cooler to recover product from damaged cartons. No
lubrication is required for the conveyors.
12. Blow molfl room:
This area is equipped with two Uniloy gallon blow molders
and a plastic recycle system. A 10,000 gal silo tank stores
plastic pellets for container manufacturer on site
13. Ice cream processing:
The equipment includes one 4,COO gal per hour A.P.V.
Gaul in HTST unit for ice cream products; one Batch-0-Matic ice
cream mix blend ing-weight system; 24 Cherry Burrell ice cream
fl-vor tanks; two 1,000 cal 3 barrel Crepaco ice cream freezers
for packaged pioducts; two 800 gal 2-barrel Crepaco ice cream
20
-------
freezers for novelties; one 500 gal. 2 barrel Cherry Burrell
freezers. There are 10 mix storage tanks. In addition/ in the
ice creaip processing area are located 4 cream storage tanks, one
tank for rinse recovery, one for buttermilk slurry and two for
whey slurry. All of these supply the Batch-0-Matic mix tank.
14. Novelty manufacture:
Four 12-wide Vitaline stick novelty machines that are
brir.e fed are used in the production of stick novelties. The
system uses Anderson Brothers bar wrappers, box formers and
polywraps.
IS. Ice cream packaging:
This area has a 555-4 Anderson half gal. filler, 325
Anderson filler, and a Lynch Mopack sandwich machine. The boxer
is a Mastercraft. An Auto Pak round container filler for gallon
packages is also used. Thu sandwich packaging nachines are from
K. A. Johnson Co. and operate at 1500 to 1800 gals, per houi.
16. Hardening tunnel:
The hardening tunnels are a Cram (16-A) and an Americo
(16-B).
27
-------
17. Carrousels:
Three carrousels palletize and transfer product from the
hardening tunnels to storage freezers.
18. Frozen dessert storage:
The storage area holds one million gals of packaged ice
cream and two million dozen novelties.
19. Refrigeration:
This area contains the compressors and sweet water tanks.
20. Boilers:
This area contains three 300 hp vapor heating boilers.
Special features in this plant that relate to water used
and waste loads are:
1. Automated CIP system:
Seven CIP units serve the plant. The units are single
use, supplied with liquid chemicals. A stainless steel trough is
located below the cnemical feed pumps to collect any leakage of
full strength chemicals and these troughs are rinsed
28
-------
automatically to dilute any spilled chemical to prevent damage to
the drains.
2. Continuous processing of by-products:
Computer-controlled standardizing clarifiers separate the
milk into cream and skim which can be automatically metered to
produce products of any desired fat content, thus eliminating
batch operations and reducing the start-up and shut-down of the
HTST units.
3. Rinse recovery:
A rinse recovery system is installed for the three milk
HTST units to automatically save water-milk blends during the
start-up and shut-down of the pasteurizers. The rinses are
stored in a 3,000 gallon tank for subsequent use in ice cream
manufacture.
4. Damaged carton product recovery:
Covered stainless steel containers are located adjacent
to the milk fillers and in the milk cooler to collect the product
from damaged cartons. An automatic vacuum system is used to
transfer the product to the rinse recovery tank.
5. Segregated sewer lines:
29
-------
There are three separate process sewer lines in the plant
(See Figure 2): (a) one for the milk receiving, processing,
filling and storage areas, (b) one for the ice processing,
novelty processing and packaging and ice cream packaging filling
and (c) one for high concentration wastes including the CIP
system, cottage cheese and hub drains for the HTST units - for
separator sludge CIP solutions of these systems. These exisiting
lines provided a basis for setting up sampling stations to
determine the waste loads from the different departments.
GENERAL PRODUCTION SCHEDULING:
The plant operates on a three shift basis:
7am-3pm
3pm-llpn
llpm-7 am
General scheduling for the various departments is as
follows;
Keceiving:
Milk is received in 6,000 gallon tankers between 7 am
30
-------
and 9 pm. Generally from 20 to 40 tankers are scheduled on
a staggered basis.
Milk Processing:
Pasteurization of milk begins between 4 and 6 am *nd
continues until about 11 or 12 pm. Clean up is scheduled
between 12 and 4 am.
Milk Filling:
Milk packaging operation begins at 7 am and continues
until 11 pm. Equipment clean-up is between 12 midnight and
6 am.
Ice Crean Processing:
Pasteurization of frozen desserts starts from between 4
..r'j 6 am. Processing is completed on most days by 8 pm.
Ice Cream Packaging:
Ice Cream packaging begins aoout 7 am and continues
until 11 pm.
Cloan-up is from 12 midnight until 4 to 5 am.
31
-------
Novelty Operations:
The novelty machines are on the same schedule as the ice
cream packaging.
Cottage cheese:
Skim milk is pasteurized during the morning and the vats
are filled in sequence oeginning about 3 to 4 pm. The whey
is drained from the vats between 11 pm and 2 am. Washing
continues until about 5 am.
The curd is creamed in the vats and the cleaning of the
cheese vats starts about 11 am and continues until 3 pm.
32
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follows:
MANAGEMENT STRUCTURE
The management structure of the Kroger dairy is shown as
GENERAL MANAGER
1
i- First Shift
•Comptroller
Marketing Mgr.
•Production
Superintendent
General Foreman
-Second Shift
General
Foreman
Third Shift
f4
I flrea
(^ Foremen
J Area <
{^Foremen /
/'Clean-up
1 Foremen 1
1 O «-.- \
56
Plant
Workers
Plant
Workers
^28
Plant
( Foreran (.Workers
•Chief Engineer
-First Shift Foreman
-Second Shift Foreman
—Third Shift Foreman
•Quality Control
Superintendent
(20
Plant
Engineers
33
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FLOW MONITORING AND SAMPLING:
Description of sewer lines:
A diagram of the sewer lines and designation of the location of
sampling stations is shown in Figure 2. There are four separate
sanitary sewer lines discharging from the plant and connecting to
a 12 inch line that connects to the city sewer system by means of
a lift station. A storm sewer line (not shown) is separate for
clean water discharges.
The separate sewer lines are: (a) an eight inch line
connectina the floor drains for the ice cream processing and
packaging and the novelty processing and packaging operations;
(b) a six inch line connecting the floor drains for the cottage
cheese processing, the trash compactor, the special drains from
the 7 CIP systems and the hub drains from the HTST pasteurizers
that collect separator sludge and CIP solutions; (c) an eight
inch line connecting the floor drains for milk receiving, milk
processing, milk packaging and the milk . iler and (d) a six inch
line from the rest rooms.
Description of the sampling stations:
The sampling stations were designated as Drains 91, 92,S3
34
-------
Station
• 11
CottageCheese +
CIP » hub drains
Figure 2. Drain Plan and Sampling Stations at Indianapolis Kroger Dairy
-------
and |4. Station H (the lift station) already existed prior to
the study and included all four sewer lines from the plant.
It is located at the corner of the property and approximately 500
feet from the last point of entry of the sewer lines from the
rest rooms. During very wet weather, there was a suggestion of
infiltration in the last 400 feet of the line, and samples were
not taken routinely from this station. An initial survey mad?
over five processing days showed that the contribution of
domestic wastes from the rest rooms contributed less that 0.3% of
the COD or BOD and less than 0.4% of the hydraulic load. For the
above reasons, station |3 was selected as being most truly
representative of the plant's processing wastes.
An existing man-hole was used for station (3 and a new
man-hole was du-j at the junction of the lines from tne ice cream
area snd the cottage cheese-CIP drain (see Figure 3). The latter
was four feet at the top and 5 feet in diameter at the bottom,
whereas the former was four feet in diameter. Drain |1 was for
the ice cream and novelty area; drain 12 was for the cottage
cheese-CIP lines; and drain S3 was just beyond the point of entry
for the milk floor drains and contained all of the processing
wastes. The waste from the milk area was determined by
difference (Drain 83 -/j>ain Jl + Drain |?7= milk wastes).
The sampling stations were equipped with permanently
installed weirs. The construction of the weirs was changed after
-------
VENTv
VERIFY EXACT
LOCATION 8
INVENT IN FIELD
2000 psi CONCRETE-
ABOVE GRADE CONSTRUCTION
SAME AS p. 2
DEPRESS GRATE l'
•12"-
j
r
J
J~
' c
* • T
A' Q"
x
E*. I2"^X
/X
2' O"— •
s/
//
/
/
-\
^
^^
~\
6'0"DIA.F
w/C.1. MA
PER CO D
SAW CUT
r VIT. AT 2
•12"-
' '' '^
y.. . . v j;\-*- 1
Figure 3. Plan Drawing of Waste Campling Station at
the Indianapolis Kroger Dairy
37
-------
initial evaluation and the final design is shown in Figure 4. The
weirs provided a satisfactory means of measuring flow in most
cases. An exception was for drain 52 when more than two cheese
vats were drained at Llie same time. In this case the 6 inch line
was not adequate to carry the flow and an error in reading existed
for a short time. However, based on calculation from known flows
through drain 12, the error did not exceed 5%. Because of the
drop in the line, a flume would not have been satisfactory
either. Chart records showed when multiple cheese vats were
being emptied and data for these situations were not included in
tnis report.
Based on experiences gained in this study, flumes were
determined to be more satisfactory for use in monitoring dairy
plant wastewaters - primarily because they are self cleaning.
Frequent cleaning of the weirs was essential to avoid recording
unreliable data, bocause of debris backing up beh.r.d the weir.
In the ice cream drain, for example, as many as 1000 sticks could
accumulate behind the weir in a weeks time. Daily review of water
meter flow and wastewater flows could be used to monitor any
abnormal readings.
Throe lanning model F-3024 portable dipping type flow
meters were used to monitor flow. Tht meters operated
continuously, and repair was necessary on each meter about once a
yuar. Three Manning Model b-IPOO discrete portable samplers were
-------
12" Sewer Line
6" Sewer Line
15"-45°V Notch Weir
TsiO gal Ions/min at full flow)
SAMPLING STATION No. I (6* diameter)
12" Sewer Line
I2"-90°V Notch Weir
(1120 gallons/min at full flow)
SAMPLING STATION No.2 (4*diameter)
figure 4. Plan Drawing of Weirs from Sample
Stations 81, #2, and j»3.
39
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used. They were capable of taking 24 samples in either time or
flow compobite .node. The minimum time for a single sample was
3.75 minutes and the minimum flow for taking one sample was 110
gallons for drains »1 and 1120 gallons for drains »2 and »3. Ice
or dry ice was used in the sample case as a refrigerant when the
ambient temperature was above 4S°F. Manning recording pH neter
wds rotated between the three drains as required. Normally pi!
was monitored routinely on Drain »3.
Sample handl in-] :
Discrete or composite samples were generally refrigerated
and shipped to tho Ohio State University for analysis.
KHfrigorated samples were shipped in refrigerated trucks within
o
two-three hours after collection. They we-e maintained at 2-4 C
and analyzed within 48 nours from time of sampling. (See Section
Uurin-, the second and third phases of the study, some
samples were frozen immediately after collection. Frozen samples
w,re shipped in dry ice. They were analyzed within 14 days after
receipt. No suspended solids analyses were made on frozen
(See Section 4 for validation of the use of frozen
l es)
were tha-ved and analyzed as discreet samples or
40
-------
composited, trozen samples were thawed, tempered at 38 C and
mixed in a karing t/pe blender to obtain a representative sample.
Analyses:
Analyses were conducted ly Standard f'ethods unless
modified as described in Section 5. Analyses conducted during
the course of this investigation included the following:
-COD
-Total solids
-Total suspended solids
-Dissolved solids
-Setcleable solidb
-Kjeldhal nitrogen
-Aromonia nitrogen
-Lipids (fats, oil and grease)
-------
-Carbohydrates
-Chloride
-Phosphate
-Sodium
-Calcium
-Magnesium
-pH
-Conductivity
Where applicable, the methods used were those from
Standard Methods for the Examination of Water and Waste water
(1976) or the EPA Handbook on Analytical Methods (1973). The EPA
Handbook on Control in Water and Wastewater Analysis was followed
as a guide in the evaluation of methods used in this study.
BOD: The 5 day biological oxygen demand, referred to as
BOD in this report, was determined routinely by the standard
bottle method, using a "SI oxygen meter to measure dissolved
42
-------
oxygen. The Hach manometric method was used to study effects of
variables on the oxygen utilization as a function of time.
A seed was obtained from the Indianapolis municipal
treatment plant, and was used fresh or was reactivated from a
freeze dried stock. The activated freeze dried stock and the
fresh seed gave the same results. Analyses were made of multiple
dilutions of waste water and a standard skim milk (9% solids
reconsitituted from non fat dry milk) was used as a control. The
control gave 72,000 +. 3,000 mg/1.
COD: Standard Methods COD was used in this study as the
reference method. Routine analyses were made with the Technicon
Model II Autoanalyzer, using five concentrations of freshly
prepared glucose as a standard. Unknown standards were analyzed
on a routine basis to serve as a control. During the final phase
of the study, the Hach digestion unit and pre-prepared reagents
were used and the results were found comparable to the
Standard Reference Method.
Solids Analysis: All solids analyses were by Standard
Methods without modification.
Kjeldhal nitrogen: The Kjeldhal method was employed
using the Technicon Autoanalyzer II for. the
determination (Technicon method 334-74A/A76). The dye binding
43
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method of protein determination was employed as a screening
technique, using the Udy method and a Foss Electric Pro-Milk
Tester. The latter procedure was evaluated as a means of
estimating protein in waste water for in-plant quality control.
For adequate accuracy, it was necessary to concentrate the
samples by a factor of 10. The comparison to protein values
determined by the Kjeldahl method was + 10%.
Livid (fats,oil and grease): Analysis of lipid in dairy
food plant wastes has been recognized as a problem in a number of
investigations. A number of different methods were evaluated,
and the Werner Schmidt method was found to be most satisfactory
for routine analysis. A chloroform-methanol extraction method
applied to freeze dried samples was most precise, but required
too much time for routine use. Standard Methods procedures for
fats,oils and grease were unsatisfactory, underestimating the
total lipid by from 30 to 50%. The automated Milko-Tester
procedure was also evaluated as an in-plant quality control
procedure and gave non-reproducible results on dilute dairy waste-
water. Concentration of samples by a factor of 10:1 and mixing
with a milk of known fat content .gave results that were within
+ 10% of those obtained by the fcerner-Schmidt procedure. Of the
methods evaluated, the Technicon procedure was the least
satisfactory.
The Vverner Schmidt procedure differed from others in that
44
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it included an acid hydrolysis step. The procedure was as
follows:
1. A 20 ml sample (or known weight) is added to a Majonnier
flask, followed by 8 ml of concentrated HC1. The contents are
mixed and place in a boiling water oath until digested, at which
time the sample will be chocolate brown. Generally about 15
minutes of digestion are need for dairy wastewater samples.
2. Add 8 ml of ethanol and gently invert tubes.
3. Add 25 ml of of diethyl ether and stopper with wet corks.
Mix, but do not shake vigorously.
4. Remove corks and add 25 ml of petroleum ether. Stopper and
shake contents.
5. Centrifuge the tubes in a suitable container for one minute at
approximately 700 rpm to separate layers.
6. Pour off the solvent layer into a clean 250 ml erlenmeyer
flask and repeat the extraction process, but using 50 ml of a 1:1
mixture of ethers.
7. Proceed as for the standard Majonnier procedure (MIF 1968)
45
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Carbohydrates: inlLially the EPA approved Technicon
Autoanalyzer method W » employed (Technicon method 302-74A). in
..king material balance of components contributing to BOD,
discrepancies v»r. traced largely to the carbohydrate method.
Experimentation revealed that the method, while reproducible,
gave only a 20% recovery of lactose at the same time it gave over
93% recovery of glucose and sucrose. Subsequently the method of
Lubois as modified by Lawrence (1968) and Clark (1977) was used.
The method is briefly as follows:
1. A known sample containing from 25-75 micrograms of
carbohydrate Is added to a 100 ml flask and then filled half-way
with distilled water. To this is added 2.5 ml of lead acetate
solution (10%w/v) and 9 ml of saturated sodium flouride. Make to
100 ml with water, mix and allow to stand for 10 minutes.
2. Filter through Whatman No 40 filter paper.
3. Pippette 1 ml of phenol solution (5% w/v) into a clean glass
stoppered test tube. Add 1 nl of filtrate.
4. Add 5 ml of concentrated sulfuric acid from a burrett,
running the acid down the side of the tube. Insert stopper, mix
and cool.
5. Measure O.D. at 490 nm. Read against a standard lactose
-------
solution containing 0, 25, 50 and 100 ug/ml, treated as above.
Phosphorous: This was determined with the Technicon
Autoanalyzer (Technicon method 334-74a/a-76).
Chloride: Chloride was determined by use of an Orion
chloride ion electrode, using four concentrations of sodium
chloride as a reference each time.
Sodium: Sodium ion was Determined by both the sodium ion
electrode and by atomic absorption spectroscopy.
Calcium: Calcium was determined by atomic absorption
spectroscopy.
pH: pll was monitored with a Manning pH meter and/or
determined with an Orion pH meter equipped with a wide pH range
electrode.
Conductivity: Conductivity was measured with a Hack
conductivity meter calibrated against sodium chloride standard
solutions at 6 concentrations.
47
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SECTION 5
DEVELOPMENT AND EVALUATION OF ANALYTICAL METHODS
EFFECT OF REFRIGERATED AND FROZEN STORAGE ON ANALYTICAL RESULTS:
Because of the distance between the Kroger Dairy and the
analytical laboratory at the Ohio State University, the handling
of samples was a major consideration. A study was made of the
effect of both refrigerated (2 4°C) and frozen storage (-28°C) on
methods reported to be sensitive to sample storage. The effects of
refrigeration and frozen storage on BOD, COD, carbohydrate,
suspended solid's, and microbial population was determined.
Refrigerated storage:
Twenty samples of wastewater were analyzed immediately
upon receipt and after 24, 48 and 72 hours of storage at 2 C. The
results are presented in Table 1. On the basis cf mean values,
the dam for all four analyses were essentially unchanged for the
first 48 hours. Individual analyses showed both positive and
negative difference with a maximum variance of 9.5%. After 72
hours of storage, there was a decrease in the BOD and
carbohydrate, an increase in SPC and suspended solids and no
48
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Table 1. Effect of refrigerated storage on mean COD,
BOD, carbohydrates, suspended solids and
standard plate count
Age
(hrs)
0
24
48
72
COD
(mg/1)
3500
3700
3400
3000
Mean
BOD
(mg/1)
1650
1800
1500
1200
Values
Carbohydrates
(mg/1)
750
780
760
550
SS
(mg/1)
850
900
880
1100
SPC*
(Number)
2,100,000
1,500,000
5,600,000
35,000,000
Standard plate cou.it.
49
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statistically significant change in COD.
Since these samples were 24 hour composites and had an
additional G to 12 hours of delay in shipment, a series of hourly
samples (taken at various times) were iced and taken directly to
the OSU laboratory and analyzed with a maximum storage time of 6
hours. These results showed no significant differences over 72
hours of storage at 4 C.
Frozen Storage:
In a later stage of this project, the frozen storage of
samples was considered desirable. Because of the statement in
the LPA Handbook on Analytical Methods for Wastewater Analysis
that freezing was unsatisfactory, a study was undertaken to
determine the possible validity and limitations of holding dairy
wastewater in a frozen state for up to 20 days.
Initial studies indicated unreliable and non-reproducible
results for COD in frozen samples, especially those with COD
levels over 2000 mg/1. The cause of the lack of reliability was
determined to be related to sample preparation of the frozen
•
samples. Elimination of the problem was achieved by thawing the
frozen samples, tempering them at 38-40 C for at least 30 minutes
to melt the milk fat and then mixing in a baring type blender for
one minute.
50
-------
Subsequently, 24 samples varying in COD levels from 1000
to 10,000 mg/1 wore frozen and returned to the OSU laboratory.
o
Samples were stored for 0, 1, 5, 10 and 20 days at -28 C. COD
analyses were made on all samples. BOP, suspended solids and
standard plate counts were made after 0, 1, 5 and 10 days of
storaye. The average results are shown in Table 2. The results
indicated that the tempered-mixed samples gave COD analyses that
were comparable to fresh samples (correlation coefficient =0.945)
over the entire 20 day period. BOD analyses were reliable up to
10 days (correlaton coefficient =0.934). A key to the success of
the LCD results was the use of freshly activated seed.
Manometric bOD results showed an increase in the lag period,
which was minimized by using freshly activated seed.
In all ?ases the suspended solids were reduced in the
fresh samples from 20 to 50%. This was caused by the use of the
Waring blender that was essential for obtaining a uniform sample.
Based on these results, suspended solids analyses were made only
on non-frozen samples.
Microbial counts (SPC) showed reduction in all samples after 10
days of storage.
Analyses. of ten of the frozen samples for lipid,
carbohydrate and total nitrogen shown no significant differences.
-------
Table 2. Effect of frozen storage on COD, BOD, SS
and standard plate count.3
Aae
(days)
Ob
1
5
10
20
COD
(mg/1)
3200
3100
3300
3250
3000
Mean Values
BOD
(mg/1)
1400
1200
1500
1100
1300
SS
(mg/1)
550
330
300
350
280
SPC
(Number)
1,800,000
1,500,000
1,000,000
1,200,000
700,000
aNo significant difference in fat, total N or carbohydrate on frozen
storage.
bBefore freezing.
52
-------
Lipids (fats, oil and grease):
Many dairy wastewaters, especially those from butter and
ice cream operations, are high in fat content. There has been a
concern in respect to measuring lipid in dairy wastewater and
also concern over observations that with very high lipid levels,
the COD and BOD values are depressed (Carawan, et al 1973 and
Harper, et al . 1971). Both of these problems v,ere investigated.
A number of different methods were evaluated for use in
this investigation: (a) standard methods for lipids (fats, oil
and grease) as outlined in the Standard Methods for the
Examination of Water and Wastewater, (b) the standard Maionnier
procedure as applied to milk, (c) the method of Carawan et
al.(1973), (d) the Werner Schmidt method as modified by the New
Zealand Dairy Hesearch Institute, (e) the Mi 1k-o-tecter and (f)
the Technicon autoanalyzer turbidometric method.
Of the«;e methods, the herner Schmidt, P-Tjonnier, Carawan
and MiIk-o-tester methods showed some promise. A comparison of
these methods is shown in Table 3. The Werner Schmidt method
was most reproducible and gave the best recovery for added lipid.
53
-------
Table 3. Reproducibility and recovery of added lipid
by three procedures for fats, oils and grease.
Lipid
Concentration
100-200 ppm
300-500 ppm
500-1000 ppm
1000-2000 ppm
Number
of
Samples
5
5
5
5
Mdjonnier
Mean % o of
Recovery Mean
78
81
80
83
5.6
5.1
3.5
4.2
Carawan
Mean "
Rerovery
82
80
35
83
o of
Mean
12.3
9.2
5.4
5.0
Herner-Srhmidt
Mean % o of
Rerovery Mean
85
87
88
87
4.2
3.7
2.4
2.2
54
-------
Although recovery of added fat was above 75% for all of
tlie extraction methods, there was continued concern as to the
true total lipid content cf the samples. For r.his reason, ten
high lipid containing samples (5 from ice cream and 5 from total
plant wastewater) were investigated. A 50f1 ml sample was
concentrated 10:1 in a roto-evaporator, freeze dried and then
exhaustively extracted with 2:1 methanol-chloroform, using a
Soxhlet extractor. This approach was based on previous -ork with
whey protein concentrates that exhibited difficulty in totdl
lipid extraction. In this method the recovey of added lipid was
3^1 ±_ 3%. The results are shown in comparison to the Najonnier,
Vverner Schmidt and Nil k-o-tester in Table 4. The Milk-o-tester
was shown to be unsatisfactory, even when wastewater was added
to a milk sample of known fat content. Concentration of samples
10:1 did improve the Milk-o-tester method so that it could be
used as a screening method.
Based on these findings the- xerner Schmidt procedure was
the best of those methods suitable for routine analysis and was
adapted as the standard .nethod for this investigation.
The chloroform methanol procedure, while most accurate,
uas too time consuming for routine use.
A study was made to determine the effect of lipids on CCD
and BCD analyses. Sample ranging from 150 to 500C mg/1 lipid were
55
-------
Table 4. Comparison of lipid methods
Sample
1
2
3
4
5
6
7
8
9
10
Mean
r
Soxhlet CHCl3:M,eOH
(rag/1)
125
186
223
276
325
625
1050
2005
2700
3600
1111.0
Majonnier
(rag/1)
90
150
176
230
270
647
900
1800
2275
3250
979
0.92
Werner-Schmidt
(mg/1)
118
176
213
280
319
526
1000
2000
2685
3500
1080
0.96
Milk-o-tester
(mg/1)
50
70
110
130
220
320
860
1800
2600
3500
804
0.83
56
-------
analyzed for BCD and COD. The results are shown in Table 5.
Vvhen the lipid content of the waste sample was in excess of 2000
mg/1 there was an apparent reduction of both BOD and COD.
Attempts were made unsuccessfully to determine the reason for the
reduction in values. COD analyses of pure milk fat did not
indicate any interference with the method at concentrations up to
3000 mg/1. Addition of carbohydrate or protein had no effect on
COD. In the case of BOD the supression of BOD values was
associated with added lipid with a marked increase in the lag
value and reduction in generation time. This inhibition was
thought to be associated with free fatty acid content of the high
lipid samples.
Further work in this area is needed to clarify the
problem and its solutions.
Carbohydrate analysis:
The initial procedure used was the EPA approved Technicon
autoanalyzer II method for sugars. It was not until attempts
were made to calculate BOD from organic analyses that
discrepancies were noted in the carbohydrate data. Analysis
revealed a markedly different concentration response between
lactose and sucrose, glucose or fructose (See Figure 5). Lactose
data were reproducible but the response was 1/12.4 that for
sucrose.
57
-------
Table 5. Effect of lipid level in Dairy Waste on
COD and BOD.
Mean
Concentration
of Lipid
(mg/L)
211
520
1360
2700
4500
2250b
Number
of
Samples
5
4
3
4
2
2
Mean
COD
fmg/U
1250
3000
4500
5100
6200
6600
Mean
BOD
(mg/L)
560
1260
2100
1750
1550
2640
Determined by Uerner-Schmidt.
bSame as 4500, diluted 1:2 with distilled water.
58
-------
V3
GLUCOSE-FRUCTOSE
0.25 0.50 0.75 1.00 1.25
CONCENTRATION
I.5O
1.75
2.OO
Figure 5. Scandard Curves for Autoanalyzer Analysis of Selected
Carbohydrates.
-------
In order to salvage the data, the various waste streams
were analyzed for carbohydrate distribution by high pressure
liquid chromatography on a V.aters HPLC using a carbohydrate
column, a flow rate of 1.0 ml/minute and a solvent of 75:25
acetylnitrile-water. The average carbohydrate distribution from
the ice cream operations was 59:37:08:04
l«ctose:sucrose:f ructose :glucose. The average carbohydrate
distribution from drain |2 was 92:8 lactose:sucrose - with no
detectable fructose or glucose. The carbohydrate distribution in
the total wastewater was 79:?0:1:1
lactose :sucrose :fructose :glucose . Knowing the ratio of
carbohydrates in the wastewater (by HPLC analysis) made it
possible to correct the initial data to within + 10% of the true
value. It was necessary to change to a method that would moie
nearly measure all of the carbohydrates. While HPLC was
reliable, the method was not adapted to routine anlaysis. The
method of Dubois, as modified by Lawrence (1963) and adapted by
Clark (1977) to dairy wastewater, was utilized. The Clark
procedure was investigated for 30 samples. The results in
cougarison with uncorrected and corrected Technicon Autoanalyzer
results are shown in Table 5. The Technicon values Eor dairy
wastes were consistently low. The DuBois method was used as the
standard procedure after the initial studies.
Calculated versus actunl BOD:
CO
-------
Table 6. Comparison of Autoanalyzer and Modified
Dubois.
Sugar
Sucrose
Lactose
Fructose
Fructose &
Sucrose (1:1
Dairy Waste
Number
of
Samples
6
6
6
:1) 6
30
True
Mean
(mg/1)
500
500
500
500
-
Aut
Corrected
510
130
400
341
440
Measured Mean
(mg/1)
oanalyzer Modified Dubois
Uncorrected
510a
485
493
496
863b
490
515
485
490
aBased on standard curve using sugars noted.
bBased on standard curve using ratio of carbohydrates found in total
waste water from Kroger Dairy (lactose: sucrose: fructose-.glucose =
60:23:6:10).
61
-------
BOD was calculated from the sum of organic compounds
round in the dairy wastewater. Fat, protein, carbohydrate,
lactic acid and citric acid were the major organic constitutents.
Fat and carbohydrates were determined by the methods developed in
this study. Standard methods for this study were used. Lactic
acid was measured by the method of Randolph and Harper (1958).
