FOOD, DRINK AND MILK INDUSTRIES

1. FOOD, DRINK AND MILK INDUSTRIES CAMINO FERNÁNDEZ RODRÍGUEZ MAITANE GAÑÁN HENALES CRISTINA JIMÉNEZ DE LA PARRA

2. MILK • Animals: Cows, goats and sheep • Compositon: • 87 % water • Protein • Fat • Lactose • Calcium • Phosphorus • Iron • Vitamins • Products: • Milk • Dairy products such as cream, cheese, yoghurt and butter

3. TREATMENT • Milk is received at the dairy and transferred to bulk storage. • Milk is centrifugally separated to produce skimmed or semi-skimmed milk and a cream stream. • Homogenisation  It disperses fat globules and prevents separation of the cream component.

4. TREATMENT 4. The milk is heat treated: • Pasteurisation: • 72 °C and 15 seconds  high temperature short time pasteurisation (HTST) • Rapidly cooled to <7 °C • Sterilisation or UHT to increase the shelf-life of the product. • Heating it indirectly: • Using heat-exchangers with various types of plates and pipes • In two stages: first heating the milk indirectly to approximately 80 ºC and then heating it directly by mixing steam and milk. • Direct heating:Milk is cooled by expanding it under a vacuum to extract the steam mixed with the product in the sterilisation phase (flash cooling).

5. TREATMENT • Long-life sterilised milk consists of two phases: • The first phase is a continuous heat treatment or pre-sterilisation. • The second phase consists of the final treatment of the closed container after filling and sealing the pre-sterilised product. It takes place in an autoclave in batches or in a continuous retort at approximately 110 to 125 ºC for 20 to 40 minutes.

6. POWDERED MILK • Concentration of the raw milk with: • Evaporators. Falling film evaporators are generally used followed by a drying step using a spray drier. • RO. Mechanically remove some of the water from the milk, without the application of heat. Electrical power is used to pump liquid through a semi-permeable membrane to increase the concentration of solids.

7. DAIRY PRODUCTS BUTTER • The process is basically a mechanical one in which cream, an emulsion of oil in water, is transformed to butter, an emulsion of water in oil. • Cream is rapidly chilled and held at that temperature for a set period in a process known as ageing. • Churning agitates the cream to partially break down the oil in the water emulsion until fat globules bind together to produce butter grains.

8. PRODUCTS CHEESE • The process steps apply are: • Production of a coagulum through the action of rennet and/or lactic acid • Separation of the resulting curds from the whey • Manipulation of the curds to produce the desired characteristics of the cheese.

9. PRODUCTS YOGHURT • Fermented milk product. • The main steps are: • The fat and non-fat solids content of the milk is first increased by the addition of milk powders. • The milk is homogenised at a temperature of 55 ºC and heat treated at 80 to 90 ºC for 30 minutes in a batch process.

10. PRODUCTS YOGHURT • The heat treated milk is cooled to around 40 to 43 ºC and seeded with two starter organisms – Streptococcus salivarius subspecies thermophilus and Lactobacillus delbrueckii subspecies bulgaricus. Fermentation takes around 4 hours. • At the end of the process, the product is cooled to 15 – 20 ºC, using either tank cooling coils or tubular or plate heat-exchangers. • Fruit and flavours are blended into the yoghurt which is cooled to less than 5 ºC

11. PRODUCTS ICE-CREAM • The ingredients (fat, non-fat milk solids, sugars, stabilisers, emulsifiers) are blended, heated to around 70 to 75 ºC and homogenised. • The mixture is pasteurised by heating to 80 – 85 ºC for 2 to 15 seconds before cooling and ageing by holding at chilled temperatures for 4 to 24 hours. • Colours and flavours are added at the ageing stage. • Continuous freezers are used to rapidly freeze the ice-cream down to around -6 ºC, with compressed air being introduced into the ice-cream during the freezing process.

12. PRODUCTS WHEY • It is normally evaporated to a supersaturated solution with a total solids content of 60 to 73 % to produce lactose.

13. EMISSIONS • Water consumption is mainly associated with cleaning operations. The main factors affecting water consumption in European dairies are: • Availability of surface and groundwater for cooling • Time and amount of water used for rinsing • A reasonably efficient consumption of water is reported to be around 1 – 5 l/kg milk.

