GE Power & Water Application Note

Water & Process Technologies

Sievers InnovOx: Food and Beverage Load

Monitoring for Total Organic Carbon (TOC)
Introduction
The food and beverage industry uses extraordinarily
large amounts of water within their manufacturing
processes. Water can be used as an ingredient, a
cleaning solvent, and as a utility, such as for boiling and
cooling. When considering how important clean water
is to the entire process, one must keep in mind the
ratio of water used versus the amount of final product
produced. For example, one liter of juice, wine, or coffee
can use more than 800 liters of water, and one kilogram
of cheese or tea can use more than 5,000 liters. 1
The food and beverage industry has four main
manufacturer classifications. The first is meat,
poultry and seafood. The second is fruits and
vegetables. The third is dairy products. The fourth
encompasses all other beverages. During the
manufacturing process of these four groups, it is not
uncommon for the process water to become loaded,
or contaminated with organics. One of the main
tests that can determine the level of loading is Total
Organic Carbon (TOC) analysis.
Manufacturing industries must comply with the
USEPA’s Clean Water Act (CWA) regulations. To
minimize costs, plant treatment processes must
be optimized. To help achieve optimization, many
facilities are using TOC monitoring to ensure quality
water while also achieving significant cost reductions.
Failure to comply with
the CWA can and has
resulted in substantial
fines for companies that
are not compliant.
What is the Process?
A wastewater treatment
process is regulated at both a national and regional
level. During a manufacturing process or in a
wastewater treatment facility, a once clean water
supply becomes loaded with impurities that may have
health or environmental consequences if released
untreated.
The first step in cleaning water is to remove suspended
solids. The next step is to chemically treat the water to
minimize release of hazardous chemicals or bacteria
into the environment.
If a process is not properly controlled, this can have
a significant impact on a company’s bottom line.
Improperly treated water can damage the materials
that come in contact with the water such as delivery
pipes or holding tanks. Water that has been inefficiently
treated can also cause plant shutdown, waste stream
diversion, or even re-treatment of stream. All of these
consequences are expensive and undesirable.

Steeping Germ Grinding Start Gluten Starch Fermentation

Separation Screening Separation Convention

Germ Fiber Gluten Starch Syrup

Oil Refining Drying Refining

Corn Alcohol,
Syrup Feed Products Starches Sweeteners
Chemicals

Figure 1. A typical fruit/vegetable manufacturing process2

Analytical Instruments
Why Use TOC for Process Optimization?
The EPA has identified five pollutants that must be
controlled. These include oxygen-demanding substances,
pathogens, nutrients, inorganic and synthetic organic
chemicals, and heat. Each of these pollutants can upset
an eco-system and negatively affect the water quality.
The pollutants that TOC is able to monitor are oxygen-
demanding substances.
In the past , companies monitored the oxygen-
demanding substances with a single test called
Biological Oxygen Demand (BOD) or Chemical
Oxygen Demand (COD). With the advances and
benefits of TOC equipment today, the EPA allows
the use of TOC for monitoring oxygen-demanding
substances. In section 133.104, Sampling and Test
Procedures, of the EPA document 40 CFR, the EPA
states that “TOC may be substituted for BOD5 when
a long-term BOD:COD or BOD:TOC correlation has
been demonstrated.” A faster TOC analysis time
is very advantageous when trying to determine a
waste stream’s composition.
An influent waste stream, or the “loaded” water, is
initially tested for TOC. This is considered a baseline
reading so the treatment facility has an idea of its
starting organic load. This will determine how much
organic carbon is in the stream and will dictate the
amount of chemicals and filtration necessary to treat
the water. The effluent, or the ‘clean’ water, is tested
again. By monitoring the effluent, the treatment
facility will know if their chemical dosing is effective.
A treatment facility can slowly reduce or modify their
chemical usage to see the effect on the effluent
stream. Some examples include:
• Initial influent testing for TOC into primary
application — initial product washing
• Compliance release TOC testing into secondary
application — blanching, separation
• Compliance release TOC testing into tertiary application
— utility usage, cooling, clean up, packaging
• Compliance release TOC testing into water
tributaries — NPDESlpermit release
If the TOC value demonstrates that release compliance
is met, then an immediate cost savings is realized.
Sievers InnovOx On-Line and Laboratory TOC Analyzers
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Conversely, if the initial waste stream’s TOC value starts
to increase due to an unknown process contamination,
the treatment facility will be able to act on the almost
instantaneous TOC analysis and correct the chemical
dosing. This type of real-time correction will allow an
end user to avoid the cost and compliance violation
from releasing bad water.
Food and beverage wastewater discharge with a
TOC value greater than 200 ppm can be costly for a
manufacturer. Publicly owned treatment works will
sometimes add a surcharge for treatment that they
deem excessive. Discharge with considerably higher
TOC values may also result in a fine by the EPA or local
representative ensuring CWA compliance.
Running this process without TOC control can be costly
and may lead to illegal discharge. The Sievers InnovOx
TOC Analyzers will allow you to monitor your process
and ensure that not only your treatment facility is
in compliance with the law, but also help to ensure
that you are optimizing your chemical treatment.
Optimization is the key to avoid over-treatment or re-
treatment of a waste stream. Regardless of the dwell
time of the waste in your treatment process, being
able to chemically dose the stream in a real-time
environment will enable your company to minimize
costs and maximize profit.
References
1
The World’s Water 2008-2009, by Peter Gleick et al,
Island Press, waterfootprint.org.
2
EPA 40 CFR, Sampling and Test Procedures, section
133.104, p. 548, 7-1-07 Edition.
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