Food, Drink and Milk Industries.E

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EUROPEAN COMMISSION

Integrated Pollution Prevention and Control

Reference Document on

Best Available Techniques in the

Food Drink and Milk Industries

August 2006


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Executive Summary

Food, Drink and Milk Industries i

EXECUTIVE SUMMARY

Introduction

This Reference Document on Best Available Techniques (BREF) in the Food, drink and milk

industries reflects an information exchange carried out according to Article 16.2 of CouncilDirective 96/61/EC. This executive summary describes the main findings, a summary of the

principal BAT conclusions and the associated consumption and emission levels. It should beread together with the preface, which explains this document’s objectives; how it is intended to be used and legal terms. This executive summary can be read and understood as a standalonedocument but, as a summary, it does not present all the complexities of the full text of thisdocument. It is, therefore, not intended to be used, as a substitute for the text of this fulldocument, as a tool in BAT decision making.

Scope

This document reflects an exchange of information about the activities listed in Annex 1 parts

6.4. (b) and (c) of Council Directive 96/61/EC of 24 September 1996 concerning integrated pollution prevention and control (IPPC Directive), i.e.

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 than300 tonnes per day (average value on a quarterly basis)

(c) Treatment and processing of milk, the quantity of milk received being greater than200 tonnes per day (average value on an annual basis)

The scope includes the whole range of activities producing food for human consumption and

animal feed that may be found in European installations with capacities exceeding the abovethreshold values.

This document does not cover small scale activities, such as catering or activities in restaurantsor activities that do not use animal or vegetable raw materials. Upstream activities such as

agriculture, hunting, slaughtering of animals and the manufacture of non-food products such assoap, candles, cosmetics, pharmaceuticals; manufacture of gelatine and glue from hides, skinand bones are also excluded. Packaging is not included except for the packing of FDM productson the premises.

General information (Chapter 1)

The FDM sector The FDM sector produces both finished products destined for consumption and intermediate products destined for further processing. It is diverse compared to many other industrial sectors.This diversity can be seen in terms of the size and nature of companies; the wide range of rawmaterials, products and processes and the numerous combinations of each as well as the production of homogenised global products and numerous specialist or traditional products onnational and even regional scales. A large proportion of companies are SMEs, although mostemploy more than 20 people.

The FDM sector is subject to very diverse local economic, social and environmental conditions,and varying national legislation. The sector is spread all over Europe, in industrialised regions

as well as in rural areas. The sector is a net exporter from the EU.


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In spite of recent increased homogeneity in the consumption and purchasing patterns for agrowing variety of goods, FDM products still retain elements of cultural specificity. So althoughconsumers want to be able to purchase the same items and quality of products throughout thewhole of the EU-15, they also demand the option/choice of different products linked to theirown tradition or culture.

The importance of food safety in FDM processing

As well as environmental considerations, there are other legal requirements and prohibitionswhich must be considered when identifying BAT in the FDM sector. All FDM productioninstallations must comply with the required food safety standards and laws. These may have aninfluence on environmental considerations, e.g. frequent cleaning is required and this usesheated water and detergents. Care has been taken to ensure that nothing in this documentconflicts with relevant food safety and hygiene legislation.

The FDM sector and the environmentThe most significant environmental issues associated with FDM installations are waterconsumption and contamination; energy consumption; and waste minimisation.

Most of the water which is not used as an ingredient ultimately appears in the waste water

stream. Typically, untreated FDM waste water is high in both COD and BOD. Levels can be10 – 100 times higher than in domestic waste water. The SS concentration varies fromnegligible to as high as 120000 mg/l. Untreated waste water from some sectors, e.g. meat, fish,dairy and vegetable oil production, contains high concentrations of FOG. High levels of phosphorus can also occur, particularly where large quantities of phosphoric acid are used in the process, e.g. for vegetable oil de-gumming, or in cleaning.

The FDM sector is dependent on energy for processing as well as for maintaining freshness and

ensuring food safety.

The main sources of solid output are spillage, leakage, overflow, defects/returned products,inherent loss, retained material that cannot freely drain to the next stage in the process and heatdeposited waste.

The main air pollutants from FDM processes are dust and odour. Odour is a local problem eitherrelated to the process or to the storage of raw materials, by-products or waste.

The driving forces which result in improved environmental performance are changing. Forexample, traditionally maximising the utilisation of materials has had the consequence of

reducing waste. An approach more directly associated with protection of the environment isnow emerging, although this challenges the sector, e.g. with respect to reducing water and

energy consumption and the use of packaging, while still maintaining hygiene standards.

Applied processes and techniques (Chapter 2)

All of the processes used in the sector cannot be described in detail in this document, but itcovers a very wide range from the whole sector. Chapter 2 is divided into two sections.Sections 2.1 – 2.1.9.6.3 describe processes at the unit operation level. Many of these are appliedin several individual FDM sectors. The processes most commonly used in the FDM sector aredescribed in nine categories, i.e. materials reception and preparation; size reduction, mixing andforming; separation techniques; product processing technology; heat processing; concentration

by heat; processing by removal of heat; post processing operations; and utility processes. Withineach of these categories, four to fourteen unit operations are described.

Sections 2.2 – 2.2.20 describe the application of the unit operations in some of the majorindividual FDM sectors.


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Techniques which apply in a number of FDM sectors are then described inSections 4.2 - 4.2.17.4. These deal with the way some specific unit operations which aredescribed in Chapter 2 are applied.

Cleaning of equipment and installations is described in Sections 4.3 – 4.3.11. The selection and

use of cleaning and disinfection agents must ensure effective hygiene control but with dueconsideration of environmental implications.

End-of-pipe techniques for minimising air emissions and for waste water treatment aredescribed in Sections 4.4 – 4.4.3.13.2 and 4.5 – 4.5.7.9 respectively. The introductions to thesesections reinforce the importance of giving priority to process-integrated techniques to preventand reduce, as far as possible, air and waste water emissions. When end-of-pipe techniques are

needed, these are designed to reduce both the concentrations and the flows of the pollutantsoriginating from a unit operation or a process. The techniques described for minimising air

emissions do not contain much information about their applicability or application in theindividual FDM sectors. In contrast, the waste water treatment techniques contain moreinformation about their applicability or application in the individual FDM sectors and addressthe treatment of typical emissions from FDM installations, containing high BOD, COD, FOG,nitrogen and phosphorus levels.