Citric acid was determined from records of use. Mean values for
CO samples is shown in Table 7. The correlation coefficient was
0.902. The variance between measured and calculated BOD was
15.2%.
-------
Table 7. A Comparison of BOD and organic
compound analysis
BOD Measured
Fat
Protein
Carbohydrate
Lactic Acid
Citric Acid3
BOD Calculated13
*
Mean
1900
261
444
1445
205
100
1917
Determined from use data.
Using factors of .9, 1.03, and .O/ for fat,
protein and either lactose, lactic acid or
citric acid.
*
Thirty samples.
63
-------
SECTION 5
HATER AND WASTEWATER CHARACTERIZATION
FOR TOTAL PLANT
This section presets data for a nine .onth period from
January thrown September for the vater use. «ste»at=r
discharge and .astewater cnaracteristics for the total Kroger
Dairy at IndLnapoll.. ,„„,,„.. Attention was givon to
deternunin., the «,ter balance for the plant, overall water use,
»««*, characteristics Snd coefficients for uater us, and
"aste parameters per unit of product processed.
hATER BALANCE
A comparison was made between the monitored wastewat-r as
-asured at Drain ,3 with that calculated from water meters and
production records for product water use. The amount of water be-
ing discharged as wastewater should be equal to the total water
metered into the plant minus the water consumed within the
water used in the plant and either recycled, discharged to thT'
storm sewer, or used in product included:'(a)water used to recon-
stitute solids for use in product, (b) boUer feed water, (c, cool.
ing tower water, (d, refrigeration compressor water, and (e, air
compressor water. Meters were in
the plant, on the line supplying the cooling
-------
soft water lines that supplied the boiler, air compressors and
refrigeration compressors. Water used in product was determined
from production data .
The calculated wastewater and measured wastewater were
determined and compared. The variation between these two values
is summarized in Table 3. Data is presented for mean calculated
and measured wastewater flows, mean difference between these
values, variance, standard deviation and the standard error of
toe means. 7he mean differences were within good agreement, but
variance in the data was a function of both the time during the
study and the inclusion or elimination of weekend data. The
data is separated into three periods; the first three months of
the study, the second three months and the third three months.
The data is also separated into that including all days and that
just including the five processing days. The results show that
the variance in the measured and calculated values decreased as
the study progressed and that the variance cor processing days
was less than fot that data that included weekends. The decrease
in variance with progression of the study could be directly
related to correction in problems with initial monitoring of
1'lpv. rpvision of weirs and increased familiarity with the care
required to obtain reliable data. The Decreased variance by
eliminating weekend data was related to much more variation in
flowu on week ends and also to a tendency of the flow monitor to
overrc-ad when flows were zero or less than ]00,noo gallons per
G5
-------
Table 8. Variation in Calculated and Measured Wastewater
Period
ALL DAYS
Jan-March d
Apr-Jun
Jul-Seut
PROCESSING
Jan-March*
Apr-Jun
Jul-Sept
A
Mean Calculated
Uastewater
(9*1 /day)
38 J. 650
484 .405
636 .560
DAYS*
442.408
536,409
718.166
8
Mean Measured
Uastewater
(gal /day)
396.333
479.040
638.980
430. 7'7
532. 356
711 .035
Mean
Di f ference
(A-B)/A
%
-3.2
1.12
-0.38
2.7
0.87
0.92
Variance
X
33.5
P1.18
10.60
28.3
11.75
6.22
Standard
Deviation
n*
7.8
5.30
J.25
5.7
3.40
2.49
Standard Error
of the Mean
X
1.56
0.89
0.58
0.93
0.61
0.45
Limited data.
-------
clay for Drain S3. During the first period, the weekend flows
varied from 45,000 to 287,000 gal/day; for the second period, this
difference was from 89,500 to 278,000 gal/day; and for the third
period, tne difference was from 166,000 to 320,000 gal/day.
hater use increased from 383,000 gallons in the first
period to 635,500 gal/day in the third period, or a 66% increase.
Over this same period the amount of milk received by the plant
increased from 1,100,000 to 1,600,000 pounds per day for a 45%
increase.
VvATEH UTILIZATION:
In plant water use (water used for cooling tower, water
used for compressors and boiler feed and water used for product)
is summarized in Table 9 Cor the second and third periods of
study. Means values ore presented and average percentage of use
for all days, processing days and weekends. Analysis of variance
for this data is shown in Table 10. There was comparatively
little change in the amount of total in-plant water use over the
nine month period, whereas the percentage of water consumed in
the plant decreased as the total amount of water use increased.
There was also a change in weekend versus processing days use.
Tlit daily vari^tion of water use for processing during
the months o£ nay and August are presented together with
67
-------
Table 9. In Plant Water Use
tTi
00
Period
All CAYS"
Apr-Jun
Jul-Seut
PKJCESSlrtG DAYS
Apr-Juii
Jul-Sept
MEEKENDS
Apr-Jun
Jul-iept
Cool ing lower
gal/day To°df,
17.700 3.6
24.800 3.9
'7.700 3.3
20,200 2.8
17.600 3.6
30.600 ||. |
tean
Values a
• !• 1-5
Compressors
dal/daw X of
16.700
9 .600
2l.70u
13.SOO
4.100
2.200
ToUl
3.4
0.6
4.0
1.9
2.0
0.8
Product
"Tof
ga_l/day Total
4.300 |.o
5,600 0.9
b .000 1 . )
7.700 1.1
Total Consumptive
use
gal /day
36.700
39.900
45.400
41.400
21.700
32.800
* or
Total
a.o
6.2
8.5
5. U
10.9
H.9
Uie rounded to the ne*n.c» h,.n^_,^ n>i/^,.. ~ •
-------
Table 10. Standard Deviation for In-Plant Water Use
Mean and (Standard Deviation) in Thousands of gal/day
April-June July-September
All Days Processing Wt>k All Days Processing Week
Days cuds Days ends
Cooling Tower 17-7(S-3) 17.7(3.3) 17.6(8.3) 24.8(5.9) 20.2(3.7) 30.6(10.3)
Boiler Feud & . . .
Compressors 16.7(8.0) 21.7(7.8) 4.1(1.8) 9.6(4.2) 13.5(4.6) 2.2*0.9)
Product Use 4.3(\3) 6.0(1.8) - 60<1.5) 7.7(2.1)
TOTAL 38.7(12.7)45.4(13) 21.7(10) 39.9(12.3) 41.4(lO.O) 32.8 (12.1)
69
-------
wastewater discharge on a probability graph in Figure 6. The
data show some deviation from linearity, but correlation
coefficients for a straight line are above 0.87 ?or all data
presented. The slopes of lines of best fit for both total water
!•=» and wastewater discharge are similar, but the August data
shows more total water and wastew,iter discharge that reflects an
increase in production.
Bar graphs depicting the percentage of samples falling in
various ranges of water use are presented in Figures 7, 8 and 9
for total water use, water conr;umed in the plant, and wastewater
discharge. Lach figure presents data for all days, processing
da>s and weekends. For these figures, only the last six months,
or defined base period are used.
WAbTEWATCR CKAHAClhKIZATlON
Strength of waste components:
Data is based on 24 hour composite samples taken primarily
as flow proportional samples. Time samples are based on samples
taken every 7.5 minutes. A comparison of flow proportional and
-------
3 600
AUG
MAY
_
O
to
O
600
O
I
400
o:
LJ
200
001
Figure 6.
50
PROBABILITY
Probability Plots of Daily Water Use and Wastewater
Discharge for the Months of August and May.
99.99
-------
to
IOC
90
en 80
01 60
u.
O
s* 50
40
30
20
10
0
D
Weekends
Processing days
H| AM *,„
0-200
Figure 7.
200-400 400-600 6OO-8OO 8OO-IOOO 1000-1200
GALLONS IN THOUSANDS/DAY
Variation in Total Water Use for All Days, Processing
Days and Weekends for Base Period.
-------
D
0-20 20-40 40-60 60-80 80-100
GALLONS IN THOUSANDS/DAY
Weekends
Process days
All days
100-120
Figure 8. Variation in In-Plant Water Use for All Days,
Processing Hays and Weekends for Base Period.
-------
D
Weekends
Processing days
days
0-200
Figure 9,
20O-4OO 4OO-600 600-800 80O-IOOO
GALLONS IN THOUSANDS/DAY
1000-I20O
Variation in Wastewater Discharge for All days.
Processing Days and Weekends for Base Period.
-------
snort time (let's tlian 10 minutes per sample) con.oosite samples
showed comparable results for this plant. Time samples taken at
time intervals greater than 7.5 minutes were consistently lower
in strength of all components than were flow proportional
samples.
Monthly mean values in mg/1 for the various parameters
measured in the wastewater from the Kroger Indianapolis Dairy are
presented in Table 11. This data represents the averages for all
days. Overall the values of the various components appear to be
similar to that expected from an average dairy plant processing
milk, cottage cheese and ice cream. Inspection of the aata
indicates that the waste strengths of the various components were
relatively constant over the nine month period.
Tha overall mean values of the monthly averages are
coin pa red to averages of the daily values for all days and for
only processing days in Table 12. In general the means of the
monthly averages and means of the individual data are in good
agreement, with the latter being consistently lower by from 0.2
co 2%. As would be expected tue standard deviations of the
monthly averages show significantly less variance than the
standard deviations for the daily values. Of interes*- i:., the
relatively close agreemenc between the averages for all ^ys and
the average strength of the components in wastewater for only
processing days. This reflects several things about the nature
-------
Table
11. Monthly Averages of Waste Characteristics for Total
Plant Waste Hater from Indianapolis Kroger Dairy.
January'
CUD
BUD
TiiUl Solids
Ash
Suspended Solids
Dissolved Solids
4.297
1.984
-
-
841
1.370
Settleable Solids 6.1
Carbohydrate
Lactic Acid
Llpid
Protein
P04
Chloride
Sodium
Calcium
Magnesium
ConJuctivity
l.«75a
-
536b
644
55
422
324
113
37
1.202
aConectPd. Tec.lnicon Method
February
4.3%
2.044
-
-
513
1,274
7.25
1 .224a
-
250b
612
64
412
243
166
30
1.722
Corrected
March Apri? May
4.541
2.073
3.174
1.064
610
1.222
9.4
1.211a
-
349b
497
48
558
164
186
34
1.782
3.606
1.776
3.269
1.125
472
1.106
9.6
1.0513
-
327b
388
36
365
245
152
33
1.642
4,085
2.003
3.511
1.082
641
6
12.9
1.297a
-
335
421
43
370
270
161
31
1.641
Majonnier Method
June
4.436
2.040
3.751
1.156
621
1,119
13.3
1,260
-
338
521
52
396
313
183
33
1.906
cl)ata for
July
4.001
1,936
3.663
1.121
576
1.536
12.
1.200
212
353
478
49
434
2a2
141
35
2.191
Month
August
4,560
2.100
3.550
1.076
650
1.420
2 9.1
i .215
227
378
444
52
423
260
134
35
-
Not Fully
4.656
2.147
3.417
1.131
710
-
8.8
1.318
247
387
510
56
365
265
156
38
-
Coiplete
-------
Table 12 Wastewater Characteristics. Means and Standard Deviations of
Daily and Monthly Averages.*
COD
HOD
TOTAL SOLI US
HON- VOLATILE
TOTAL SO1 IDS
SUSPENDED
SOL 1 OS
DISSOLVED
c -ii 1 ne
aOL i u a
Settleable
solids
GARBCHYURATE
PROTEIII (N\6.
FAT
PHOSPHATE
CHLORIDE
SODIUM
CALCIUM
MAGNESIUM
Monthly
Mean
4.288
2.052
3.431
1.108
6?o
1.3/P
9.8
1.2b5
.38) 496
339
64
421
261
154
34
(all days)
Standard
Deviation
335
125
110
35
35
150
2.5
110
90
40
8
55
45
25
2.5
Mean
4.160
1.940
3.333
-
580
1.250
ID
1.240
485
J20
52
410
230
-
-
Daily
All Days
Standard Deviation
2.100
850
1.700
-
200
310
a
420
160
120
18
135
110
-
-
Mean
4.210
2.021
3.460
-
620
1.320
10
1.285
500
380
47
400
220
-
-
'recessing Days
Standard Deviation
1.640
790
1.560
-
170
200
7
360
135
115
15
200
130
-
-
amg/l
-------
of the plant operations:(a) whereas the total wastewater
discharged on Saturday and Sunday is about one-third of full
processing days, raw milk is received on both Saturday and
Sunday, (b) processing often carries over into early Saturday
morning with clean-up continuing until mid-morning and (c)
cottage cheese making is started on Sunday night in most
instances.
hith the exception of sodium and chloride, all
.".iponents of the wastewater were slightly higher in strength
for processing days, as would be expected. In the case of sodium
and chloride, the low values for processing days would reflect a
greater contribution of cleaning and sanitizing to the weekend
wastewater than during processing days.
The pK of the wastewater varied continuously through
the processing aay, reflecting cleaning, processing of cottage
cheese (pH
-------
Figure 10.
Typical pH Chart for Kroger Dairy Wastewater.
79
-------
wastes. Probability plots for hourly values were typically " S»
shaped, whereas daily variations were reasonably linear.
Exceptions were noted when there was a marked change in the
production scheduling, such as no ice cream processing or no
cottage cheese processing. Because of overlap of departmental
operations being reflected in the total wastewater picture,
graphs do not provide much specific insight to causes of
variation. Therefore, plots for the overall plants wastewater
are not shown, but will be detailed in the next section of
individual departments where the variability can be specifically
related to unit process operations.
Kel.itionship between Kostewater Characteristics:
The monthly average values (Table 11) were used to
evaluate which parameters of the wastewater were dependent and
independent of each other using linear regression analysis. The
data for February through September were used, since inclusion of
the January data markedly altered correlation coefficients. For
example the correlation coefficient between BOD and carbohydrate
was 0.44 with the January data and 0.76 with this data excluded.
be 1 tic ted data are presented in Table 13, showing co, relation
coefficients, the linear regression equation and the standard
orror of the esti-nate. The parameter listed first was always X.
Prediction ot a given parameter from a dependent variable was
considered feasible when the correlation coefficient «« = greater
80
-------
Table 13. Linear Regression Analysis of
Selected Waste Characteristics
PARAMETERS
COMPARED a
Correlation Regression Standard Error
Coefficient Equation of Estimate
COD/30D
COD/TS
COD/SS
CCD/CHO
COD/LI PIO
COD/ PROTEIN
BOD/COD
BOD/TS
BOD/SS
BOD/CHO
BOD/LIPID
BOD/PROTEIN
.87
.85
.53
.72
.42
.21
.87
.82
.50
.76
.89
.24
593.2 + .03418X
35 + 0.314X
-226.7 + 0.2108X
-19.3 + (8.36 x 10"2)X
285.44+ (3.1034 x 10"2)X
-321 + 0.213X
5370.9 + (-0.7999X)
235 + 0.0341X
875.6 + (-0.1138X)
-?49.6 + 0.2785X
-37.614* 0.1933A
-
-------
than 0.75 and the standard error of estimate was less than 1C%.
As ex[jected there was good correlation between BOD and
COD and those parameters directly related to them: including
total solids and carbohydrate. Surprisingly, the correlation
coefficient for protein and either BOD or COD was less than
0.5. This suggests a disproportionate amount of protein
remaining on soiled surfaces that is either carbohydrate or
fat.
based on the stanaard error of the estimate, COD was
better for predicting BOD than was faOD for predicting COD.
Suspended solids were only poorly correlated to FOD or
CUD, but were correlated to total solids and protein.
bodium and chloride were well correlated only to ash, and
v.ore- not correlated to other constituents or to each other.
-odium ion concentration would reflect the use of alkalir-
cleaning compounds, whereas chloride would reflect the use of
sanitizin-j solution and regeneiation of water softeners.
Phosphate, a constituent of Loth milk and cleaning
CQ.J. pound &, was not well correlated to calcium ion content. Also,
the rat-10 of. calcium to phosphorus was lower than expected based
on milk coBj-obition. Tins suggests that much of the calcium
32
-------
content was associated with protein films remaining on equipment,
especially on hc-ated surfaces.
Conductivity was not correlated to any other parameter by
a correlation coefficient greater than ().5 and its use was
considered to be of limited value and was dropped as an
analytical method.
Based on these data, characterization of dairy plant
wastewater may be made from limited analyses. COD or BOD,
suspc'nded solids, Xjeldahl nitrogen (protein) , chloride, and sodium
ion would be the most useful parameters. For organic matter COD
and suspended solids measurements would provide the minimum
analyses.
Wastewater Coefficients:
The determination of wastewater coefficients was
considered essential to interpret the results in respect to other
dairy plants and to provide a basis for comparison among
departments and also to provide baseline data for use iri the
litter stages of the project.
Two approaches were used during this study to determine
coefficients: (a) calculation of the amount of BOD processed from
production figures and (b) determination of the amount of COD
-------
processed through analysis of the COD of all ingredients and
calculation of COD processed from ingredient use figures. The
former approach was used in the initial phases of the study and
the 1ftter evolved during studies of losses in invididual
departments and unit processes on a daily basis.
Calculation of BOD processed was based on the use of
standard values for protein, fat and carbohydrate:
-protein = 1.03 pounds of BCD/pound of protein
-lipid = 0.9 pounds of bOD/pound of lipid (fats,oil and
grease)
- carbohydrate = 0.7 pounds of BOD/pound of carbohydrate.
The amount and composition of milk, cream, non-fat dried
milk, whey solids, buttermilk solids, and various carbohydrates
were used to compute the amount of EOD processed. This approach
was valid for weekly or monthly average data, but because of the
bookkeeping system used, it was not practical or convenient on a
daily basis. For daily data, the use of COD was much more
convenient and proved to be more reliable. For working with
weekly or monthly averages, both approaches gave comparable
results.
To determine yields, it was also necessary to convert
waste strengths into mass weight values. The pounds of a given
waste component were calculated by the formula:
84
-------
pounds of component = gallons of wastewater x 8.3' x
(mg/l)/l,000,000
The pounds of four constitutents of concern are shown in
Table 14. The data ere present as averages for the three separate
three-month periods. Vvhereas the waste strength was relatively
constant over the nine-month period, there was a continual
increase in the pounds of COD, BOD, SS and phosphate during this
time. This was reflected in an increase in wastewater volume
that was noted previously, as well as an increase in production.
The dataareshown for all days and for processing days. Again
the differences are not as great as night bo expected because of
some processing on botli Saturday and Sunday.
'Aastewater volume coeffients in terms of gallons of
wastewater/lOR pounds of BOD processes and coefficients for COD,
BOD, SS and phosphate in terms, of pounds/100 pounds of EOD
processed are presented in Table 15. The data are given for the
three separate three-month periods and for both the entire nine
months and the last six months. The last six months data were
used as the base for comparison, although a comparison of
coefficients wit'. ;lie last three months was made also. The
increase in coefficents during the nine-month period indicates an
increasing cifliculty in waste control with increased production.
Average deiily pounds of bOD processed were:
85
-------
Table 14. Pounds Discharged Pei Day of Selected Uastewater Components
Characteristic
COD
BOO
SS
PHOSPHATE
All Days
Jan-Mar Apr-Jun
14.5bj 16.108
6.720 7.922
2.156 2.309
185 175
Mean, Pounds/Day
Jul-Sept
23.298
11.590
3.437
277
Processing Days
Jan-Mar Apr-Jun
15.847 17.945
7.304 8.804
2,350 2,566
201 195
Jul-S^pt
25.947
12.908
3.828
308
-------
Table 15 Uastewater Coefficients in Gallons of Wastewater and
Pounds of Components/100 Pounds BOD Processed
PtRlOO
l_
Gallons
100 Ib
"111 Day*"
of
BOD
H,
Uastewater
Processed
ocessinq Da)
I
• — r
ton
bays
ihT/in<> 1 hs PrnrcsseJ3 . —
3D"
Processing
Days
BOC
Days
Processing
Days
r si
All Processing
Days Days
PHt
All
Days
SPH1TE
Processing
Days
Jan -Mar
co Apr-Jun
-J
Jul Sept
Jan-Sept
Apr-Sept
2S6
333
412
347
373
Calculated from
287 10.8 10.5 5.0 4.. • .»
327 11.0 10.3 5.5 5.1 1.6 1-5
409 15.0 14.9 7.4 7.3 2.2 2.?
341 12-3 11.9 6.0 5.5 1.8 I./
363 13 12.6 6.5 6.2 1.9 1.9
Production Data
0.12 0.12
0.17 0.17
0.14 0.14
0.15 0.15
-------
January - March 1,200
April - June 1,155
July - September 1,738
During July to September, the plant was processing more products
than it was originally designed for.
Coefficients for water and waste parameters were also in
general agreement with what would be expected in an average
multiproduct dairy plant.
Hie baseline coefficents used in later phases of the
study were:
VJastewater = 3f>3 gallons/100 pounds of
BOD processed
COD = 12.6 pounds/100 pounds of
bOD processed
faOD = 6.2 pounds/100 pounds of
bOD processed
08
-------
SECTION 7
DEPARTMENTAL WASTE CHARACTERIZATION
'Hie departments and their contr ibutinq sub-units that arc
covered in this section a.'c:
1 . Ice Cream
a. Mix processing
b. Ice cream freezing
-------
shut-down and cleaning
3. Milk
a. Milk receiving
b. f'.ilk processing
c. Milk packcrjing and storage
The departmental contribution to the total plant's waste
water volume and major characteristics is shown in Table IS. Tata
are presented for all days and Cor processing days in both
average amounts discharged to the druin and the percentage of
each department's waste discharge to the total for the plant.
IVitn are for Lhc; base per lot. of The study.
The percentage waste-water volume -ind amount of COD, HOD and
suspendoc solids were- quite uimilnr en a departmental basis. For
A processing day, the milk receiving, processing, packaging and
i^torogc contributed an avorjuu of nhouL 19--. of the hydraulic load
.ind lf>6 of thu bCD load. The ice crcjm and novelty operation
contr ibutL'U about "Jf)" of thu hytlr.iulic load and 3R% of the POO
lojd. 'Ih-.: cottago ch.joiie-CIP ciupar tinunt contributed 42", of the
volume ,incl IGy, of the- UCAJ lond. Cn 1 y abut r>m of this lo.id is
-------
Table 16. Departmental Contribution to Mean Daily Wastewater Values for Total Plant
DEPARTMENT
All Days
Ice Cream
i£ Cottage Cheese
MI Ik
TOTAL
Processing Days
Ice Cream
Cottage Cheese
Milk
TOTAL
Wastewater Volume
Gallons/ .- of
day Total
217,322 39
245.748 44
96,000 17
5b9,570
242,567 39
261,235 42
117:000 19
620,802
Wastewater Characteristics
COO
Pounds/ % of
day Total
7,146 38
9,486 50
2,244 12
18,876
7,958 38
10,084 48
3,094 14
21,136
BOD
Pounds/ % of
day Total
3,731 38
4,677 48
1,383 14
9,791
4,155 38
4,971 46
1,738 1G
10,864
SS
Pounds/ % of
aay Total
1,193 42
1,068 38
567 20
2,828
1,328 34
2,000 52
536 14
3,364
For base pe-iod.
-------
from cottage cheese operations and the rest can be assigned to
cleaning of ice cream and milk equipment and operation of the
hTST pasteurizers.
ICE CREAM
Tne mean wjste stren-jrh and standard deviation of the
various wastewater parameters for the ice cream department are
shown in Table 17 for all days and for processing days. Using
fat, carbohydrates, protein and citric acid values, a mean
calculated bCD was 2,10'J as compared to 2,054 mg/1 .
Comparison of these c!std with the total plant wastewater
rovLals some distinguishing characteristics that would be
expected Irom the ice cream and novolty operations. A higher fat
tind carbohydrate content and a lower protein concentration was to
SJG expected because of the composition of the products being
manufactured. Lower phosphate reflects the absence of milk salts
in many of the novelty products. The markedly higher chloride
iind calciij;:, ion content reflects the fact that the Vitaline
discharges calcium chloride to the ice cream drain. The data
indicate that approximately 38,000 pounds of calcium chloride
br incnrc dischor-jed each month. This compares favorably with the
purchase records of 40 tons ot calcium chloride per month.
prudent.:; r eg ruxi, ion an.ilysiu of pairs of waste
-------
Table 17. Mean Waste Strength of Characteristics of
Ice Cream Department Westewater
Parameter
HJ
too
TOTAL SOLIDS
ASH
SUSPENDED SOLIDS
DISSOLVED SOLIDS
SETTLEABLE OOLIDS
CAR30HYMATE
CITRIC ACiD
L'.PiD
PROTEIN
PHOSPHATE
CriLOSlDE
SODIUM
CALCIUM
MAGNESIUM
CONDUCTIVITY
All
tesn
3,943
2.051
3,541
1,667
657
1,596
13
1,294
154
780
382
38
888
214
817
31
2.08«
Days
Standard Deviation
516
607
7'. 2
378
130
3/3
3
232
45
242
158
8
432
91
367
3
121
Processing
Days
Mean Standard Deviation
5,520
2,376
4,957
2,333
920
2.234
18
1,810
215
1,092
535
S3
760
290
720
43
2.053
722
850
998
529
132
530
5
322
63
336
224
11
370
127
300
4
63
mg/1.
-------
Table 18. Regression Analysis of Selected V-stewater
Characteristics for the Ice Cream Department
Parameters
Compared
COD/BOD
COD/SS
COD/TS
COD/CHO
COD/LIPID
COO/ PROTEIN
BOD/COD
BOO/5S
BOD/ VOL. SS
HOD/CtIO
BOD/L1P1D
BOD/PROTEIN
DISSOLVED
S/CHO
DISSOLVED
S/COND.
SS/CnO
SS/SE1 SOLIDS
SS/T01AL N
Correlation
Coefficient
0.86
0.92
0.93
O.S6
0.04
0.86
0.86
0.39
0.99
0.12
0.39
0.70
0.87
0.83
0.92
0.73
0.86
Regression
Equation
•
421.6 + 0.4150X
-16.88 * 0.1942X
3827 * 0.02761X
8.10 + (-9.96CX)
776.5 + (-2.639X)
-31.82 + 0.0233X
238.8 + 1.798X
447.9 + 0.1115X
-2.79 + 7.685E-3X
507.8 + (-2.434E-2X)
-392.4 + 0.5184X
-20.24 + 3.897E-2X
-279.2 + 0.4697X
293.4 + 1.129X
609.7 + 4.353X
8.2952 + 1.225E-3X
-78.7 * 0.1978X
Standard of
Error of Estimate
_— — — ^ —
342
58
225
187
903
18.7
712
137
6
200
833
27
107
176
279
3.6
17
-------
parameters. The correlation coefficient between COD/BCD was
0.36, and both CCD and BOD were well correlated with both total
solids and suspended solids.
In contrast to the total wastewater, the best correlation
witn organic components is protein with very poor correlation
v-ith lipid and carbohyd rate. This can be explained on the bnis
of relatively constant protein level in both ice cream and
novelties, but markedly different fat content and carbohydrate.
Lack of correlation then would reflect large differences in the
amount of loss of ice cream and novelties on different days,
wnich would be in ag reement with observations.
Multiple regression analysis of COD and LOD with protein
plus lipir: plus carbohydrate gives a multiple correlation
coefficient of 0.23 and 0.88, respectively.
The pounds per c"ay of the various waste characteristics
are shown in Table 19.
Vtaste coefficients for the ice cream operation ere shown in
TaLle 20 for processinj days. Based on processing days
coefficients, the ingredient loss averaged 5.3% conpared to a
computed loss of less than 2% on the basis of production data.
Selected coefficients per 100 pounds of fc-CD processed for
-------
Table 19. Mean Selected Wastewater Characteristics Waste
Loads for Ice Cream Department
PARAMETER
COD
BOD
SS
TS
SETTLEA6LE
SOLIDS
SOLUBLE
SOLIDS
CARBOHYDRATE
LIPID
PROTEIN
PHOSPHATE
CHLORIDE
All Days
7,146
3,731
1,193
6,417
23
2,850
2,352
1,437
689
68
1,613
POUNDS/ DAY
Processing Days
7,958
4,155
1,328
7,162
26
3,174
2,426
1,601
721
76
1,797
-------
Table 20. Mean Wastewater Coefficients for
Ice Cream Department a
PARAMETER
WASTEWATER VOLUME
COD
BOD
SS
TS
CARBOHYDRATE (CHO)
LIPID
PROTEIN
PHOSPHATE
CHLORIDE
All Days
572
18.8
9.8
3.1
16.9
6.2
3.8
1.8
0.18
3.46
Per 100 Ibs of BOD Processed
Processing Days
457
15.0
7.8
2.5
13.5
6.0
3.0
3
5
4
aWdter volume in gallons; other values in pounds.