14. WASTE WATER • Waste water is the main environmental issue in the dairy sector. • Waste water volume in a well managed installation is reported to be about 1 – 2 l/kg of milk processed.

15. WASTE WATER • Pollutants: • Average BOD load ranging from 0.8 to 2.5 kg BOD/t milk. • Phosphorus, nitrogen and chloride. • Pathogens from contaminated materials or production processes.

16. AIR EMISSIONS • Main emissions: • Carbon dioxide, sulphur dioxide and nitrogen oxides. • Halogenated compounds in their cooling systems, mostly HCFCs. • Ammonia used in cooling systems may leak or accidental releases may occur which also result in odour complaints.

17. ENERGY • Thermal energy from the combustion of fossil fuels to generate steam and hot water that is used for heating operations and cleaning (80 %) • Electricity to drive machinery, refrigeration, ventilation, and lighting (20%) • The most energy consuming operations are the evaporation and drying of milk. • In pasteurisation energy is needed for the heating and cooling steps.

18. CONSUMPTION OF CHEMICALS • Most of the chemicals are used for the cleaning and disinfection of process machinery and pipelines. • Fresh product dairies mainly use caustic and nitric acid and some disinfectants, such as hydrogen peroxide, peracetic acid and sodium hypochlorite.

19. NOISE • Noise is caused by the movement of milk tankers and distribution lorries; evaporators, spray driers, and cooling condensers

20.  Waste water characteristics ► Large daily variation in flowrate ► Variable pH ► Waste water may be nitrogen deficient, unless the raw water has a high nitrate content or nitric acid is used. ► Waste water may be high in phosphorus if phosphoric acid is used for clean-up. ► The treatment of dairy waste water results in lower surplus sludge than domestic waste water treatment, owing to : -The lower content of suspended solids -The higher waste water temperatures

21.  Waste water treatment ►1. Solids from washing water from vehicle washing units are generally removed at source. - Using sand or grit traps. - The rainwater from the sealed surfaces is generally passed into the on-site waste water treatment system This may be carried out by : ► 2.Segregation of waste water is generally applied, by high solids content, very high BOD and high salinity.

22. Segregation 3. Primary treatment  Screening  Flow and load equalisation  Neutralisation.  Sedimentation  DAF  Centrifugation  Precipitation

23. 4. Secondary treatment ► BOD concentration greater than 1000 – 1500 mg/l, Anaerobic treatment processes ► Lower strength waste water streams Aerobic treatment

24.  Techniques applicable in some individual sectors MILK ► Segregation of outputs, to optimise use, re-use, recovery, recycling and disposal (and minimise water use and waste water contamination) DESCRIPTION : Outputs, whether or not they are intended for use in the product, can be segregated for optimised and easier use, re-use, recovery, recycling and disposal. This also reduces both the consumption and the contamination of water. It can be done either manually or mechanically. Examples of where the technique is applied • Collect whey which is not intended for making mitzithra cheese, baby food or other products • Collect milky waste water generated at the start-up of pasteurisers • Separate and collect buttermilk, first rinses and residual fat in butter churning oprations, to use it in other processes. • Collect rinsings from yoghurt vats • Collect the drainings of yoghurt and fruit throughout the dairy

25. ► Dry cleaning Examples of where the technique is applied • Adopt dry cleaning methods to collect the solid residues from cheese production. • Treat spills of curd, yoghurt or ice-cream mix as waste rather than just washing them to the drain. • Use dry processes to collect excess salt rather than just washing it to the drain. • Fit drains with screens and/or traps to prevent any solid material from entering the waste water

26. ►Continuous pasteurisers DESCRIPTION:  Flow-through heat-exchangers, e.g. tubular, plate and frame, are used. These have heating, holding and cooling sections. ADVANTAGES: They are used to reduce energy consumption and waste water generation instead of batch pasteurisers. • Operational data : Batch wise pasteurisation uses a temperature of 62 to 65 ºC for up to 30 minutes. Continuous pasteurisers include high temperature short time pasteurisation (HTST) and high heat short time pasteurisation (HHST). HTST uses a temperature of 72 to 75 ºC for 15 to 240 seconds. HHST applies a temperature of 85 to 90 ºC for 1 to 25 seconds.