Sections 4.6 – 4.6.6 address the prevention of accidents at FDM installations. These sectionsdescribe a methodology for preventing accidents and minimising their impact on theenvironment.

Techniques which are only applicable in individual FDM sectors are described inSections 4.7 - 4.7.9.8.2. Most of these apply to specific unit operations in the individual FDMsectors.

Best available techniques (Chapter 5)

The way the BAT conclusions are presented in Chapter 5 is shown in the figure below. The

BAT conclusions are presented in two tiers. The first tier shows the sections listing BAT for allFDM installations and the second tier shows the sections where additional BAT for some of theindividual sectors are listed. Chapter 5 follows the same structure as Chapter 4. Many of theBAT are operational and, therefore, require very little investment in new equipment. Theirapplication may require some investment to provide, e.g. training, maintenance or ongoingmonitoring and review of performance levels.

The conclusions represent what the TWG considered to be BAT in a general sense for the FDMsector based on the information in Chapter 4 and taking account of the Article 2.11 definition of“best available techniques” and the considerations listed in Annex IV to the Directive. Thischapter does not set consumption and emission limit values but gives information for theguidance of industry, MSs and the public on achievable consumption and emission levels when

using specified techniques.

The following paragraphs summarise the key BAT conclusions relating to the most relevantenvironmental issues. Very few of the BAT provide only one environmental benefit, so they arenot listed according to environmental issues. The BAT take various approaches to protect theenvironment as a whole. These range from techniques about general management and operation,which are applicable throughout all FDM installations, to the use of very specific technology insome individual FDM sectors.

During the discussion of the information exchanged by the TWG, many issues were raised anddiscussed. Only some of them are highlighted in this summary and it should not be read insteadof the “Best Available Techniques” chapter, which should not be read in isolation from the rest

of this document.


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5.1General BAT

for wholeFDM sector

5.1.1

Environmental

management

5.1.2

Collaboration

with upstream

and downstream

activities

5.1.3

Equipment and

installation

cleaning

5.1.4

ADDITIONAL BAT

for some

processes and

unit operations

5.1.5

Minimisation of

air emissions

5.1.6

Waste water

treatment

(contains some

sector specific

BAT information)

Acc

re

5.2

ADDITIONAL BAT

for some individual

FDM sectors

5.1.4.1 - 5.1.4.14

ADDITIONAL 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 meat

sector

5.2.2

ADDITIONAL BAT

for the

fish and shellfish

sector

5.2.3

ADDITIONAL BAT

for the fruit and

vegetable

sector

5.2.4

ADDITIONAL BAT

for the vegetables

oils and fats

sector

5.2.5

ADDITIONAL BAT

for the dairy

sector

5.2.6

ADDITIONAL BAT

for the starch

sector

5.2.7

ADDITIONAL BAT

for the sugar

sector

ADDITI

for t

s

5.2.5.1

ADDITIONAL BAT

for milk powder

5.2.5.2

ADDITIONAL BAT

for buttermaking

5.2.5.3

ADDITIONAL BAT

for cheesemaking

5.2.5.4

ADDITIONAL BAT

for ice-cream

manufacturing

5

ADDITI

for

How the BAT conclusions are presented for FDM installations


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General BAT for the whole FDM sector

Although the FDM sector is diverse, the individual sectors have common issues, e.g. similar keyenvironmental issues and the same BAT are applicable to preventing and controllingconsumptions and emissions, e.g. dry cleaning, to minimise, e.g. water consumption. Also,some BAT can be applied to more than one environmental issue, e.g. maintenance ofrefrigeration equipment to prevent leaks of ammonia or maintenance of fish skinning machineryto minimise waste caused by unwanted removal of fish flesh during skinning.

General managementThe general management BAT contribute to the overall minimisation of consumption andemission levels, by providing systems of work which encourage good practice and raiseawareness. The BAT focus on issues such as using an environmental management system; providing training; using a planned maintenance programme; applying and maintaining amethodology for preventing and minimising the consumption of water and energy and the production of waste and implementing a system for monitoring and reviewing consumption andemission levels for both individual production processes and at site level.

General operationOther BAT address some key environmental issues more directly, e.g. by transporting solid

FDM raw materials, products, co-products, by-products and waste dry. This reduces waterconsumption and consequently also reduces waste water production and pollution. It also

increases the potential for the recovery and recycling of substances generated in the processwhich, in many cases, can be sold for use as animal feed, so it reduces waste production.

Another example applicable to the whole FDM sector is the segregation of outputs, to optimiseuse, re-use, recovery, recycling and disposal and minimise waste water contamination.

Numerous examples exist in the FDM sector where raw materials, partially processed foods andfinal products either originally intended for human consumption or from which the part intended

for human consumption has been removed, may be used as animal feed. This has bothenvironmental and economic benefits.

General application of technologySome more technologically based BAT include the application and use of process controls, e.g. by using analytical measurement and control techniques to reduce waste of material and waterand to reduce waste water generation in processing and cleaning. An example of this is

measuring turbidity to monitor process water quality and to optimise both the recovery ofmaterial/product from water and the re-use of cleaning water.

Collaboration with upstream and downstream partnersThe operations of those involved in the supply of raw materials and other ingredients to FDM processing installations, including the farmers and the hauliers, can have environmentalconsequences in those FDM installations. Likewise, the FDM installation can affect the

environmental impact of those downstream installations they supply, including other FDM

installations. BAT are to seek collaboration with upstream and downstream partners, to create achain of environmental responsibility, to minimise pollution and to protect the environment as awhole, e.g. by providing fresh materials at the time they are required, which minimises theenergy required to store them as well as waste and odour associated with their decomposition.

Equipment and installation cleaningThe application of BAT for cleaning, minimise water consumption and contamination; wastegeneration; energy consumption and the amount and harmfulness of detergents used.

