Melting Organics Waste - Seeing Waste Diversion Value in Ice Cream

Transcription

1 Melting Organics Waste - Seeing Waste Diversion Value in Ice Cream Compost Council of Canada September 2011 Nicole Chardoul, PE, Principal and C.O.O.

2 Overview Project Objectives Background Data Collection Internal/External Ice Cream Collection Waste Diversion Options Business Case Summary Recommendations

3 Project Objectives Identify waste diversion options through recycling and organics management and potential savings for a midwest ice cream facility Reduce the waste water treatment plant surcharges for high BOD process water Identify potential end users of ice cream waste Provide recommendations for other recycling opportunities

4 Background information Midwest ice cream facility Facility operates 24/7 Produce 1.5 quart size containers of ice cream Facility size 275,000 square foot Overall facility goals Achieve zero waste operation Full recovery of unavoidable by-products Eliminate waste sent to landfills

5 Background Information Facility FY09 facts Reduced waste by 11.4% Increased reuse/recovery by-products by 23.5% Spent $226,511 on waste disposal Not including City utility surcharges Offset/recycling savings totaled $77,615

6 Facility recycling Currently recycling following materials 100% of cardboard and cores 100% of metal scraps 99% of wood pallet waste 90% of fiber ingredient bags 50% of plastic film

7 Waste water treatment plant Waste water treatment plant issues High levels of BOD in process water Melted ice cream waste discharged to sewer Annual surcharges over $1 million, even though WWTP has a wet AD system and wants BOD

8 Ice cream waste generation Generated from areas on manufacturing line Majority from filling and quality check areas Process line malfunctions Line shutdowns due to flavor change-overs Ice cream in lines is dumped Quality check points Container/wrapper not properly aligned or sealed Container removed from line and disposed

9 Ice cream waste destination Waste from filling, line malfunctions and flavor change-overs Dumped directly into drains Transported to WWTP Waste from container/wrapper check points Collected in gray tip carts Ice cream waste mixed with containers/wrappers Transported to external compactors Ice cream melts & allows drain out of compactor

10 Ice cream Waste diversion Overall waste diversion strategy Divert some liquid ice cream waste from WWTP Evaluate possible alternative end users Hog farmers Anaerobic digesters Compost sites

11 Organics mgmt Hierarchy

12 Animal feed Ice cream waste not consumable to humans Next best options animal feed Nutrient and energy content dictates use Hog farmers

13 Anaerobic digestion Industrial use Potential to break down waste Methane produced for biogas Ability to generate electricity and heat Residuals from process are composted Availability Closest location 200 miles Potential at WWTP but at a high cost

14 Composting potential Composting Process requires minimum moisture content Ice cream waste could replace water requirement Ice cream nitrogen content improve compost product Availability Storage tanks needed to store waste Unable to locate site permitted to take waste Costs to upgrade site for industrial food residuals is cost prohibitive

15 Data collection - internal Quality control areas Waste collected in large trash cans Pumped into totes and then tanker truck Transported to WWTP AD pit Assume two 1 cubic yard (.75 cubic meter) totes filled each day Assume 1 metric ton (1000 kg) generated from totes

16 Data collection - internal Filling and processing areas Waste collected in grey whales 1.5 cubic yard (1.1 cubic meter) tipcarts Located throughout process floor 35% full when dumped Assume 10.5 tons generated

17 Data Collection - External External waste collection 2 waste compactors on site 35 cubic yards capacity Pulled 7 days a week Each contain 8 tons of material Estimate 75% of weight is ice cream waste

18 Data collection - external Compactors 75% ice cream waste Approximately 12 tons daily from both units Assume potential capture rate is 75%, so 9 tons daily could be drained from compactors Required to be pumped into refrigerated stainless storage tanks Stored until delivered to end user

19 Data Collection - recycling Total compacted waste 16 tons 12 tons ice cream waste Remaining 4 tons organic waste: Waxed half gallon containers Plastic cone wrappers If separation occurs composting could occur 1 compactor soiled ice cream containers 1 compactor soiled cone wrappers/other non-recyclable plastics

20 Data collection - recycling Wood pallet recycling 2 roll-off containers per week Estimate 288 pallets each week 0.76 tons of pallets recycled daily

21 Recycling savings Current landfill diversion savings of $330 per day Item Unit Unit Cost Total Cost Per Day Pallets 41 pallets/day $2.25/pallet $92.57 Ice Cream Containers 1 ton/day $25/ton $25.00 Cardboard 2.93 tons/day $65/ton $ Plastic Films 0.07 tons/day $300/ton $21.67 TOTAL $329.91

22 Cost and pricing data Needed capital expenditures 6 wheeled Grey Whale tip carts $600 each 2 refrigerated stainless steel storage tanks 20,000 gallon $87,400 Includes tank, freight and 30% contingency

23 Cost and pricing data Needed capital expenditures Replacement of rented 35 cy self-contained compactor $50,000 for new unit Includes cart tipper and 20% contingency Purchase dechiming machine Removes metal bands from fiber drums $1,200 for a manual machine $26,000 for duel automated machine

24 Dechiming machines

25 Capital cost summary Item Units $/Unit Total Tip Carts 6 $600 $3,600 Refrigerated Storage Tank 2 $32,500 $65,000 Storage Tank Valves 2 $2,000 $4,000 Storage Tank Freight 2 $3,500 $7,000 Storage Tank Contingency 30% $38,000 $11,400 Fiber Drum Dechiming Machine 1 $26,000 $26, CY Compactor 1 $42,000 $42,000 Compactor Contingency 20% $42,000 $8,000 TOTAL $167,000

26 Ice cream waste unit costs Ice cream waste hauled for $0.09-$0.12/gallon for hog feed 2,167,200 gal per year = $260,000/yr High strength and high purity Estimated density 4.8 pounds/gallon Material Unit Cost to Landfill ($/Ton) Unit Cost to Hog Farm ($/Ton) Liquid Ice Cream Waste $39 $ $50

27 Current Disposal costs Landfilling/dumping all liquid wastes $809/day dispose of waste $3,836/day to dump ice cream down the drain Total $4,645/day

28 Cost savings If able to cut WWTP surcharges in half Continue recycling at current level, add dechimer and recycle metal bands Divert 10.5 tons/day of ice cream waste Divert 3 tons/day of contaminated ice cream containers Save $1,000/day in operations ROI = less than 1 year

29 Environmental Benefit per year Equivalent to taking 304 cars off the road EPA Waste Reduction Model --

30 Review of Benefits Facility is closer to achieving goals for zero waste landfilled and full recovery of unavoidable byproducts Reduce surcharges to the WWTP by diverting waste ice cream to beneficial reuse Reduce volume to the landfill by diverting waste ice cream cones and their paper and plastic packaging to beneficial reuse and recycling Manage and continuously improve overall plant re-use and recycling of raw material packaging

31 Final recommendations Negotiation with WWTP to reduce surcharge Continue discussions with ice cream waste end users Purchase Additional tip carts for inside facility 2 refrigerated tanks for ice cream storage Dechiming machine Work with broker/resource manager to negotiate contracts and maximize diversion from landfill

32 Questions/Discussion Thank you for your time and attention! Nicole Chardoul Principal and C.O.O. Resource Recycling Systems, Inc (cell) x 227 (office) nchardoul@recycle.com