WATER AND SEWAGE MANAGEMENT

IN THE FOOD INDUSTRY

Smoczyński Michał
Associate Professor
Chair of Milk Science and Quality Management
Faculty of Food Sciences
Warmia and Mazury University in Olsztyn
michal.smoczynski@uwm.edu.pl
www.uwm.edu.pl
FOOD INDUSTRY:

A. Processing of animal products

 meat processing
 poultry
 dairy industry
 fish processing

B. Processing of agricultural products

 processing of grain and pasta
 processing of potatoes
 vegetables and fruit processing
 sugar industry
 oil production

Water and sewage management in the food industry 2

FOOD INDUSTRY IN POLAND

 Approx. 15% of the whole industrial production,

 7% contribution to the GDP (Gross Domestic Product)
 It employs more than half of million people
 About 27 thousand companies
 Only 350 large companies, and only 1400 had the status of medium-sized
companies
 It provides 21% of the food products sold on the domestic market
 Many processing plants are characterized by the seasonality of production
(mainly fruit, vegetable, sugar and starch industry)

Water and sewage management in the food industry 3

CONSUMPTION OF WATER IN THE FOOD INDUSTRY IN POLAND
(YEAR 2002)

Food industry branch Water consumption [mln m3]

Meat production 13,1

Fish processing industry 0,6

Fruit and vegetables industry 18,3

Production of oils and fats 1,7

Production of dairy products 23,3
Production of sugar 7,8
Production of beverages 15,3

Total:  82,8

Water and sewage management in the food industry 4

WATER CONSUMPTION OF DIFFERENT FOOD PRODUCTS

Production Water consumption [dm3/kg]

Jam 13-25
Canned bean 13
Frozen bean 12
Canned vegetables 10
Frozen fruits 7
Vegetable juices 16
Concentrated fruit juice 40
Puree 6-12
Pickles 9
Depends also on:
- type of production
- the applied technology
- implementation of closed loop water systems

Water and sewage management in the food industry 5

POLLUTION GENERATED BY THE SELECTED BRANCHES OF THE FOOD INDUSTRY
Pollutants emitted into the
Branch
atmosphere
-flue gases from coal fired
Meat boilers (CO, SO2, NO2), dust
industry hydrocarbons
- smoke from the smokehouse
(over 250 compounds)
- odor (eg. ammonia, hydrogen
sulfide) coming from livestock,
slaughterhouses, fertilizers,
wastewater treatment
burdensome for local society
- ammonia from special cooling
systems, typically discharged
into the atmosphere
Water and sewage management in the food industry
Type of wastewater Type of waste
- waste water from production - slaughterhouse
(technological), the storage of waste eg. skin,
livestock, slaughtering and bristles, blood
processing division, contains - used machine oils,
organic substances (fat and scrap metal, etc.
protein), suspension, bacteria, - manure from
they get into the sewage in the storage of livestock,
form of blood, piece of meat, fat, slag, ash
hair, soil, fertilizer, detergents etc. - sludge from sewage
- non-production waste generated treatment plants,
during washing vehicles and communal living
equipment waste
- sewage exceeds acceptable - packaging waste
levels of pH, BOD5, COD, dissolved  
solids and slurries
6
 Pollutants
Branch emitted into the Type of wastewater Type of waste
atmosphere
- carbon - waste water resulting from washing - solid waste from
Fruit and monoxide (CO), the raw materials and blanching of agricultural products
vegetables sulfur dioxide - waste water resulting from washing - remnants of peeling
industry (SO2), dust from facilities and equipment vegetables and fruit
  the boiler - waste water from the boiler and - ash and slag from boilers
- ammonia of cooling water systems - packaging waste
cooling systems - chemicals used in water treatment. - sludge from sewage
- specific indicators of pollution are: treatment plants
variable pH value, high value of BOD5,  
high concentration of suspension