In common with other BAT, the BAT for cleaning minimise the contact between water and

FDM materials, by, e.g. optimising the use of dry cleaning. The environmental benefits includereduced water consumption and volume of waste water; reduced entrainment of materials in

waste water and, therefore, reduced levels of, e.g. COD and BOD. Use of the various drycleaning techniques increases the potential for the recovery and recycling of substances

generated in the process. It also reduces the use of energy needed to heat water for cleaning andthe use of detergents.


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Other BAT associated with cleaning include cleaning-in-place of closed equipment, minimisingthe use of EDTA and avoiding the use of halogenated oxidising biocides.

Additional BAT for some processes and unit operations applied in a number of FDM sectorsThe TWG reached BAT conclusions for some of the individual unit operations which are

applied in a number, but usually not all, of the individual FDM sectors. BAT are listed formaterials reception/despatch; centrifugation/separation; smoking; cooking; frying; preservation

in cans, bottles and jars; evaporation; freezing and refrigeration; packing; energy generation anduse; water use; compressed air systems and steam systems. The application of many of theseBAT achieves reduced energy consumption, e.g. by using multi-effect evaporators, optimisingvapour recompression related to heat and power availability in the installation, to concentrateliquids. Many reduce energy consumption by optimising operating conditions. Some reduceemissions to air. For example in smoking, BAT is to achieve a TOC air emission level of


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Additional BAT for some individual FDM sectorsAdditional BAT have been determined for the some individual FDM sectors. The general BATin Sections 5.1 – 5.1.7 apply to these sectors and to the other sectors for which no additionalBAT have been determined. The application of, e.g. general BAT such as segregation of outputsand optimising the use of dry cleaning can significantly reduce the overall environmental impactof a process.

The additional BAT for the meat and poultry sector apply to specific unit operations applied insome parts of that sector. They reduce the consumption of water, energy and packaging.

The main environmental benefits of the additional BAT for the fish and shellfish sector arereduced waste and less water consumption and several apply to the thawing, scaling, skinning,

eviscerating and filleting of fish. For example, BAT have been determined for thawing mackerelto achieve a water consumption of


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Executive Summary

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The main environmental issues addressed by the application of the additional BAT for thecoffee sector are related to energy consumption and emissions to air, including odour. Whenroasting coffee, where process-integrated BAT which minimise air emissions by the selectionand use of substances and the application of techniques do not achieve emission levels of5 - 20 mg/Nm

3for dry dust;


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Preface

Food, Drink and Milk Industries xi

PREFACE

1. Status of this document

Unless otherwise stated, references to “the Directive” in this document means the Council

Directive 96/61/EC on integrated pollution prevention and control. As the Directive applieswithout prejudice to Community provisions on health and safety at the workplace, so does this

document.

This document forms part of a series presenting the results of an exchange of information between EU Member States and industries concerned on best available technique (BAT),associated monitoring, and developments in them. It is published by the European Commission pursuant to Article 16(2) of the Directive, and must therefore be taken into account inaccordance with Annex IV of the Directive when determining “best available techniques”.

2. Relevant legal obligations of the IPPC Directive and the definition of BAT

In order to help the reader understand the legal context in which this document has been drafted,some of the most relevant provisions of the IPPC Directive, including the definition of the term

“best available techniques”, are described in this preface. This description is inevitablyincomplete and is given for information only. It has no legal value and does not in any way alteror prejudice the actual provisions of the Directive.

The purpose of the Directive is to achieve integrated prevention and control of pollution arisingfrom the activities listed in its Annex I, leading to a high level of protection of the environmentas a whole. The legal basis of the Directive relates to environmental protection. Itsimplementation should also take account of other Community objectives such as the

competitiveness of the Community’s industry thereby contributing to sustainable development.

More specifically, it provides for a permitting system for certain categories of industrialinstallations requiring both operators and regulators to take an integrated, overall look at the polluting and consuming potential of the installation. The overall aim of such an integrated

approach must be to improve the management and control of industrial processes so as to ensurea high level of protection for the environment as a whole. Central to this approach is the general

principle given in Article 3 that operators should take all appropriate preventative measuresagainst pollution, in particular through the application of best available techniques enablingthem to improve their environmental performance.

The term “best available techniques” is defined in Article 2(11) of the Directive as “the mosteffective and advanced stage in the development of activities and their methods of operationwhich indicate the practical suitability of particular techniques for providing in principle the

basis for emission limit values designed to prevent and, where that is not practicable, generallyto reduce emissions and the impact on the environment as a whole.” Article 2(11) goes on to

clarify further this definition as follows:

“techniques” includes both the technology used and the way in which the installation isdesigned, built, maintained, operated and decommissioned;

“available” techniques are those developed on a scale which allows implementation in therelevant industrial sector, under economically and technically viable conditions, taking intoconsideration the costs and advantages, whether or not the techniques are used or producedinside the Member States in question, as long as they are reasonably accessible to the operator;

“best” means most effective in achieving a high general level of protection of the environment

as a whole.


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Furthermore, Annex IV of the Directive contains a list of “considerations to be taken intoaccount generally or in specific cases when determining best available techniques ... bearing inmind the likely costs and benefits of a measure and the principles of precaution and prevention”.These considerations include the information published by the Commission pursuant toArticle 16(2).

Competent authorities responsible for issuing permits are required to take account of the general

principles set out in Article 3 when determining the conditions of the permit. These conditionsmust include emission limit values, supplemented or replaced where appropriate by equivalent parameters or technical measures. According to Article 9(4) of the Directive, these emissionlimit values, equivalent parameters and technical measures must, without prejudice tocompliance with environmental quality standards, be based on the best available techniques,without prescribing the use of any technique or specific technology, but taking into account thetechnical characteristics of the installation concerned, its geographical location and the localenvironmental conditions. In all circumstances, the conditions of the permit must include provisions on the minimisation of long distance or transboundary pollution and must ensure ahigh level of protection for the environment as a whole.

Member States have the obligation, according to Article 11 of the Directive, to ensure that

competent authorities follow, or are informed of, developments in best available techniques.

3. Objective of this document

Article 16(2) of the Directive requires the Commission to organise “an exchange of information between Member States and the industries concerned on best available techniques, associatedmonitoring and developments in them”, and to publish the results of the exchange.