97
-------
the period of July to September wore as follows:
PARAMETER ALL DAYS PROCCSSING DAYS
Ir.ater, gallons 453 388
COD, Ib 14.9 12.7
BOD, Ib 7.8 6.h
SS, Ib 2.5 2.1
In interpreting these resulcs, the fact must be kept in mind
that trie above coefficients do not include the total waste load
that is associated with ice cream operations. Wastes associated
with pasteurization of mix and CIP of processing equipment,
storage vats, flavor vats and ice cream freezers are not
included .
COTTAGE CHEESE PLUS CIP
The mean strength of various characteristics of the waste
water from the cottage cheese-CIP drain is presented in Table
21. The wastewater is high in carbohydrate and protein and low
in lipid content, reflecting the cottage cheese manufacturing
process from skim milk and the discharge of whey to the drain.
98
-------
Table 21. Mean Waste Strength Values for Characteristics of
Cottage Cheese CIP Department Wastewater
PARAMETER
COO
BOD
TOTAL SOLIDS
ASH
SUSPENDED SOLIDS
SOLUBLE SOLIDS
SETTLEABLE SOLIDS
CARBOHYDRATE
LACTIC ACID
LIPIO
PROTEIN
PHOSPHATE
7HLORIDE
SODIUM
CALCIUM
MAGNESIUM
CONDUCTIVITY
Mean
4.615
2.076
4,053
975
495
?60
5
1.850
540
280
520
45
320
231
79
29
1,261
A1 1 Days
Standard Deviation
1,800
1.050
1,449
509
110
172
0.5
418
80
142
136
15
120
219
15
5
99
lean
4,829
2,282
4.455
1,070
521
1,009
5.3
2,120
548
302
578
60
321
243
85
31
1,389
Standar.1 Deviation
1,917
1,150
1 ,'526
565
125
179
0.5
490
87
158
172
20
132
37
22
5
105
mg/1.
-------
The lactose is the major whey component and the elevated protein
level indicates the loss of casein in the form of curd fines.
The fines do not appear to show as suspended solids. The waste
strength values shov, more variability than those for the total
wastewater or for ice cream. The reasons for this will be
discussed later when detailed studies of this department are
presented in unit process investigations.
Table 22 expresses the regression analysis of selected pair
of data. The BOD/COD correlation coefficient was 0.94. BOD was
also correlated (r=>0.8) with carbohydrate, lactic acid,
lipir' ar.ri protein. Multiple regression analysis showed
COD and bOD related to protein, lipid and carbohydrate with
correlation coefficient of 0.97 and 0.98, respectively. SS
correlated with protein (0.99), carbohydrate (0.93) and
lipid (0.87). Inclusion of lactic acid increased these
coefficient-, to 0.92 and 0.95, respectively. The higher
correlation between BOD/COD and components relates to less
variability in composition of the wastewater from this
department.
Table 23 shows the mean waste loads for selected wastewater
characteriatics from the cottage chcese-ciP department. The load
o£ settleatalGSolids is inuch lower than mi-jht be expected because
of thd presence of solid curd particles in the wastewater.
]CO
-------
Table 22. Regression Analysis of Selected Characteristics
in Cottage Cneese Department Wastewater
PARAMETER £|J]
COD/BOD
COD/SS
COD/CARBOHYDRATE
COD/LIPID
COD/PROTEIN
BOD/COD
EOD/SS
BOD/CNO
BOD/LIPID
BOD/ PROTEIN
PROTEIN/SS
PROTEIN/PO.
rrelation Regression Standard
efficient Equation Error of Estimate
.94
.87
.86
.87
.94
.94
.69
.96
.96
.84
.99
.99
-329.8 +0.5642X
-IF. 5 n.i081X
16.7 ^ 5.9823X
-76.3 + 7.2096E-2X
6.38(28.8 + 1.3344X)
1055.1 + 1.5659X
124.7 + 0.1553X
7.3 + 0.1108X
49.9 + 0.1316X
6.38(45.3 + 1.9828X)
-328.8 + 8.858X
-7.3 + 0.7495X
453
151
75
89
10.3
755
219
40
53
16.9
46.2
3.3
101
-------
Table 23. Mean Loads for Cottage Cheese-CIP Department
Selected Wastewater Characteristics
PARAMETER
COD
BOD
SS
TS
Settleable Solids
Carbohydrate
Lipid
Protein
Phosphate
Chloride
All Days
9,486
4.2M
1,014
8,306
11
3,792
573
1V065
92
659
Pounds/Day
Processing Days
10,084
4,971
1,136
9,378
11
4,615
658
1,256
132
700
102
-------
V.aste load coefficients £or the cheese-CIP department are
presented in Table 7<. The coef fie ients are relatively low on
the basis of hundred pounds of BOD processed, since the BOD
processed through this department includes all cottage cheese plus
milk plus ice cream processed in the plant as a result of the CIP
operations. Detailed studies reported later will clarify these
coefficient values, which have relatively limited value in
assessing major waste problem areas in the cottage cheesc-CIP
dcpar tment .
MLK DKPAK7MLNT:
The characteristics of the wastewater from the milk floor
drains was determined by difference in the total- (ice cream +
cottaye cheese-CIP). The wastewater reported for this
deportment did riot include that associated with cleaning tankers,
itorjje tanks or lines of pasteurizers. Nor did it include the
waste fron the separators cr start-up or shut down of l.he KTST
systems. The wastewater is primarily clean water, whereas the
oryanic matter is olmost entirely associated with preventable
WlStUS.
mean waste strength of the various parameters of the
milk -iL-portmcnt wastewalor it in Tablu 25. Rocauso they are
clut crmined by diflurence, the values should be considered only as:
estimate:,. Couponent composition (fat, protein, carbohydrate)
103
-------
Table 24. Mean Wastowater Coefficients for
Cottage Cheese-CIP Department*
PARAMETER
Wastewater
Volume
COD
BOO
SS
TS
Carbohydrate
Lipid
Protein
Phosphate
Chloride
Per 100 Ibs of BOD Processed
Al 1 Days
163
6.3
3.1
0.7
5.8
2.8
0.4
0.8
0.43
0.08
Processing Days
155
5.9
2.9
0.7
5.4
2.7
0.4
0.75
0.41
0.08
Water volume in gallons; other values in pounds.
10-1
-------
Table 25. Mean Waste Strength Values for Characteristics
of Milk Department
mg/1
PARAMETER
COD
BOD
TOTAL SOLIDS
ASH
SS
SOLUBLE SOLIDS
SETTLEABLE SOLIDS
CARBOHYDRATE
LIP1D
PROTEIN
PHOSPHATE
CHLORIDE
SODIUM
CALCIUM
MAGNESIUM
All Days
2,766
1,383
2,069
782
567
1,057
7
860
320
400
58
180
163
76
26
Processing Days
3,000
1,500
2,246
849
615
1,147
7
933
345
434
60
175
160
82
27
10!
-------
would oe relatively constant from day to day, which accounts for
the high correlation coefficients. Regression analysis of
selected parameters for the milk department are shown in Table 26.
COD/BOD and lipid showed the lowest correlation coefficient which
suggests variability in usage. The characteristics of the
wastewater are different than for either ice cream or cottage
cheese and the organic components more nearly approach the
composition of milk. As a basis of overall comparison, the
following is the percentage of fat, protein, and carbohydrate in
the total plant wastewater and that of the three departments:
Pat Protein Carbohydrate
Total baste v..itcr K, 2/! r,0
Ice Cream LCfjartmcnt :J? \f, 53
Cottajc Cliaoso I\.-j,t. m 19 71
Milk rcv.-jrtn.ent ?\ 25 54
MluicJ Mil. Pro-.iir: u ;>j 27 50
•ccilcuUtod avtr.i.jo vdluc- of fluid ,n i 1 k products
100
-------
Table 26. Regression Analysis of Selected Characteristics
in the Wastewater from the Milk Department
PARAMETERS
COMPARED
COD/BOD
COD/SS
COD/CARBOHYDRATE
COD/LI PI D
COD/PROTEIN
BOD/COD
BOD/SS
BOD/ CARBOHYDRATE
BOD/LIPID
BOD/I ['ROTE IN
Correlation
Coefficient
0.95
0.96
0.98
0.81
0.87
0.95
0.89
0.98
O.b8
0.83
Regression
Equation
484.4
-873 +
99.5 +
267.9 +
286.0 +
-1290.7
378.0 +
840.5 +
404.9 +
223.7 +
+ 0.3279X
0.5817X
0.2735X
2.203 E-2X
4.060-2X
+ 2.909X
0.1539X
6.214E-2X
(-4.713X)
C.1329X
Standard Error
of Estimate
153
54
45
14
37
358
112
47
78
84
107
-------
M«an loads of selected characteristics are presented in
Tjble 27. haste coefficients are given in Table 28. The full
i.ii^act ot milk processing cannot be ascertained from these
data, but it does have significance in that the organic matter is
mostly preventable wastes.
ion
-------
Table 27. Mean Loads for Milk Department Selected
Wastewater Characteristics3
PARAMETER
COO
BOD
SS
TS
SETTLEABLE SOLIDS
CARBOHYDRATE
LIPID
PROTEIN
PHOSPHATE
CHLORIDE
All Days
2,191
1,359
534
1,448
7
641
262
328
47
147
Pounds / Day
Processing Days
2,926
1,462
599
2,191
7
910
336
423
58
170
3Based on Waste Strengths of Characteristics for Milk Department.
J09
-------
Table 28. Coefficients for Selected Characteristics in
Milk Department Wastewatera
PARAMETER
WASTEWATER VOLUME
COD
BOD
SS
TS
CARBOHYDRATE
LIPID
PROTEIN
PHOSPHATE
CHLORIDE
Per
All Days
67
1.5
0.95
0.4
1.0
0.45
0.2
0.2
0.03
0.10
100 Pounds of BOD Processed
Processing Days
73
1.8
1.0
0.4
1.4
0.6
0.2
0.27
0.04
0.11
Water volume in gallons; other values in pounds.
11C
-------
SECTION 8
'.•.AbTL'A'A'lL'X ChAKAClfRIGlICS OF UNIT TKCCCCSLS
To more fully characteiize the wastes from this plant and
lo establish the significant woste loads that could be targeted
for reduction through cither managment control or
process/equipment modification, a number of detailed studies was
i.icde to establish the total water use and ingredient losses in
frozen des&erts, cottage cheese, culture products and fluid milk
products:
-frozen dessert operations were separated into ice
cream and stick novc-lty operations (drain .11) and
included the wastewater associated with cleaning the
ice crean stordje tanks and lines and the start-up
and £,iiut-aov.n of the pasteurizer (drain 32)
-cotta-je cheese operations included those processes
associated with cheese nuking, cream dressing
manufacture dnd cottage cheese packaging t->nd the
clean-up ot associated equipment (drain S2).
-cuJturtrd products oporation included the processing,
arn.1 cleaning of ecjui[>incnt usud for the
111
-------
manufacture of yoghurt, scur cream and buttermilk.
(drain ,12)
-Milk processing operations included the receiving of
fluid milk, processing, packaging and clean-up. The
wastewater associated with these operations was all
of that generated in the milk department (drain
J3- drain Jl -drain S2), plus that going out drain
,12 from CIP cleaning and HTGT operations.
The objective of these studies was to obtain base data for
further study and there was no need for complete analysis. Based
on previous data, analyses were limited in most cases to water
volume and BOD and/or COD. In some cases SS was also determined.
These special studies generally involved a combination of
individual observations and analyses over a least three separate
processing days. Care was tahsn to choose days when the
production in the area under study was typical, hhere possible,
the time was chosen to permit maximum interpretation of the
wastewater from the product area under study.
'Ihe contribution of CIP operations to a specific product
area could be isolated, since each of the seven CIP units served
a specific area and tlio discharge to the sewer was metered. The
designation of the CIP unit and the area served were as follows:
112
-------
CIP unit Area Served
1 Milk Receiving
2 Milk Receiving
3 «aw milk storage
4 Frozen desserts
5 Milk lines and tanks
6 Cottage chepse and
cultured products
7 Frozen desserts
hater flows discharged to the sewer were either metered
or flow was diverted into a container and timfd with a stop
watch. HTST units could be monitored individually and waste loads
estimated on the basis of diversion times snd flow rates.
Analyses wore made of wastewater discharge on an hourly
or half-hourly basis and correlated to observations cf what was
occur ing in the plant at that time.
Loss studies generally were conducted by measuring COD in
all the ingredients used and by measuring COD in the wastewater.
KUUZKM UESIJKKTS:
113
-------
The frozen dessert area could be separated into two major
product areas: (a) ice cream, sherbets and stickless novelties
and (b) stick novelties. In terms of COD processed about 35-45%
was from stick novelties and 55-65% was from ice cream
operations. The mean contribution to COD processed was 38 and
52% respectively.
Attention was given to: (a) wastewater volume and (b)
COD.
Vvastewater volume:
Overal-1 mean wastewater flow for all frozen dessert
operations for the base perio-1 of study was as follows:
tloor drains 242,000 gallons (37%)
CIP 11,560 gallons ( 4%)
* HTST 24,GOO gallons ( 9%)
TOTAL 278,160 gallons/day
* The daily water use for the pasteurizer varied widely,
depend in-j on the amount of time the unit was run on. water with
the flow diverted to drain. Ivater use ranijed from 7,f)CO to
114
-------
122,000 gallons /day.The former would be considered minimum ,/ater
use and would include one start-up and one shut down.
The mean coefficient of wastewater for frozen dessert
operations was 527 gallons/100 pounds of BOD processed.
Hourly wastewater flows (floor drains only) for a typical
processing day are shown in figure 11. Start-up, processing and
clean-up areas are marked on the graph. During the operating
day, the water flow was relatively constant at 9,600 gallons per
hour .
Not included is about 15,000 gallons of water per day used
for the cooling tower, boiler and compressors or about 7500
gallons/day of water used for product, since this water use is not
fischarged to the sewer.
Direct water use by unit operations can be summarized as
follows:
Unit Operation Gallons/Pay Gallons/ ICO lb
BOD Processed
Mix processing (41,220) (78)
I1TST heating 4, 3?0 8
115
-------
22
20
^ 18
n
O
^ 16
V)
12
8
6
4
2
8
in
1
_L
J I L
i ' I
10 12
am
6
pm
8 IO 12
4
am
6
TIME
Figure 11. Hourly Wastewater Discharged for
Floor Drains from Frozen Dessert.
-------
HTr/r cleaning 26,000
HTJT start-up and
shut-down 10,000 19
2
water hose for
washing spills 900
ice Croam Processing (48,700)
freezing and
packaging 7,000 21
rinsing freezers
and vats and lines 32,000 97
water hose for washing
spills and clean-up 2,500 8
CIP 7,200 22
Stick Novtlty Processing (161,850)
A Vita-freeze units 1/1/1, COO 709
Uinsimj frceezers and
equipment If"""0 79
water hose for washing
spills and clean-up ?>500 1?
The total wnstc water from frozen dessert operations was
117
-------
256,780 gallons or a coefficient o£ 488 gallons for the three
days studied. This was lower than for the base period and could
be associated with the presence of project personnel in the
Product Losses:
Product losses were measured in term of COD. Based on
the COD/bOD ratio for the ice cream drain (0.53± 0.05) , BOD
values were- calculated and reported as estimated values.
Overall COD and BCD losses associated with the processing
of frozen desserts is summarized below:
COD
(Ib/day) (Ib/day)
Floor drains 7000 (83%) 3710
|1T:;T iroo (12%) a 30
cir 414
This jives a tot.il COD and BOD of 8414 and 4460 Ib/day
and coefficients o£ 17.7 and 0 . 4, respect ivel y.
A -jraM, of hourly d is.chonje of COD tor frozen dessert
-------
operations is shown in Figure 12. The start-up, processing and
clean-up tiiiies are indicated. Increased COD loss was observed
during start-up, at several periods during the processing day and
during clean-up. The increased losses during the processing d?y
wore related to equipment operations problems at either th«
vitaline or ice cream packaging machines and at 4 pm the peak
loss was due to the lose of 25 galjons of 40% cream in the mix
processing arei.
A breakdown of COD losses by unit operation is as
follows :
Unit Operation
pounds of COD/
day
Pounds of COD/
ICC Ibs COD
processed
Nix Processing
IITS'L L>tart-up und
stiut-doun
Leaks and spills
]0()0
1H3
1.89
0.35
Ico Cruain Processing
Start-up
I" r u e z i n-j
flfin
100
110
2.5
0.3
-------
3LKJ
400
cC
a:
>v "*r\n
j
-------
Packaging H20 3'/l1
Hinsinj equi pmc-nt 450 I-3
CIP 218 0.75
Novelty Processing
Freezing 55 °'28
Vita-freezo 234fi 1 1 . 59
Packaging 15G4 7-73
Klnsing equipment 380 I.!1
CIP 165 "•-
In term of bUD processed tie over-oil loss during this
study wjb 3. 11 pounds o£ HOD per 100 pouruis of BOD processe-! or a
a. 4% loss. IMC- loss for the sUck novelty operation was 10.?%
Tl.orc w.,s J marked difference in losses for various operating
day^. llio range in CUD d i senary t-d ranged from 3900 to 10,700
pounOs/ -lay and an overall percunt^ge lobs of from 3.1 to 13.7.
•i!ie fflcnr- i«rc«nt..v,.-, lo^s w,i£. r,.r.X. liign losses were generally
J!>s,ocia«.cd i/it». one or more oC the following: (a) spoilage of
product and -lumping at st^rt-.ip. ( b) ovor production of products
such ns aherbct or ice ^Ps thnt could not be used in overrun and
.Jumping .it end of production or ( c) equipment malfunction,
primurily in ice ,«ck.jjing equipment and/or tl.o Vir.a-lincs. The-
luttur W.TS the :no^t common cau'je of" 1,'irgc loi.:icii .
-------
COTTAGL CHEESL AND CULTURED
The basic cottagu cheese making system involved the use
of 6 three -thousand gallon vats an<' 2 sixteen-hundred gellon
vats. During the period unc^er study, from 15,000 to 19,000 gallons
per dav of skimmilk was set Cor cottaqe cheese manufacture. All
cheese was sold as creamed cottage cheese with
-------
second wash 2300 gallons 77%
third wash 1600 gallons 53%
total 8300 gallons 277%
Water was also used in the jackets of the "ate
and for a plate heat exchanger, which were used to adjust
the temperature of the skimmilk to the desired setting
temperature. Total mean water discharged to the drain
was:
123
-------
Unit operation gallons of water gallons/ICO
pour.ds of BOD
processed
* cheeseinaking
** settinrj
** cooking
** cooling
CIP
hand cleaning vats
total
•includes whey and 2 washes
** clean water discharged to drain: heat exchanger=
setting, vat conoensate water = cooking, vat circulating water to
drain = cooling.
23,930
1,000
3,295
8,435
2,320
5,000
4^,980
220
9
58
78
22
«''
433
124
-------
COD and casein loss:
Analyses were made for COD and for casein (pH 4.5,
insoluble nitrogen x 6.38) in the skircmilk, dressing, starter,
whey, wash waters and finished product. The mean values for
total wlids. COD strength and pounds of COD are summarized as
follows:
Ibs COD
Sample '* total solids
bkimmilk 9-70
SKiminilk-casein ^.9
Dressin-j 20.0
•Jtarter addition 10. 0
v.hey 7>0
First v.ash c-y
Second w.ish r"5
mg/1 COD
113,000
71,000
315,000
123,000
<58,noo
3, POO
4,700
1G.COO
10,090
4,770
760
6,720
Third wasn
0.2
95(
471
95
125
-------
Coefficients of losses in cheese making operations were
follows:
Unit process *PouncJs COD/100 pounds CCD processsed
based on curd based on final
whey 39.8 34
first wash 5.3 4.1
second wash 2.8 2.1
third wash O.G 0.4
* This is also equivalent to pounds of BOD per 100 pounds of
BCD processed or % loss of COD.
tines loss was significant in this operation and two
approaches were used to measure this loss. One was the removal
of the fines by centrifuyotion (Table 29) and the second was, the
measurement of the casein loss. The second was more accurate
than the first, since centrifugatic removed only from 30 to
of the casein due to the small size of some particles.
126
-------
Table 29. Effect of Fines Removal on BOD of
Cottage Cheese Wheya
BOD5, mg/1
Before
35 ,000
29,500
31 ,000
35 ,000
43,000
After Fines
Removal
23,000
17,500
18,500
18,200
24,000
% BOD
Attributed to
Fines
34
41
40
48
44
alnclude a Portion of the First Rinse-
127
-------
The loss of casein in the whey and washwaters was
different in the 3COO and 1600 gallon vats, as shown in the
following:
Unit process percentage casein loss
small vat large vat
3.1 3.5
first wash 2.1 1.8
second wash ].fi 0.6
third wash o.<1 0.3
total 7.7 f,.2
About one-half of the casein loss was associated with the
washing procedure and the loss in the small tanks was greater
them in the larger vats. There was considerable difference
between trials in the loss which could be attributed to the
characteristics of the curd and also to the time the nechancial
agitators were in use. The highest loss observed was J2.1% for
one vat. other vats made on the same night had losses below fft.
ln-2 lowest loss was 4.1%. One single trial was mndo to determine
the effect of hydrolysis by either rcnnin or microbial cultures
-------
on casein loss. The results indicated that up to 5* of tho
total casein loss could be attributed to hydrolysis.
Ine bOD/COD ratio was 0.45. Overall the BOD loss
issociatec witli Lhe cheeseinaking process ranged from 3300 pounds
to 5500 pounds, defend iny on the amount of cheese mede and the
of casein loss.
COD arid bOU losses and coefficients for all operations
with cott;.
-------
Hand wash 70 .32 32 0.32
CIP 151 0.7 R9 0.7
total 8329 39.4 3745 39.4
The whey and wash waters made up over 97% of the total
loss of organic mattei in the cheese making process. Of the
other losses, about 50% were due to leaks or spills.
TLUID MILK PKODUCTS:
All o£ the milk and cream for all products processed in
the plane passed through the receiving room, raw milk storage and
milk processing area. Total milk intake was used as a basis for
coefficients in receiving and processing and packaged fluid milk
products as a basis for coefficients in packaging and storage
ope rations.
'/.ostev/ater use in fluid milk r [^rations:
The water use associated with the milk operation included
that being discharged through the floor drains in the receiving,
processing, packaging and storage? areas and a major portion of
the wat-.r goin-j out drain ¥2 from the hub drains of the 11TST
130
-------
units. ivecin water use by unit processes was as follows:
Unit Process
gallons /
day
gallons/lOOlb
BOD processed
Receiving
(25.CCO)
( 16 )
Milk Processing (104,520)
-------
fillers 6,000 5
host: stationj 1,500 1
Storage 12,100 11
CIP of tanks and
lines ( 1-1,000) ( 15)
TOTAL (251,420) 188
Major water use was for the case wastier, clean-up of the
liTbT units, and CIP separators. The IITGT start-up and shut-down
was variable, depending upon the use of the rinse recovery
system. This system was not used about one day in three, because
of production scheduling problems.
'ihc water used in the clean-up of the IITST was mostly
cleiri-watr;r for final rinsu. The amount of water used for
rinsing and discharged to a rain for the three HTST units
ranged from about 6,500 to 155,000 gallons / day.
Product losses:
Determination of prod»ct lobsos froti unit processes for
the milk (lL'p-jrLinu:it Weir; most, rliificult, since thare was no direct
-------
drain access. Determination was made when no other plant
production was in operation, such as receiving on week ends when
no processing was being done or when either cottage cheese or ice
cream processing was not being done. Generally these studies
were conducted for only portions of the total days operation end
values obtained on hourly data projected for the full days
operations
Estimation of bOD and CCn for unit processes for fluid
products is, summarized below:
Unit Lperation 1« COD/ 1 L> BOD/ Ib BOD/100
Ib of
bOD processes
Kec.iiv ing
(700)
(37C!
(0.73)
Pasteurization (17f>4)
start-up & shut-
down
leaky triL>'i'ii3
creosn HTST over-
flow
poinoij t-ii i z.i t ion
mrpij ra L ion
IITL-.T ovorflouu
(937)
(0.53)
200
150
109
20
1'J'J
-10
G39
50
5'i
11
10ri
13
0.40
n.n3
o.o/i
0.0]
0.07
O.C3
133
-------
Storage before
packaging (950) (505) (0.31)
Defective air blow 1C>0 85 .C5
CIP (raw and past.) 800 f,2< 0.2G
Packaging (1502) (799) <0.50)
Storage of packc. god
product (301) ( IfiO) (0.1)
* Miscellaneous leaks
and spills (592) (31/!) (O.?0)
TO'JAL 5826 3080 1.9
* COL) estimated from analysis of drain «2-GOD from unit
processes d i:;r;Jirirg iny from drain .11.
About 10% ot the product losses in the processing of
fluid -nilk products is from the milk floor drains and the
remainder is from drain it 2.
The v.i lues for milk rue (jiving were from anys where the
wuro urjlo.'.'Ifd promptly. Tlic effect of time of standing
un loj'i ing of tankers is oliown in li-jurc '. 3.
-------
290 r
25°
o
o
a
o
200
150
en
a
z
o
a.
iOO
50
05 05-20 0.2-30
HOURS
30
Ti'-jure 13. FfCcct
-------
Although there was considerable variation, a linear
rul at ionsli i y was obscrvud bcwteen tir.e of standing and tlic amount
ot" LCL' IOSL, during washing. The average loss of BCD per tanker
wau 70 pounds £or those unloaded promptly and up to 350 pounds for
those that stood for 3 hours before unloading.
•Itnj fiata presented in this section of the report provided
a basic understanding of the plant operations and a basis for
uciurniiiution of major areas to which to give attention during
subsiMiuur.t periods of the study. The coefticents could be
compared to those reported in the literature for design
coefficients and provide a basis for estimating the preventable
V,M ste V..T te r 0 i ;:c h.'i ry es .
13G
-------
SECTION 5
DEVaLOPMCNT AND I MPLhH ELATION OF
WASTE MANAGLMENT CONTROL PK9CRA1
The management control phase of the study was conducted
in three separate stages:
Stage 1 Management used basic cats, obtained in the
plant survey and undertook a control program with no outside
assistance ir the planning or execution.
Stage II Management appointed a waste control committee
to supervise the program and The Cnio State University personnel
pro'-ioed input in planning and execution of the progra.n.
Stage III A single resource control manager was placed
ir. ciiurge of the control program, reporting directly to the plant
mi.na.jer with no other responsibilities. The managment control
f,«nobook developed curing Stoje II was utilized b^ the resource
control ncnsger .
Prior to trie initiation of the ner.a-gemer.t control phase
of cue [.rogrin, the following steps .
-------
1. A meeting was held to acquaint Kroger management
with the findings of the plent survey. The economic impact
of the losses was reviewed.
2. A PDP-11 computer was installed to monitor wate-; use,
water discharge to the sewers and the production of fluid milk
products. The system printed a daily summary and could print
nourly reports as requirec.
3. Goals were established f^r the management control
am bosed :>n data end an estimation of what should be
achievable in the reduction of water being discharged to the
sewer and reduction of bOD/CCD.
LCC'UO/.IC IMPACT OF KROGER PLANT WAS TEW* TEN :
Tlifc cost, of wastewater discharge from the Kroger
Indianipol is plant was computed on the basis of the baseline
perioc cata ind was computed in respect to cost per day, per four
week period ana per year. Different levels of management were
found to relate differently to the various time frames.
Total water use for the plant per year was 17K,£OC,POO gallons as
cted from tne base period cats. The municipal treatment
s costs for trcitneni of t'^e dairy plsnt wastes were:
133
-------
water $n./2/10CO gallons
volune discharge to sewer 0.47/1000 gallons
service charge O.T3/1GOO gallons
BCD (over 250 m Value
per day j.c r pe r i od per year
252 7,050 91,72«
*dter volumu to
sewer 252 7,C5G 91,723
L.ov,yr service
cl.or.je 13 504 ''.,552
139
-------
TOTAL 522 14,616 190,008
The projected annual BOD discharged to the sewer was
3,38S,2CC pounds. The cost of BOD was:
Pounds per year 3,385,200
Pounds bOD/year cxe,;i|-ted 547,938
Pounds per yi>ar chargable 2,837,26i
surcharge- (2,837,2^2 x 0.02S) S73, 768/year
Tuis breaks down to n daily cost of $202 or a period cost
of $5674.
'ill'.- perccntd'jt contribution of various areas to BOD loss
was :
milK 18.0«o $13,275
ice cream 36.0 26,557
cotta«je cheese J<.0 25.08C
14C
-------
CIP, Hub drains 12.0 8,851
The LOD contribution of the CIP and hub drains must be
divided among the milk, ice and cottage cheese operations. About
two-thirds of the load may be charged to the milk department.
The effect of low, median and high BCD loads on the BCD
surcharge is depicted in Hgure 14, which is a reproduction of
one of the visual aids used in the management meeting.
For suspended solids the charges project for one year
would be:
pounds Ei,/ year 1,054,CG3
pounds S5/year exempted 368,628
pounri L,S/Yt)AR CAhtAbLC
Surcharge (^SD,<35x 0.015) $30,844
This breaks down to a dairy surcharge of $84.74 and a
period surcharge of $2372.
