1 Food, drink and milk BREF Tallinn - 27 and 28 March 2007 Rosemary Campbell [email protected].

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Food, drink and milk BREFTallinn - 27 and 28 March 2007

Rosemary Campbell [email protected]

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BREF scope (Annex 1) 6.4. (b) Treatment and processing intended for the production

of food products from:

- animal raw materials (other than milk) with a finished product production capacity greater than 75 tonnes

per day

- vegetable raw materials with a finished product production capacity greater than 300 tonnes per day (average value on a quarterly basis)

6.4. (c) Treatment and processing of milk, the quantity of milk received being greater than 200 tonnes per day

(average value on an annual basis)

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BREF scope• veryvery wide scope

• large number of FDM sectors• large number of processes• similar products processed differently• different products processed similarly

• advantages• many common environmental issues – also with other BREFs• many common BAT – also with other BREFs• learning from sharing - first opportunity at European level

(develop for revision)

• disadvantages• large document• amount of information and detail varies between sectors• difficult to address all the key issues

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Information submitted/exchanged• 258 references

• BREF - 638 pages

• some general, some detailed

• BREF outline and guide - structure

• late, even at the final TWG meeting

• data compared where consistent units used

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• Estonia

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Key environmental issues

• for processing• for washing raw materials, product• for cleaning packaging, equipment, installation• for transport of product• from drying of FDM material

- then to the WWTP!

Water consumption/contamination •drinks manufacture

- in the product

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Energy • processing

- mechanical/heating/cooling/drying

• maintaining freshness/food safety - refrigeration, freezing

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Solid waste• trimmings, peelings• spills• leaks• overflow• off-specification• inherent loss• heat deposited waste• residues in equipment

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Other driving forces at FDM installations

• food safety/hygiene– public health– shelf life

• quality– taste– appearance– nutrition

• customer preferences/market forces– regional eating habits of consumers– downstream industry requirements

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BREF structureEXECUTIVE SUMMARYPREFACESCOPEChapter 1 GENERAL INFORMATIONChapter 2 APPLIED PROCESSES AND TECHNIQUESChapter 3 CURRENT CONSUMPTION AND

EMISSION LEVELSChapter 4 TECHNIQUES TO CONSIDER IN THE

DETERMINATION OF BATChapter 5 BEST AVAILABLE TECHNIQUESChapter 6 EMERGING TECHNIQUESChapter 7 CONCLUDING REMARKSChapter 8 REFERENCESGLOSSARY

How BAT are presented5.1

General BATfor whole

FDM sector

5.1.1Environmentalmanagement

5.1.2Collaboration

with upstream and downstream

activities

5.1.3Equipment and

installationcleaning

5.1.4ADDITIONAL BAT

for some processes and unit operations

5.1.5Minimisation ofair emissions

5.1.6Waste water

treatment(contains somesector specific

BAT information)

5.1.7Accidentalreleases

5.2ADDITIONAL BAT

for some individualFDM sectors

5.1.4.1 - 5.1.4.14ADDITIONAL BAT for some processes and unit operations where those processes and unit operations are applied

(these processes and unit operations are widely applied in the FDM sector, but not in every sector)

5.2.1 ADDITIONAL BAT

for the meatsector

5.2.2ADDITIONAL BAT

for thefish and shellfish

sector

5.2.3 ADDITIONAL BAT

for the fruit andvegetable

sector

5.2.4ADDITIONAL BATfor the vegetable

oils and fatssector

5.2.5ADDITIONAL BAT

for the dairysector

5.2.6ADDITIONAL BAT

for the starchsector

5.2.7ADDITIONAL BAT

for the sugarsector

5.2.8ADDITIONAL BAT

for the coffeesector

5.2.9ADDITIONAL BAT

for the drinkssector

5.2.5.1ADDITIONAL BATfor milk powder

5.2.5.2ADDITIONAL BATfor buttermaking

5.2.5.3ADDITIONAL BATfor cheesemaking

5.2.5.4ADDITIONAL BAT

for ice-cream manufacturing


for winemaking


for brewing

General BAT for whole FDM sector

Additional BAT for some individual FDM sectors

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BAT for whole FDM sector

Many BAT are concerned with “in-process” managementmanagement and operationoperation of FDM processinginvolving• low investment in technology • require training and supervision• provide significant protection of the

environment as a whole

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General processes and operations

• environmental management system

• training

• design/select equipment

• maintenance

• apply and maintain a methodology to minimise consumption of water and energy and the production of waste

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Apply and maintain a methodology

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General BAT for whole FDM sectorApply and maintain a methodology

• obtain management commitment (financial benefit!), organise and plan

• analyse process steps to identify opportunities for reduction (mass balance) – possibly use external benchmarks

• assess objectives (initial)

• identify prevention and minimisation options

• evaluation and feasibility study

• implement prevention and minimisation programme

• monitor by measurement and visual inspection

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General BAT for whole FDM sector• landspreading MAY be BAT - consider

– Nitrates Directive (Council Directive 92/46/EEC)

– nutritional value to plants

– geographic (soil, climatic, hydrologic, may affect food or livestock)

– traceability – origin and destination of spread substances

– monitoring, e.g. soil and groundwater

• implement a system for monitoring and reviewing consumption and emission levels for individual processes and at site level– e.g. emissions to water and air; product and by-product yield

• transport solid FDM materials dry

• segregate outputs to optimise use, re-use, recovery, recycling and disposal (and minimise waste water contamination)