The purpose of the information exchange is given in recital 25 of the Directive, which states that“the development and exchange of information at Community level about best availabletechniques will help to redress the technological imbalances in the Community, will promotethe worldwide dissemination of limit values and techniques used in the Community and willhelp the Member States in the efficient implementation of this Directive.”

The Commission (Environment DG) established an information exchange forum (IEF) to assistwith the work under Article 16(2) and a number of technical working groups have beenestablished under the umbrella of the IEF. Both the IEF and the technical working groupsinclude representation from Member States and industry as required in Article 16(2).

The aim of this series of documents is to reflect accurately the exchange of information whichhas taken place as required by Article 16(2) and to provide reference information for the

permitting authority to take into account when determining permit conditions. By providingrelevant information concerning best available techniques, these documents should act asvaluable tools to drive environmental performance.

4. Information sources

This document represents a summary of information collected from a number of sources,including in particular the expertise of the groups established to assist the Commission in itswork, and verified by the Commission services. All contributions are gratefully acknowledged.

5. How to understand and use this document

The information provided in this document is intended to be used as an input to thedetermination of BAT in specific cases. When determining BAT and setting BAT-based permitconditions, account should always be taken of the overall goal to achieve a high level of protection for the environment as a whole.

The rest of this section describes the type of information that is provided in each section of thedocument.


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Chapters 1 and 2 provide general information on the industrial sector concerned and on theindustrial processes used within the sector. Chapter 3 provides data and information concerningcurrent consumption and emission levels and the production and use of by-products of the main processes, reflecting the situation in existing installations at the time of writing.

Chapter 4 describes in more detail the emission reduction and other techniques that areconsidered to be most relevant for determining BAT and BAT-based permit conditions. This

information includes the consumption and emission levels considered achievable by using thetechnique, some idea of the costs and the cross-media issues associated with the technique, andthe extent to which the technique is applicable to the range of installations requiring IPPC permits, e.g. new, existing, large or small installations. Techniques that are generally seen asobsolete are not included.

Chapter 5 presents the techniques and the consumption and emission levels that are considered

to be compatible with BAT in a general sense. The purpose is thus to provide generalindications regarding the consumption and emission levels that can be considered as anappropriate reference point to assist in the determination of BAT-based permit conditions or forthe establishment of general binding rules under Article 9(8). It should be stressed, however,that this document does not propose emission limit values. The determination of appropriate

permit conditions will involve taking account of local, site-specific factors such as the technicalcharacteristics of the installation concerned, its geographical location and the local

environmental conditions. In the case of existing installations, the economic and technicalviability of upgrading them also needs to be taken into account. Even the single objective ofensuring a high level of protection for the environment as a whole will often involve makingtrade-off judgements between different types of environmental impact, and these judgementswill often be influenced by local considerations.

Although an attempt is made to address some of these issues, it is not possible for them to be

considered fully in this document. The techniques and levels presented in Chapter 5 willtherefore not necessarily be appropriate for all installations. On the other hand, the obligation toensure a high level of environmental protection including the minimisation of long-distance or

transboundary pollution implies that permit conditions cannot be set on the basis of purely localconsiderations. It is therefore of the utmost importance that the information contained in thisdocument is fully taken into account by permitting authorities.

Since the best available techniques change over time, this document will be reviewed andupdated as appropriate. All comments and suggestions should be made to the European IPPC

Bureau at the Institute for Prospective Technological Studies at the following address:

Edificio Expo; c/Inca Garcilaso, s/n; E-41092 Seville, SpainTelephone: +34 95 4488 284Fax: +34 95 4488 426

e-mail: [email protected]: http://eippcb.jrc.es

mailto:[email protected]:[email protected]:[email protected]


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Best Available Techniques Reference Document onFood, Drink and Milk

EXECUTIVE SUMMARY .................................................. ........................................................... ........... I

PREFACE .......................................................... ........................................................... ........................... XI

SCOPE....................................................................................................................................................XLI

1 GENERAL INFORMATION ...........................................................................................................1 1.1 Description, turnover, growth, employment ........................................................... ....................1 1.2 Sector structure ..................................................... ............................................................ ..........3 1.3 Trade...........................................................................................................................................3 1.4 Market forces: demand, distribution and competition ...................................................... ..........4

1.4.1 Demand ...................................................... ........................................................... ...........4 1.4.2 Distribution.......................................................................................................................4 1.4.3 Competition .......................................................... ........................................................... .4

1.5 The importance of food safety in FDM processing .......................................................... ..........4 1.6 Legislative framework for food, drink and milk products ..........................................................5 1.7 The FDM sector and the environment .......................................................... ..............................5

1.7.1 Key environmental issues.................................................................................................6

2 APPLIED PROCESSES AND TECHNIQUES ...............................................................................9 2.1 Processing techniques and unit operations ................................................... ..............................9

2.1.1 Materials reception and preparation (A).........................................................................10 2.1.1.1 Materials handling and storage (A.1)......................................................................10

2.1.1.1.1 Objective.........................................................................................................10 2.1.1.1.2 Field of application .................................................. .......................................10 2.1.1.1.3 Description of techniques, methods and equipment........................................11

2.1.1.2 Sorting/screening, grading, dehulling, destemming/destalking and trimming (A.2)................................................................................................................................11

2.1.1.2.1 Objective.........................................................................................................11 2.1.1.2.2 Field of application .................................................. .......................................11

2.1.1.2.3 Description of techniques, methods and equipment........................................11 2.1.1.3 Peeling (A.3)...........................................................................................................12 2.1.1.3.1 Objective.........................................................................................................12 2.1.1.3.2 Field of application .................................................. .......................................12 2.1.1.3.3 Description of techniques, methods and equipment........................................12

2.1.1.4 Washing (A.4) ........................................................ ................................................12 2.1.1.4.1 Objective.........................................................................................................12 2.1.1.4.2 Field of application .................................................. .......................................13 2.1.1.4.3 Description of techniques, methods and equipment........................................13