The total cost of the sewer related bill is:
.-Jaily $ 308. DO
141
-------
BOD DAILY COEFFICIENT VARIATION
0
UJ
tf)
UJ
o
o
-------
4 week period $22,639
yearly $294,620
The percentage of cost for volume, DOD and SS was 65,
25, and 10%, respectively. However, these costs do not fully
indicate the total cost associated with product losses. In
addition to the sewer bill, product losses, packaging materials
losses, labor associated with loss product and energy associated
with product losses must also be taken into consideration. The
overall breakdown of these losses for the total plant were:
C Annual Cost % of Cost
* Sevver bill 292,620 19-8
Product losbes:
rou Milk 135,COO 10.5
product losses 7!ifJ,C59 51-5
** Labor 203,r,'n 13-8
143
-------
iinergy 7,307 0.5
Packaging 58,458 4.0
Total $1,476,904
Mncludes water, sewer volume charge and surcharges fo» EOD
and £S.
"*casec1 only on lost product.
Product losses were estimated on the basis of the rean
losses from ice cream , milk cultured products and finished
cottage cheese. Ivhey was deducted and no value was assigned to
it. The sewer bill included the cost o£ water discharged to
sewer. Labor and energy are based on coct of lost product only.
The above cost figures are estimates, suspected to be on
th<: conservative side.
the preventable wastewnter and EOD in this plant
was found to runrju from /1 0-80%. The losses as measured at the
scwur wure consistently greater tlion determined from production
records. Trie muan pound:; of bOD ]oss/10T pounds of EOC procestied
( iii'.l ucJ iiig all in>j rud luntb) wjs 7.72 find the loss meosi-r.c from
wdstcwr.ter anolvuis '^'~> r>-? or ?.2« tnnoy higher than shown by
144
-------
records. A comparison of lot^ai; based on production
and those based 01 sewer analysis ore compared in Table
3C tor Jjnuary to September 1977.
V;iiey, which is the inost visible i»aste Emm a dairy plant,
contributed ubout 25'i ot the totdl JiOD and rn an annual
t-rojc-ction the plant would dischsryo 1,231,5(!8 pounds of BCD from
whey. The volume and surcharge cost would be $52,000 per year
or $4000 per period and $200 per processing day. The cost per
pound of fjnished cottage cheese would be $0.008 and the cost
per pound of fluid whay would be $0.0015.
-------
Table 30. BOD Losses Based on Market Report Values
for Dairy Product Losses Only
Month
1977
January
February
March
April
May
June
July
August
September
f BOD Lost
77,230
69,926
42,971
42,176
71,180
51,999
208,112
221,112
238,000
gBOD Lost/100*
BOD Processed*
1.20
1.87
1.08
1.13
1.88
1.33
0.54
1.75
1.22
% of Loss Measured
in Effluent
32
30
21
23
38
23
8
28
22
*Based on skim and fat losses from Production Reports
14G
-------
Computer Monitoring of Selected Plant Operations:
Computer Concepts of Knoxville, Tennessee, installed a
PDP-11 computer with Computer Concepts I/0's to monitor selected
production and water flows in the Kroyer Plant. The system was
not pro'j rammdble by the project personnel.
Th* sybten gave a daily summary and could also be set to
•jive hourl> or half-hourly reports that permitted monitoring of
events in the plant. Neports could be called for at anytime
within intervals sufficient to complete the report (2.5 minutes).
A typical day's Luminary report is reproduced below (values in
Ions) :
K.tCCIJK - lil'A DAILY HI. POUT ?7-£ept-77 1)0:00:00 |>a:jo ]
/. M LK/ LKW KK b Ui-ll'.AK Y
V.ATLK LUl'PLILL
ur'.l 73 IP
MM? /1P779T
117
-------
UN', 87312
TOTAL 615971
WATL'K ULiLC
Cll'l /7C5
C1P2 823o
CiPJ 4837
CiPG S37
C1IJ/ 4327
HATCH WLICIl /(f/\i
LANC*. 0
G1CJ4G
I.INt.1
Ll.'Jt;?
LIHIJ3 502'.^(
il'i.'.T 1*] :,UI'-ii-lAKY
»/.-. MILK U:»I.C o/o? 1
.-.ATLl: U':i.l; 1 \yjf,
(tiesI, ,-IAI;L o
L.LU
-------
/L:. t /-.'i .iOU:< ciu.A.1-;
,UU'< 'Jill All I'J'i
CI-LAM P.t'JDUCLD 5121
CliLiiSL 'Jia:-1 271/13
JKLi-l MILK J.451
LC'.% I AT 0.55i
ill N'U ?.00% 1
ll^i-lC 3.2L%
TO liL.'.NU VAT
KAV. MIL;;
117?0
0
0
CM:AM rnouuci.u
CI'l.AM UlAC ] ICJ
C.n.t-ih LS'.ill "
:.,Ai/n.K t:
L'T ! i 1 .•'• 1 LK 1 '4
-------
CilOCCLATL -1ILK U 5525
CUOCULATL CHINK (H7
-------
i AT sou'i C.
-------
ICL C-U././. /,!>.
T'J JLLNJ VAT
TOTAL 'iILK IttCLIVED ***********
MILK RLCCVtKLL FROM ULLEK 2534. '0
MANAGE/. Li. 7 CONTROL GOALS:
Thw following joals were set for reduction of water
utilization anc. BCD (ingredients) throu-]li the implementation of a
control program.
viator utilization:
Current water use et Indianapolis at the end of the
best j-oriod was approx iinatul y
-------
The BCD discharge per IOC pounds of BOC processed was 0. 2
[./oundi. 'Jhe best combination plant in the country operates at
1.5 pounds of bOC per 1UC pounds of KCD processed. Tlie target at
Krojer Indianapolis plant was to reduce the BOD to 3.5
pounds of LCD per 100 pounds of F.OR processed. This target
included the discharge of whey. The minimum estimated savings
vould have been $250,000 per year.
STAGE 1
Stage 1 management control w«js directed by the plant manager
»ithout any assistance from The chio JJtdte University project
personnel. After presenting the naterial in terms of waste loads
and economic impact and potential savings to the manager, the
manager v»as then left in charge of development of the. control
[.rogra.;i. In this stage, there was no specific assignment of any
individual personnel and the nanager really indicated an
increased c^areiiess of need rnd passed on through channels the
n'ifcu for water and woste reduction.
There was no statistically significant decrease in either
»ater utilization, hCL/CDD dischargs or suspended solids
discharge- o*/cr the threo-montli period. The mevin v;ater, EOD and
suspendec' solidt, values for t!;e months of Cctooer, Nove:nber and
Co c e.n ofc r v;erc as follows:
-------
wastewater
gallons/day BOD POUNDS,/DAY
October 521.000 11,375
November 625,000 11,100
December 510,COO 12,225
The computer daily readout was not utilized by the
personnel. One ot their major objectives was to use this as a
production review procedure tut because of air incorporation in
processinj to varying degrees, the quantities indicated on the
computer review were not accurate. The information that could be
gleaned from this was not used, but it should be indicated that
no interpretations were provided.
There *cre several lessons learned in this stage of
investigation, none of which was unexpected. These were:
1. A control program is not easy to install
in a operating dairy plant. It must meet
a specific production schedule.
2. Without specific responsibilities assigned,
y no control will be achieved.
154
-------
3. Kaw ddta generated either by an inplant monitoiing
computer or from v,aste analysis data have very
little meaning at any level of management.
4. Interest alone on the fart of plant management
and personnel is insufficient to achieve a
control program.
155
-------
L.TACI; ii
There was a change in management at the Kroger dairy in
January of 1973, just proceeding the initiation ot Stage II cf
the management control program. This necessitated bringing the
new manager up to date on previous studies and the results of the
Sta-je I control program. Following this, n new management
control program was initiated, which built on the previous
ex pericnces.
Program Development:
The program was designed to cover a six month period of
time. In January, a committee was formed which consiste' of Mr.
John Korrison (Plant Manager), Mr. Non.ian Clark (Production
Superintendent.) , ;-irs. Art Push (Chief engineer), Mr. Joseph
ijdl unb^no (Quality Control Manager) and b. James Harper from the
OLD project staff to discuss prior findings and to plan an
o/era 11 prog ruin.
The philosophy and general procedures used in the Stage
H progrdi.i are detailed in .1 separate document "Waste Management
Control Handbook for the Liiiry Industry" prepared under this
grant. This docuiru-nt is available from EPA.
156
-------
I'.vj mana-jt.'iiienL pro.jrum involved a combination of an
educational projron, waste control supervision 6nd implementation
of i.nprovec procedures anil cvul uat ion .
Lducetional Prooj ro.ii; Vhc education program was
conducted by '.\. J. h.jrper of The Ohio rtdte University project
jroup follov-in-j tJ,^ jcneral fornot and subject matter j.rescntod
in the nicnajciacnt control iiondbook.
IniLioll> all msnayc-int-nt personnel, which included
obout 23 peo|.lc, v»cre introduced to the si.-jni 1 icance of wastes at
the dairy and ^ivun on overview of waste control procedures^
lollow-u;; :ncotimjs were iicld with mcnajcment personnel to provide
more bockjrounr: in rc3,ject to all aspects of dairy food plant
wastes and hjistb control, 'iliis included halt di.y meetings on
Oetailb ol plant ei;uipi.ionL operations and .no intenance procedures.
Meot irnj s vvjrt.' h'^lc: at shift c!iangc.L v.ith all ciiiplo>»cs
(.'rnulij^i zir.'j tin. env i rori::njnlol ii.ipact of dc-iry food |lc.nt wastes
anc outliniivj .jcncr cil control procedures. A follo*/-up jeneral
•lo-.'tni'j w,ib hslo- to indicot'j specific procedures. In addition,
inc-ctinijs wero iiolcJ with interested L-.nplo/ucs in Dll 'Inprjrtnientu
over a bovoral inonth ;;oriod of tine to discuss specific nerds for
s in -Jiffcrcnt -Jep-ir tnenLs of the (lant. /'Sjout ir:
-oi L!IC rlc.nt o|'.-ruLor ij developed fi stroii'j interest in the
projrc.in ; rid ,.robei.tcc: vrlu.iblc jLijijt'tt ions Cor waste control
prodedures.
-------
Program f>uperv ii,ion : At the beginning of the program,
two V.sste Control Co-supervisors were named to head up the
control program that was given the name "RESOURCE CONTROL
PROGRAM" . They wore: Mr. Joe Salimbene, Quality Control Manager
who work»d the first shift and Mr. Trie Perkins, second shift Ice
n loreman.
A committee wna mode up of the Co-supervisors,
Production Superintendent, Chief Kngineer and Plant Manager to
iiCar reports on progress, make suggestions for improvement and
facilitate implementation.
In addition, \r.. „. Harpor provided back-up nnd direct
assist&ncc through weekly visits to the plant over a four month
period of time be two en "iid Icbruary anr1 mid June. These
visits permitted observations to be mode of progress, reinforce
educut ional programs .ind m/ike studies of needed rh.nnges in the
pro j ram. Lpecial studies '/..-re made to define problem areas and to
the control j.rojram. A detailed report was made to the
manager of uach plnnt visit to k^ep the manager fully
informoO of pro>jresa and areas in need of attention.
l.vclu.jt ion o£ Needs for (.ontrol Program
358
-------
Observations .ni.de by the supervisory staff in the very
narly phases of the program indicated the following needs:
a. Additional definition o£ preventable waste
loads
b. Study of causes for preventable wastes
c. Investigation of whether production loss or
sewor analysis reports were correct
d. Development of a system of loss reporting
e. Development of proper records, and forms
to facilitate co .rol
f. Conversion of raw data from the wnste
analyses and the in-plnnt computer to make
the results more meaningful to management
g. More complete implementation of the preventative
maintenance program that wns on the books, but
not actually in practice and to rradify the
program to include maistonance that specifically
related to waste problems,
ii. nettrminatiori of methods to motivate inidrtle-
minagemeut to t;ik-j a more active interest in
tho control program.
i. 'ih£ for.LL-nnj of communication bet wen operators
and .iiricTjeinfeiit
j. incr-.-J^inj the rate of response from mnnagomynt
Lo problems, ds.'.ocicJtud with »fl£,te and well
known Lo plririt work»n;
-------
k. Development of an ongoing j.nd continuing
educational program Cor operators in the use
and maintenance of equipment
Lvaluation of Preventable haste Load: Further study
was made to determine on a product basis the percentage of
preventable waste predominately from the point of view of product
losses with some attention to water.
based upon the low co£>t for municipal treatment of
whey, a decision was made to continue to discharge whey to the
municipal treatment syste.n. Other studies were in progress to
provide a long term boution to this problem.
I.xclur! 111.3 wlicy, tha preventable wastes load from the
c ciidOGL.- operation ninjed froi.i 3S to 85 percent with an
t of C'3 percent. In the ice cruam departinont oporat'on,
from bO to .'30 percent of the waste going out the SI drain from
the ice cream procc-sbing , freezing and packaging floor drains was
assessed to be preventable. 1!>ci average wns 71 percent. For the
novelty operation, with m:cliin»tJ in their current cone it ion, it
V.QL, '.KltTm incd that 7'j percent of current losses could be
,-rc'VC-nte'l. Lst-f-nt i 'il 1 y, 8S percent of all w-jstcs going through
Ui'i I loor cift-.in^ in tho milk rcceivinq, processing, packaging ;
ICC
-------
store. jc urur. V..TS uscertainuri to be iroventdblc.
The provcnt.ible LOP/COD cotff ic icnts , '-cro 3.0, 5.2,
1.7 uiid l.r tor tlic prevcntnblc wastes in cottage cheese,
novelties, ice cream «-.ncl £luicl milk products. In addition, there
w,-,b indication that a further reduction of r.3 pounds of COP per
inn pounds of Bf'D processed coul'i be saved in tl.e milk operation
..roviuci! Lliat tli--- rinro system -*«TS us^cJ .
i-ojor j.r event. -:--le wjccr losses i nc 1 u J L :'. :
1. Lpnoc-eL>'..,jr y uiL.cL.Trjo oi v,.itcr to the drrin duritvj
clcc.i,in.j of l.v:/r u-iits,. Cn tl.e .ivcrojc up to '.C.crO gallons of
v.,iLu-r per i\: y couU! be oOVL-d in tliiL, -nannor
2. 1:0 1 le.wiiKj lio:..'S runnin.j nn^ttentlcf! t.oulrl reduce tne
U-..JL- by -jp
j. I.JC-II'.-LIOT of flo'..- r.Ucfa could rcrJucV the- v,oter use
iro., th,- no^lty mochi ..c:, to on..-ll,irrt of current level x.it»i.,ut
iiii[.'i i r i ii'j o;. • .'•!. ion j .
l-rocuction vt-ri-us r^sir, Lo-•..;:,: Hoc.-u-.f of continual
'.ori-J-.-rii f.:i tM'. ,«.rL o I i.!«.n.- j'.-ni-iit «TS, to tl.-- r- .-.-Jons, f.h.it IOEEOS
!.,•.. :,..ir-..c: :i. Lho *-iMCW i tr r wjrc hijn-.-r tl..-n ti.oLe ba^-'c; upon
ironui.-Uo.i r- ji.J-.. i,evc'...l CL t-'i i U-n :.tui! !••:. h-.-re inflde to
-------
invcbtijotc this further. Th-.- ice croam dop.irfnent was user' as,
the biJis tor j,tu(Jy, since totul pounds of p-ruvc-ntflblcf losses
.jr.. tbti..i.'iti-d to be dijlioat in this or?*..
Comi-lcte reconciliation of the differences was not
pu^iblo. •ihere- wore u nu'.ibtr of factors ir.tl none inq this
jitftrunco:, Miicn included production reports not actually
re flue Liny thu .vnount of specific: product product; the
utilisation ot Lt.-.ncau vnlucs, rnti.er thi-n actual values of
P.IC.-KCJC wjijhtb jncl co.ni.obition; counters, on jncksjinj :iiochii»os
that countuc ^ckajc-o, but c'.if! not excliKlt- those- {n^k.-KjcB lost
.-Itui couritiriij,- uiic! unrci-trtcci lous«n. An ex,,i,.ple is presented
lor uiiruj-ortcci lo^s^i- tor one d.iy when production figures bliowed
a U.Vi 'jc.in and *.,is,ttwuLei dnalysii. snowed ci ' . ?l loss. for this
..articul.ir ua> thc-ru v,-j^ n s,ericu of unrecorcieii loB5.cs «is
folio*:,:
1. i,(j 'jdlonb of cream wore ]ost when a line was not
attnchcf! to the cream receiving vat and croam was pumped directly
onto the floor.
?. /.1
-------
f.. 'Iho loss of sticking in the ncvo1. t / o|«jrntions was
<"i>j,GOU by count, whicli equaled about s'>,000 ounces of novelties
to tlie drain.
5. Approx niicitel y 35 ijallons rf ic2 crcjn wos loft in the
Lldvor vats uiul WHS rinsed to drain prior to the GIF operator..
1!»9 total LOU lost, for the <-ibo r tor] Io3f-.ci;.
Ih'.jf? r •_• !v u 1 1 o iJonLinncd [.ri.-viour. obr^-rvnt ions tli.'it
v. j -. t (. '..'-'i t e r jn.ily;::; '/..TO inr.ro j.rcrl icLi vo of truo |.lnrit lot,!-Jori. th-in
,. r oc; uc Lion record.
'III-.- '.tuc.1^ <}',•} 1 inl ic.it.L-0 'So ffjct, to di.volop bi-Ll-r-r
rccor^ k-_'i.riiij pro'.-i". ur u-j , Lo u'-ili/i.1 .u-lu.il j-sc k,->'j(.- w 1'jhtij , t.o
-------
uos actu.il ''uluos of produces [jrocessud ,..•' 1 to rcconl packages
the •. arc lost after Iillin.j.
/. portion o£ tho i.roblu:n coultl be Dttributori to x lack of
sensitivity on ui'j (-art of both, supervisory incjn.i'jiucnt ar.fi
u;nrv>l to events tii.it haci Licccnc corin.ion pl.-.cu in the
oi in n-_'fH.'(' i. .j u.ti ii..ii'_' .
(i:J i'r«!}! i ,i. . id , i -A! in~ L i o . ... !.••': in i irj tli.it. r L-u u 11 crl in
Mvrjil«.-. , ij';ij(.'. , 'ii.n;.--1. ,.• ')•!!.• I >r i ri .!j i'. i'. y to o|.-'1 r "«t'.1 [
d-.:. ! j i...,j i I.-! I ' ••.>'. . :. j t -i '. i j in ! i < . il 1 n:.:••'.•••..
-------
Loss KeLortmj: Unrfj ortu'd losses w»re considered to bt
d si i ru f icfint prcbi^n. A fsm ^as c'eveloped that was mc.de
dVt'il&lJit: to ill lore-ncn for rej>or'cin3 losses. initially, this
..os labeleo as a "ITFILL RLTOHT". A ->osK sfter initiation there
i.ad ucer. no reports filed, even though tliore were observed m-j^or
losjc-s duit to overflow, usckage failure, etc. Discussion revealed
trial 'loLioJy -»3nisei to fill out an account of a spill. Therefore
utiv for:n ricne. v,as ction^ed to "LOS^ i;CI CRT" (Se^ /ppendix fc.) .
I'.uri.n.; tlie follo»irg v-.-ek s iv-r.Litr of loss Deports v>ere filed.
Loos reports v.ore rouiec to the Ccne-al l-oretifin, Fraductio".
Superintendent, Accountant and Laboratory.
jecords: A large- nun be r of different record forms were
i>tveloped cn.'J :ried. All forms utvelopec &re presented in tne
iVina j on en t l.'anribook, 'sn> wore not useJ routinelv- Those record
fori-iis me!, *'fre useful in t'.is particular r,l?nt ?re inclulec in
/.^,-^iirj ix h. 'J;:?Sfc inclulfd fornib for:
1 . Lob£ i.e^Drt
2. rta i n t •- ri. ri c f_ F-.u c; j 3 r. f
.?. :lci."t (v.jsoi.' ce 7or.trol ZTspcrtior. Form
' . Co'ij.ut or ' u.nnary
^. 'vD.-.-cJi i ry ing rcci lent I'so l-eport
'>. f j ] J. ]." 3 rec : ent Js? ;.r.ri LOSE fepo't
7. let 'Jri...-.- ] n j r cr! ir£r . L>r;:- Kt-^ort
'"o 11 n j '. C.' i L . i- _• I,': j •-::: I f r, t. Us o 'c- po r t
-------
1C. v.a-ste Luiai-ic.ry Kuport
11. I'.astfc Cost /-no lysis t-eport
Calculations: Lurin-a initial stages, it becane
immediately apparent. that the plant personnel did not -nske the
si ,10 interpret 10-. that trie CSU project persomel niede fro.^ the
Suiiir computer one: *astev>3ter Citta. This emphasized tne vftlue of
personnel e/i er ieuccjc in wastewa ter control £nc slso
ttifc r.'.-ed far develo^i n j calculations that would transfonn
the rai.' fata into a for.n tlist msns^einent could easily understand
c.nd taKf- action or.. Lxa.nple calculations ere presented in
/ pp^ .-itj ix C .
1h= data that could be- generated in one day required fron
tvo to three hours of hsnd calculation to convert it into a forn
that uas usaljli: by Msna-jtnient. In the latter stairs of the
project, a .ucro.o.npu'.c r vis used to develop smple pro^rans that
r-c-rforr.fd thes> iaTie calculations in from 10 to 2C minutes.
Preventive .ia intena-.co Frogra.n: Detailed study
indiratec that t;io :nu: ntenar.ce pro'jru.Ti as established was not
.-.•ci.-irj strictlj followed because of the anount
oi •--."."-r jcr:-, .icir t'.r.snct *.-ork that noedcc to to done. In
„_:„: •_ i :>• , t'crt /;ere f- nu/.-er of ni2inter.;.nC'3 arees thst ^ore not
i,.vl u-.-_- i.. ti.'.- crar.iiarc preventive . .aintonanc<3 pro^rain i:ir-.
-------
wr* a cau
i
-------
possible becrusc- of justifiable deloys, this information neederi
to be passed on to operators. Active interest on the part of all
inanacjMent personnel in the |,ro;jra:n was recognized as essential to
tlni success of the
1G8
-------
LOGS Acoun t ing :
on a determination that wastewater analysis provided
the btisc means or. loss accountimj, the following procedure was
1. Cotennino CDC for all ingredients used in the
.i]r t.-neiit or ti.o total pl^nt, depending on the type of report
i r eci .
2.tfake a daily accounting of all ingredients used.
3. Letenninc CJi: produced for the day.
a. Calculate the COD for each ingredient based
on prior analysis of COD for each
irnj re'J lent
exa.nple: 10CC pounds of cream x n.55 Ibs
CCi;/[.ound of crea:n= 55C pounds of CCD in
Cue cream.
u. I.uin the pounds, of CCD to ^et the total.
c. y»nnure the COD in the v/aste v^.iter and
co/ert to [>ounrjs of COD.
c. . Ciilculc.te loss in turms of (COD out/COD
ui,od)X l(jf% =t]oi,s
c; . Co.nparc- ths lost, value to tl.o de-sign vrilue
Lo aucor.-ni ne L'IO prcvtnt.-«blc waste levc;l .
i:etcr::iiiii tn-: 3 i'j n 1 1 i c.incc of IOSL,: \, lois
.n».ibure:J-'i oosijn IOLS = (, {rovcntnblu
1GQ
-------
f. Corwi-rt to j loi'.s:
,;omif.;s CCD used x"i loss XCw.l ue/pound
CCO = C loss.
/•M e^ril and the last two v,eeks of f'-ay. lor
LI 10 period re i-resentf-'i1. , the aver?..-je daily ingredient loss at a
L'C:, valuo of 50. 41 per pound was $11 2S, for an annual ct,uiv«-.lont
ot < 37J,10U of loi,t ingredients. It should h» noted that this
v.Mb jibout o:i'J-liulf of ".hot of the b.iae period.
lurtlicr cost s-countirKj V. ^oi.ii.nry -ilio^Ls «..-re iiu.rio :.o i nil ic.~ t o Lotcil COi:
i,ro'.-..^.,eri, LoL.sl v,.-»Li-r -uif! C'fji, coof f ic icnts .me the v.luu of
170
-------
Table 31. COD Cost Accounting for Ice Cream Department
Ibs COD/1 b lb COD
INGREDIENT Material
Cream (42X) 1.10 28,242
Milk (35%) 0.173 7,113
Whey Powder 0.88 4,135
Sugar (7%) 0.56 42,538
Chocolate Solids 1.32 4,606
Stabilizer Slurry 0.58 420
Egg Yolk Solids 1.0 100
TOTAL 87,154
Average Cost
Pounds COD discharged = 3,. ',00
« lois = 3,500 x 100 = 4.02
$/lb
COO
0.48
0.52
0.15
0.21
1.82
1.22
0.55
0.41
Daily lo:s = 3,500 x 0.41 = $1,435
Yearly loss = $1,435 X 260 = $373.100
171
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Table 32. Summary of Chemical Oxygen Demand Entering the Ice Cream and Frozen
Novelty Drain Catchment Area, the tosses of Chemical Oxv-jen Demand
and thp Percentages of COD Lost in the Effluent.
Chemical Oxygen Demand
Input COD
92.050
101.305
94,135
91.430
'01 .>,50
108.055
94,348
108.8bO
98.055
112,680
110,324
88 ,042
106.000
91.455
128.694
101.400
Effluent Loss
COO (Ib )
3.000
3.000
3.385
2.713
4.290
3.260
4.635
4,490
5.445
i.sau
4.600
5,460
2,962
1,381
1.969
3.910
ReporteH Loss
Butterfat
+226
+574
-154
+1561
+53
-132
-477
+ 1027(+6.9)
12.8(7.45)
555(3.17)
+273
193(4.4)
-89
-85
72
MIX
3.077
+312
-423
-423
+797
-340
-771
+102
-2002
-2039
-1211
/6<(4 |)
7510
+730
208
% Loss
3.26
2.96
3.59
2.97
4.21
3 02
4.91
4.12
5.55
3.18
4.17
b.20
£.79
1.51
1.53
3.86
* Report
B of Loss
1.05
4.0
0.9
*13
+0.7
0.9
2.3
+6.5
7.6
3.17
+7.1
2.25
.72
.91
1.2
*-/-?
-------
PREVENTABLE WASTES
WATER USE TO
MAINTAIN
CLEAN FLOORS
BOD/COD
LOSS IN
EFFICIENCY
SS
LOST PRODUCT
ADDITIONAL PRODUCTION
FOR SUBSEQUENT
PROCESSING DAY
FOG
ENERGY
LABOR
PACKAGING
MATERIAL
Figure 15. Contributions to Preventable Wastes.
-------
sower c!:ur.je in mill: ec;ui vdlcnts . (Thu necessary calculations are
shown in tho /^ppendix). / typical report is shown in Table 33.
Interpretation of In-Plant Computer Output:
Tho computer [.rovided valuable information on a dsily
byi.it>, primarily in respect to water and wasttwster
rcl at io:iMiips . because of previously mentioned cir problems,
production fi-juros were not reliable. Tlie air problem would
require coribtcint attention and robC'tt in j o£ [iressuro differences,
o;i ttiy b^parcitor by t^ oper.itinij [.ersonne] . The settin'-js had to
bo done by h/ind .irui wab 'jcnerally conaidcred to be too difficult..
fjtlmr responsibilities prccludc-a the operator having time to
tMs 3reo tlio cloi,e attention rocju
V,!;_>njoii chio r;tnte Project [jersormcl could glance at the
rcj.orta an.'! obtain instintaneous interpretive
inlur.ii-.L 10:1 , LMt, •«••»•: not. jen-jral 1 y rlono rty the j-l-^nt pe r boniiL-l .
/ nuin!;'ir ot Cnlcul < t ions, fuvl to he- don-7 to convrt Lho rav* \,:t;,
into j for.n of v.'J uc ro jinnr. mane ju:ucnt . Invest, i jat ion «//.•; in-i1!?
ot iii'.or [.o r,-, t. i rvj trie nc Lhoi'ii t i c.i I corwu r :., i on into tho COfn[,ntcr
,.rojr.i:». Isccau1.-.1 oJ ']».•(. i.-n-Jt. net- on outsidi- computer pr O'j r.-.-nmT s ,
t.ti
-------
Table 33. Weekly Summary - Kroger, Indianapolis
BOD
PROCESSED
in 100's Ib
4/24 Monday 1,622
4/25 Tuesday 1,457
4/26 Wednesday 1 ,875
4/27 Thursday 1 .848
4/25 Friday-
4/29 Saturday 2,448
WeeHy Average
Base Data
''Improvenent
Gallons/ Ib
100 Ib BOD BOD
284 8,591
323 8,616
337 9,922
260 8,055
220 10,050
285 9,046
400
29
Ib BOD/
100 Ib BOD
5.3
5.9
5.3
4.4
4.1
5.0
6.2
19
Sov/or \'jt 11
S538
SVdljc Product Loss $2,713
l$ viluo o HOD = 0.30)
Yea_r
SI 0.760 $139.880
$$4,260 $705,180
-------
]. Peroruinotion of. [>rc|.L-r opor.-.tion of the wostewar.pr
Llow ..icni to r:..
