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Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
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Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A

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This Case study was prepared with a third party auditor. The findings showed the amount of waste generated in beverage plants and the Recovery Potential of Recovery Systems are together accurate …

This Case study was prepared with a third party auditor. The findings showed the amount of waste generated in beverage plants and the Recovery Potential of Recovery Systems are together accurate within +/-1%

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  • This Presentation was presented at ISBT April 09, by Alan Sheppard and co-written by Pat Anderson. Data for case study comes from AquaCheck survey results and Recovery Analysis prepared in advance.
  • The beverage industry is seeing this in real time where BOD Surcharges are significantly increasing. This case study had the Customers Surcharges at $150k a year before re-evaluation of municipality. Charges went to$799,833.00
  • These are the rates for the case study. Note the overage rate implemented in June of 06 and increased in September 06
  • This slide shows BOD concentration in PPM annually in 05 & 06
  • This slide shows the average daily BOD load in Pounds
  • This slide shows BOD load factored with the Brix content
  • This slide shows Brix content measured every three minutes and the changeover times identified across the top.
  • This slide shows the BOD load measured every three minutes and the changeover times identified across the top. Note how this slide and last slide match. BOD load matches the Brix in wastes from changeovers
  • Brix vs time for 24 hour period
  • BOD vs time for 24 hour period. Again Note how similar these two slides are.
  • This identifies the waste is mainly at the end of the runs and during changeover periods.
  • Water and Waste Water base rates and overage rates
  • Most important to note the 22,800 gallons of Recovered syrup on line 1 that was measured in Recovered BOD Pounds. The AquaCheck program measured the same amount of raw syrup in BOD measuring as the next slide shows as the Recovery Potential in the Recovery Analysis prepared in advance on site
  • Note the last two lines in the Recovery Analysis. The calculations we use came up with 22,800 and matched to BOB monitoring after being factored in brix and gallons of raw syrup.
  • Transcript