2.1.1.5 Thawing (A.5) ........................................................ ................................................13 2.1.1.5.1 Objective.........................................................................................................13 2.1.1.5.2 Field of application .................................................. .......................................13 2.1.1.5.3 Description of techniques, methods and equipment........................................13

2.1.2 Size reduction, mixing and forming (B) ...................................................... ...................13 2.1.2.1 Cutting, slicing, chopping, mincing, pulping and pressing (B.1)............................13 2.1.2.1.1 Objective.........................................................................................................13 2.1.2.1.2 Field of application .................................................. .......................................13 2.1.2.1.3 Description of techniques, methods and equipment........................................14

2.1.2.2 Mixing/blending, homogenisation and conching (B.2) ..........................................15 2.1.2.2.1 Objective.........................................................................................................15 2.1.2.2.2 Field of application .................................................. .......................................15 2.1.2.2.3 Description of techniques, methods and equipment........................................15

2.1.2.3 Grinding/milling and crushing (B.3).......................................................................16 2.1.2.3.1 Objective.........................................................................................................16 2.1.2.3.2 Field of application .................................................. .......................................16 2.1.2.3.3 Description of processing techniques, methods and equipment......................16

2.1.2.4 Forming/moulding and extruding (B.4)..................................................................16 2.1.2.4.1 Objective.........................................................................................................16 2.1.2.4.2 Field of application .................................................. .......................................16 2.1.2.4.3 Description of techniques, methods and equipment........................................17


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2.1.3 Separation techniques (C) ...................................................... ........................................ 17 2.1.3.1 Extraction (C.1)............ ............................................................ .............................. 17

2.1.3.1.1 Objective ...................................................... .................................................. 17 2.1.3.1.2 Field of application................................................. ........................................ 17 2.1.3.1.3 Description of techniques, methods and equipment ....................................... 17

2.1.3.2 Deionisation (C.2) .......................................................... ........................................ 18 2.1.3.2.1 Objective ...................................................... .................................................. 18 2.1.3.2.2

Field of application................................................. ........................................ 18

2.1.3.2.3 Description of techniques, methods and equipment ....................................... 18 2.1.3.3 Fining (C.3) .......................................................... .................................................. 18


2.1.3.4 Centrifugation and sedimentation (C.4) ...................................................... ........... 19 2.1.3.4.1 Objective ...................................................... .................................................. 19 2.1.3.4.2 Field of application................................................. ........................................ 19 2.1.3.4.3 Description of techniques, methods and equipment ....................................... 19

2.1.3.5 Filtration (C.5) ..................................................... .................................................. 20 2.1.3.5.1 Objective ...................................................... .................................................. 20 2.1.3.5.2 Field of application................................................. ........................................ 20

2.1.3.5.3 Description of techniques, methods and equipment ....................................... 20 2.1.3.6 Membrane separation (C.6)...................................................... .............................. 21 2.1.3.6.1 Objective ...................................................... .................................................. 21 2.1.3.6.2 Field of application................................................. ........................................ 21 2.1.3.6.3 Description of techniques, methods and equipment ....................................... 22

2.1.3.7 Crystallisation (C.7) ....................................................... ........................................ 22 2.1.3.7.1 Objective ...................................................... .................................................. 22 2.1.3.7.2 Field of application................................................. ........................................ 22 2.1.3.7.3 Description of the technique, methods and equipment................................... 22

2.1.3.8 Removal of free fatty acids (ffa) by neutralisation (C.8) ....................................... 22 2.1.3.8.1 Objective ...................................................... .................................................. 22 2.1.3.8.2 Field of application................................................. ........................................ 23 2.1.3.8.3 Description of techniques, methods and equipment ....................................... 23

2.1.3.9 Bleaching (C.9) .................................................... .................................................. 23 2.1.3.9.1 Objective ...................................................... .................................................. 23 2.1.3.9.2 Field of application................................................. ........................................ 23 2.1.3.9.3 Description of techniques, methods and equipment ....................................... 24

2.1.3.10 Deodorisation by steam stripping (C.10) .................................................... ........... 24 2.1.3.10.1 Objective ...................................................... .................................................. 24 2.1.3.10.2 Field of application................................................. ........................................ 24 2.1.3.10.3 Description of techniques, methods and equipment ....................................... 24

2.1.3.11 Decolourisation (C.11) ................................................... ........................................ 24 2.1.3.11.1 Objective ...................................................... .................................................. 24 2.1.3.11.2 Field of application................................................. ........................................ 24 2.1.3.11.3 Description of techniques, methods and equipment ....................................... 24

2.1.3.12 Distillation (C.12) .......................................................... ........................................ 25


2.1.4 Product processing technology (D) ........................................................... ..................... 26 2.1.4.1 Soaking (D.1) ....................................................... .................................................. 26


2.1.4.2 Dissolving (D.2)................................................... .................................................. 27 2.1.4.2.1 Objective ...................................................... .................................................. 27 2.1.4.2.2 Field of application................................................. ........................................ 27 2.1.4.2.3 Description of techniques, methods and equipment ....................................... 27

2.1.4.3 Solubilisation/alkalising (D.3) ........................................................... .................... 27


2.1.4.4 Fermentation (D.4) ......................................................... ........................................ 28


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2.1.4.5 Coagulation (D.5) ................................................... ................................................29 2.1.4.5.1 Objective.........................................................................................................29 2.1.4.5.2 Field of application .................................................. .......................................29 2.1.4.5.3 Description of technique, methods and equipment .........................................29

2.1.4.6

Germination (D.6)...................................................................................................29 2.1.4.6.1 Objective.........................................................................................................29

2.1.4.6.2 Field of application .................................................. .......................................29 2.1.4.6.3 Description of processing techniques, methods and equipment......................30

2.1.4.7 Brining/curing and pickling (D.7)...........................................................................30 2.1.4.7.1 Objective.........................................................................................................30 2.1.4.7.2 Field of application .................................................. .......................................30 2.1.4.7.3 Description of techniques, methods and equipment........................................30

2.1.4.8 Smoking (D.8) ........................................................ ................................................31 2.1.4.8.1 Objective.........................................................................................................31 2.1.4.8.2 Field of application .................................................. .......................................31 2.1.4.8.3 Description of techniques, methods and equipment........................................31