?. re termination of whether or not tho rinpu recovery
system on t.'ie li'l'ST units w;is bein-j us-jd .
j. 'ituj ..-If. iciency of voter use in the UTS':' syste-ns.
^. 'ihc- efficiency of tho C1P syteins.
0. I'robU'.ns .isjoci.sLirfi with Lilling ojcrationi,, rfvc.ilofl
:jy tlrj nmourit of 1.11J K Jivurtccl to tliu rinse tnnk from the milk
Lillinj nroa.
o. l>jtcr:ninrTtun of coc ft ic icnts for water use cnrl
v..-. -.tow-itor c.iBcJ..ir.jo from the- iliflorcnt cifei^r Lsncnts .
7. L«jLiHicition Irom th'j ice crfn.n p.istour i zo r, wucre rinse
w.st, rocortsed ; r.d not s«v«.-ti , of tlie losses in start-up anJ
bilU t-(!i>' 1 OpO fu t 1 Oil!) •
/, ty,-icdl ro.n|,utcr s.mai,if.ry .irwl I'Tl'T por fonn-inco report
UTL i.rcoi.nL'ij in IIJIH.JS. lr> c.n'l I'/ r «.s;ject ivcl y.
/.I turni:
.. . cool i n ) to«/" r
!;. -jofr. v,-iti:r •,.1,^-1 i "•: to co -i [ r •_••.•. o r :. .-.ml
17f,
-------
Figure 16. RESOURCES CONTROL PROGRAM
COMPUTER SUMMARY
TOTAL GALLONS OF WATER SUPPLIED
TOTAL GALLONS OF WASTE WATER DISCHARGED
GALLONS WATER DISCHARGE FROM ICE CREAM
TOTAL GALLONS WATER CONSUMED IN PLANT
CORRECTED FOR WHEY
WATER USED FOR CIP (GALLONS)
HTST WATER USED - ALL UNITS
HTST WATER USED - MILK
HTST WATER USED - ICE CREAM
GALLONS WASTE WATER X 100 1b BOD INTO
ICE CREAM
RINSES MADE
RINSES SAVED
RINSES DISCHARGED TO DRAIN
MILK RLCOVERLD FROM FILLER
TOTAL MILK PROCESSED (POUNDS)
GAIL ON1: fj! WAjlL'JAirR (1000)
"ii'iik 1'KocEssEo""
505,500
475.470
180.000
3U,000
25.511
107,541
52,969
54,575
693
7,416
3,000
4.416
562
l.,69p_,jy_2
2f!l
$ 213.000
Z OF TOTAL
DISCHARGED 37.9
7, OF TOTAL
DISCHARGED 5.4
' OF TOTAL „ fi
DISCHARGED
2 OF TOTAL ,, ,
DISCHARGED—-
X OF TOTAL ,, ,
DISCHARGED-
177
-------
Figure 17. RESOURCES CONTROL PROGRAM
HTST PERFORMANCE REPORT
Date
HTST
HTST
HTST
HFST
: 4/10/78
" ' Volune of water discharged to drain
Volume
12:00 a-n - 6.00 am 5,690
5:00 am - 6:00 am 0
6:00 pm - 12:00 am
Total fo" Day 5,690
Vulune of Rinses Made: 0
No. of Start-ups & Shut-downs: 2
-9 •
'""" Volume of water discharged to drain
12:00 am - 6:00 am 9,, '24
6:00 am - 6:00 om 10,205
6:00 pm - 12:00 am 34,646
Total for Day 54,575
Volume of °inses Made: 0
No. of Start-ups & Shut-downs: 5
-3.
" " Volune of water discharged to drain
12:00 am - 6:00 am 712
6:00 am - 6:00 pm 2,895
fj;00 pm - 12:00 am
Total for Day 3,607
Volume of Rinses Ma do: 0
i'Ju. of Start-ups >, Shut-downs: 3
Volume of water discharged to drain
12.00 am - 6:00 am 24,960
6-DU am - 6:00 pm 2,534
6: [JO pm -l^'OO din K,C?7
(gal):
Time to Drain
5.7 min
0
5.7 min
(gal):
1.62 hr
1.7 hr
9.1 hr
"12.4 hr
(gal):
7 mm
29 mi n
36 mm
hal):
4.16 hr
2b min
1.4 hr
Vol Rinse Made
0
0
0
0
0
1148
1148
0
0
100
100
635
107
5376
lotdl for l)u/ 30,121 :> 9>, hr
Mn. of Start-up'i ?• Shut-down'i 4
Totdl 'i-jlloii', t»flr,ii:i: H)7,'!'7; ('''"'1.41)
Total ivcvlL-fl. 20,000 20,000
S74.11/d.v/ >l ,4!ifi/P'.'riod Sl'KS/lb/yo.ir
1?:?
-------
boiler feed
c. cf.sc we.slier
d. C1P separators
c. the 4 vitrifrueze novelty machines
3. Addition of inputs from fillers currently beinrj
recorded on a recording chart.
f>. Addition of inputs from package counters on
vita freeze units
S. Incorporation of software to provide for input of
analytical dcita and compilstion of a complete
mariagment report in terms of "D Vc-lue of losses.
because of advances in micro and minicomputers, it may be
more economical to replace the current unit with a system that
the plant personnel can program. Simple programs in basic were
developed to do this with the data from the computer and by the
addition of COD data from wastewater analysis and input of
ingredient usaje, a complete waste report was generated. (See
Appendix DJ
Determination of Kajor />reas of Losses and Causes*
Table 34 shows for uacl. department the major processes
contributing to either vaier or CCD (LCD) loss the estimated
mount of the loss and the causes of this loss. This information
resulted in mdriugcment action and was also utili?ed in
170
-------
Table 34. Processes Contributing to Major Losses in Kroger Dairy
Process
Water Related Looses
HTST Cleaning
HTST Hot Waster
HTST Start-up
CIP Separators
Milk Case Washer
Vita-freeze
Daily Amount
(gall ons ) :
29 ,000
24,000
2,000
36 ,000
88,000
70,000
Cause
No controls on time to drain
Condensate discharged to drain
Production scheduling problem
Hand controls on separator water lines.
Hand control of water lines
Hand controls on water lines
Product Loss Related Areas (BOD Loss - Ib):
320 Cleaning of tank trucks
80 Leaks
80 Improper operation of air blow
58 Improper setting of pump speed
30 Improper setting of pressures
164 Poor operating condition and leaks
Milk Receiving
HTST #3
Milk Processing Lines
Cream Pasteurizer
CIP Separators
Remy plastic
gallon filler
Vi ta-freeze 540
Flavor Vats 200
Ice Cream Clean-up 200
Fi nes 80
C C skim storage 20
tanks
Machines need overhaul, stick feeding
faults, missing clips, improper
defrosting temperature, packaging
machine jamming
Product left in processing vats, cannot
be fully drained
Product left in lines and freezer
Curd break-up in cooling and washing
steps
Leaks
180
-------
determination of possible process and equipment changes to reduce
losses in tlie last phase of the study.
Management Changes During Study:
In response to the finding of the investigation, a number
of changes were made during the waste management control phase to
improve management control.
These we r e:
I. Creation of a new position of General Foreman of the
Second Shift to provide more management supervision during what
was indentificd as a high loss period of time.
2. Helocation of several Foremen to improve management
efficiency.
3. Creatioi. of a -:ew position of OperaiJons Coordinator
of stick novelties operations, by appointing an experienced
novelties operator to this position to oversee all four machines
and to assist training of operators on a continuing basis. (This
was the area of highest loss in the plant and also where the
jreatcst labor turnover occurred.)
Progress of Management Control Program:
-------
1C through ?' sho\. t'ie chnnnos in coefficients
Cor water anri LUU Cor the total plant, ice cream opcr; tions ,
stick novelty operations, fluid milk products ?nd BOC
cotitCic iunts Cor total plant less whey BOI3.
Over the period sliov.n, there was a marked decrease in
both the volijinc of waste-water discharged and the LCD discharged
per 100 pounds of milk equivalent. Overall the lowest level
achieved was lor Lho month of Nay. For ice cream, the lowest
level of coefficients was achieved in the first part of June. In
most cases the 'joc.ls established were met. 'Hie greatest reduction
was tichiuvcu in the stick novelty area, where the greatest
sis was placed.
Mien \\. J. liar IJG r stopped makiny weekly visits, the
losses in tiie (.lc.rit increased. However, they never went back to
t.Jie same level oS for the base comparison period. The results
were noL Lo L>t unexpectea , since the OGU personnel was actually
serving in cli» capacity of a V.'aste Control Supervisor. Of
interest was the Luct that during April and May, the days that he
v«dr, present, the plrnc showed a significantly lower loss than the
nt-in values. 'inn, amounted to a coefficient reduction of about
50 gallons Cor Wcjter and 0.5 pounds Cor bCD per IRQ pounds of BOH
processed .
132
-------
Mao
3 35°
in
m
VJ
LJ
O
§300
a
a
0
m
250
03
_J
O
O
~ 200
en
GALLON
8
TOTAL PLANT
-
N
N
a
0
Z
Ul
a
Ul
in
<
O
ff
5
a:
3
a
o
u
U.
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£
i
P
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a.
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•^•^i^
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(O
T
UJ
o
-»
P
9}
O
m
i
u>
-j
PERIOD
18.
effect of Management Control Trogram on Wastewater
Volume Coefficient for Ttotal Plant,
183
-------
7 -
TOTAL PLANT
Q
fcJ
W
H
U
U
§
Q
O
a
o
o
H
Q
O
o
6 -
5 -
3 -
2 -
-
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^^^^^H
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PERIOD
CD
00
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C£
m
llJ
LL.
00
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^1^^^^
1
2
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UJ
3
^^^^
CO
N
0'
rO
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PERIOD
Figure 19. Effect of Management Control Program on
BOD Coefficient for Total Plant.
184
-------
3.5
1 3'°
V /
CO
UJ
o
§2.5
Q.
Q
0
m 2 0
00
0
O
8
CO
CO i.O
05
TOTAL PLANT-
-
-
_
-
-
•••••••••I
i
0
o
cr
UJ
a
UJ
in
CD
WHEY
2
gj
cr
FEBRUA
2
g;
MARCH
2
E
a.
CO
gj
5
CO
gj
z
-j
2
s"
(0
z
PERIOD
Tigure 20. Effect of Management Control on BOD
Coefficient for Total Plant Less Whey.
-------
S 30°
(O
UJ
o
o
tr
0.
Q
0
CO
-------
MILK
D 5
uJ 3
co
UJ
CJ
O 4
tr *
a.
o
O
CD
co 3
m
O
o
a
O
03
CO
CQ 1
0
M
_
-
•^^^•M
BASELINE 1977
FEBRUARY i978
,^^^M_
I
o
-------
ICE CREAM
gsoo
CO
in
V /
LJ
0
9 400
a:
0.
o
CQ
CO 300
0
O
^ 200
CO
z
3
^J
g '00
-
-
f-
2?
LJ
Z
Ul
(/)
<
m
P
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K
a
FEBRU/
CD
r>-
at
MARCH
P
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Q.
^^•^^^
CD
I
0
o>
in
i
z
-»
00
N
•
s
1
(0
UJ
z
PERIOD
Figure 23. Effect of Management Control Program on
Wastewater Volume Coefficient for J79
Cream Operations.
13d
-------
8
7
c
u
C
'J5 6
u
u
o
u
£ s
c)
a1.
.a
1-1
o
0 A
,- ( ~
Q
0
m
.a
-1 3
-
-
-
BASELINE 197 r
I
ICE CREAM
FEBRUARY 1978
MARCH 1978
1 .
P
2
03
JUNE 1-15. 1978
P
gj
0
(0
(0
LJ
-j
PERIOD
Figure 24. Effect of Management Control Program on
BOD Coefficient for Ice Cream Operations.
IB:
-------
1200
O 1000
Ld
V)
UJ
i
Q.
O
O
CO
CO
CD
O
O
Z
o
800
600
NOVELTIES
400 -
200 -
-
r-
S
UJ
BASELIN
00
gj
Q?
FEBRUAI
••^^^M
03
h-
0»
MARCH
^^^^HW
00
_J
cr
0.
00
g>
2
s
qj
(£}
i
UJ
D
-5
00
r-
CJ
o"
m
1
LJ
-»
PCRIOD
1'iguro 25. Effect of Management Control Program on
Wastewater Volume Coefficient for Novelty
Operations.
130
-------
12
O 10
UJ
CO
CO
UJ
O „
0 8
cc
0.
0
6
O
0
^ 4
Q
O
CO
.3
- 2
NOVELTIES
_
-
^^•^^^
N
£
UJ
Z
4
CD
00
N
tr
I
UJ
L-
|
ff>
X
U
or
i
I
E
a.
£
|
00
in
z
D
CO
gj
0'
(O
UJ
z
PERIOD
Figure 26. Effect of Management Control Program on BOD
Coefficient for Novelty Operations.
191
-------
'I he results led to tin? conclusion that iwastu reduction of
about 5(H in both voter and product losses could be achieved , but
that constant attention v»as required. The job wis more tine
demanding than recognized and could not be achieved by making the
responsibility an additional one to existing personnel,
regardless of the intcrp.-L such individuals obviously had toward
the project.
III:
based on the findings during the second stage management
cor.trol [jrogiuin, an individual was hired as Kesource Control
Manager . Ttie only responsibility of this individual was to
devott attention to the control of water losses, ingredient
losses and energy losses. He reported d i rectly to the manager and
was independent of all current departments. lie operated on a
flt-xiole schedule, jiving attention to all three shifts.
The success of this approach can not be fully assessed at
thib time, since insufficient time has elapsed since the hiring
of the individual to fully assess the impact. Initial
indications are that the degree of control v^ill surpass that
achieved in Ljtage II.
102
-------
i,LCTION 1C
PROCESS AND EPUII'MCNI CHANGES TO HLDUCE hACTL LOADS
purpose of this section is to describe the
invostiyfction of process and/or equipment changes that could
result in naterial savings in water and product losses, bone of
these changes would eliminate operator discretion through the
installation of controls and thus reduce preventable waste loads;
.heruas others would reduce unavoidable waste loads by altering
the design coefficient.
•Ihe Kroger aairy had a number of waste saving features in
Oi-.-r.tion a, the tine this -udy was initiated. These included:
1. Coolin-j tow«r with evaporative condenser and a recyle
system.
?. :,olenoids on air conpreasors and refrigeration
co.aKess.ors with recycle of wacur to cooling tower suf.ply tank.
l-roduct Loss [.elated:
103
-------
1. Kinsc recovery syste-n for start-up and shut-down o£
the three milk hTiiT units;.
2. I;ecovory system for demoted milk containers.
3. Ice re-tun system.
The modifications included for consideration in this
stud> were both those that were water related and those that were
product loss related. Loch potential modification was considered
in relation to the following:
(a) Determination of the technical feasibility of
the change.
(b) Significance of the changes in reducing water
and/or product losses.
(c) Estimation of costs of making the change and
determination of cost/benefit of the change.
UJTUM-IINATION OF I'OSSJULi: CHANGES
Two approaches were used initially to assess possible unit
cs. tor stucJy: («} delineation of coefficients for unit
194
-------
operations under design end actual conditions and (b) utilization
of tiicse coefficients to model weste loads and interpret these in
tennis o£ costs. Tlie computer model described in Appendix D was
used tor this purpose and dlso to assess the change in waste
loads and costs that could be expected from any proposed waste
savings change.
Coefficients for Hcsi:jn and Actual Operations
To utilize the model, it was necessary to have
coafficents for incori-orat ion into the model. For this purpose,
the coefficients ware given in units of gallons of water or
pounds ot waste characteristics per 1000 pounds oC product
processed, because of difficulty of generating consecutive
processes with either BCD or COD processed. A second basic
computer program was utilized to generate coeff cients in common
units (100 pounds ifCL or COO).
Vhe coufficlentb utilized for the LP modeling for design
purpose (unavoidable loss related to process and equipment
gn) for nilk, ice cream, stick novelties, and cottage cheese
in Tables I<5, 3'5, .17 ond 3
-------
Table 35. Actual Coefficients for Fluid Milk Process-Ing in Kroger, Indianapolis Plant
Process
Receiving
Separation
Clarification
Raw Storage
HTST
Pasteurized
Storage
Filling
Conveying
Storage
Miscellaneous
{Spills, over-
flows, etc.)
TOTAL
Code
rtC
PR
CL
RS
HT
SP
FF
CV
SF
SP
Mater Use
(BUYWA)
{gal/1000 Ib)
16
17.5
\7.5
15
80
15
98
4
10
12
285
Effluent
(SAN SEW)
(gal/1000 Ib)
16
17.5
17.5
15
67
15
98
4
2
12
264
BOD5
(lb/1000 Ib)
0.23
0.75
0.075
0.44
0.58
0.25
0.5
0.1
o;i
0.3
3.32
Product. Loss
(milk loss)
(lb/1000 Ib)
2.3
7.5
0.75
4.4
5.8
2.5
5,0
1.0
.1.0
3.0
33.2
Units/lOCO Ib Milk Processed.
-------
Table 3? - Design Coefficients for Fluid Milk Processing
Process
Receiving
Separation
Clarification
Raw Storage
iUST
Pasteurized Storage
Filling
Conveying
Storage
Miscellaneous
Code
RC
PR
CL
RS
HT
SP
FF
CV
SF
_.
Water Use
(BUVWA)
(gal/1003 Ib)
16
2
2
20
BO
20
IS
1
10
10
Effluent
(SANSEW)
(gal/1030 Ib)
16
2
2
20
40
20
15
1
2
10
BOi'j
(lb/1 00 Ib)
0. 3
0.025
0.025
0.15
0.3
0.1S
0.1
0.05
0.05
..
Product Loss
(milk loss)
(lb/1000 Ib)
1.5
0.25
0.25
1.5
3.0
1.5
1.0
0.5
0.5
..
Fat Loss
(lb/1000 Ib)
0.05
0.008
0.01
0.05
0.11
0.005
0.035
0.012
0.012
.-
TOTAL
176
128
1.0
10
0.29
-------
Table 37 - Design Coefficients for Cottage Cheese Processing
Process
Code
Product
Water Use
(5UYWA)
(gal/lOOa Ib)
S'
-------
Toble j9 Actual Coefficients for Cottaqj Checis Processing 1n Kroger, Indianapolis Plant.
Process
Skin Transfer
f'fam Transer
HTST
Starter
Preparation
Set, Cut 4
Cook
Drain
First Wash
Second Wash
Third Hash
Blending
Filling
Storage
Distribution
Dressing
Preparation
Code
TCCSMUS
CXCMUS
CCHT
CCST
CCHF
CCUR
CCW1
CCW2
CCU3
CCBL
CCFF
CCSF
CCSH
CCDS
Product
Skin
Cream
Sklirani'*
Starter
SklmilV
Water Use
(Hater or
Potwater)
(gal/1000 lb)
3.0
(Not in 15
Design)
16
10
24
Curd (No H20 10
in Design)
Curd
Curd
Curd
Curd
Cottage
Cheese
Cottage
Cheese
Cottage
Cheese
Dress 1 no
116
116
58
50
40
7.5
5.0
2.0
Effluent
(Sever TR)
(qal/1000 lb)
3.0
15.
16.
10.
24.
107
116.
116.
58.
50.
40.
2.5
5.0
2.0
OODS
(SCO)
(lb/1000
0.2
3.0
0.22
0.36
0.1
33.1
8.7
4.1
0.6
1.5
0.5
0.1
0.1
0.2
Product Loss
(Loss TflCC)
5b) (lb/1000 lb}
2.7
10
(Loss 3.0
TR FM)
(Loss 5.0
TR FH)
1.39
36
16
8
2
3.6
1.5
0.5
0.5
1.0
V'hey nol recovered; assume C.1% fines loss.
-------
Table 39. Design Coefficients for Ice Cream Processing in the Kroger, Indianapolis Plant.
Process
Receiving
Storage
Standardizing
Blending
HTST
Pasteurized Storage
Flavoring, Fruit and
Nuts
Freezing
Filling
Convey ng
Hardening
Storage
Distribution
TOTALS
Code
(HHRC)
(RMST)
(RMSP)
(CBL)
(KCHT)
(ICDP)
(INCIN)
( ICAF)
(ICFF)
(ICCV)
(ICZZ)
(KCDF)
(ICSH)
Water Use
(gal/1000 lb)
16
4.5
2
28
80
20
10
30
20
10
--
3
_5
2Z3.S
Wastewater
Ice Cream
(gal/1000 U)
16
4.5
2
28
80
20
10
30
20
10
—
3
_5
228.5
BOD5
Processed
(lb/1000 lb)
.15
.15
.025
.25
.75
0.15
0 02
0.35
0.35
0.04
0.04
0.04
-------
40 Acf-.il Coefficients for Ice Cream Processing 1n the Kroger, Indianapolis Plant.
?'ccess
Receiving
Srorace of Milk
Stndiral^lng
Slendlng
HTST
Pasteurized Storage
Flavoring, Fruit
and Njts
Freezing
Filling
Conveying
Hardening
Storage
Distribution
TOTALS
Coce
(P,W)
(RMST)
(R.MSP)
UCSL)
UCHT]
(ICSPJ
UCIN)
(ICAFJ
(ICFF)
(1CCVJ
(ICZZJ
(ICSF}
(ICSH)
Product
Milk
H1lk
Ktlk
1C Mix
1C Mix
1C Mix
1C Mix
1C
1C
1C
1C
1C
1C
Water Use
(gal/lOOOlb)
16
4.5
4.5
75
2£5
40
26
180
132
S3
—
3
5
634
Wastcwater
(gal/1030 Ib)
16
4.5
4.5
75
265
40
26
180
132
53
~
3
5
804
BODj
lib/ 1000 Ib)
0.19
0.27
0.075
0.25
2.2
i.O
1.0
1.25
1.9
«
0.1
0.1
0.1
8.44
Product Loss
(lb/1003 ID}
1.95
2.75
0.75
1.0
10.0
4.0
3.0
5.0
7.5
4.0
0.4
0.4
0.4
41 2
303 H factor • 2.S4
*-.., ._ _,iinnc nr rwiunds/lGOO pounos of product produced.
-------
Table 41. Design Coefficients for Stick Novelty Processing in the Kroger Indianapolis
Dairy
Process
Blending
o Pasteurization
M
Mix Storage
Freezing
Packaging
Store :rozen
CODE
IPOPBL
CPOPHT
IPOPST
lOPOVr
IPOPBG
IPOPSF
r«ater Use
(gal)
0.07
80
5
800
3
2
l.asteuater
(gai)
Units per 1000 Pounds
-
80
5
800
3
2
BOO
(ID)
of Product
1.0
1.3
2
i
2
.5
-------
Table 42. Actual Coefficient for Stick Novelty Processing at the
Kroger Indianapolis Dairy*
PROCESS
Blending
'-> Pastc-urizina
o
luJ
Storage
Fuzing
Packaging
Frozen Storage
CODE
IPOPBL
IPOPHT
IJPOST
IPOPVF
IOPOBG
IPOPSF
Water Use (Gal)
0.07
240
30
2400
30
5
Waste Water (Gal)
—
240
30
2400
30
5
BOD5(lb)
1.6
1.3
2.0
10
10
1
Per 100 Ib of product.
-------
Yhe costs associated with losses under design ;;nd actual
conditions are pri-sentcd in Tables 43 to 50.
The major cost associated with losses was product loss,
tollof..od Ijy the sewur bill, labor, packaging losses and energy.
Knt-rv-jy wns a minor overall cost, even though analysis reveals
th-jt overt-.il about Silt of all product losses followed the
pasteurization and cooling of the product. In the ice cream
Jepartment, 75i of ttie product lost followed pasteurization
cooling, storage cind freezing.
Labor, which was more intensive for the ice cream and
novelty operations was a greater percentage than for other areas
in the i».!ijnt.
A -jeneral rule of thumb was that the total plant loss was about
2 tints the product loss anC about 5 times the sewer bill. The
lutter would vfiry markedly from community to community depend inrj
on sewer charges. The surchurges in the Indianapolis market were
lower tnan in most major cities.
on observations made durinj this investigation, and
earlier reco.nnicndot ions in tho literature of process and
ocjUi |>:n--_nt i.i of', i f icationL. th.it coiil'1 reduco wastes, all
i,o^..ih 1 1 it IL-L, wure listed for subsequent evaluation. Those
204
-------
Table 43. Waste Associated Costs of Fluid Milk Operations Under
Design Conditions
OPERATION
RM Loss
Product Loss
Pkg Loss
BOD Loss
Sus Solids
Buy Water
San Sewer
Energy
Labor
TOTAL
QUANTITY*
1,800
14,400
14,400
1,880
676
135,000
128,250
14,400
14,400
**
COST
$ .112
.112
.004
.026
.045
.00042
.00045
.0015
.0032
COST/ DAY
$201.60
1612.80
57.60
48.88
30.42
56.70
57.71
21.60
46.03
2133.39
PERCENT OF COST
9.4
75.6
2.7
2.3
1.4
2.7
2.7
1.0
2.2
Total Yearly Cost = $554,680
Cost/It Product SI.7094017E - 11
Coefficient for BOD (Ibs BOD/100 Ibs BOD processed) = 2.0
Coefficient for Suspended Solids (lbs/100 Ibs BOD Processed) = .75
Coefficient for Water Use (Gallons/100 Ibs BOD processed) = 150
*
Pounds 01 gallons per day.
Dollars per gallon or pound.
205
-------
Table 44. haste Associated Costs of Fluid Milk Operations Under Actual
Conditions (Incudes Buttermilk and Sour Cream).
OPERATIONS
Rm Loss
Product Loss
Pkg Loss
BOD Loss
Sus Solid
Buy Water
San Sewer
Energy
Labor
TOTAL
QUANTITY*
1,800
28,200
28,200
3,525
1,410
432,688
411,054
28,200
28,200
**
COST
$.112
.112
.004
.026
.045
.00042
.00045
.0015
.0032
COST/DAY
S 201.60
3153.40
112.80
91.65
63.45
181.73
184.97
42.30
90.24
4127.14
PERCENT OF COST
4.9
76.5
2.7
2.2
1.5
4.4
4.5
1.0
2.2
Total Yearly Cost = $1,073,056
Cost/Lb Product S1.7E-11
Coefficient for BOD (Lbs BOD/100 Ibs BOD Processed) = 3.9
Coefficient for Suspended Solids (lbs/100 Ibs BOD Processed) = 1.6
Coefficient for water use (Gallons/100 Ibs BOD Processed) = 480.8
*
Pounds or gallons per day.
**
Dollars per pound or gallon.
20C
-------
Table 45. Waste Associated Costs of Cottage Cheese Operations Under
Design Conditions
OPERATION
Rm Loss
Fm Loss
Os Loss
Product Loss
Pkg Loss
BOO Loss
Sus Solid
Buy Water
San Sewer
Energy
TOTAL
QUANTITY*
1.037
399
25
710
710
4,117
1,647
38,576
51,176
710
**
COST
S .112
.08
.16
.44
.003
.026
.045
.00042
.00045
.00262
COST/DAY
$116.14
31.92
4.16
312.40
2.13
107.04
74.12
16.20
23.03
1.85
-j89.00
PERCENT OF COST
16.9
4.6
0.6
45.3
0.3
15.5
10.3
2.4
3.3
0.3
Total Yearly Cost = $179,140.00.
Cost/lb Product S7.7E- 11
Coefficient for 600 (Ibs BOO/100 Ibs BOD Processed) = 36.1
Coefficient for Suspended Solids (lbs/100 BOD Processed) = 14.4
Coefficient for Water Use (Gallons/100 Ibs BOD Processed) = 338.4
•*
Pounds or gallons per day.
Dollars per pound or gallon.
207
-------
Table 46. Waste Associated Costs of Cottage Cheese Design Under
Actual Conditions.
OPERATION
RM Loss
FM Loss
DS Loss
Product Loss
Pkg Loss
BOD Loss
Sus Solids
Buy Water
San Sewer
Energy
Labor
TOTAL
QUANTITY *
1,037
399
40
2,089
2,089
4/70
1,656
38,576
53,176
2,089
2,089
**
COST
3.112
.08
.16
.44
.003
.026
.045
.00042
.00045
.00262
.0332
CCST/DAY
$116.14
31.92
6.40
919.16
6.27
116.22
74.52
16.20
23.93
5.47
69.35
1385.58
PERCENT OF COST
8.4
2.3
0.5
66.3
0.4
8.4
5.4
1.2
1.7
0.4
5.0
Total Yearly Cost = $360,250.00
Cost/Lb Product S7.7E-11
Coefficient for BOD (Ibs BOD/100 Ibs BOD Processed = 39.2
Coefficient for Suspended Solids (lbs/100 IK BOD Processed) = 14.5
Coefficient for Water Use (Gallons/100 Ibs BOD Processed) = 338.4
*Pounds or gallons per day.