Water and sewage management in the food industry 7

 Pollutants emitted into
Branch
the atmosphere
- carbon monoxide (CO),
Dairy sulfur dioxide (SO2),
industry solids from the coal fired
boiler
- dust coming from
manufacturing lines of
dry milk and whey
- ammonia from cooling
systems
Water and sewage management in the food industry
Type of wastewater Type of waste
- waste water from washing of floors and - Ash and slag from
equipment boilers fired with coal
- whey coming from cheese production - sludge from sewage
- waste water from washing machines, treatment plants
boilers and cooling systems - rejects and scrap
- chemicals precipitated during water - packaging waste
softening - municipal waste
- types of pollution: variable pH, high
value BOD5, fats, total suspension
8
Branch Pollutants emitted into the atmosphere Type of wastewater Type of waste

- carbon dioxide (CO2), sulfur dioxide - waste in the form of - sludge and solid
Sugar (SO2), nitrogen dioxide (NO2), dust and plant residues, dirt, sand, waste (beet and
industry dirt hydrocarbon from coal fired boilers oils and fats, chemicals, Packaging waste)
and pulp dryers additives, products and - liquid waste (waste
- dust created in lime (calcium oxide), detergents oils)
sugar dust created during the transport, - cooling water - slag, sand, stones
storage, packaging and briquetting of - sewage usually exceeds and contamination
sugar acceptable levels of COD, from beet
- carbon dioxide (CO2)and carbon BOD5, total nitrogen,
monoxide (CO) in bulk gases generated in suspended solids and
the saturation process dissolved solids
- sulfur dioxide (SO2)from the sulfur
furnace

Water and sewage management in the food industry 9

CONCENTRATION OF POLLUTANTS IN RAW SEWAGE FROM SELECTED FOOD
PLANTS

Ether Total Total

BOD5 COD TSS
Branch extract phosphorus nitrogen pH
[g O2/m3] [g O2/m3] [g/m3]
[g/m3] [g/m3] [g/m3]
Potato
400-2500 700-4000 No data 200-1800 10-60 20-250 5-8
industry
Sugar
600-1300 2500 No data 100-6500 10-70 10-200 6-9
industry
Meat and
poultry 200-1800 1000-3500 300-1000 400-1500 10-20 50-200 6-9
industry
Dairy
100-2500 1000-5000 45-110 800-1000 5-20 55-160 6-9
industry
Fruit and
vegetable 200-1500 400-2800 10-1400 50-800 <1 <5 6-9
industry
Fish
>7000 >10000 100-700 <3500 5-50 500 5-9
industry
Oil
>5300 >8700 >6300 >2400 <100 No data 9-11
industry

Water and sewage management in the food industry 10

SEWAGE MANAGEMENT IN THE FOOD PROCESSING PLANTS

Wastewater and sewage from production

Factory sewage pre-treatment plant Other waste

Sewage system

Municipal wastewater treatment plant

Environment

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FOOD WASTEWATER IN THE ENVIRONMENT

Main problems:
 organic substances (fat, oil, protein, carbohydrates)
 residues of detergents and disinfectants
 hot sewage, unfavorable pH
 microflora (pathogens, viruses etc.)

How to reduce possible threats?

 equalizing sewage
 avoiding the wave discharges
 work organization and cooperation

Water and sewage management in the food industry 12

BASIC OF WASTEWATER TREATMENT IN FOOD INDUSTRY

  Dissolved Colloidal particles Suspension Rapidly sedimenting

particles suspension
Size of particle, µm <0.01 0.01-1 1-100 >100

Pre-treatment Biological treatment Specific

- mechanical - grates or sieves, settling including removal of ultrafiltration,
tanks, flotation units, grease biocompounds - reverse
interceptors nitrogen and osmosis
- mechanochemical - coagulants and phosphorus
polymers
- fermentation of raw sewer (biogas
recovery)

Water and sewage management in the food industry 13

CHEMICAL WASTEWATER TREATMENT PROCESS

involves application of selected chemical reagents, which due to their

characteristics can be divided into:
 coagulants and flocculants

 disinfectants

 oxidizing agents

 reagents for correction of pH

Chemicals 1992 Chemicals 2012

PIX PIX
Calcium Polymers
Iron blends
PAX
Aluminium blends
Iron aluminium coagulants