2.1.4.9 Hardening (D.9)......................................................................................................31


2.1.4.10 Sulphitation (D.10) .......................................................... .......................................32 2.1.4.10.1 Objective.........................................................................................................32 2.1.4.10.2 Field of application .................................................. .......................................32 2.1.4.10.3 Description of techniques, methods and equipment........................................32

2.1.4.11 Carbonatation (D.11) ....................................................... .......................................32 2.1.4.11.1 Objective.........................................................................................................32 2.1.4.11.2 Field of application .................................................. .......................................32 2.1.4.11.3 Description of techniques, methods and equipment........................................33

2.1.4.12 Carbonation (D.12).................................................................................................33 2.1.4.12.1 Objective.........................................................................................................33

2.1.4.12.2 Field of application .................................................. .......................................33 2.1.4.12.3 Description of techniques, methods and equipment........................................33 2.1.4.13 Coating/spraying/enrobing/agglomeration/encapsulation (D.13) ...........................34


2.1.4.14 Ageing (D.14).........................................................................................................34 2.1.4.14.1 Objective.........................................................................................................34 2.1.4.14.2 Field of application .................................................. .......................................34 2.1.4.14.3 Description of techniques, methods and equipment........................................34

2.1.5 Heat processing (E) ........................................................ ................................................35 2.1.5.1 Melting (E.1) .......................................................... ................................................35

2.1.5.1.1 Objective.........................................................................................................35

2.1.5.1.2 Field of application .................................................. .......................................35 2.1.5.1.3 Description of techniques, methods and equipment........................................35 2.1.5.2 Blanching (E.2).......................................................................................................35


2.1.5.3 Cooking and boiling (E.3) ......................................................... .............................35 2.1.5.3.1 Objective.........................................................................................................35 2.1.5.3.2 Field of application .................................................. .......................................36 2.1.5.3.3 Description of techniques, methods and equipment........................................36

2.1.5.4 Baking (E.4)............................................................................................................36 2.1.5.4.1 Objective.........................................................................................................36 2.1.5.4.2 Field of application .................................................. .......................................36

2.1.5.4.3 Description of techniques, methods and equipment........................................36 2.1.5.5 Roasting (E.5).........................................................................................................37 2.1.5.5.1 Objective.........................................................................................................37 2.1.5.5.2 Field of application .................................................. .......................................37


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2.1.5.5.3 Description of techniques, methods and equipment ....................................... 37 2.1.5.6 Frying (E.6) .......................................................... .................................................. 38


2.1.5.7 Tempering (E.7) ................................................... .................................................. 38 2.1.5.7.1 Objective ...................................................... .................................................. 38 2.1.5.7.2

Field of application................................................. ........................................ 38

2.1.5.7.3 Description of techniques, methods and equipment ....................................... 39 2.1.5.8 Pasteurisation, sterilisation and UHT (E.8)........................................................... . 39


2.1.6 Concentration by heat (F) ...................................................... ........................................ 41 2.1.6.1 Evaporation (liquid to liquid) (F.1) .................................................... .................... 41


2.1.6.2 Drying (liquid to solid) (F.2).................................................... .............................. 42 2.1.6.2.1 Objective ...................................................... .................................................. 42

2.1.6.2.2 Field of application................................................. ........................................ 42 2.1.6.2.3 Description of techniques, methods and equipment ....................................... 42 2.1.6.3 Dehydration (solid to solid) (F.3)....................................................... .................... 43


2.1.7 Processing by the removal of heat (G) ...................................................... ..................... 45 2.1.7.1 Cooling, chilling and cold stabilisation (G.1) ....................................................... . 45


2.1.7.2 Freezing (G.2) ...................................................... .................................................. 46 2.1.7.2.1 Objective ...................................................... .................................................. 46

2.1.7.2.2 Field of application................................................. ........................................ 46 2.1.7.2.3 Description of techniques, methods and equipment ....................................... 46 2.1.7.3 Freeze-drying/lyophilisation (G.3)..................................................... .................... 47


2.1.8 Post processing operations (H)..................................... .................................................. 48 2.1.8.1 Packing and filling (H.1).......................................................... .............................. 48


2.1.8.2 Gas flushing and storage under gas (H.2) ................................................... ........... 50 2.1.8.2.1 Objective ...................................................... .................................................. 50

2.1.8.2.2 Field of application................................................. ........................................ 51 2.1.8.2.3 Description of techniques, methods and equipment ....................................... 51 2.1.9 Utility processes (U) .................................................... .................................................. 51

2.1.9.1 Cleaning and disinfection (U.1) ......................................................... .................... 51 2.1.9.1.1 Objective ...................................................... .................................................. 51 2.1.9.1.2 Field of application................................................. ........................................ 51 2.1.9.1.3 Description of techniques, methods and equipment ....................................... 52

2.1.9.2 Energy generation and consumption (U.2)............................................................. 52 2.1.9.2.1 Objective ...................................................... .................................................. 52 2.1.9.2.2 Field of application................................................. ........................................ 53 2.1.9.2.3 Description of techniques, methods and equipment ....................................... 53

2.1.9.3 Water use (U.3) .................................................... .................................................. 53 2.1.9.3.1 Objective ...................................................... .................................................. 53

2.1.9.3.2 Field of application................................................. ........................................ 54 2.1.9.3.3 Process water...................................... ........................................................... . 55 2.1.9.3.4 Cooling water ......................................................... ........................................ 55 2.1.9.3.5 Boiler feed-water...................... ............................................................ .......... 56


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2.1.9.4 Vacuum generation (U.4) .......................................................... .............................56 2.1.9.4.1 Objective.........................................................................................................56 2.1.9.4.2 Field of application ................................................... ......................................56 2.1.9.4.3 Description of techniques, methods and equipment........................................56

2.1.9.5 Refrigeration (U.5) .......................................................... .......................................57 2.1.9.5.1 Objective.........................................................................................................57 2.1.9.5.2 Field of application .................................................. .......................................57 2.1.9.5.3

Description of techniques, methods and equipment........................................57