**Dollars per pound or gallon. 208
-------
Table 47. Waste Associated Costs of Ice Cream Operations Under
Design Conditions
OPERATION
RM Loss
Product Loss
Pkg Loss
BOD Loss
Sus Solid
Buy Water
San Sewer
Energy
Labor
TOTAL
QUANTITY *
601
1,952
1,952
795
211
83,680
78,545
1,952
1,952
~
COST**
$ .112
.195
.00495
.025
.045
.00042
.00045
.0049
.02
COST/ DAY
$67.31
380.64
9.66
20.67
9.50
35.14
35.34
9.56
39.04
606.86
•
PERCENT OF COST
11.1
62.7
1.6
3.4
1.6
5.8
5.8
1.6
6.4
Total Yearly Cost = $157,783.00
Cost/lb Product 2.0
Coefficient for BOD (Ibs BOD/100 Ibs BOD Processed) = 2.6
Coefficient for Suspended Solids (lbs/100 Ibs BOD Processed) •- .7
Coefficient for WUer Use (Gallons/100 Ibs BOD Processed) = 274.1
*Pounds or gallons per day.
**Dollors per pound or gallon
209
-------
Table 48. Waste Associated Costs of Ice Cream Operations Under
Actual Conditions
OPERATIONS
RM Loss
Product Loss
Pkg Loss
BOD Loss
Sus Solid
Buy Water
San Sewor
Energy
Labor
TOTAL
QUANTITY*
653
4,699
4,699
1,718
670
72,300
68,685
4,699
4,699
COST**
.112
.195
.00495
.026
.045
.00042
.003
.003
.06
COST/ DAY
$73.14
916.30
23.26
44.67
30.15
30.37
30.91
14.10
281 .94
1444.84
PERCENT OF COST
5.1
63.4
1.6
3.1
2.1
2.1
2.1
1.0
19.5
Total Yearly Cost = $375,658.00
Cost/lb Product 2.9
Coefficient for BOD (Ibs BOD/100 Ibs BOD Processed) = 5.6
Coefficient for Suspended Solids (lbs/100 Ibs BOD Processed) = 2.1
Coefficient for Water Use (Gallons/100 Ibs BOD Processed) = 236.8
Pounds or gallons per day.
Ooliars per pound or gallon.
210
-------
Table 49. Waste Associated Losses for Noveltv Operations Under
Design Conditions
OPERATION
Product LOSS
Pkg Loss
BOD Loss
Sus Solid
Buy Water
San Sewer
Energy
Labor
TOTAL
QUANTITY
2,260
2,260
452
122
54,600
51 ,308
2, 260
2,260
**
COST
$.45
.042
.026
.045
.00042
.00045
.02
.06
COST/ DAY
$1017.00
94.92
11.75
5.49
22.93
23.09
*r>.?Q
135.60
1355.38
PERCENT OF COST
75.0
7.0
0.9
0.4
1.7
1.7
3.3
10.0
Total Yearly Cost = 5352,555.00
Cost/lb Product 1.3 - 9
Coefficient for BOD (Ibs BOD/100 Ibs BOD Processed) = 2.0
Coefficient for suspended Solids (lbs/100 Ibs BOD Processed) = 0.53
Coefficient for Water Use (Gallons/100 Ibs BOD Processed) = 227.7
*Pounds or gallons per day
Dollars per pound or gallon.
211
-------
Table 50. Waste Associated Costs for Novelty Operation Under
Actual Conditions
OPERATION
Product Loss
Pkg Loss
BOD Loss
Sus Solid
Buy Water
San Sewer
Energy
Labor
TOTAL
QUANTITY*
5,235
4,235
1,920
762
189,170
1 80 ,000
4,235
5,235
**
COST
$ .4637
.042
.026
.045
.00042
.00045
.02
.06
COST/ DAY
S 2427.47
177.87
49.92
34.29
79.45
31.00
84.70
314.10
3243.80
PERCENT OF COST
74.7
5.5
1.5
1.1
2.4
2.5
2.6
9.7
Total Yearly Cost = 5844,658.00
Cost/lb Product 2.7 - 10
Coefficient for BOD (Ibs GOD/100 Ibs BOD Processed) = 8.5
Coefficient for Suspended Solids (lbs/100 Ibs BOD processed) = 3.1
Coefficient for Water Use (Gallons/100 Ibs BOD Processed) = 796.9
»
Pounds or gallons per day.
**Dollars per pound or g-jllon.
212
-------
moaificntions that were considered arc discussed briefly in tl.c
follov»iri.j by product areas.
PI i 1 k:
1. Kaw milk receiving recovery system by using 2-20
yallonb burbc unbos and transfer r inm.
4. CIl' 3G[!arator controls to control pressure
oj-orotion jnd prL-veiit sir incor[-oration into product.
5. Ne'RoclL-liny ot tn- crcom p,ist«urizor to prevent
tiir incorporation c.nfJ Ireu-zu on.
6. saving clean water Iro.n IITi:T vnc-hoat systems.
7. i,jt automatic conrrols, of water uupply f'^r CJP
irntorL,.
;'. |...p.iir or rc| loc" HTST ^3 that continual ly leaks.
213
-------
(J. Kobuilf! l>e:ny filler.
10. Install drifj shield.
11. luvesti'jatc onimsl feed for filler drips.
IP.. Installation of high pressure ho so stations
13. Clarificr sludge recovery.
1-1. Collection tank for product-water residues.
Ib. lluid milk fillurs drip shields.
lr>. C1I1 initial rinse rocovery.
17. Ku model in j of
-------
21. CIF rou-.; of final rinses.
Irozen Cusserts:
1. Lirifj collectors in ice cream packaging machine.
2. A rinse recovery system for matori.nl loft in
vats, lines ami ice cruoin iroeztrs.
3. Collection for use as animal feed of frozen
L p.u-teridls than con not be re-iun, such as stick novelties
_'t. (inquires troxen stordje in drums).
r>. I.obuiliJin'3 of Vita-Creezo machines.
b. Automutic controls on v.oter feed lines for Vita-
'i. Ju i 1 ti i rrj of flt-vor vrti> to permit more complete
rtinovol be fort cl i.-onirnj .
7. C111 rc-usr; of r in30u .
CottcTje C'li^r.-^o:
J. I/.1,-! id-v-nvni of '.ui.il 1 clii.'f.c v^t;; to reduce fin^s
215
-------
loss.
tanks .
2. Linn mat ion of final wash of cottaje cheese.
3. uejijir of damaged linos at skimmilk storage
/I. ITOCVSS revision to reduce fines.
5. lines recovery by screen inj.
f,. lines rf.-covery by ccntr Uu-jotion.
7. v.hey ut 1 1 i
a . anii.iol tccd
b. hydrolysis .ind fenacnt-Jt ion for bakers
ye i'i i. L (3 r or 1 uc 1 1 o n
c. i,!iip!!u;nt to flnotlicr j.rocomiing pl.int for
u. ul fdf il trcition on-Vor
rovi;rso o!3i»osij
c. ino'Jif ic«:tion ol [.rc.cer.s procedures '.o
,.:n.iit in-i-l.inl ut 1 1 i 2-1 tion
f. -Iryinj
210
-------
LLJLL'CTIOW OF ALTtltMA'J I VCb:
All alternatives »ere studied in detail to determine
their feasibility. Th_- LP program was utilized to evaluate each
possibility. Table 51 presents the results of projected
co&i-boncf it in inc icat ing the time required for pay back. An
urbitrary decisic-i wio. The cost of this procedure is less
than C. Id, CO" iinrj the recovery ii, ubout fj(H. I-ollo^/irvj further
L-Vul unt Jon, Liu:, ti.chiiiL.uo will be considered lor use in the
liidirJii.irulio doiry plo.nt. The pn.-iteur i zud lines recovery system
v.oulu 'jL.Ticr.iLc- i.iorii iiJluLc rinr.;t? than could be utilized in ice
cn.ei!.i production. Lic'couse of current l-.oaU.li Department
ru jul i;t 10:1.., in-^Ldl let ion of tliiL, system *'ill linve to w,i i t for
i"jrilL;i U'.>p'jr tin --nt u[
217
-------
Table 51. Projected Savings fro,.' Process and/'or Equipment Modifications
Reduction/Day
Description Waste Water 301)
of Change (gal.) (!b.)
$
Product
Valer Reduction
Vita-Freeze (C) 70.000
HTST Hot Water 24,000
Separator Controls (C) 20.160
Case Washer 47.400
Sub-Total 161,560
BOO Reduction
Raw Milk Hec. A
Raw Milk Rec. B
HTST Replacement (C)
Air Blow Revisions
Cream Pasteurizer
Past Line Rin'.e Rec.
Reny Filler Rec.
Vita- Freeze (C)
lea Cream CIP
CC Wash Revision (C)
Fines Rec.
Curd Saving
Replace CC Skim &
Cream Lines
Sub-Total
1.200
1,200
-
-
30
-
100
70,000
2,000
12,000
-
-
_
85.330
320
320
80
43
58
100
164
540
400
32
80
14
17
1843
130,816
130.816
23.296
12.521
17,500
29,120
47.756
260.000
156,000
33,130
50.000
9.000
3.449
724.458
Savings/Year
Sewer
Charges* Other*"*
15.834
5.211
4.500
10.721
36,266
5.637
5.637
936
503
585
1,170
1,918
22.152
5,132
4.084
936
163
198
42,912
-
-
-
383
107
117
234
383
5.538
1.539
800
200
_
9.362
Cost***
5,000
3,500
1,800
6.000
16.300
5,500
30,000
55,000
-
5.000
20,000
5,000
75,000
20, COO
-
50,000
_
5,000
265,000
Total
246.890
1818 724,458 79,182 9,362 281,300
Total Savins Projected*** $813,000
Total Cost Projected*** $281,300
*Sewer = cost of water discharges to s«w«>r and hydraulic sewer charge + BOD + SS
surcharges.
**0ther - caculable labor + energy costs of lost product.
***Total cost based on most expensive approach nhere two alternatives exist.
****(C) • change comoleted bj December 31. 1978.
218
-------
v.Jic-y A1 terr.Jtivcs: 1v;o of the :1 tern." tives \y-ire
c. L-t a i I (id stuoy: (s) lactose hydrolysis and fermentation for the
prouuction of baker's yoast and (b) process modification to
1-en.ut. direct incor pc rat ion of fluid whey into n'oducts in the
j.lant.
•i.le use of whey as a substitute for baker's yeast
production v,is evaluate-; at the Kro.>T research laboratories on .?
laboratory b^sis ai>d found to indicate that the process \.oulc be
ecor.0lnicall> feasible. A pilot plant has beer, constructed, where
intensive itu-jy is ir. ;,ro-jress to evaluate tl-e teclmoJo-j ic^l ?nrt
economic tea-iuil ities of the {.rocsss. ihs results of these
studies will not be co.n^etec for one year.
'.',4 use ui --hay for in-plcint uso ..-is i nvesn jntc-d for
oil :-roi:ucts> t.'i^t used ȣter as a part of tne process. Vhos-3
induces (i) taC.ey slurries, (b) butter-nmiU. sli:rric-s, (c)
s.iir.-ct, (<,) ice J-OI-G ar/J (f) fruit flavored drinks. Ice cresin,
3..cruet, ice i-oi-s ar.d fruit flavored drir.ks »ere made in *hic!.
^cia v...-j> *r.j, usec e.s a Circct substitute for ~r.ti.-r. The- results
ol or j oriolei-tic m/ul uct-ions : re 3lio«'n in ".a^le 52.
..-,-: r^ojl cs siiO»-ia that ice cr-.>: T end sv,2rbot coul'i b-3
.....L t-!:---t .ore ^..o^liv uCCtfi,*.c-bla to -r. u:.t.rfinc:' cor.£.i.ner -panel.
219
-------
Table 52. Consumer Acceptance of the Use of Fluid Acid Whey as a
Substitute for Water in Selected Dairy Products.
PRODUCT
Sherbe*
Ice Pop (orange)
Ice Pop (orange)
Fruit Flavored
Drink (orange)
WHEY APPLICATION
ORf,ANOLEPTIC RESULTS
Ice Cream
Ice Cream
Ice Cream
Replacement of water
solids in 20" slurry
Replacement of water
in buttermilk slurry
Replacement of water in
Statistically significantly pre-
ference for whey slurry in water
No significant difference from
control
Statistically significant differ!
both whey and buttermilk,
in slurry
Replacement of water
Replacement of water
Replacement of 25% of
water
Replacement of 25* of
water
but no significant difference in
preference
No signficant difference in pre-
ference, but statistically signi-
ficantly different
Inferior product, salty
Slight preference for whey product
Inferior product
220
-------
Ice pops could substitute 25% acid whey for water without loss
of consumer acceptance.
About flfOGC gallons (50% to 70".) of the whey discharged
to the drain could be used in the plant without serious effect on
Duality. Ho -ever, legal restrictions on the use of acid whey in
trozen cesserts imposed by standards of identity by the rood and
LTuy Administration *oi:ld have to bo cnan.jtd before this approach
could be utilized.
Any decision about tiie final utilization of vvhey was
deferreu until the results of the pilot plant study of yeast
production could oe fully assessed and in the Meantime whey would
continue to be discharged to the municipal treatment plant. In
tuis instance, the whey locd mnr'.e up less than 0.38% of the ECH
load of the treatment plant and would have no effect on
operational efficiency.
EVALUATION OF HLSAILTF OF rRCCCEE AMP
The periotj of time for evaluation after completion of
nc clioii-jfes v.0!, v,uite short, so that the data presented for a
rf^ek period ere less comprehensive than earlier data.
A IJ.TSC! in.- stuoy «/as marie rluring Decemlvir before chnn-ie-s
-------
were uuice. Ky the end o£ January, a number of changes had been
completed, including: (a) Vita-freeze rebuilding, (b)
installation of separator controls, (c) saving of HTST hot water,
(a) replacement o£ HTGT S3, (d) raw milk recovery system A, and
(e) partial improvement of air blow systems.
Analyses made at the end of January indicated the
results sho.n in Table b3. Overall, the predicted effect would
hove been a water reduction of Ifil.COO gallons and a bOO
reduction of 1,8<0 pounds £or all changes. The actu.il redaction
wa* 37, COO gcllons of v/ater and 720 pounds of POT. By the middle
of K-bruary oil changes were complete except the cream
pasteurizer and the case *,asher. The total redu.-tion in water
use was lie,COO gallons anc the total reduction of bCD load w.is
1550 [jouncs. The case washer revision should achieve an
additional r,()| ooo gallons reduction in the wastewater.
Based on these results, the projections made by the
LP computer program would appear to be reliable.
based on the unit operations that were to be used in the
iit:w Kro-jer dairy in Chio, the LP model was used to predict the
wastewater loads for this plant prior to construction. The
1-ruOictior, wos, 200,000 gallons of wastewiter and 7,000 pounds of
L.^o per cay. Actual values, bosad on municipal analyses,
;p.uic3led 720, COO yallons and '.,700 pounds of iiOl) wore bein-j
oibliar.ji.d ' months attcr tl.c plant w.is opened.
222
-------
Table 53. Effect of Process and Equipment Changes on
WasLe Leads.
July - Sept, 1977
December 1978 Base
Water
Gallons
450
320
BOD*
Ibs
6.8
5.0
After Changes in
January 233 4.5
After Changes in
February 200 3.9
*Per 100 Ib of BOD processed.
223
-------
APPENDIX A. GLOSSARY
bacteria; Primitive plants, 'jenerally tree of pigment, which
reproduce by dividing in one, two or three planes. They occur as
sin.jle cells, chains, fil^nents, well-oriented groups o£
amorpuous iiicisses. Most bacteria do not require light, but a
limited number are pho tosynthct ic and draw upon light for energy.
Most bacteria are heterotrophic (utilize organic matter for
energy and £or food growth materials), but few are autotrophic
and derive their bodily needs from inorganic materials.
tAT: Best available treatment. Level of treatment established
by LFA .
BCT: best conventional treatment. Level of treatment which is
to be obtained for conventional pollutants.
(moclic-miiiical Oxygen Dcnund) ; An indirect measure of the
concentration of biologically degradable material present in
organic wastes,. It is tho amount of free oxygen utilized by
j-jrobic or-jdruwiis, wlicn allowed to attach the organic matter in
an aerobic-ally maintained er.v i ronment at sp'.'cificrl tcmpornture
224
-------
(20 C) tor a specific time period (5 days). It is expressed in
inilliirams of oxyjen utilized per liter of liquid waste volume
(iiuj/1) or in milligrams of oxygon per kilogram of solids present
(my/kg = ppm = parts per million).
L50U5: Hve day biochemical oxyjen demand. The most common time
period for the measurement of a BCD.
BQOu; The ultimate biochemical oxygon demand. The highest value
for the amount of oxygen needed to oxidize an organic waste.
biological oxidation; The process whereby, through the activity
ot living organisms in an aerobic environment, organic matter is
convertec to more biologically stable (less outrifiable) matter.
biological Treatment; Organic waste treatment in which
bacterial and/or biochemical action is intensified under
controlled conditions.
buttermilk blurry; A nigh solids, mixturcd of churned buttermilk
powder in water or ski mini Ik. to be jsed as a source of milk solids
in ice cre&m manufacture.
C/iJ, Curbon-Nitr.-iLo Katio; The weight ratio of carbon to
n 11 r og c n .
225
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Chemicul Oxidation: Oxidation of organic substances without
benefit of living orysnisms. Examples are by thermal combustion
or by oxidizing aqents such PS ct.lorine.
Chlorine Contact: ." detention basin where chlorine is diffused
through the treated effluent which is held a required time to
provide the necessary disinfection.
Churntici Buttermilk; by-product resulting from the churning of
cream into butter. It is largely defatted cream and its typical
composition is 91% water, 4.5* lactose, 1.41 nitrogenous matter,
0.7% ash and 0.',* fat. Churned or "true" buttermilk is
distinjuished from cultured buttermilk, which is a fermentation
product of skim milk. The latter is sold in the retail market
and referrud to simply as "buttermilk."
Cit>; A term used to describe cleaned- in-pl nee. The system for
circulation cleaning of food plant equipment including the spray
cleaning of tank trucks and p-roccssinq tanks rjnd
CIP-L.Gp«jr£toi : A centrifu'j.i: nachine that separates, standr.rizes
clnrifies milk. If. .lutomrtical 1 y deslodges un ci preset
226
-------
program, generally one second every 45 minutes. The machine can
be cleaned in plc-ce without being dissnse>nbled.
CPU (Chemical Oxygen Demand); An indirect moasurs of the
biochemical load exerted on tl.e oxygen assets of a body of water
when organic wastes are introduced into the water. It is
determined by the amount of potassium dichromate consumed in a
boiling mixture of chromic and sulfuric acids. Trie amount of
oxidizable organic matter is proportional to the potassium
dichromate consumed. Wiere the wastes contain only readily
available or-janic bacterial food and no toxic matter, the COD
values can be correlated with UOU values obtained from the sar.it:
wa s t e s .
Condensed: The term "condensed" as used in this report, applies
to any liquid product which has been concentrated through removal
of some of the water it nornidlly contains, resulting in a product
wnicli ib s'.ill in the liquid or semi-liquid rtatc. v.hen applied
to ,nilK, the term "condensed" is used interchanged! y with
"evaporjte" to designate ,nilk which has been concentrated.
Co.ni.ujrcially, however, the term V-vaporaced milk" is commonly
ui.uu to define unsweetened concentrated milk.
Consumptive ubc: Portion of Uio jrobs water applied that is
ccnsumod cr depleted - i.e., evaporated into the atmosphere or
incorporated into Lh'j product itself.
227
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Contamination; A general tern signifying the introduction into
water of microor'jer.isins, chemical, or-janic or inorganic wastes,
or sewage, which renders the water unfit for its intended use.
Cost; That which must be given in order to acquire, produce or
ef fact something .
Cultured Products: I'ermentation-type dairy products manufactured
by inoculating different forms of milk with a bacterial culture.
THis designation includes yoghurt, cultured buttermilk, sour
cream, and cultured crcan cheese, among other products.
Cream; The product resulting from the separation of whole milk
into skiinmilk and the high fat product cream. It contains about
«n fat jnd has a I.or) oC C.32 pounds per pound and a CCD of about
0.55 per pound.
resign haste Load; l»at wuste load that is unavoidable and
ruldtes to the design of the plant and equipment. This includes
Matt-rial leCt on equipment surfaces, in pipe lines and
delioc-ratcly wjstc-d, such as in the start-up of an HTST unit.
L i solved oxygen; The oxygen dissolvad in sewage, wnter, or
jLU«r liquid usually uxpresaed ao in ill ii rams per liter or as
228
-------
percent of saturation.
Efficiency ; In cng ineer in-j analyses, it is most commonly applied
as a measure of the input which results in output of useful work.
L'fficiency in percent is obtained by dividing the output by the
in^ut and multiplying by 100. (input = Output + loss).
That which flows out from a space. The waste
u ischarijc(&) froi.i the
Lnaogenous; An auto oxidation of cellular material that takes
place in the absence o£ assimilable organic material to furnish
energy required tor the replacement of worn-out components of
protoplcism .
LPA: Tlie Lnv i romnuntal Protection Agency. The Feric: al agency is
somctines referred to as such, but individual states may have an
LPA. It is preferable to UGO U.S. Knvi ronmental Protection
(U'J EPA) when referring to the lederal agency.
1 1 r.y or Kxterricil (u i r.) economy: An economic influence of
one activity or .mothor activity, with no cust to the activity
causing the ex ternc-l i ty . Pollution is nn external diseconomy
-•lion some-one not connected to the pollution causing activity must
Gutter pori.o;i.T 1 or economic loss ns a result of the pollution, or
inir.i |j.-iy the cost o£ •_• 1 im i nat i ng it wi th no recourse to those
229
-------
causing it.
L-'at; As used in this study, Cat will be used synonymously with
butterfat, a part o£ fats, oil and grease (FOG).
b ilti at ion: Tlie process of passing a liquid through a porous
medium for the removal of suspended or colloic'al material
contained in the influent liquid by a physical straining action.
Huvor Tanks: Small processing vats of 50 to 2CC gallons for
i:.-iki rrj-up different flavors of ice cream, sherbet and novelties.
KjC: Kats, Oils arid Grciscs. See hex an*: solubles.
I ood to Microorganism Hatio; An aeration tank loading parameter.
lood may be expressed in pounds of COD or BOD
orjjud pur dciy to tiio u':ration tank, nnd m icroorijanisms may be
i-xprr-suiid cis mixed liquor suspended solius (MI.5J1;) or mixed liquor
volatile su:>[)crrJud bolids (MVI'.S) in Llie aeration Lank.
23C
-------
Cross Viater Allied: Total quantity of water necessary to
process a unit of raw Material or to process a unit of output.
luixane Solubles: The uoncentrcit ion of IOC recoverd from a sample
of wostewater usiny the hexane distillation procedure.
l.TST ; High temperature short time pasteurization. A plate heat
exchcinjcr for the pasteurization of fluid dairy products. For
milk all particles of milk are heated to a minimum of !GJ°r for a
.ninimum of J5 seconds.
llydraulic Loading: The flow (volume per unit time) applied to
the surface area of the clarification of biological reactor units
or tlie uastev-ater flow from a process plant.
JT'<: industrial Coot Uecovery. System of c ha ryes levied to
recover from an industrial usor of the V.VISLC water trc.iLr.ent
facilities the Ledural yr.int a'mounL, issued under Public Law
'J2-500, us ainunflc-J . allocablc to the conrtr uc t ^on of facilities
Lor Lrceilmcrit or v>o:.tuc Lro.n the industrial user. These charges
ore soparutu from .-is..-d product .-.old ns frozen fooci. lood re'julnLory .Tjcncies
231
-------
ic-o cream in terms of composition, to distinguish the
f.roduet from otlier frozen dessert-type products contnining less
inilk-lcit or none at all, such <*r, shorbt-rt, water ices and
Kiul lor ii>£ .
Inl i Itration u.ite; Tha rate at which water can enter the soil.
Units are usually inches of water per day.
ln£ lient : '/.astawa ter or other liquid - rav,, or partially treated
- i lowing into a r«.5urvoir, bosin, trcatnent process or treatment
f-ulk il^uivcilont; Quantity o£ milk (in pounds) to produce one
pound o£ proJuct. lue milk equiVdlents used wher^ those ^iven by
tuo U.S. LV-par tment ot Aj r icul turo , Etatisticcl Lullttin Wo. 3ri?
"Conversion kactorb and Xeiyhts and Measures for Agricultural
it ics rind tl.eir Products."
f-'.unicitifll i3Jll; Locol bill which represents the cost of water
the cost ot V.OSLOWU ter treatment if the user discharges into
i^u'jJic ownc.-cJ treatment works. Vic cost of i^ste^otcr
troat.nciit ifd) be ba^ed on the mtterud woK.c'r suppl :crj *-o the user
.jfnJ may contain a sur c:h,.ir'jc foi c-xcessive 6inounti> of ? pollutant.
Ml'.;i..'ij i.cJt I'-inrfl Pollution l)i scluifji: i: J iminat I on System.
232
-------
.M-cjulctC'S the cisrl.aroe of wc-.i,t<.-v>aturi, to the- ncvigcbU* v.atcrs of
U.e United Utati-s pursuant to l.&ctlon 4C2 of Public L.'JW Ori-217,
The Clear, .\ci^er Act of 1977.
Qt.tinizat.ion; Process of sclectin-j the ;nix of «ic-t ivi ties , and
the levels of th'jse activities, winch ere o.'.ti.Tiuin under the
Jcsired conditions - in this stud> , tJi£t nix which 3
rr.turol cu^lity of the- body o ;' v.3ter (or so.l or .-?ir) is riogra^er:
so it iiK-irs ti.o --atu-r's usefulness or renders it offensive to
the senses of sij.'it, t:.ste, or s,:-ell. Contain i nat ion in?> -Tccompany
;.ollLtion. In ijtr.erel, a -tublic health l-3^.=.rd is trrr-.tec, but i<-
some ca^es or.l-, :;cono.T, of estnetics arp in/olver:f =.J when ^rtSte
s--lt urines contaninatf surface waters or v.'i2n fo-jl odors -rolli.te
t : : » C.IT .
r-o^ulaLior mbivclert: T;i= cjlcul -tt-J ^.un?.n poi.ulot.ion -.:iic!
233
-------
•..ould nornicil 1 v contribute1 the s.ime ^moLirit of bcr pc"- nay. A
coniMon bosy is, 0.2 Ib (fjr:.7 / ot 5-f!«y !iCD per capita per day.
/ diiry procii^-iny ?GO II) (CM). 7 H.j) of !-CD per day will have a
l-onilatio:i equivalent (PP.) of l,COf).
.-.aste; h/istc which can bo avoided by proper
Gc-nerally refers to leaks, spills, spoiled [-roducts
ciiHj from imj.ropcr ly oporc-tcd ecui prnent .
l-'rocess; A continuous anil regular actior, or success ior. of
iicLions, takinj jlc.cc or carried on in a definite manner.
iJroctfSi» LJ'fluL'nt (C iscluryc) : In e volu.nc of wostev^ater emerging
fro.n « j-articuljr us^ in the |.lant.
Putrof cct ion: A process of dcconposi Lion in which, as a
consequence of t!ie breakdown of organics , er.d-produc ts with
oifensive o^ors ore fo
!-:£ •.; I- 1 1 k ; -iilk u.-; rteaivc-d fro-n the fern or o£ standardized
t io;-i that has :,ot b-.-un i-nsteur i ?GU or se^a rated.
I.oac': Nuinoricel value of sny wjstc- [.aramster that
.->£.•<> . .TS
'jt fines tl.<-' cf.ot cc ti_r i stiCLi of & ,-.lr.nt effluent as it leaves the
,-ij.r.r. oc-iori it is treotL'o in En^ v«ay.
234
-------
Kiicyclc: Use of water over and ever again for the identical
nppl ication whence it came.
Sanitary Sewer L.ystc.n: A sewer intended to carry wastewater from
rioines, businesses jnd industries. £torm water runoff sometimes
is collected and transported in a separate system of pipes.
Settlecblc bolicJs: Those suspended solids contained in sewage or
wastewa ter that will separate by settling when the carrier liouid
is held in quiescent condition for o specified tine interval.
Luwjge : '.'.ater after it hcis been fouled by various uses. From
the sc^nii point of sourct.-, it may be a combination of the liquid
or watar-ccirriud wastes from residences, business buildings, and
institutions, tojethtr with those from industrial cn<1
ojricultural establishments, and with such around water, surface
v..jcer, find ston.i »-av.er as may be present.