Water and sewage management in the food industry 14

 EXAMPLE OF EFFICIENCY OF SEWAGE TREATMENT FOR MEAT
PLANT (SLUGHTER AND PROCESSING) WITH CHEMICAL
TREATMENT

[Flotation type DAF, PIX112 at a dose = 250 g/m3, flocculation with the anionic polyelectrolyte]

Sewage after Terms from municipal

Parameter Raw sewage
treatment treatment plant

COD [ mg O2/dm3] 1954 480 1000

TSS [mg/dm3] 458 75 330

Ether extract [mg/dm3] 922 19 50

Total solutes [mg/dm3] 1083 1166 1200
Sulfur [mg/dm3] 194 292 420

Phosphates [mg/dm3] 26 0,3 Not applicable

Water and sewage management in the food industry 15

SPECIAL CONSIDERATIONS OF CHEMICAL WASTEWATER TREATMENT IN
FOOD INDUSTRY

Branch Strategies for wastewater treatment

- wastewater from washing - due to the low content of COD/BOD5 application of coagulants
Fe (III) and Al is not necessary; they must be used for removal of hydrogen sulphide
particularly when pH <8 iron coagulants, optionally oxidizing agents
Potato
- technological sewage containing starch - the most common method is precipitation with
industry
the use of the coagulant and anionic or cationic polymer
- in the biological purification iron coagulants are especially effective, which additionally
eliminate hydrogen sulphide during dehydration and the storage of sludge
Spirit and
use of Fe (III) is most commonly recommended for removing of hydrogen sulphide from the
yeast
anaerobic processes
industry
Fruit and
removal of suspended solids with its simultaneous compaction with the use of Fe (III) salts
vegetables
and appropriate polymer
industry
- due to low content of suspensions and colloids, coagulants are not used.
Brewery
- in the presence of hydrogen sulphide salts of Fe (III) may be used or oxidizing agents
industry
containing sulphate (VI) iron (III) and nitric acid (V)

Water and sewage management in the food industry 16

Branch Strategies for wastewater treatment

Sugar Similarly to potato industry, but at pH<8 sewage comprising simple sugars, more easily
industry undergoes anaerobic processes, combined with the emitting of hydrogen sulphide

- mechanochemical pretreatment of wastewater by means of DAF flotation system,

involving salt of Fe (III) or Al and adjustment of the pH with the NaOH and the use of
anionic polymer; main objective is fat removal before biological treatment or discharge to
Meat industry
the sewage system
- polyaluminum chlorides and iron (III) compounds are used to remove phosphorus, scum
and swelling caused by bacteria

- the pretreatment of wastewater by means of DAF flotation assisted with chemical

coagulant and the polymer before discharge to sewer is used
Dairy industry
- coagulating compounds based on iron or aluminum are used during biological treatment
processes

- mechanochemical pretreatment is frequently used; problems and methods similar to

Fish industry
meat industry

Water and sewage management in the food industry 17

DAIRY WASTEWATER TREATMENT

 11,183 million litres of milk were processed in Poland in

2011.
 milk consumption amounted 194 litres (without milk used
for butter production) per capita
 water consumption was 0,7-2,5 m3/t of processed milk
 25.4 hm3 of sewage was formed, of which 13.8 hm3
wastewater was treated (9.0 hm3 biologically and 4.8 hm3
with increased nutrient removal) and removed to the
environment. The remaining 11.4 hm3 did not require
treatment or after pretreatment were discharged into the
sewer
 BOD5 value of milk is equal to 104 000 mg O2/l

Water and sewage management in the food industry 18

THE SEQUENCE OF PROCESSES USED FOR CLEANING

 pretreatment:

removal of the contaminants of large size – straining process

mineral removal – sedimentation on sand traps
removal of fat - flotation process,
averaging of wastewater
coagulation of colloidal particles
 treatment
removal of impurities easily degradable – biological processes (aerobic and
anaerobic)

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FLOTATION

 spontaneous flotation- spontaneous flow of fat to the surface

 assisted flotation- fat is taken up on the surface by means of gas bubbles

(usually pressurized air)

Water and sewage management in the food industry 20

COAGULATION

In the initial treatment of dairy wastewater process of coagulation

may be used:

 during pressurized air flotation (coagulants are dosed before the

flotation chamber)
 during biological treatment, when the precipitation will greatly
reduce the pollution load

