LIFE ECO-DHYBAT - Demonstration of hygienic eco-design of food processing equipment as Best Available Technique LIFE12 ENV/ES/001070

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1 LIFE ECO-DHYBAT - Demonstration of hygienic eco-design of food processing equipment as Best Available Technique LIFE12 ENV/ES/ Project description Environmental issues Beneficiaries Administrative data Read more Contact details: Contact person: Alfredo RODRIGO Tel: Fax: arodrigo@ainia.es Project description: Background Meeting required hygiene standards is essential for the food industry. Food companies, therefore, devote considerable time and resources to achieving and maintaining safe standards through the cleaning and disinfection (sanitation) of installations and equipment. However, cleaning activities consume large amounts of water and chemicals, including alkalis, acids and disinfection agents. This generates large amount of contaminated wastewater and organic waste. Cleaning is also one of the most energy-consuming operations in the food industry, generating greenhouse gases from fuel combustion for steam production and high-temperature processes. Within the dairy and fish processing industries, cleaning and disinfection is considered to be the main source of environmental impacts. Objectives The objective of the LIFE ECO-DHYBAT project was to demonstrate hygienic ecodesign techniques for food processing equipment, and to promote them as candidates for Best Available Techniques (BATs) in the updated BATs Reference document (BREF) for the food sector. The application of this pollution preventive approach will contribute to reducing the environmental impact of sanitation procedures in European food industries, with the aim being to show that

2 eco-design of food equipment is a cost-effective approach that reduces the consumption of water, energy and chemical cleaning agents, and wastewater and CO2 emissions during sanitation processes. The project aimed to develop four industrial-scale demonstration production lines in representative dairy and fish processing industries, with equipment re-designed following new hygienic and environmental criteria. Results The LIFE ECO-DHYBAT project demonstrated that hygienic ecodesign (or eco-hygienic design ) is a feasible preventive technique that can significantly reduce environmental impact during the sanitation of food processing equipment and installations. Therefore, it promoted specific hygienic ecodesign techniques as candidate Best Available Techniques (BATs) in the updated BAT Reference document (BREF) for the food sector. LIFE ECO-DHYBAT implemented hygienic ecodesign modifications to 14 pieces of equipment at industrial scale in two representative EU companies in the dairy and fish processing industries. These equipment modifications were made on two process lines of Leche Pascual (dairy processing) and two process lines of Frinova (fish processing). The equipment was re-designed following new hygienic and environmental criteria under an integrated approach. Two new soiling and cleaning protocols were defined for sanitary and environmental performance in closed (diary processing) and open (fish processing) equipment, respectively. Sanitation demonstrations compared the environmental impact of eco-hygienically designed equipment with that of conventionally-designed equipment. Comparisons were made using Life Cycle Assessment (LCA) methodology. The results showed that all of the project s eco-hygienic design equipment provided environmental benefits, including reductions in the use of water, energy and chemicals. Furthermore, the equipment is easily cleaned, gives a better guarantee of sanitation, and contributes to reducing the global warming potential of sanitation processes. The project s innovative hygienic ecodesign approach combined the reduction of environmental impact with the maintenance, or even improvement, of hygienic results. These cost-effective techniques could prevent the consumption of significant amounts of energy, water and chemicals during sanitation operations. Water consumption: An overall average of 44% estimated savings in water consumption. For the dairy processing industry, the project tests achieved up to 50% savings and in the fish processing industry up to 28% savings were obtained; Energy and CO2 emissions: According to BREF, dairies use 80% of their energy as thermal energy to generate steam and hot water from fossil fuels. An average 21-33% reduction in energy consumption was obtained, equating to a reduction of 20-49% of CO2 emissions; and Wastewater: The new eco-designs reduced the quantity of sanitation chemicals used and the quantity of wastewater produced in volume. Overall, on average, wastewater was reduced by 36%. These results were sent to the European IPPC (Integrated Pollution Prevention and Control) bureau. As a result, eco-hygienic design techniques were included