Lystcin; Th« tern "sewerage system" means any system,
wh?tl.or coir.muni t y , individual, publicly or privrf.cly owned, for
the collt'.'tion and disposal of sewage or industrial wastes of a
ln-uic; luilurc, or both including various devices for the
treatment of sucn sewage or industrial wvistes.
'.cwcr Jsc- Oi c: iPfcncc : / lojislative on^ct-a2nt of a municipality
235
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Skim Milk; In common usage, skiin milk (also designated non-fat,
defatted, or "fat-free" milk) from which Fat has been separated
as completely as commercially practicable. The maximum fat
content is normally established by law and is typically fi.1% in
the United Ltates. There is also a common but not universal
requirement that non-fat milk contain a minimum quantity of milk
solids other than fat, typically 3.25%. In many states the
mining of the tc-r.n skim n , ] k is broadened to include milk that
contains less fat than the legal minimum for whole milk, such as
the low-fat sold in tha retail market. The turm skim milk used
in this study refers to non-fat milk.
bludge; The accumulated settled solids deposited from sewage or
other wastes, raw or treated, in tanks or basins, and containing
more or less water to form a semi-liquid mess.
l£: Suspended solids. Particles of solid matte,- in suspension
in the effluent which con normally be removed by settling or
f il tra 1 10:1 .
Ltcindc.rd Manufacturing Process (SPP) : An operation or e series
of o[er«itions which is essential to 3 process anri/or which
produce a waste load that is substantial 1 y different from that of
an olt.erri.3tc' -nethod of performing the sane process. The concept
v.i=, dc-vtlopud in orcitr to have o flexible "building block" means
236
-------
for chdract&riziny the waste from any plsnt within an industry.
Standard Haw haste Load (SUM.); That waste load thar is
unavoidable and associated with the design of the process (See
Design kaste Load). Generally refers to a unit operation.
Storm sewer Syatein; A sewer intended to carry storu water runoff
other waters to the nearest surface waters.
SurcUrcjo; A chsr.jc levied by a municipality for wastewaters of
strengths greater than those defined as normal.
:'>'&tcl": A -3r°uy. sot or aggregate of processing forming a
connected or complex whole.
Total Product; Quantity of total production of all product
produced ana pickogud for distribution.
•lotfil solids; The residue remaining when the water is evaporated
uwc,y from a win pie of water, sewage, other liquids, or semi-solid
ot material and the residue is then dried at a specified
(usually 1C3°C).
'l'>'>-- Total Suspended L,oi:c!s.
1ot..l •.-.atcr Utilization COSLS; All costs of obtaining, handling
227
-------
and disposing of water from intake to outlet.
Unavoidable Waste;That waste which cannot be prevented,
User Charge; System of charger levied on users for the cost of
Gyration drici maintenance including replacement reserve
requirements on new and old wastewater collection and treatment
£ac il it ies .
Vila-Line or Vita-Freeze: A machine for the freezing of stick
novelties. Vtie novelty mix is metered into a series of metal
molds (usually 1E-24 molds wide) that pnss through a calcium
chloride brine tank for freezing. A stick is inserted into the
parLidlly frozen product and then hot water is spi eyed on the
bottom ot the mold to release the novelty. Tie melds arc then
rinsed ar/J washed for re-use.
Potentially polluting material which is discharged or
disposed of from a plant directly to the environment or to a
treatment facility which eliminates its undesirable polluting
'-•f fuct.
Coefficients; Used to express 3 jiven waste parameter in
terms of units of product processed or product manufactured. In
thi*; report, cocff icicntsaro -joncrally reported in terms of ICO
238
-------
pounds ol bfiO or COD processed. The coefficients also yi"e s
direct value for I loss.
'.\astt Discharged; The amount (usually expressed as weight) of
some residual substance, if any, which is suspended or dissolved
in the pir-.nt effluent after treatment.
ste Load: Nui.isncal value of any waste parameter (such as
bCDb, tOG, etc.) that serves to define the characteristics of a
plant effluent.
hdstewater; Xaste-conta in i ng water discharged from a plant.
Used synonymously with "effluent" in this study,
hater Utilisation (uscl ; The totality of water and steam flows -
including intak-j water and wastewater treatment - for all water
ub-is within j production unit, from one or more points of intake
throu-jti one or more points ol dischar-je of the final effluent.
khejt: ay-product in the manufacture of cheese which rwmains
jfLtr scparatinn the chocsc curd from the rest of the m;lk used
in Die process, v.nc-y resulting from the manufacture of natural
cheese is ttrncd "aw-jet whoy" t-nd its composition is somewhat
different than "acid whey" rtsultiny fron the manufacture of
cl.^esu .
239
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,liey slurry A high solids (generally about 701 of sweet whey
t.o«ler in water or bkim.ilk) for use as a milk solids source in
ice cream manufacture.
Ml0le Hill.: m its broad sense, the term whole milk refers to
ailk of composition such as produced by the cow. This
composition depends on many factors and is seasonal tith tat
content typically ranging between 3.5* and 4.in. Ihe term whole
uilk is also used to designate market rnilk whose fat content has
be.,, standardized to conform to a regulatory definition,
typically 3.5o.
2-10
-------
APPENDIX B. KhCCRD FOIU-1L; FOK '.\ATIiR AND MOTE CONTROL
KECUUD t'OUM
USE
PAGC
1. haste ivcnaij (.-merit Control
form
Plant survey
for problem
areas
2. Maintenance
He 1^0 r t i nrj
maintenance
problems
3. Product. Loss Ko^ort
All overflows,
spills, 'nijor
leaks, etc.
t. Daily I ny red lent Loss
IM.' [JO r t
No port ing
loss control
vsw f-iri c.t.-r i til Use
Ice Crccim i i.'ovcltius
l;o po r t i
i 1 y :• i 1 K LO is» he- ,/o r t
Loss control
241
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7. Ravi Materials Use
Cottage Cheese
He po r t i ruj,
calculations
d. Iri'j rod iont Use tor
H uid Products
Ke po r t i no r t
Loss control
10. Milk Operations li
Kdnajoment control
11. Total CUD and Loss Report Loss control
12. t.'cekly V.aste Summary
hanagement control
242
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1. >%AGTt: r/V-IAGL>l,NT COdTKOL INSPECTION FOUfr
Milk, Ice Croam and Cottage Cheese
Plant: Location:
Date:Time InTime Cut livaluated Hy_
Compliance Comments/
Kecommondat ions
IttlCEIVINC UOOM;
Tankers - unloaded promptly _
i-Jo leakt froin unloading pumps _
Pipe connections free from
leaks _
Tankers completely drained
before v,ashin-j _
Unloading note t.roperly
drained _
Air-blow system in proper
operation _
CIP bysten operctin'j properly,
no leaki> _
Burst rinses recovered to
rav. s 11 oL;
KAV. MLK S
Outlet valves free from leaks
Connect i one free from leaks
Air actuated Vclvcs free from
leaks
Sampler not !<. tiki 113
U:il o^fl iii'j pumpi, Lrte
', 3
-------
MLK PUJCESSING AUEA;
1 :
Plato sections free
leaks
TF, bp sc-ulo not leaking
Homo seuls riot leaking
oj-c rating properly,
no overflow and sliootin free from leaks
TP, UP &GC.IS not leaking
iioino oucils not lc-akinrj
.'i'-V-r. ra to r o{,oraiirij [;ro|/orly,
no overflow; <";ni.l L'
rly times,
Conrn.-cLio.-ii, free from
Wo over How of balunco tank
Volvub tree Iroin Icoks
No cxcc'i>:. ivu './otc-r usj'je
JITL.'!' rf3:
I'liTlu L.o'Jtionb Iroi. fro.-n le.
TP, I'.l1 o".il i, not li'.i I 1 11 j
homo nol 1 '.\ 4
-------
Separator opemtiii j
no overflow; one! shcotinj
Connections free from leaks
No ovcrtlo* of balance Lank
Valves free from leaks
No excessive use of w-i
CKI:AM
l-late iicctioni, free trom lc.-.k-,_
l'u.:ip seals free trom Itaks
NO lrOOil.'-U{J Ot' ijlclLf.'b
Conn-iCLions froe oi leaks
No overflow of boluiice tank
Valves free froin Kaks
Cutlet valves free from
Pum^ free from lusks
Connect loriL, freo from
!3ry in j red lent S[- illmje
ML.; I ILLI'JC AKI.A;
,-i 1 1 K. tiller i 1 :
tiller valve-: free from Ic
No fojni overflow
Line con.n.cL ions free Iron
;f. r oi-e r«.a i ivj
7.4'
-------
Uritj stiields in ua
Contoiners for dmuojcd cartonb
in use
Proper ui>e of r:i"ot:ucL recovery
system
lK lille-r J 2;
tiller valvt'S fret; Irom leaks
No to an) overflow
Line connections free from
r free Irom
Drip shields in use
Containers for dimujjed cartons
ill U5C'
l'ro;jcr use of product recovery
jystem
:• i 1 K 1 1 1 1 g r ,; 1 -.
l-illur vulvc-s Crcu from it'uks
No fooi.i overflow
Lino connnec t ions free from
looks
pro^or ly
\ p s!i 1 c 16 ii in U
;<;r a tor
in u-:e
oi^r.-i- uju oL [>ro<..'uct iccovury
L, ybCCI.I
;•. i ] I. i t 1 1 c r
1 i I 1 c r v o 1 v c • , I r L c 1 r om ] L .-) k -,
. ' ) /ci '/i ovf-.-r Ho1.;
24G
-------
Lino LOiii'iOJLJQ'iO irjc :io.i
o;-- r.. L i :i j
s in i:dti
t,or.t.u insrb ior L.--. IJJ
j.rot. net u in i.st_
rroirt i,i.o o! -.roiLC
lilli. r vjlvts freo fr
•»o fo j.n avt-r 11 j *
. e d 1 <-- r/c a-,-,- 3 r o ;.e r j 1 1 :
i r. j j o
= ,.cr u5-_' of ,.ro-jjct reccvc-
i, ;•
;•:..-. f i \ I c r - '•:
i;ll<.r vr.Ives froe.- rc~. Kv-.r
.'oios.no/erflo* _
.-;e <, K- r / c r. ^ :-o r o i-c r. •.: :-.rj
jr i r. s: j olc i:; 'jjc _
Lo.it -. i ne r :or •.-;• •..'.jco. {.roduc:
i .1 -t.C _
.Jroj-cr us:- of ;- r o -.'. uc t icc;ucr^
:.r..I :.;...] :;. . . : . " i J • -cc .ors:
..-..-_- --. ^ --r o: rr-Tti--j ;ro.:r:>_
247
-------
•J_5c lexers opu-rutinj j.ro|.er
1^ , c.iusu.'j no bi-ill' je
Case htockars o;-er6tinj j.ro|.-
, causinj i.o s^illa'jc
ars oi-crdtin-j [.roj-crly,
in no Si-illc-.'jLJ
.,0 locks in cooler
.0 lobb of i-roouct ir. lo-!
Mu.i[.i.Lt.T not: KoKin-j
CL c.>LAK p ' i JC^:-. :''!•«!" I>I»I:A:
U-UP tanks:
Vjlves froe from leaks
pjin^s trt'j fro.-n le£».s
Uttinys free fro.n Icsko
,>lo o/or il: .. of tanks
\.-.lvc-i trec fron l-.-n
l'j.i,.a frc-c- fron leaks
Lin* conncctioi.i. trco
1 C .il '• 5
Lro-n
.-io 3<;ilii not lusk iPj
Tr.-itcLio-.s trc- Iro-1 1'-. .>
z s^trflo, T! j- !:..',= .• •.•?-'
248
-------
ice Crc..i.i fix ^tore-go Y<,nks;
Outlet v.ilvos £ !•*«.- from lea
I'jijj tree froi'i Icokb
Cor.noctior.b free fro.n le.^ks
ConrvjctMM linoi frco *.ro:P.
leak:.
Air bJo'-f'o-n ot lines oi-'.-r-
oiin; |-r overly _
Nix flavoring tanks;
Valves trc« from looks
:!o overllo- of t/inks
Connectir.j lines frso of le?k<3
Ice 'Jrcar. t-reozors;
Xo lenKs in Volvos or conriect-
IMJ lines
.,o leaks in seols
bu,:;:ly i--uin^3 frt-c froi Ic-aks
Detunes oj-oretin-j ^ropurly
ice 'Jrean Pc.ckat, ing ••• cctiinus:
:.o looks in Ve.lvc.-a or lir.^s
on--ratin-j
Ice crct.n collec^L'J
s.-rjt. do*:1. ~~>
Ice crc.ro on fiov. 'incle'j c.s
L,Ol 1U '..'.: Stli
249
-------
Proper disposal of cJdiia'
ccrtons
not. lcaK.incj proouct _
NOVELTY 3V KHAT I O.MS :
Vita Line H :
:io overflow, foamiivj at fil-
ling
-j properly
No loss of novelties from
ii free from leaks _
Jju^ply linos frc-e from leaks _
Float valve operating properly_
No excessive use ot v,/iter _
Vita Line ,12;
No overflow, fooiiiiny ct fil-
ling area _
'.iv icks feeding properly _
No loss of novelties from
holders
Pumps frej fron
Valves fret from leaks
r.u^ply luies frc-e from leaks
Hoot valve operatin-j proper] y
.Jo cxccbuive use of v»ater
Vila Li ne ,! 3 :
Wo overflov*, fo.nnin'-.j at fil-
1 1 n-j a r t a
o ifcci iii-j
230
-------
No loss of novelties fron
holders
Pumps free from leaks _
Valves free from leaks _
Supply lines free from leaks _
Float valve operating prop°rly_
No excessivt. use of water _
Vita Line i4i
No overflow, foaming at fil-
1 i n--j a r o j
Sticks feeding properly _
No loss of novelties from
holders _
Pumps free from leaks _
Valves free troin leaks _
Supply lines free from leaks _
Float valve free from looks _
Mo excessive use of water _
Novelty ijacka
-------
oTTACi: OIF. LSI:
bljrtcr vc.t and fittings free
from leaks
Cream dressing tanks, valve
and fittings free from leaks
Linus and valves supplying
cheese vats free from leaks
C.TOOSC vat properly filled
vat valves free from
1 eaks
V.hey excluded iroin drain
Upilltd curd handled is solid
wasti1
Packaging;
Lines and valves free from
leaks
Filler valves free- fro.n leaks
Spilled product on tloor
handled as solid waste
252
-------
2. ut:r.n-iuc:KJ CON'THGL PHOGHAK
f-'ci intonance Request
Note- Tliin Conn is to facilitate maintenance and is to
be filled out by the foremen and cnn bo initiated by the operator
or torcmnn.
CAlb:
>\IO. . (To Ijc filled ir, by Ln-j ineer in-] HepL.)
ISIT1ATCC BY: FOKL1AN:
A R LA: —
fc;f,UIPMLNT:
l-.HEN PKOULLM MUST OttSLKVCD:
HdUVING: (initial unrj forward to Chief Lng ineer)
production Lu^ervisor
Ln>j incur ni'j lorentn
Chicf I.n-j inuer
i-./.li.'TIJliA'.'Ct. OUDMl N'O.: .
-------
3. ITLKIAL, SUCIi AH OVEKFLOU'S, RUM Pi: I) PRODUCT,
MAJOK LI:AKS, LPiLL'i, PACKAGED PRODUCT LO^T, CTC.
DATE : TI .-I L:
LOCATIUN:
PRODUCT LOST:
CAUbE OF
V'.)LU"1L LCUJ.:
N' OF HxJbLLM (OVlIiU'LOW, Li:AKACL, L'.TC) :
.COMhtiMDATlCrtS F0'< CCHRECTIOM:
-------
COMTIiOL PUOSUAN
IMGUi:iJIKNT LOoS
TOTAL TC;YAL NOT ACCOUMTCI: i
INGia:DIfc.NT _ UiJE!) t-QK IN t'HQD'JCr LOSS
fjuc rose- ice cream
tucrosc-r.ovel ty
Corn
''••hoy p
(JilOCOlC.Lfc
Concleribed skim
Non I at Cry Milk
Citric Acid
255
-------
b. UAI-. hATUUAL U'JC
CULAM
MLK
TOTAL IJ/tAT
bTD. li/taT
Ct • 1*1 • 1 w**» L L> it
S.UCKOSE;
CCK.M L,Y!
-------
ILY K.ILK LOS^ HI'-POUl1
UATL: .
1. TOTAL POUNDS OF NILK IlLCLIVED
2. TOTAL POUNDS OF FA'l ULCLIVED
3. TOTAL POU.MDU CF a KIM MILK HrELIVED
4. -iO'iAL POU^I::: CF MILK PUOCELLRD
5. Y1LLD LC1,L IU 1'KOCLLS L'JC (POUUi/'O . - C_
S. l/'Y LOLL, IN I'KOCLbLINC (PCU.^I.) - S-
7. an. -i m LI: LU3b IN PKCCLSMMC (POUNDS) - s_
S. VlVi'AL I'OUiiD'J 'OF MILK PACiiAGKL; - . S.
' $
10. FAT LO'JO IN HACKACING (POUNO'j)
11. bKI:-1 MILK LUOf. IN CACi'-ACINC (POUNDS)
12. TOTAL NU'IULK OF MI IK CAKTOU:; USLD
13. TCTAL Vj/ Jf.l-i OF /.ILK CAHTO'^J LOi'-T
14. VJTM, I' J'JN.-l. CF ,-ilL< . LCCViJMO
IS. 'lUTAL LI/IIi-lATLI.' LO1;^ Ci + '! H r,-l '
17. TOT/IL i::;'i I-I/.TLL FA-I i/j:^-
1C. VJ'I/.L L'./I II-'/.TLl; !.':!/ "'' L<: LOV,
i-j. i.:/ii'i.vrLr LOL', 1.1 HUI; FIUJM "•'•ii-i'-
-------
7. KA'A hA'i'LMAL U^L: CGITAC.t: CliI.ESt:
L'cJ t0 :
bKii.unilk to choose vats __ »- fat_
to clieeso vats ___
Cueese Lrt-ssirij __ » fat_
Curd yiula ___
'.-,,ioy volume
Caucin in skiriL + stnrtur
Casein in tirsL wo^h
Ccisc.it in iiicond wtish
Casein in third was'i
TOTAL in Casein lot-s
'* C'.3s-.iin Ions
-------
u*:i: fc.iv nuiu
Gallons Pounds
'to t a i Milk r oc c i v cci
i'ot.il niilK processed
Cru.T-i to CC
•-r.1111 tO 1C
Mill tO JC
torn
H I- r uc to t;o
i CilOCOl uLC
•jr ^n JL> Juic-.-
-------
1J. MILiOUItCLS CJ'TI'K'JL i-i^iw
LC.'L CM1 A" LO".'". Ur
l. TOVI\L GALLON:-) n i-ix ,-IAIL; ____ TOTAL
2. TOTAL POUNr/, OF I AT UT ] L IX I L1 __
3. 'IOTA I. POUNJU Of MILK SOLID .JOT LVT UTJL17.LL
'!. 'lUTAl. POJvll.:, Or L/'JUAK UTILIXI.D _
b. 'ii:'lAL '-.Uli-.Lf 'JF FACKAGi:^ UM.D
'iC'iAL NJ.ial.l. OF tV-C K<" Ci:;i IJLLKu
a. 'ii'-'iM, f.AlLUi'"., OF iCl. CMIAil IV CKAC'.El1
Total Pounds
(J. 'lO'iAL PO'J :0:j 01- ICL fi.LAM l.OE'l1 J
11. l-OUMUi OF lid- CXilM.C'l'lJ'i l-'Olv ••• .JLT7 OI'L'<\TION
. '.'..] n/.Tl.i: ICl Ci.LA-l LOLif, 1 I ';.-', nCr3 VALtJJ I'l 1]
2f,C
-------
i i . i' i L.I -!'• i. \.". ^ »'
ioi.c.1 ,:1K t-o 'ccoi.nt. :or:
'iotul c i i K /• jcou.it;c-J tor:
.-ilk to ]ce Crec..;,:
Jriruii °-o i c v. Cr \if. ;.i:
...1:1 : J 1 i. co C.J tt.;-. :«. '«.;• _es>-j :
jr<_-i.;ji"j to CotLc-jje C:.e«.3_:
To L --1 Cr *.• ^.7. i3 r o^ u ~ cc; :
'I'ocui L-rt i TI -:iK 10 /ccouriw for
Votc-J il. in ••.ill. /rco'.iiTteo for:
'iot^l IdC LO /•c^CL'it for:
7or.il i f t /rco'j.Ttec1 for:
I'oifll C. oc-'oluLe javiJer u^ej :
10 til ' : • -I u =.-'(.. :
Vo t;. 1 s ij. r LS^f :
'i j t .->."[. ~or - 5, r L.; .;.5-.-^ :
.'otci irL~lC'S<_ Li-;- :
njCcivnj LOLS 5:
f c. n L I c. r i u r J n j i-1: f L j j s 'L :
I'.T.-L t-c tur !i j :-'. in Loss ',.
i .-. /i u.; c ; u r i .-i j i fl L Lo s. s -a :
261
-------
M. 'lOt-M [OUIKJi CC.:> [5roCe3St;'J
L. C^J iti VioLiJoJ tor
c. cc,; loss (I/P x i::r,j
'). \t. lut r>i C.T - (t X L)
r,. I,ooS/L.\»y (L x L)
t . Loos/Pi.- r lev: (1. x 2 .)
lhs
202
-------
1L'. '. I.f.-.LY :A.,.-...'Y "•' ' 'VLiv .V«t: './^li. C, lT f 1C ] l.^'TS
L.'Yl .
L,\Y ](C'!.,! C •>[.'.'./. 'll.lv/ "r.^P ;lJ.Cr/ DAILY r-ILK
H.ii >V
3 ''I .
:.L".J\Y
.M'.Lr'LY .'V.:.
t V.*L-Ji Cf T..L.-I i: BJLL •"-"'
fv^J^CTLL; Y£p: LY £ V/.LUi
P,-•.?.::ucT LOCP
263
-------
APPLM- IX C. CC.'.rJYA'irj-", V-'D CM-dlLA-lION"!
I. CALCULATION JK :30'J i'KOCLS'Jl.D
Tli-j simplest dpproacli m to use i:iilk equivalent v.-il ues to
convert, all products back to 1.5% is.ilk. In this caso, the pounds
i-.CD processed = [(pounds of product) x (milk equivalent)! x 0.1
pound of Li_:j/pounJ of 3.5'* .iiilk.
Milk 'juuivalents:
k ''.7?
21 /ilk r'.??
3.2S% '.ilk R.?7
: . r. '.-, i .1 i i k i . r n
Cottc]e cheese 'i.Z^-
ice croein ^ . 70
Ur y i of the calcul -itior.s naeclud
L >r u uilk, ico cr-,3-1 .••nil cottu-ji choose [lent.
-ilk:
U) for I'.l'e :i. ilk,
i.ooncs ol i-CT'j = Bounds of milk x 0 . ] fi
hOH5 = 1,000,000 m«j/l
(b) for ..-iix—; fluio products,
b of L(,r.!j = pounds o£ product x [ (1 fnt x
f).9) + (° protein .< 0. 1^3 +
I rarbohyc: rcTte x P.C.MJ
-..h^re ,! of L-C!)5/J of product = O.r, 1.T3,
nr.f' :/.7 for fr.t, protein and
ccirtjo:sy:iriitc , resi-octi vcl y .
(c>) for ] ()o fcit ice >_ri.'on,
1-ouiKir, o I !.O!-L = pounric of ice crefi:n x ::.?-?"
L'.CS = 3?n,00:J
254
-------
(b) for froiiL'n desserts of mixed composition,
pounds of f.CV^ = pounds of product x f (?, fat x
n.Ol1 f (a protein x i.K."j)
+ (% carbohydrate x 0.07)]
Cheese:
Cotttige ciieese is o blond of curd and cream dressin-j.
pounds of LCD5 [>rocesscd = [(I curd/100) x It of HC05
in skimmilk processed] + [(1 drossi ruj/100) x
•! of l.Otl in dresairi]]
pounds of LiCDb nrocossod into curd = pounds of cure!
x (ino/o yield of curd/inn) x .072
where skimmilk = 7?, 000 m-j/l bODS; yenorally
tni:. v,oulo bo pounds of curd x 0.'752
^ouiujs of bCI)5 from dressing = pounds of dressing x
('i lot x O.oy) + (i protein x 0.103) + (I
carbotiyd rntes x C.C^S)
II. '../.STC CALCULATION?..
hCD
A. founds of btD bised on sower Jet a
1.
r. . Volumt ot" water ir
o. Co:wersic:i factor for cf..in<] i ny fjallons to [
(8.3/1. i1 /gal)
c. LCD in iiKi/ 1
cJ. Conversion for m.j/ 1 to fr^ctior, ". (l,roO,onr;
2. Cal'jul .it ion :
jallorib < '-.2'. x M.J L-r-L/1 ,Crr!,fi!,f! = !'s of l-CP
H. L]X'i;npl c :
a. Given 1(10,1, 'in cjtillorib at £ POP strength of IP'ir
:»y/l
u. 5 -ico = (i(;'-,co( x ?].
ndb of i M: b.-i:;.'i on i-.'rk-.1'. rc,.ort
o. PouiirHi of L.rvin it ill
265
-------
b. 14C.D v-'.lu'.1 tor bkihi milk
[(72,000 HM/D/I ,r.onfooo] = o.P7?
c. founds of f.it
d . LUD v.'<] ue for fat
[{9f)0,U:0 nuj/1)/! ,nOC,CUO] = 0.90
Calculation:
(pound a of skim milk) x(0. 072) + (pounds o f fat)x(0.
-------
LODb Load (Ibs) = [P, . 34x (2 , OGU . 0^0) ] x[ (3, "'00) ] /
!,oco,ocr(]
li'JOS Lo.d = 50040 Ibs
L-urcharcjc. Bill Known: (a) L.OD5 Lo^rl (Ibs)
(b) How (tjallons)
(c) Normal L-or;5 Concentration
rsuc'j :;urchanji; cost
rvir.no lb)
whore: ( Loflrl - Normal bOC5
LO rid }
,-!•-) r:nal l-CD5Lo.=iri ( 1 L»s) = fa . 34X C? , (.00 , rOO) x( 300 ) ) /
1, COO, LOG
Normal hCDD = ^00^- Ibs
Lxcoas KCU lo.ia = /1 51! 3 5
i.crj'. -lurchc-r-jc = ( f ^"Ox (451* 3/^ lbs)]/UJPO IhsJ
KCI/ '-urcfi.--roi.- = ?3 ,'".(,/!.'.'".
M]K -i«-.b J I'ODb ol Ifir-, i;"l) :-i.j/l (M-KI). 'Ir.us, 1 lb -ilk =
u.nj Loy.-u wno savo'-, JO ij-j]lr.T, of .ailk Hm L-fTc) x
/, :!,iiri, -j-ni'loy-JL1 *'iO doc c, not uso ],()(:;; y.-. lions of wit or
([<.:,, tlnn ! -'. i. inui-UJ oJ -T Wr-:Lcr l.fii.'. runniri]) ;> :!ry m-iy snvf ms
;:.'nt 1,('.C fjMllor.L, x ,?!}'. v.-,iy:j/ypnr x 1,0 . '* 'VI '.':'-• ^i.-l = ?l?r. lliu
t->lu.4 is noL Loo mu(.-h, but it i r. :.
* J, \ u«> o f j.ro.j i.c t.
**Co'jt ol *,». t'j tr CM tin out
2r,7
-------
Y1I.U3 CALCULATIONS FHCtt COD
L;xain:..le for Ice Cream
ha l o r i a 11>
Ibs oC
pr od ui: t
C r u iin
.-•ilk
Luttennil 1-.
Co nd en Led
L, k i ,n
i.jj yolk
SOl 105
Corn i./ru|<
I r uj to^u
C.;io-ol f LU
Citric
Ib COD/lb
product
Ibs COD
processed
cor
" 'J'i t L
YI o; !
.-d on [,ro;luct
Ib;-, ot CLl. proci-'j'* -(\
Ibs Cf-I- MOA'i '.!]•-• '.irci
COD + Ibs product x 1
lb:. CC.VH.U I''-. !,roc.-L,Gfrl [ A/ (I./ 1 Of.) ]
'i lo1.',. »- C x 1C"
y:-. k; = !»!!; - I-1 '
268
-------
-'llNPlX PI
Or1 [••\lliY 1>LA"."1
A linear analysis (LI1) model v»as developed by Carawnn (1077)
Cor a combination r.iilk, ice cretin and cotto-jc cheese plant ond
rur. pled to this study. Initially an attempt was mnde to use tin.-
C'jr.-v.-jr. niouL'L by addni'j processes and altering input
c:ucf L ic icnis. liOA'.-vcr, wncn the no coed rnir' 1 1 ional unit process
inputs '..ore inclu
-------
conditiorib anu (b) to evaluate the cost c E Eoctivenoss of proposed
chan.jes in jrocobscs or equipment to reduce witsr and/or product
losses .