    • 1. Opportunity For BOD Source Reduction The Beverage Industry 2009 Alan Sheppard Global Director Sales, Marketing and Distribution Recovery Systems ; Pat Anderson Director Innovation Responsible Resource Solutions JohnsonDiversey
    • 2. Risks
      • “ If risk is a measure of sustainability, the world faces some massive challenges in the 21st century.”
      • Quoted from Alistair Johnston of KPMG, convener of the WBCSD Risk Champions Group
      Historically the biggest risk to the beverage industry has been water Current and future risks include Pollutants, including oxygen-demanding pollutants (BOD, etc.), released in discharge at a level which, either singly or by interaction with other pollutants, will cause interference with the POTW;
    • 3. Water Footprinting
      • Water footprint accounting ;
        • Blue water
        • Green water
        • Grey water
      • the grey water footprint is the volume of polluted water, calculated as the volume of water that is required to dilute pollutants to such an extent that the quality of the water remains above agreed water quality standards.
      • it is possible to reduce a company’s water footprint through pollution prevention and water reuse
      And now comes…………….
    • 4. Rising Costs of Treating B.O.D. Waste in Beverage Plants
      • Municipal Plants face maximum Capacity
      • EPA's Multi-Sector General Permit (MSGP)
      • SECTOR U: FOOD AND KINDRED PRODUCTS
      • Nations Infrastructure Gap
      • Full Cost Pricing
      • Costs of on-site treatment
    • 5. Sources of B.O.D. Waste
      • Start-Up of a Flavor (Sweeten the Filler)
      • Out of Spec Product during runs
      • End of Flavor Run (Matching Containers to Beverage)
      • Pre-rinse in syrup tank CIP
      • Product returns to drain (can crusher)
      • Spills/ breakage at the filler or on the production line
      > 70% of beverage plant BOD comes from sugar based products
    • 6. Options
      • Status quo (Reactive)
      • Continue to pay for on site treatment or POTW surcharges – risky and not “Sustainable”
      • End of pipe (Proactive)
      • Treat at end of pipe (MBR,etc. ) –capital intensive,
      • Haul it
      • Capture at source (Proactive)
      • Waste haul – expense and not “sustainable”
      • Concentrate (UF,etc.) – sell
      • Re-use internally
    • 7. Four Barriers of Pollution Prevention Implementation
      • Regulatory Structure Companies have become accustomed to complying with the mandates of the EPA after a regulation has been set, and generally have not acted to reduce effluents or other pollutants before regulations are in place
      • Risks
      • To alleviate this fear of risk, it is important to recognize that Pollution Prevention measures are often small changes in manufacturing strategies, but small changes that can significantly improve efficiency and reduce waste
      • Ruts
      • If the process is working, why change it
      • Resources
      • P oor resources -- as a barrier to pollution prevention takes two forms - lack of knowledge and lack of proper accounting
    • 8. BOD Base & Overage Rate Changes normal overage* rate, $/lb rate, $/lb 31-Dec-04 0.249 30-Jun-05 0.271 30-Jun-06 0.288 0.289 30-Sep-06 0.317 0.755 * overage rate is added to base rate for overage pounds
    • 9. BOD Variability 0 1,000 2,000 3,000 4,000 5,000 6,000 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec BOD Concentration , ppm 2006 Flow-Wt. BOD (mg/L) - average 3807ppm 2005 Flow-Wt. BOD (mg/L) - average 3504 ppm
    • 10. Historical BOD Data 0 800 1,600 2,400 3,200 4,000 Jan- 05 Feb- 05 Mar- 05 Apr- 05 May- 05 Jun- 05 Jul- 05 Aug- 05 Sep- 05 Oct- 05 Nov- 05 Dec- 05 Jan- 06 Feb- 06 Mar- 06 Apr- 06 May- 06 Jun- 06 Jul- 06 Aug- 06 Sep- 06 Oct- 06 month - year average daily BOD, pounds average daily BOD limit: 1,037 pounds per day
    • 11. BOD as a Function of Brix - 8,000 16,000 24,000 32,000 40,000 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 Brix Units BOD, ppm 0 25 50 75 100 125 TSS, ppm Measured BOD, ppm Calculated BOD, ppm BOD = 8,458.5 • Brix
    • 12. Brix vs. Time During Flavor Changovers 0 1 2 3 4 9:54 10:03 10:12 10:21 10:30 10:39 10:48 10:57 time, Brix Line 1 changeover Line 2 changeover Line 3 changeover production A B C D E F G samples taken every 3 minutes Dumping Cola Dumping Orange Line 1: Orange to Diet Caramel Line 2: Diet Cola to Diet Caramel Line 3: CF Diet Cola to Cola A: pale yellow B: orange C: brown D: pale orange E: brown F: brown-orange G: pale yellow
    • 13. BOD vs. Time During Flavor Changovers 0 6,000 12,000 18,000 24,000 30,000 9:54 10:03 10:12 10:21 10:30 10:39 10:48 10:57 time, 21 BOD, ppm background: 3,020 ppm production production samples taken every 3 minutes A B C D E F G Dumping Cola Dumping Orange Line 1 changeover Line 2 changeover Line 3 changeover Line 1: Orange to Diet Caramel Line 2: Diet Cola to Diet Caramel Line 3: CF Diet Cola to Cola A: pale yellow B: orange C: brown D: pale orange E: brown F: brown-orange G: pale yellow
    • 14. Brix vs. Time 24-hour Sampling 0.0 0.5 1.0 1.5 2.0 17:05 20:05 23:05 2:05 5:05 8:05 11:05 14:05 time, 21-22 Feb 2007 Brix Line 2 CIP samples taken every hour Thursday Wednesday
    • 15. BOD vs. Time 24-hour Sampling - 3,000 6,000 9,000 12,000 15,000 17:05 20:05 23:05 2:05 5:05 8:05 11:05 14:05 time, BOD, ppm Line 2 CIP samples taken every hour Thursday Wednesday background: 1,180 ppm
    • 16. BOD vs. Time Product Changeover – Root Beer to Diet Root Beer 0 2,000 4,000 6,000 8,000 10,000 9:43 9:52 10:01 10:10 10:19 10:28 10:37 10:46 time, BOD, ppm changeover samples taken every 3 minutes Production: Root beer Production: Dt .Root beer background: 1,980 ppm
    • 17. Effluent Billing Rates $ per k-gal Water Rate 0.70003 Rate: $/k-gal for all k-gals 1.344 Rate: $/k-gal for overage k-gals $ per pound BOD Contaminant Rate 0.31677 Rate: $/lb for all pounds 0.75473 Rate: $/lb for overage pounds
    • 18. BOD Opportunity
      • based on Brix-BOD relationship (BOD = 8,458.5 • Brix)
      • based on overage rate of $ 1.0715 per pound BOD
      Annual Diet & nonDiet recovery as syrup, gallons 22,800 29,600 38,950 Recovered annual syrup “floor value” $114,000 $148,000 $194,750 Total annual recovered syrup “floor value” $456,750 Line 1 Line 3 Line 2 Total annual non-Diet changeovers 682.1 590.1 610.7 Total annual Diet changeovers 271.4 226.1 303.6 71.5 % 72.3 % Percent non-Diet changeovers 66.8 % Grand total opportunity $ 799,833 Annual nonDiet recovery as syrup, gallons 16,310 21,400 26,017 Annual nonDiet recovery as syrup, pounds 147,791 192,600 234,156 Recovered BOD, pounds 1 81,948 107,521 130,720 BOD surcharge avoided 2 $87,807 $115,209 $140,067 Total annual recovered syrup “surcharge value” $343,083
    • 19.  
    • 20. Pollution Prevention (P2.ORG)
      • Promotes the development, implementation, and evaluation of efforts to avoid, eliminate, or reduce pollution at the source
      • Pollution Prevention is a win-win concept -- both for their business and for the environment
      • Pollution Prevention is a means of reducing costs, increasing productivity and reducing waste
      • For the environment, a lower effluent discharge equates to a "greener" planet
      Accountability, Without it, Sustainability is just a good idea.

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