27. ► Two-stage drying in milk powder production  After the milk has been thickened from 11 % to 50 – 60 % dry matter in an evaporator, the condensed milk may further be dried to 95 – 97 % dry matter content. Spray driers or roller driers are used in milk powder processing.  Two-stage drying process is carried out by using a spray drier with a rotary atomiser. The outlet air is filtered by a CIP filter, which consists of a tubular filter without cyclone

28. BUTTER ►Minimisation of losses during buttermaking  Due to the high viscosity of cream, the cream heater may be rinsed with skimmed milk, which is then retained and used, before the cleaning. This reduces fat losses.  Buttermilk which results as a by-product can be used as a product and not disposed of. These savings may be used, e.g. as a base for low fat spreads.

29. CHEESE ►Use ultrafiltration (UF) for protein standardisation of cheese milk • As using UF leads to an increase in the cheese yield per processed milk unit, the generated quantity of whey is smaller compared to traditional standardisation. BENEFITS • Reduced energy and water consumption, whey and waste water in comparison with traditional standardisation

30. BAT

31. GENERAL BAT FOR THE WHOLE FDM SECTOR GENERAL BAT APPLICABLE TO ALL FOOD, DRINK AND MILK INDUSTRIAL OPERATIONS: • Employees aware of the environmental aspects/responsibilities • Design/select equipment, which optimises consumption and emission levels • Control noise emissions (designing, selecting, operating and maintaining equipment; enclosing noisy equipment) • Apply and maintain a methodology for preventing and minimising: • Consumption of water and energy • Production of waste • Promote use, re-use, recovery, recycling and disposal

32. BAT FOR DAIRIES • PARTIALLY HOMOGENISE MILK: • Energy savings ( homogeniser) • REPLACE BATCH PASTEURISERS WITH CONTINUOUS ONES: • HHST & HTST   Energy consumption • REDUCE THE REQUIRED FREQUENCY OF CLEANING OF CENTRIFUGAL SEPARATORS: • Improving the preliminary milk filtration and clarification processes  Water consumption

33. BAT FOR DAIRIES • USE REGENERATIVE HEAT EXCHANGE IN PASTEURISATION: • Energy savings (90%) • USE JUST-IN-TIME “COMPONENT FILLING”: • Two lines •  losses & minimise water production Skimmed milk Standarised fat content

34. BAT FOR DAIRIES • MAXIMISE THE RECOVERY OF DILUTED PRODUCT: • Pipelines filled with water before start-up • Water is then pushed out by the product through a drain valve • Conductivity transmitters and using optical sensors • USE SEVERAL SMALL CIP SYSTEMS • Instead of a centralised CIP system • Alkaline solution (fat,proteins)+ Acid (mineral) • No acid   water and energy consumption

35. BAT FOR DAIRIES • RE-USE WATER • Condensates (evaporation/drying) • Permeates (membrane separation) • Cooling water • Cleaning water

36. BAT FOR THE PRODUCTION OF MARKET MILK • Achieve

37. BAT FOR MILK POWDER PRODUCTION • To produce powdered milk use • Multi-effect evaporators • Optimising vapour recompression • Apply an early warning fire alarm • Achieve:

38. BAT FOR BUTTERMAKING • REMOVE RESIDUAL BUTTER FROM PIPEWORK USING COMPRESSED AIR: • It can be used to gain access to parts of equipment where other equipments cannot physically pass and any risk of contamination from introducing cleaning tools or equipment can be avoided. • RINSE THE CREAM HEATER WITH SKIMMED MILK BEFORE CLEANING IT

39. BAT FOR CHEESEMAKING • USE THE HEAT FROM WARM WHEY FOR PREHEATING CHEESE MILK: • Savings in energy for heating the incoming milk and cooling energy for the processed whey are achieved. • MAXIMISE WHEY RECOVERY AND USE: • 90% milk  Whey • Sweet/Salty whey  by-products/ animal feed/ babies feed • REDUCE FAT AND CHEESE FINES IN WHEY AND SCREEN LIQUID STREAMS TO COLLECT FINES. • MINIMISE THE OCCURRENCE OF ACID WHEY • Whey processed quickly   acid whey (lactic acid formation)

40. BAT FOR ICE-CREAM MANUFACTURING • Achieve:

41. THANK YOU FOR YOUR ATTENTION!