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Segregation of outputsAchieved environmental benefits

• reduced water consumptionreduced water consumption

• reduced volume of waste water

• reduced wastereduced waste water contaminationwater contamination

• reduced energy consumption energy consumption (to heat water, for WWTP)

• reduced waste reduced waste and can dispose of appropriately

• increased recovery/recycling of materials

• reduced use of detergents

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Collaboration with upstream and downstream activities

• minimise storage times• manage on-site vehicle movements• selection of less harmful materials, e.g. cease use of

pesticides ahead of supply• supply fresh, but not over-ripe raw materials• high quality fish

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Equipment and installation cleaning• remove raw material residues asap after

processing• provide and use catch-pots• optimise the use of dry cleaning

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Dry cleaningAchieved environmental benefits

• reduced water consumptionreduced water consumption

• reduced volume of waste water

• reduced wastereduced waste water contaminationwater contamination

• reduced energy consumption energy consumption (to heat water, for WWTP)

• reduced solid wastereduced solid waste

• increased recovery/recycling of materials

• reduced use of detergents

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Equipment and installation cleaning• pre-soak before wet cleaning• manage the use of water, energy and

detergent• operate CIP optimally - measure

turbidity, conductivity or pH - automatically dose chemicals

• minimise the use of EDTA

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Additional BAT for some unit operations

– freezing and refrigeration

• avoid keeping aircon and refrigerated areas colder than necessary

•minimise transmission and ventilation losses from cooled rooms and coldstores

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Additional BAT for some unit operations– compressed air systems • review the pressure level and reduce it

if possible• optimise the air inlet temperature• fit silencers at air inlets and exhausts,

to reduce noise levels

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Additional BAT for some unit operations– steam systems • maximise condensate return• avoid losses of flash steam from condensate

return• isolate unused pipework• improve steam trapping• repair steam leaks• minimise boiler blowdown

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Waste water treatment

• waste water arises from water consumption during processing and cleaning and from the drying of FDM materials.

• apply process-integrated BAT to minimise consumption and contamination of water

• apply end-of-pipe treatment waste water treatment techniques

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Waste water treatment

• BAT not concluded on whether it is better to treat waste water from FDM installations

on-site or off-site, except some primary on-site techniques, i.e.

– apply an initial screening of solids

– remove fat using a fat trap, if the waste water contains animal or vegetable FOG

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Waste water treatment - BATAELs

TWG supported BATAELs for whole diverse FDM sector–no sector-specific BATAELs– some sector-specific evidence of low

achievable levels available–no lower level concluded for COD, BOD5,

oil and grease or total nitrogen (low levels achievable at some installations)

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Waste water treatment - BATAELsParameter

Concentration(mg/l)

BOD5 <25

COD <125

TSS <50

pH 6 – 9

Oil and grease <10

Total nitrogen <10

Total phosphorus 0.4 – 5

Better levels of BOD5 and COD can be obtained. It is not always possible or cost effective to achieve the total nitrogen and phosphorus levels shown, in view of local conditions. SPLIT VIEWSPLIT VIEW

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Additional BAT for meat and poultry

• thaw meat in air

• avoid using flake ice, by mixing chilled and frozen raw materials

• dose spices and other solid ingredients from a bulk container, not plastic bags

• stop water flow to sausage fillers during production breaks

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Additional BAT for the fruit and vegetable sector

E.g.• where storage of fruit and vegetables and by-

products cannot be avoided, minimise storage time and, subject to weather, store outdoors in clean covered area

• after blanching fruit and vegetables, pass through cold water before freezing

• optimise the re-use of water, whilst maintaining hygiene

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Additional BAT for dairies

E.g.• replace batch pasteurisers with continuous

ones

• maximise the recovery of diluted, but otherwise uncontaminated, product from CIP initial rinses, HTST start-up, shut-down and change-over and from the rinsing of other equipment and pipework

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BAT - dairies

BATACLs and BATAELs for• market milk• milk powder production• ice-cream

addressing• energy consumptionenergy consumption• water consumptionwater consumption• waste water volumewaste water volume

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BAT – dairies

BATACLs and BATAELs – ranges

• indicative of levels achievable by in-process BAT

• energy consumption levels vary due to, e.g. production volumes

• warm climates may use more energy for cooling and vice versa

• water consumption and waste water emission levels vary due to, e.g. various product portfoliosvarious product portfolios, batch sizes and cleaning

• waste water emission levels may be lower than water consumption levels if dairies measure intake of cooling water, often from their own wells, but then discharge it unmeasured

• warm climates - water may be lost due to evaporation

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Additional BAT for drinks manufacturing

E.g.• if CO2 is used in the installation, use CO2

which is either recovered from the fermentation process or as a by-product of another process, to avoid the production of CO2 directly derived from fossil fuels especially for use in the installation

• recover yeast after fermentation

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Recommendations for future work

• olive oil extraction – more information

• NOx from coffee roasting (techniques/levels)

• EDTA – avoiding use – existing information!

• exploration of wider applicabilities of techniques

• economic data, including payback times

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Suggested topics for future R&D projects

• composition and harmfulness of odours

• reducing NOx emissions from coffee roasting

• EDTA – avoiding use

• reverse osmosis – economic and cross-media effects

1 Food, drink and milk BREF Tallinn - 27 and 28 March 2007 Rosemary Campbell [email protected].

Documents

product slide

determination of bat

additional bat

general bat

freezing slide

estonia slide

general information

common bat