Of
Ttie LI1 model was flusi^ nuci to represent tho Kroger dairy in
Indian.-; poliu. The objective function wns minimi zed to select
least cost o£ oil w.Ttor and ».ioto rolnted costs wliicl. inclurtcri
v/r.luui, for .ill products. An option built into the moool wns the
jbility Eor the pl^nt Lo purchase ,n,;]or products that could not
l,u oi-tiMUialy iJrocs3s,«5l :'.ue to costs of wat'.-r or vxasr.e rolatcil
poro.in.tcrs. 'ih-j .nodcl could be used to determine effect of actu.il
or [ropoiiec] rcatr ic tions on any parameter on the plant operation,
o I uf[oct of chon'jcc in unit
7nc :ii3c!i>l coriL'iiii^ all o' th'-- nocossjry processes to trert
uiid or ciiopoi-f ol .ill w.Ti.to ^i.rr-,.i,u. o.-n'jratof! in oil unit
pro.-tus^s. An '.rr.iv » £ rl {.L-rn.-.t iv».". is provider! for
Lunction to .ill ov, :Jl.int conf i-jur.ituin -me Lo -ir:.TpL ch.-.njrs
oi-r..Linj ..o i.! it 10-,:,, pruc'uct ,111 x '.nc! or cillu-.-nt moci.ar.
.. I LI. r«i L io.,s .
.,. ,HM:I. 1 ••.-:; run n^i.j Inti. r nnt ion.il
270
-------
a
b.
c.
„. 1MO
.-as :c llse-wrrc -**c -l',',, -*," -*l,
PrULjCt lOSS -Jj^ "Sj,; *3je "*Jf
,, . . .„.. -CF
!'0« it*. V. JS .0
•.u'C'.ntrjlicn
* j ,, „ 1C IU
c».-iJ'.Ujry -a||(. -a,d -«m|J -*,„,
'ccc.tr/
Trj isfcr.
'•» »„
Transfer Of
csl \c'.cd
-777;^ Co'ts ef cost cost of
:'.'L-.'I»J. Irput: of water
dltor-
na'ivc
pioccss
Waste Product Product Recovered Fecd Truck , , -3!!S_, „
e Parai-ctcr loss Recovery P.oduct Collection Sales Disposal ConstralrS
-i ' °a
••bn i "»
— C
i bu
i be
I br
• h
9
"h
1000 • bi
1000 • ' bj
.1199 - \
\ i bl
1 < >>
• — in
-11 — bn
.1 11-".
•1 O
e c, c -CB c- • f(mlnl-
Cost for Cost of Cost of Value Cost for nillc>
Wj$tc recovery collection of disposal
discharge system system
T?ble 55. Representative Segment of Case Study PIant'Model, (from Carawan 1977)
-------
Corporation (Iti.l 37G/lrirj) computer usimj the f-in thematical
I ro'jrc'iiui;mi.j i'yitLT.i (l-iI'U)/3oO (A-CO-1'.X) version ?. The use of LP
JIKJ Llio i-irs/3GU packci-jc is closeribvjn in IBM manuals. The dnuo of
input format is completely described in the iHtf manuals and v/ill
not be included in thij report. Specific adaptions of the
•iPIj/JSG packa-je ore detailed by l^cCdllistoi (1073).
'Iho T.ociul is ovailible on com put or cards in The l.ata Kitrix.
'iiu LJtci .'-otrix for tlic ino'it-'l used in this study is in Appendix L
b;io«iiij description oi' rows and columns.
Information needed for Liie model incluiuu definition of
activities, activity cool L ic iL-nts , costi> coef f ic icntb i»ith the
ubjectivt function, internal restrictions for the activities an
ox t'.-rn.al robtrictionb Lor tlm iiiodul. A rtr-rosontat i ve St3ctioii of
tli-j niooel is i/rosentcr: in 'lablc.- 'j5, A complete overview of one
oL the moc-'L-li: (novel t IL*I) is j-rosunteo «o tnc conputcr pictures
output lit tfic ona of thio tip pi.-rid ix.
objective function. 'ilic objective. of tl'o .nocit'l , js
fji cbontco , ->/C.L, 1.0 Lujl'.ct t;ic lo.jat cost of till w.itor cind wostc
rulc-'L' i nc t iv 11 *(js includin'j Tf'iv. .jro'ii- ••.' co-.tij. 'iiiyse £irc
-|.j..:i 1 ri '1-jblu 'jb <,', tr._ '•U.Jr.C'I I Vi. Kl'-Jf.11! 10'J (1) flr.iJ tl:t; costs
'_•'.•• L f u J • nt (C-j'j). Co->t .si i riim i «... 110-. */.T-. ij!.o-,<>r. lor the
.
-------
Ttid objective- function slio»n in "Kible 55 includes tl.c cost
iu;./.-. luo is 'jivcn .is the L-i'b.
Jntc-rii.jl rc-otr ictiona u.!icretiL in the i.u'nuf nctur inl '1 r--,c r ihcci in
'n^.-.-ti'. i/ I..
i.'i" ,.-«_•._• .•. ,.'.- 1 i v i r. I-. ., itv.li'1'.' L!.'.- LU.-^IV or ; rot.-u.:i 10:1
1".1"-'- ---1 '••" -I 'f1- ' !•• i o (X-,i, X-!xJ , rt ;o ;i r^t: :n-.'t i»r i..l u iio^r! for
27J
-------
product (X-m) , tl.c ,-rocobS so^u-jnrc irwolviryj first o blend or
mix [ ro'jiias (X-c) Collowjd b> i-'«o (reduction j-rocosaoE (X-ci .^nd
/--•) and 6n al tonvitive procoss. for x-c(X--l) v/f. ICH coin I; ire to
jivo product (X-:j) . lor o_c!. of Lno prochioLior. processes, trie
activity cocf Eicicr.ts l.'.-i] volues) .spociCy tho u-,: or
co;n.r ibutun ot tiuiL activity to -v..itc>r, '.v-iKtc-, i-ostL-iMi tcr ,
jjroLiuct lobs, i/rodu.-:L recovery rintl trrin^Lcr of the product to the
112 in 'ijblu 'j7; arc
«ut>-r siijVly (X-li) i ••-'..'-•r JibCturjc (X-i), v.nst.c po rcmctci
tibcliorrjc- (X-j) , ijroou t IOSL. (X-k) , s.-.niLjry .jrociucts reco^fry
(X-l) , u-c ol ij.-riit.-jr 1 1 y r Hcovoro-i products (X-ni), collection of
\«.jLi.'r - ,.ro(.ucc iiiix Lun:^ (X-n) 'or ili.s^osol i.5 rmniiTl feoc! (X-o) ,
or tra:ib(.oi La t ion (X-p) .
lo*^: Illustration oC ro..s cis -j ivcn in 'jd!>le !i!; to e
i.:,.- 1 n-.-vir rc-l.it icn'.ii i|- of tne r.ctivity to ttsc .-.ctivit1/
co-. Lficn-r-t., .MI i LI ic- rrjhL h.Miii '.idc-. (!Ji..--'s). '.MIL, 1 1 1 ii---.tr.it ion
^iio.-'j tlic't t;..- rov*'; in-.-luufc i.-i/ut :.y.-i;li5bl il i ty
:i) , product .u< (b), prodii." t triinsTcra (c, ci , o , n Tno o* ,
i.ro'!ii:t ri_Jb': 1 10:1 ri-i.ui rc> II.I.L (J)f ».itor i-.u;.,-ly usw (y), s.'-v.^r
•.lr,_l., r-jc '.oTt.ribut.io:. (.j), ..•••, \.<- t'. i '.jh.-i r jc (i), pro.-hsct loss
( j) ..i_< i..,u» -*^^i •" ri-^tri-rnn (k), pro: n.:t rocowLry (1), and
i. ->; -.,.-,, iiL-..rv r •_-.-•)•/« r> (m). 'i!'- i •-" ' r r stricts t!.c ,-rtwiLy of
•'t',;. ro.; .L'jj-.-.t. >.o t.hu -:>.ii-.liLy or i .!•' ',...'1 1 i Ly ri'^troint ;-l r.co on
LI... i. rr. , .
-------
Couf t icients for the moc'el :
Cost Coefficients: cost coefficients (C-j) for product
salts, purchases and disposal activities were estimated
for desijn purposes using data from the Kroger dairy.
Coefficients for actual situations were obtained from the studies
at tha Kroyer dairy.
/•ctivity coefficients: the developcment of the
activity coefficients (a-ij's) proceeded as follov;s. A
cotibist :ntl y si'jned convention was followed in that a negative
sign was a sign Lo the activity coefficients for any activity
supplying something to another activity; i.e. water supply as an
activity coefficient of 1,OCC for the water supply activity in
row (d) in Table 55. The unit activity coefficients were
determined b/ exjmining the units of activities and making unit
consistency for the rows. The activities had units of pounds
(16).
Acceptable water and sewer activities which are given in
gjllons (cjcil). Activity coefficients wer« expressed in pounds per
pound except thu water uso , sewor discharge, product loss, BOD
discharge, suspended solids discharje and I-OC discharge. k.iter
u^a and sev*er discharge activity coefficients were expressed as
-jollont. per thousand pounds of activity. Product loss, HOC
discfior'je, suspeiuied solids end I-OC <1 i sv.-h.irgc activity
27!
-------
coefficients were expressed pounds per thousands pounds of
activity.
A special case was used for the product transfer
coefficients or product was lost in the activity. In these
cases, the transfer coefficient from that activity was developed
by subtracting the absolute value of the lost activity
coefficient (pounds per thousand pounds) divided by a thousand
pounds from one. For example, in Table 21, production activity
X-e has a loss coefficient (A-je) which is divided by b,COO and
subtracted from one equals one minus A-je over one thousand (1 -
A-je over 1,000). This expression equals th* coefficient for the
product from X-e to X-g of A-ee.
Model Limitations:
Y!i* -nodel is first limited by the analysis method
chosen. Lven though LP is a very powerful tool for management to
consider alternative approaches tc water and waste reduction, the
inherent limitations of LV must be considered. First, the use of
LI' requires a linear equation for each particular combination of
activities. In actual practice, all activities in a dairy plant
may not always have a linear relationships.
wcxt the formation of objective function costs (C-j
values) often required assumptions to be made about projected
276
-------
costs and depreciation. For tlio purpose of this study, costs
were pro-rated over j 1.5 year depreciation.
A major limitation is a lack of specific information
for a given plant situation of coefficients to be applied to the
model. However, the utilization of best estimates available have
been shov.n to be of value in other application.
Another limitation of the model is a difficulty in
incorporating individually a number of small activities. Examples
include CIP systems, COP systems, and water station uses. If
information wore specifically available these activites could be
individually incorporated in the model, but vould require
consiucroble model expansion. They ore currently incorporated as
i po-fion oi the coefficient of each activity using the function.
Uairy plant management in 'jcneral may not be in a
position to directly utilize the model without outside
assistance. However, once the model has been formulated, any
dairy manager may be .iblr> to obtain useful information. Not only
wobtc reluted, but oLher assets that impinge upon management
dec is ions.
?77
-------
Table 55. Raw Products Codes
Code Raw Products
BO Butteroil
BP Buttermilk powder
CA Chocolate based additive
CM Cream
CS Condensed skin
FC Fruitade concentrate
FN Fruits and nuts
IG Ingredients other than those specified
LC Corn syrup
LS Cane sugar, liquid
LU Lubricants
RE Ice cream renelt
P.H Recovered product, high solids
RM Raw milk
RT Returns
WH Whey
WO Water for other uses
WP Product water
278
-------
Table 57. Operations, Activities and Process Codes.
CodeOperation, Activity or Process
AF Continuous Freezers
BG Bag
BL Blend
CL Buy
CO Clarify
CU Cool Culture
CV Convey
CX COP, Clean out of place in vat
DC Discharge
DR Drain cottage cheese whey
FF Fill
FN Fruit and nuts feeder, 1C
HA Heat
HL HTST, long holding tube
HO Homogenize
HS Hose Stations
HT High temperature, short, time
PR Separate
ST Starter preparation
RC Receiving
RT Product returns
SF Store.- packaged product
SH Ship
SL Sell
SP Pasteurized, store processed
ST Store, raw
SV Save
TR Transoort, pump
US Use
VC Vat cooling
VF Cita free
WA Wash cottage
Wl First was, cottage cheese
W2 Second wash, cottage cheese
W3 Third v»ash, cottage cheese
ZZ Freeze
279
-------
Table 58. Processed Product Codes.
Code Processed Products
AF Animal food
BM Buttermilk
BOD BODB
CC Cottage cheese, dressed
CD Curd, cottage cheere
CH Chocolate
CR Cream
DR Drinks
DS Dressing
FA Fruitede
FB Fudge bar
FL Fat loss
FM Fluid milk products
FN Fines
FP Fluid products
HO Homogenized
IB ice milk bar
1C Ice cream
IP Ice pop
IM Ice milk
IR Frozen products
If Low fat
Is Loss
OJ Orange juice
RH Recovered product, high solids
SC Sour cream
SK Skirn
SR Starter
SS Suspended Solids
SO Storm sewe-
SW Sewer, sanitary
TP Total products
WH Whey
WW Wash water
280
-------
Table 59. Description of Vectors for Basic Solution (Columns)
Code
BUYHAT
RMRC
RMPR
RMUS
STUB
CMUS
WHUS
CSUS
LCUS
LSUS
FCUS
SBUS
OCUS
IGUS
CAUS
BPUS
BOUS
REUS
TOfPRODS
SURCK3
FOG
STORMSEW
SANSEMER
CCCMUS
CCST
CCHT
CCCU
CCHA
CCVC
CCBL
CC
CCDS
CCFF
CCDK
CCW1
CCW2
CCW3
Activity Unit
Potable water buying and supplying for
use
Raw milk receiving
Raw milk separating
Raw milk use
Skim Milk use
Cream use
Whey use
Condensed skim use
Liquid corn syrup use .
Liquid cane sugar use
Frritade concentrate use
Stabilizer use
Orange juice concentrate use
Ingredients use
Chocolate based additive use
Buttermilk 'powder use
Butteroil use
Ice cream remelt use
Total products processed
Paying for BODs in effluent
Accumulation of fats, oils and greases
lost during processing
Discharge of effluents to storm sewer
Discharge of products and process water
to sanitary sewer
Use of cream for preparation of cottage
cheese dressing
Preparation for use of cottage cheese
starter
Pasteurization of skim for cottage cheese
by HTST
Process processing skim milk Into cottage
cheese curd
Process of draining the whey, washing the
cottage1 cheese curd and fines loss
Cooling of cottage cheese curd
Blending of cottage cheese curd and
dressing
Creamed cottage cheese
Blending ot cottage cheese
dressing
Fill ing of creamed cottage cheese
Cottage cheese drain
Cottage; cheese wash 1
Cottage cheese wash 2
Cottage cheese wash 3
281
of Activity
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
gal
gal
Ib
Ibs
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
-------
Table 59. continued
Code
SCHO
SCVC
SCCU
SCSI
SCTR
SCFF
SCCV
SCSF
FABL
FAVC
FAFF
FASF
FACV
FAWPUS
FALSUS
FPFCUS
FAFCUS
OJBL
OJVC
OJFF
OJCV
OJ5F
OJWPUS
OJOCU3
I CUP US
ICCflUS
ICSMUS
1CRMUS
IClliTJS
ICLSUS
ICLCUS
ICCSUS
ICSfJUS
ICBPUS
Activity Unit
Homogenization of sour cream mix
Vat cooling of sour cream mix
Culturlng of sour cream mix
Storage of sour cream
Pumping of sour cream to fillers
Filling of sour cream
Conveying sour creau including casing
Storage of sour cream in cooler
Blending of concentrate, sugar and
water to make fruitade
Vat cooling of fruitade
Filling of fruitade
Storage in cooler of fruitada
Conveying filled containers of fruitade
through casers and stackers
Use of product water for dilution of
fruitada concentrate
Use of liquid sugar in fruitade
Use of fruitade concentrate in
fluid milk processing
Use of fruitade concentrate in fruitade
processing
Blending of orange juice concentrate and
water in vat
Cooling of orange juice in vat
Filling of orange juice
Conveying filled containers through
casers and stackers
Storage of orange juice
Potable water used for dilution of
orange juice concentrate
Orange concentrate use for orange Juice
Use of water for dilution of ice cream
ingredients
Use of cream in ice cream
Use of skin milk in ice cream
Use of raw milk in ice cream
Use of neutralized v/hsy in ice cream
Use of liquid cane in ice cream
Use of liquid corn syrup in ice crenr
Use of condensed skim milk in ice
crec-Ti
Use of stabilizer in icn crcnin
Use of buttcnr.il!; powder in ice- cream
of Activity
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
ii>
Ib
Ib
Ib
Ib
282
-------
Table 59. continued
Code
CCSF
DSSMUS
BMSMUS
BMCMUS
BMBL
BM5T
BMVP
BMCU
BHVC
BHTR
BMFF
BMCV
BMSF
FMILK
BUYFM
FMSMUS
FMCMUS
FMBL
FMHT
FMSP
FMFF
FMCAUS
FKCSUS
FHLCUS
FMCV
FI1SF
SCCMUS
SCSWJS
SCCSU3
SCSBU5
3CBL
SCVP
Activity "Unit
Storage of filled cottage chev. e
containers
Skim milk use for cottage cheese
dressing
Skim milk use in buttermilk
Cream use in buttermilk
Blending of buttermilk ingredients
Production of buttermilk starter
Vat pasteurization of milk for buttermilk
Culturing skim and starter to make
buttermilk
Vat cooling of buttermilk
Transfer of buttermilk from vat to
fillers
Filling of buttermilk
Conveying, casing and stacking of
buttermilk containers
Storage of cased buttermilk in cooler
Fluid milk products
Buying of cartoned fluid milk
products
Skim milk use for fluid milk products
Cream use for fluid milk products
B'lend for fluid milk products
HTST pasteurization of fluid milk
products
Pasteurize] storage of fluid milk
products
Filling of fluid milk products
Chocolate additive use for fluid milk
products
Condensed skim use for fluid milk
products
Liquid corn syrup use for fluid milk
products
Conveying, casing and stacking of filled
fluid milk products
Storage of fluid Milk products
Croon) use for sour cre<-m
Skim nilk use for scur cream
Condensed skim use for sour crocm
Stabili7er use for sour cream
Blending of sour crcdin irnrvclients
Vat pasteurization of sour crccm mix
of Activity
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
*ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
1:,
Ib
Ib
Ib
Ib
283
-------
Table 59. continued
Code
Activity
Unit of Activity
ICBOUS Use of butteroil in ice cream
RHUS Use of recovered product-high solids
for ice cream
REUS Use of ict! cream remelt for ice cream
ICBL Blending of ice cream ingr nts in a
vat •
ICHT HTST processing of ice cream mix
ICSP Vat storage of ice cream for aging and
f1avori ng
ICAF Partial freezing of ice cream in
continuous freezers
ICTRF Transfer of frozen ice cream
ICFN Fruit, nuts and flavor addition to
ice cream
ICFF Filling of ice cream
ICZZ Hardening of filled packages of ice
cream in plate unit
ICSF Storage of ice cream in -20F frozen
storage
ICBY Buying of ice cream
1C Ice cream
OTHER Ancillary activities for plant including
offices, garage, refrigeration systems,
air supply system, etc.
IPSU Ice pop sugar use
IPBL Ice POIJ blend
IPHT Ice pop heating
IPVK Ice pop freezing
IPBG Ice Pop baggino
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Tb
Ib
Ib
Ib
1!)
Ib
Ib
Ib
Ib
2R4
-------
Table 60- Description of Vectors (Rows) for CASESTUD
TYPE
L
L
L
L
L
L
L
L
L
L
L
L
L
N
G
L
L
L
L
L
L
L
L
L
L
L
L
G
L
E
E
L
L
L
G
G
G
G
L
L
L
L
ROM NAME
MAXFOG
MAXBOD
GOODRTTR
COLLTR
RECRHTR
BADRTTR
DRIPTRIC
RHTRFM
DRIPTRFM
RMRCBTR
WHEYTR
REMELT
FMHTASTR
OBJ
LOSSTRIC
BLTRIC
HTTRIC
SPTRIC
TRMTRIC
FNTRIC
AFTRIC
TRFTRIC
FFTRIC
STQRIC
FNTR
MAXWH5IC
MAXIC
MIMIC
MAXBPIC
WEIGHTIC
ICTR
MAXLACIC
MAXCRMIC
HAXTSIC
MINSUG1
MINSBIC
MlflMSHFl
nniMFic
STOREOJ
FFTROJ
VCT.ROJ
BLfROJ
DESCRIPTION
FOG transfar
BOD transfer
Good return transfer
Transfer from COLLECT
Transfer from HISOLID
Bad return transfer
Drip collection transfer from ice cream
Fluid filler recovery transfer
Fluid filler drip transfer
Clarifier sludge recovery transfer
Whey transfer-
Remelt transfer
HTST recovery transfer
Objective function
Ice cream loss transfer
Ice cream transfer from blend
Ice cream transfer from HTST
Ice cream transfer from surge
Ice cream transfer from pumping
Ice cream transfer from feeder
Ice cream transfer from freezer
Ice cream transfer from pumping
Filled ice cream transfer
Ice cream transfer to storage
Fruit and nut transfer
Whey solids restriction for ice cream
Product restriction for ice cream
Product restriction for ice cream
Buttermilk powder restriction for
ice cream
Ice cream b* nd transfer
Ice cream transfer
Lactose restriction for ice cream
Corn syrup solids restriction for
ice cream
Solids restriction for ice cream
Sugar restriction for ice cream
Stabilizer restriction for ice cream
Solids restriction for ice cream
Fat restriction for ice cream
Orange juice transfer to storage
Orange juico transfer irrm filling
Orange juice transfer from vat cooling
Orange juico transfer from blend
285
UNIT
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
$
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
1000 Ib
1000 Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
-------
Table
continued
TYPE
E
6
L
G
L
L
L
G
G
E
L
L
L
L
G
E
E
E
G
G
1.
G
L
G
L
G
L
G
E
L
L
L
L
L
I
L
G
L
L
E
1
l^
L
ROVJ NAME
WTOJ
MIMOC
MAXOC
MINOJ
MAXO.J
MAXFCFA
MAXLSFA
HINFCFA
MINLSFA
WTFA
BLTRFA
VCTRFA
STOREFA
•* 1 VI\W| fl
MAXFA
MINFA
FOGTR
BODS
SEUERTR
LOSSTRFM
LOSSTRRM
MAXSUGFM
MINSUGFM
MAXBFFM
MIN3FFM
MAXMSFH
MINMSFM
tfAXCAFM
MINCAFM
MIXFM
BLTRFM
HTTRFM
SPTRFM
FFTRFM
STORFM
FMTOT
MIIIFM
MAXFH
MAXSBSC
MIXSC
BLTRSC
TRTRSC
DESCRIPTION
Oranqe juice blend transfer
Orange .iuice concentrate restriction
Orange juice concentrate restriction
Orange juice production restriction
Orange juice production restriction
Fruit Concentrate restriction
Sugar restriction
Fruit concentrate restriction
Sugar restriction
Fruitade bland transfer
Fruitade transfsr from blend
Fruitade transfer from vat cooling
Fruitade transfer to storage
Fruitade production restriction
Fruitade production restriction
FOG transfer
BODs trdnsfer
Sanitary sewer transfer
Fluid milk loss transfer
Raw milk loss transfer
Sugar restriction for fluid milk
Sugar restriction for fluid milk
Fat restriction for fluid milk
Fat restriction for fluid milk
Milk solids restriction for fluid milk
Milk solids restriction for fluid milk
Chocolate additive restriction for
fluid milk
Chocolate additive restriction for
fluid milk
Fluid milk blend transfer
Fluid milk transfer from blend
Fluid milk transfer from HTST
Fluid milk transfer from surge
Fluid milk transfer from filling
Fluid milk +r£nsfer to storage
Fluid milk ">.wsfer
Fluid milk production restriction
Fluid milk production restriction
Sterilizer restriction from sour cream
Sour cream blend transfer
Sour cream transfer from blend
Sour ream transfer from pumping
UNIT
Ib
Ib
• •
Ib
1000 Ib
1000 Ib
« •
Ib
• •
Ib
• •
Ib
Ib
• i
Ib
Ib
Ib
« •
Ib
1000 Ib
10UO Ib
1 1*
ID
4 •
Ib
•
gal
< i
Ib
• •
Ib
Ib
• »
Ib
•t i
Ib
Ib
Ib
Ib
• i
Ib
Ib
• •
Ib
Ib
Ib
« L
Ib
• •
Ib
« t
Ib
1 U.
ID
1000 Ib
1000 Ib
* •
Ib
* *
Ib
^ i
Ib
1 W
ID
2CG
-------
Table 60. continued
TYPE
L
L
L
L
L
G
E
L
G
G
G
G
G
L
G
E
G
L
G
E
E
L
E
E
E
E
E
E
L
L
E
G
L
G
E
L
L
L
L
ROW NAME
CUTRSC
VPTRSC
HQTRSC
FFTRSC
STORSC
MINSTSC
vrrsc
MAXSNFSC
MINStiFSC
HINS3SC
MINFSC
MIMFSC1
MIfISC
MAXSC
MIUBM
MIXBM
HINSTBN
MAXSTBN
MINFBM
BLTRBM
OTTBM
KAXBM
FFTRBM
TRTRSM
VCTRBM
CUTR3M
STORE?
RCTRRM
PRTRCM
PRTRSM
TOTPRODT
SSEWTR
POTWATER
LOSSTRCC
TPTR
STABIL
SKIM
RAWMILK
ORAtlGEC
DESCRIPTION
Sour cream transfer from culture
Sour cream transfer from vat
pasteurization
Sour cream transfer from homogerrization
Sour cream transfer from filling
Sour cream transfer to storage
Starter restriction for sour cream
Blend transfer for sour cream
Solids restriction for sour cream
Solids restriction for sour cream
Stabilizer restriction for sour cream
Fat restriction for sour cream
Fat restriction for sour cream
Sour cream production restriction
Sour cream production restriction
Buttermilk production restriction
Buttermilk blend restriction
Starter restriction for buttermilk
culture
Starter restriction for buttermilk
culture
Fat restriction for buttermilk
culture
Buttermilk transfer from blend
Buttermilk blend transfer
Buttermilk production restriction
Buttermilk transfer from filling
Buttermilk transfer from pumping
Buttermilk transfer from vat cooling
Buttermilk transfer from culture
Buttermilk transfer from conveying
Raw milk transfer from receiving
Cream transfer from separation
Skim transfer from separation
Total products transfer
Sanitary sewer transfer
Potable water transfer
Cottage cheese loss transfer
Total products transfer
Stabilizer transfer
Skim transfer
Raw milk transfer
Orange concentrate transfer
287
UNIT
15
Ib
Ib
Ib
Ib
•••;•>
ib
Ib
Ib
Ib
Ib
Ib
1000 Ib
1000 Ib
1000 Ib
Ib
Ib
Ib
Ib
Ib
Ib
1000 Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
gal
Ib
Ib
Ib
Ib
Ib
Ib
-------
Table 60 • continued
TYPE
L
L
L
L
L
L
L
L
L
L
L
G
G
L
E
L
G
L
L
L
G
E
G
L
E
L
L
L
ROW NAME
LCORNSUG
LCANESUG
INGRED
FRUITCON
CREAM
CONDSKM
CHOCING
BUTTOIL
BUTMPOWD
FRUITflUT
CCMAXFDS
CCMINFDS
CMIMTSDS
CMAXTSDS
CCWTD",
MAXCC
MINCC
CCBYTR
STORCC
MAXFCC
MINFCC
WTCC
CCMINST
CCMAXST
CC5ET
YIELDCC
WATRCC
BLTRCC
DLSCRIPTION
Corn syrup transfer
Sugar transfer
Ingredient transfer
Fruitade concentrate transfer
Cream transfer
Condensed skim transfer
Chocolate ingredient transfer
Butteroil transfer
Buttermilk powder transfer
Fruit and nut transfer
Fat restriction for dressing
Fat restriction for dressing
Solids restriction for dressing
Solids restriction for dressing
Dressing transfer
Product-Ion restriction for cottage
cheese
Production restriction for cottage
cheese
Buy cottage cheese transfer
Filled cottage cheese transfer to
storage
Fat restriction- for cottage cheese
Fat restriction for cottage cheese
Equality restriction for cottage cheese
Starter restriction
Starter restriction
Culture transfer
Curd yield transfer
Curd transfer from washing
Cottage cheese transfer from blend
UNIT
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
1000 Ib
1000 Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
Ib
288
-------
Table 6l Examnle of Computer Print Out for Novelty Operations
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Table 61. Continued. Page 3 of 12 pages
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Table bl Continued. Page 4 of 12 pages
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Table 61 Continued. Page 8 of 12 pages
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