2.1.9.6 Compressed air generation (U.6).......................................................... ..................58 2.1.9.6.1 Objective.........................................................................................................58 2.1.9.6.2 Field of application .................................................. .......................................58 2.1.9.6.3 Description of techniques .................................................. .............................58

2.2 The application of unit operations in the FDM sector ...................................................... ........58 2.2.1 Meat and poultry.............................................................................................................61

2.2.1.1 Canned meat (beef muscle in gelatine)...................................................................62 2.2.1.1.1 Thawing (A.5).................................................................................................62 2.2.1.1.2 Cutting (B.1)...................................................................................................63 2.2.1.1.3 Mixing/blending (B.2) ....................................................... .............................63 2.2.1.1.4 Packing and filling (H.1).................................................................................63 2.2.1.1.5 Sterilisation (E.8)............................................................................................63

2.2.1.1.6 Secondary packaging (H.1).............................................................................63 2.2.1.1.7 Refrigeration (U.5)..........................................................................................63 2.2.1.2 Cooked ham............................................................................................................63

2.2.1.2.1 Thawing (A.5).................................................................................................64 2.2.1.2.2 Cutting (B1)....................................................................................................64 2.2.1.2.3 Pickling (D.7) .......................................................... .......................................65 2.2.1.2.4 Homogenisation (B.2).....................................................................................65 2.2.1.2.5 Cooking (E.3) .......................................................... .......................................65

2.2.1.3 Cured ham...............................................................................................................65 2.2.1.3.1 Brining/curing (D7) ........................................................... .............................66 2.2.1.3.2 Ageing (D.14) .......................................................... .......................................67 2.2.1.3.3 Washing (A.4).................................................................................................67 2.2.1.3.4 Coating (D.13) ......................................................... .......................................67

2.2.1.3.5 Packing (H.1)..................................................................................................67 2.2.1.3.6 Gas flushing (H.2)...........................................................................................67 2.2.2 Fish and shellfish............................................................................................................67

2.2.2.1 Frozen processed fish/moulded fish products and fish fingers ...............................68 2.2.2.2 Canned fish/shellfish products................................................................................68 2.2.2.3 Crustaceans.............................................................................................................69 2.2.2.4 Molluscs ....................................................... ..........................................................69

2.2.3 Fruit and vegetables........................................................................................................69 2.2.3.1 Ready meals that predominantly contain fruit and vegetables................................70 2.2.3.2 Fruit juice................................................................................................................71 2.2.3.3 Heat treated fruit ..................................................... ................................................71 2.2.3.4 Frozen fruit ................................................... ..........................................................72 2.2.3.5 Fruit preserves ........................................................ ................................................72

2.2.3.6 Dried fruit ..................................................... ..........................................................73 2.2.3.7 Tomatoes ...................................................... ..........................................................73 2.2.3.8 Potatoes...................................................................................................................73

2.2.3.8.1 Potato chips.....................................................................................................74 2.2.3.8.2 Potato crisps....................................................................................................74

2.2.3.9 Vegetable juice ....................................................... ................................................74 2.2.3.10 Heat treated and frozen vegetables ...................................................... ...................75 2.2.3.11 Pickling of vegetables.............................................................................................75 2.2.3.12 Vegetable drying.....................................................................................................75

2.2.4 Vegetable oils and fats....................................................................................................75 2.2.4.1 Seed oil extraction ........................................................... .......................................76 2.2.4.2 Refining of edible oils and fats...............................................................................76 2.2.4.3 Crystallisation of edible oils and fats......................................................................78

2.2.4.4 Further processing of edible oils and fats – margarine ...........................................78 2.2.4.5 Olive oil ........................................................ ..........................................................78 2.2.4.6 Olive-pomace oil .................................................... ................................................79

2.2.5 Dairy products ...................................................... ..........................................................79


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2.2.5.1 Milk and cream .................................................... .................................................. 79 2.2.5.2 Condensed and powdered milk .......................................................... .................... 82 2.2.5.3 Butter................................................ ........................................................... ........... 84 2.2.5.4 Cheese ........................................................ ........................................................... . 85 2.2.5.5 Yoghurt ...................................................... ........................................................... . 87 2.2.5.6 Ice-cream.......................................... ........................................................... ........... 88 2.2.5.7 Whey .......................................................... ........................................................... . 89

2.2.6

Grain mill products ...................................................... .................................................. 89 2.2.7 Dry pasta .................................................. ............................................................ .......... 90

2.2.8 Starch ....................................................... ........................................................... ........... 91 2.2.8.1 Maize starch ......................................................... .................................................. 92 2.2.8.2 Wheat starch................. ............................................................ .............................. 93 2.2.8.3 Potato starch......................................................... .................................................. 94 2.2.8.4 Sweeteners ........................................................... .................................................. 96 2.2.8.5 Modified (physical/chemical) starch ........................................................... ........... 96

2.2.9 Animal feed.................................... ........................................................... ..................... 96 2.2.9.1 Animal feed and dry petfood....................................................................... ........... 96 2.2.9.2 Moist petfood ....................................................... .................................................. 97 2.2.9.3 Semi-moist petfood ........................................................ ........................................ 97

2.2.10 Bread........................................................ ........................................................... ........... 97

2.2.11 Confectionery........................................... ........................................................... ........... 99 2.2.11.1 Biscuits............... ............................................................ ........................................ 99 2.2.11.2 Cakes........ ............................................................ .................................................. 99 2.2.11.3 Cocoa ......................................................... .......................................................... 100 2.2.11.4 Chocolate ................................................... .......................................................... 100 2.2.11.5 Boiled sweets ....................................................... ................................................ 101

2.2.12 Sugar ........................................................ ........................................................... ......... 101 2.2.12.1 Sugar beet extraction.............. ............................................................ .................. 101 2.2.12.2 Sugar cane ............................................................ ................................................ 102 2.2.12.3 Sugar refining............... ............................................................ ............................ 102

2.2.13 Coffee....................................................... ........................................................... ......... 102 2.2.13.1 Roasting coffee..................................................... ................................................ 102 2.2.13.2 Instant coffee........................................................ ................................................ 103