Water and sewage management in the food industry 21

 ACTIVATED-SLUGDE METHOD

 single-use bioreactor - working with the secondary settling tank and

a device for recirculation of sludge
 three-stage biological reactor - the division into three chambers:
anaerobic, aerobic and hypoxic which allows for implementation of
biological phosphorus removal, denitrification and nitrification
 Sequential Batch Reactor (SRB)

Water and sewage management in the food industry 22

EXAMPLES OF RESEARCH TRENDS FOR WASTEWATER MANAGEMENT IN
THE FOOD INDUSTRY
Short characteristic Reference

Parashar A., Jin Y., Mason B., Chae M., Bressler D.C. Incorporation
Use of whey as an addition to cereals in of whey permeate, a dairy effluent, in ethanol fermentation to
the production of ethyl alcohol provide a zero waste solution for the dairy industry. Journal of
Dairy Science, 2015, 99: 1859-1867

The use of condensate from UHT

process to provide high quality water
for the boiler - purification by reverse
osmosis
The possibility of using of a fat layer
from dairy wastewater for production
of biodiesel
Suarez A., Fidalgo T., Riera F.A. Recovery of dairy industry
wastewaters by reverse osmosis. Production of boiler water.
Separation and Purification Technology, 2014, 133: 204-211
Sivakumar P., Anbarasu K., Renganathan S. Bio-diesel production
by alkali catalysed transesterification of dairy waste scum. Fuel,
2011, 90: 147-151

Das B., Sarkar S., Sarkar A., Bhattacharjee S., Bhattacharjee C.

New methods for the recovery of whey Recovery of whey proteins and lactose from dairy waste: A step
proteins and lactose from the whey toward green waste management. Process Safety and
Environmental Protection, 2016, 101: 27-33

Water and sewage management in the food industry 23

Short characteristic Reference

Parashar A., Jin Y., Mason B., Chae M., Bressler D.C.
Use of whey as an addition to cereals in Incorporation of whey permeate, a dairy effluent, in ethanol
the production of ethyl alcohol fermentation to provide a zero waste solution for the dairy
industry. Journal of Dairy Science, 2015, 99: 1859-1867

The use of condensate from UHT

Suarez A., Fidalgo T., Riera F.A. Recovery of dairy industry
process to provide high quality water
wastewaters by reverse osmosis. Production of boiler water.
for the boiler - purification by reverse
Separation and Purification Technology, 2014, 133: 204-211
osmosis

The possibility of using of a fat layer Sivakumar P., Anbarasu K., Renganathan S. Bio-diesel
from dairy wastewater for production of production by alkali catalysed transesterification of dairy waste
biodiesel scum. Fuel, 2011, 90: 147-151

Das B., Sarkar S., Sarkar A., Bhattacharjee S., Bhattacharjee C.

New methods for the recovery of whey Recovery of whey proteins and lactose from dairy waste: A step
proteins and lactose from the whey toward green waste management. Process Safety and
Environmental Protection, 2016, 101: 27-33

Water and sewage management in the food industry 24

References:

Konieczny P., Szymański M. Ścieki przemyslu spożywczego –

charakterystyka, zagrożenia, korzyści. Eko-net.pl – Firma i środowisko,
2005, 3, 16-22.
Kasztelan A., Kierepka M. Oddziaływanie przemysłu spożywczego na
środowisko w Polsce. Stowarzyszenie Ekonomistów Rolnictwa i
Agrobiznesu, Roczniki Naukowe, 2014, 16(2), 109-116.
Puchlik M., Struk-Sokołowska J., Wołejko E., Wydro U. Problem
oczyszczania ścieków z przemysłu spożywczego w małych i średnich
przedsiębiorstwach. EKO-DOK 2016, VIII Konferencja
Interdyscyplinarne Zagadnienia w Inżynierii i Ochronie Środowiska,
2016.
Smoczyński M. Nowe trendy w gospodarce wodno-ściekowej w
przemyśle mleczarskim. Przegląd mleczarski, 2016, 7, 3-6.

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