January 17, 2006
Volume 2 Issue 45

 Processors Cut Costs by Watching Waste

Food Processors not only use resources such as electric and water (the two largest) but they also produce waste. Both consumption and removal add additional costs to this special food community. Not only are resource costs an issue but environmental regulation and conformance can add a large price tag to already skyrocketing costs.

Today we will focus on water and waste removal to help reduce your cost of operation.

How much money is pouring down the drain? Well it is estimated for poultry processors almost 60% of water usage is spent in processing alone. Using a systematic approach to water usage alone can save 15 to 20 % a year of water costs. The meat processing group uses water extensively in their operations and can see cost savings as well. The easiest way to learn how to apply an approach to save money is to contact your state’s Agricultural Services Extension group as they can provide extensive free literature and consulting help to put water saving approaches into place. Penn State University, Texas A & M and many other Universities run these extension services as well and they are available for your use. Also contact Trade Associations like NAMP and AAMP for help. 

Measures To Reduce Water and Energy Consumption

1.      Optimize process layout to allow for separation of cooling waters from processing waters to allow for recirculation and thus save money.

2.      Use of taps with automatic shut offs and flow restrictors.

3.      Use of high pressure hoses with automatic shut off for cleaning operations.

4.      Improvement of thermal insulation on coolers, chillers, and cooking appliances.

5.      Using waste heat from refrigerators for heating operations i.e. preheating water.

6.      Install screens and fat traps to recover and reduce course material and reduce your solid waste expense.

7.      Install air jets and dry vibration systems to reduce water usage in cleaning activities (This has implications for the produce distributor).

8.      Avoid using water as a “conveyer” to move things. Transfer solids using augers or conveyers.

9.      Utilize dry cleanup methods whenever practical.

REDUCING WASTE INCREASES PROFITS

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