3 as a candidate to Best Available Techniques (BATs) in the first draft of the updated version of the BAT Reference document (BREF) for the food, drink and milk sectors. This was conducted within the framework of the Industrial Emissions Directive (IED) (2010/75/EU). The project also contributes to the implementation of the EMAS Regulation ((EC) No 1221/2009), which aims to improve the environmental performance of companies, and the SCP/SIP (Sustainable Consumption and Production/Sustainable Industrial Policy) Action Plan (COM (2008) 397), by demonstrating production technologies that encourage innovation in two strategic sectors (food industry and food machinery). The project helps achieve policy objectives relating to increased water efficiency and water savings in the EU, particularly through the Water Framework Directive (Directive 2000/60/EC). By introducing eco-hygienically designed equipment into food processing industries, the project also contributes to the EU Circular Economy Package and the transition towards a circular economy. If the concept of ecodesign is replicated, the environmental, economic and social benefits can be significant. There is a good potential for transferability. The LCA data showed that the eco-hygienic design equipment is about 5%-10% more expensive, on average, than conventional equipment. However, the cost of the sanitation operations could be reduced by up to 30% (considering savings in water, water treatment, energy and chemicals). Further information on the project can be found in the project's layman report and After-LIFE Communication Plan (see "Read more" section). Environmental issues addressed: Themes Environmental management - Cleaner technologies Industry-Production - Food and Beverages Keywords clean technology water saving food production energy efficiency Target EU Legislation Water Directive 2000/60 - Framework for Community action in the field of water policy ( ) Waste COM(2015)614 - "Closing the loop - An EU action plan for the Circular Economy" ( )

4 Industry and Product Policy Directive 2010/75 - Industrial emissions (integrated pollution prevention and control) ( COM(2011)899 - Innovation for a sustainable Future - The Eco-innovation Action Plan (Eco-AP) (15... Environmental management & assessment "Regulation 1221/ Voluntary participation by organisations in a Community eco-management an... Natura 2000 sites Not applicable Beneficiaries: Coordinator Type of organisation Description Partners Asociación de Investigación de la Industria Agroalimentaria (AINIA) Professional organisation AINIA is a research and technological development centre focused on the agro-food sector and related industries. It works with more than 900 associated food companies and aims to increase production quality, competitiveness, modernisation and diversification in the agro-food industries. Asociación Multisectorial de Empresas Fabricantes de Maquinaria, Spain Grupo Leche Pascual S.A.U., Spain Pescanova S.A., Spain Administrative data: Project reference LIFE12 ENV/ES/ Duration 10-OCT-2013 to 30-SEP Total budget 874, EU contribution 434, Project location Galicia(España) Castilla-León(España) Comunidad Valenciana(España)

5 Read more: Leaflet Project web site Project web site - 2 Publication: After-LIFE Communication Plan Publication: Article-Paper Publication: Article-Paper Publication: Layman report Title: "Hygienic Eco-design for Food Processing Equipment" (993 KB) Editor: LIFE ECODHYBAT No of pages: 2 Project's website Project's Twitter page Title: After-LIFE Communication Plan Year: 2016 Editor: LIFE ECODHYBAT No of pages: 6 Title: "Hygienic ECO-DESIGN. In: Food & Drink Technology [Online]. url" (818 KB) Year: 2014 Editor: Food & Drink Technology No of pages: 2 Title: "Diseño eco-higiénico y sostenibilidad en la industria láctea. In: Tecnifood: La revista de la tecnología alimentaria. p " (214 KB) Author: Alfredo Rodrigo, Gala de Bastida Year: 2014 Editor: Tecnifood No of pages: 3 Title: Layman report (Spanish version) Editor: LIFE ECODHYBAT No of pages: 12 Publication: Layman report Title: Layman report No of pages: 12 Publication: Technical report Title: Project's Final technical report Editor: LIFE ECODHYBAT No of pages: 55 Project description Environmental issues Beneficiaries Administrative data Read more