Water Conservation in Poultry Processing

Transcription

1 Water Conservation in Poultry Processing Mitch Staugler Marketing Manager Prime Equipment Group, Inc. Tel:

2 Water Conservation in Poultry Processing Water usage in food processing Opportunities to reduce fresh water usage Water-saving solutions abound in the plant Food safety guidelines for water reuse Incremental improvements & program management Challenges in maintaining momentum

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4 Water Consumption in Poultry Industry Water usage figures in the U.S. poultry industry range from gallons per bird (GPB) Water costs in the U.S. poultry industry vary greatly and range from $ $15.00 (per 1,000 gallons) depending on location and availability 9.1B birds/year x 7 GPB = 63.7B gallons/year $286,650,000/year (@ $4.50 per 1,000 gal) 9.1B birds/year x 6 GPB = 54.6B gallons/year $245,700,000/year (@ $4.50 per 1,000 gal) Saving 1.0 gallon per bird saves the industry approx. $40.95M

5 Water Consumption in Poultry Industry Consider an example for three (3) similar facilities processing 250,000 head per day in different parts of the country: WATER COSTS PER YEAR GPB Plant 1 Plant 2 Plant $562,500 $1,125,000 $2,250, $750,000 $1,500,000 $3,000, $937,500 $1,875,000 $3,750, $1,125,000 $2,250,000 $4,500, $1,312,500 $2,625,000 $5,250, $1,500,000 $3,000,000 $6,000,000 Cost per 1,000 gal: $3.000 $6.000 $12.000

6 Water Consumption in Poultry Industry Consider an example for three (3) similar facilities processing 250,000 head per day in different parts of the country:

7 Opportunities for Conservation & Reuse Step 1: Evaluate current process operations to determine areas of potential savings Step 2: Implement a plan to address the opportunities to reduce water consumption without added technology Step 3: Identify high volume water users in operations that could potentially be reuse options Step 4: Implement a plan to address reuse opportunities with additional technology for screening and/or treatment

8 Opportunities for Conservation How can we save water right now? Check for leaks in pumps, pipes, valves, fittings, hoses Downsize spray jet opening sizes for less volume Check equipment valves during breaks to reduce waste Install simple devices such as: o Water savers on goosenecks o Flow/pressure regulators (actuators) o Pipe plugs (restrictors) to reduce volume

9 Opportunities for Process Water Reuse Common water sources or collection points: Inside/Outside Bird Washer (IOBW) Brush Scrubbers Vacuum Pump Systems or Seal Water Paw Picker Scalder Drip Pan Rinse Feather/Offal Trough Rinse

10 Process Water Re-Distribution Points Common reuse points or re-distribution points: Evisceration Equipment (Ventor, Opener, Cropper) Bird Scrubbers Whole Bird Chiller Whole Bird Scalder Final Rinse Cabinet Offal Screen Spray Bars Trench and Drip Pan Rinse

11 Water Screening or Filtration Technology Many simple technologies available to remove particles and improve water quality prior to reuse. Screen particles of varying sizes from used water Provide a fast payback with low upfront capital cost Example payback: Save 200 GPM x $4.50/k gal = $ savings per day $216, savings per year (based on 2 8 operating hrs/shift, 250 operating days/yr)

12 Sample Screening System for 200 GPM

13 Opportunities for Conservation & Reuse Saving 500 GPM or $540, annually

14 Water Reuse Guidelines (3) Water, ice, and solutions used to chill or wash raw product may be reused for the same purpose provided that measures are taken to reduce physical, chemical, and microbiological contamination so as to prevent contamination or adulteration of product. Reuse that which has come into contact with raw product may not be used on ready-to-eat product. - CFR 9 Section 416.2

15 Water Reuse Guidelines (5) Any water that has never contained human waste and that is free of pathogenic organisms may be used in edible and inedible product areas, provided it does not contact edible product. For example, such reuse water may be used to move heavy solids, to flush the bottom of open evisceration troughs, or to wash antemortem areas, livestock pens, trucks, poultry cages, picker aprons, picking room floors, and similar areas within the establishment. - CFR 9 Section 416.2

16 Implementing a Water Conservation Program Where should we start? Appoint a Water Specialist to manage the programs objectives and drive improvements Audit the plant, then review and implement a savings program with specific and measurable goals (GPB) Get started with basic water saving opportunities and focus on incremental improvements Target processes in the plant using higher volumes of water where reuse equipment may be a valid option

17 Benefits of Implementing a Water Program Lower Operating Costs: Water cost savings, BTU savings, treatment costs Screening reduces amount of material leaving plant in water stream Environmental Improvements: Environmental stewardship and public perception Marketing advantages with quantifiable reductions

18 Greatest Challenges in Conservation Sure, sounds easy but. Enforcement of policies or initiatives Cost to implement Ownership of the program How can we overcome these challenges?