2.2.13.3 Decaffeinated coffee ...................................................... ...................................... 104 2.2.14 Yeast ........................................................ ........................................................... ......... 105 2.2.15 Malting... ............................................................ .......................................................... 105 2.2.16 Brewing................................ ........................................................... ............................. 106

2.2.16.1 Mashing.................................. ............................................................ .................. 107 2.2.16.2 Fermentation ........................................................ ................................................ 107 2.2.16.3 Maturation/conditioning............................. .......................................................... 107

2.2.17 Distilling ............................................................ .......................................................... 108 2.2.17.1 Scotch whisky ...................................................... ................................................ 108 2.2.17.2 Cognac ....................................................... .......................................................... 108

2.2.18 Wine....... ............................................................ .......................................................... 109 2.2.18.1 Reception ................................................... .......................................................... 109 2.2.18.2 Grape crushing and destemming ........................................................ .................. 109

2.2.18.3 Pressing ...................................................... .......................................................... 109 2.2.18.4 Fining ......................................................... .......................................................... 109 2.2.18.5 Fermentation ........................................................ ................................................ 109 2.2.18.6 Ageing...... ............................................................ ................................................ 109 2.2.18.7 Cold stabilisation.............................. ........................................................... ......... 110 2.2.18.8 Bottling................................................................. ................................................ 110

2.2.19 Soft drinks.......................................................... .......................................................... 110 2.2.20 Citric acid................... ............................................................ ...................................... 110

3 CURRENT CONSUMPTION AND EMISSION LEVELS .......................................................113 3.1 General consumption and emission information.......... .......................................................... 115

3.1.1 Water.......................... ............................................................ ...................................... 115 3.1.1.1 Water consumption ........................................................ ...................................... 115 3.1.1.2 Waste water.................. ............................................................ ............................ 116

3.1.1.2.1 Quantity of waste water................................ ................................................ 116 3.1.1.2.2 Composition of waste water ....................................................... .................. 117

3.1.2 Air emissions ..................................................... .......................................................... 118


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3.1.2.1 Odour....................................................................................................................119 3.1.3 Loss of materials...........................................................................................................119

3.1.3.1 Exceed weight/volume specification .................................................... ................119 3.1.3.2 Spillage ......................................................... ........................................................119 3.1.3.3 Leakage/overflow ................................................... ..............................................119 3.1.3.4 Product defects/returned product ......................................................... .................120 3.1.3.5 Inherent loss..........................................................................................................120 3.1.3.6

Retained material.................................................... ..............................................120

3.1.3.7 Heat deposited waste ........................................................ ....................................120 3.1.4 Energy ........................................................ ........................................................... .......120

3.2 Consumption and emissions in unit operations.......................................................................121 3.2.1 Materials handling and storage (A.1) .......................................................... .................123

3.2.1.1 Water ............................................................ ........................................................123 3.2.1.2 Air emissions .......................................................... ..............................................123 3.2.1.3 Solid output...........................................................................................................124 3.2.1.4 Energy...................................................................................................................124 3.2.1.5 Noise............................................................. ........................................................124 3.2.1.6 Accidental release.................................................................................................124

3.2.2 Sorting/screening, grading, dehulling, destemming/destalking and trimming (A.2) ....124 3.2.2.1 Water ............................................................ ........................................................124

3.2.2.2 Air emissions .......................................................... ..............................................124 3.2.2.3 Solid output...........................................................................................................124 3.2.2.4 Energy...................................................................................................................124

3.2.3 Peeling (A.3).................................................................................................................125 3.2.3.1 Water ............................................................ ........................................................125 3.2.3.2 Air emissions .......................................................... ..............................................125 3.2.3.3 Solid output...........................................................................................................125 3.2.3.4 Energy...................................................................................................................125 3.2.3.5 Noise............................................................. ........................................................125

3.2.4 Washing (A.4) and thawing (A.5) ..................................................... ...........................125 3.2.4.1 Water ............................................................ ........................................................125 3.2.4.2 Solid output...........................................................................................................125 3.2.4.3 Energy...................................................................................................................126

3.2.5 Cutting, slicing, chopping, mincing, pulping and pressing (B.1) .................................126 3.2.5.1 Water ............................................................ ........................................................126 3.2.5.2 Solid output...........................................................................................................126 3.2.5.3 Energy...................................................................................................................126 3.2.5.4 Noise............................................................. ........................................................126

3.2.6 Mixing/blending, homogenisation and conching (B.2) ................................................126 3.2.6.1 Water ............................................................ ........................................................126 3.2.6.2 Air emissions .......................................................... ..............................................126 3.2.6.3 Solid output...........................................................................................................126 3.2.6.4 Energy...................................................................................................................127 3.2.6.5 Noise............................................................. ........................................................127

3.2.7 Grinding/milling and crushing (B.3) ........................................................... .................127 3.2.7.1 Water ............................................................ ........................................................127

3.2.7.2 Air emissions .......................................................... ..............................................127 3.2.7.3 Solid output...........................................................................................................127 3.2.7.4 Energy...................................................................................................................127 3.2.7.5 Noise............................................................. ........................................................127

3.2.8 Forming/moulding and extruding (B.4)........................................................................127 3.2.8.1 Water ............................................................ ........................................................127 3.2.8.2 Air emissions .......................................................... ..............................................127 3.2.8.3 Solid output...........................................................................................................127 3.2.8.4 Energy...................................................................................................................127

3.2.9 Extraction (C.1) .................................................... ........................................................128 3.2.9.1 Water ............................................................ ........................................................128 3.2.9.2 Air emissions .......................................................... ..............................................128 3.2.9.3 Solid output...........................................................................................................128

3.2.9.4 Energy...................................................................................................................128 3.2.9.5 Noise............................................................. ........................................................128 3.2.10 Deionisation (C.2) .......................................................... ..............................................128

3.2.10.1 Water ............................................................ ........................................................128


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3.2.10.2 Solid output .......................................................... ................................................ 129 3.2.11 Fining (C.3)...... ............................................................ ................................................ 129

3.2.11.1 Water.......................................................... ...................................................

Food, Drink and Milk Industries.E

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Transcript of Food, Drink and Milk Industries.E