This document discusses sustainability in food processing factories. It notes that food production accounts for up to 29% of global warming from consumer economies. Regulations in California and Europe establish limits on carbon emissions and water/energy use for tomato processors. More efficient techniques are presented, like multi-effect evaporators that increase evaporation efficiency 6 times over standard evaporators. Recent installations of these evaporators in various countries and industries are outlined. The document advocates for continued adoption of efficient technologies and processes to reduce the environmental impact of food production.

1. SUSTAINABLE FACTORY – JUNE 10 th 2014
THE SUSTAINABLE FACTORY

2. SUSTAINABLE FACTORY – JUNE 10 th 2014
THE IMPACT OF FOOD PROCESSING
…the food system looms large as a major user of fossil fuel.
Recent studies suggest that the food system is responsible for up to
29 % of global worming generated by the consumer economy in
industrialized nations…
Scientific paper: Comparing environmental impacts of regional and national scale food supply
chains: a case study of processed tomatoes – July 2013

3. SUSTAINABLE FACTORY – JUNE 10 th 2014
CALIFORNIA PROSPECTIVE
TOTAL CO2 (2010):
117,6 M t
FOOD PROCESSING CO2 (2010):
1,86 M t
(NAICS categories: 31 311 31131 31142 311315 311421 311423
311611 312130)
“CAP AND TRADE” MECHANISM
ENTERED INTO FORCE SINCE JAN
1ST 2013
1st Chevron Refinery: 4.500.000 t CO2
221st First tomato processor: 83.264 t CO2

4. SUSTAINABLE FACTORY – JUNE 10 th 2014
EUROPEAN PROSPECTIVE
DIRECTIVE 96/61/EC
of 24 September 1996
Concerning integrated pollution prevention and control
Best Available Techniques
In the
Food, Drink and Milk Industries
Applies to tomato processors with 300 t per day production of
finished products.

5. SUSTAINABLE FACTORY – JUNE 10 th 2014
Best Available Techniques or «B.A.T.»
THE MOST SIGNIFICANT ENVIRONMENTAL ISSUE ASSOCIATED
WITH Food Drink and Milk SECTOR ARE:
WATER ENERGYWASTE

6. SUSTAINABLE FACTORY – JUNE 10 th 2014
BAT: APPLIED PROCESS AND TECHNIQUES
UNIT OPERATIONS COVERED
1) MATERIALS RECEPTION AND PREPARATION
2) SIZE REDUCTION
3) MIXING AND FORMING
4) SEPARATION TECHNIQUES
5) PROCESSING TECHNOLOGY
6) HEAT PROCESSING
7) CONCENTRATION
8) PROCESSING BY REMOVAL OF HEAT
9) POST PROCESSING OPERATIONS

7. SUSTAINABLE FACTORY – JUNE 10 th 2014
BAT: CONSUMPTIONS & EMISSIONS LEVELS FOR CANNING
TOMATOES

8. SUSTAINABLE FACTORY – JUNE 10 th 2014
BAT: CONSUMPTIONS & EMISSIONS FOR TOMATO PASTE

9. SUSTAINABLE FACTORY – JUNE 10 th 2014
WHERE DO WE STAND: PASTE
Data supplied by two north Italian companies and one south Italian company for 2012 and 2013
seasons

10. SUSTAINABLE FACTORY – JUNE 10 th 2014
WHERE DO WE STAND: PASTE
Data supplied by two north Italian companies and one south Italian company for 2012 and 2013
seasons

11. SUSTAINABLE FACTORY – JUNE 10 th 2014
WHERE DO WE STAND: PASTE
Data supplied by two north Italian companies and one south Italian company for 2012 and 2013
seasons

12. SUSTAINABLE FACTORY – JUNE 10 th 2014
Scientific paper: Comparing environmental impacts of regional and national scale food supply chains: a case study of
processed tomatoes – July 2013
WHERE IS THE ENERGY CONSUMED: LIFECYCLE

13. SUSTAINABLE FACTORY – JUNE 10 th 2014
WHERE IS THE ENERGY CONSUMED: LIFECYCLE
Scientific paper: Comparing environmental impacts of regional and national scale food supply chains: a case study of
processed tomatoes – July 2013

14. SUSTAINABLE FACTORY – JUNE 10 th 2014
WHERE IS THE ENERGY CONSUMED
0
2000
4000
6000
8000
10000
12000
14000
1 2 3 4 5 6 7
Steam Consumption [kg/h] Power installed [10xkW]
Reference: 1000 t/day tomato line
63%
62%

15. SUSTAINABLE FACTORY – JUNE 10 th 2014
WHAT CAN BE DONE
ENERGY:
• MVR EVAPORATORS INCREASING
EFFICIENCY 6 TIMES
• HIGH PRESSURE BOILERS (30 bars – 450
psig) TO SUBSTITUTE ELECTRIC MOTORS
WITH TURBINES ON EVAPORATORS
• ELIMINATION OF COOLING TOWERS WITH
OPEN AIR PONDS
• TOMATOS UNLOADING FROM AN
ELEVATION (HILL) TO AVOID ELEVATORS
• COUPLED FINISHERS POWERED BY
TURBINES

16. SUSTAINABLE FACTORY – JUNE 10 th 2014
WHAT CAN BE DONE
• CO GENERATION
• HIGH EFFICIENCY MOTORS AND
VFDs
• THERMAL INSULATION ON PIPES
AND EXCHANGERS
WASTE AND WATER:
• TURBO PRESSES TO RECOVER
WASTE
• WISE WATER TRANSPORT
CIRCUIT

17. SUSTAINABLE FACTORY – JUNE 10 th 2014
MVR: HOW IT WORKS
• Virtually no steam needed for heating.
• Exhaust steam from turbine recovered in downstream evaporators
• Evaporation efficiency up to 1:20.
• CFT technology: APOLLO falling film evaporator + centrifugal fan @ maximum
3,200 rpm as MVR.

18. SUSTAINABLE FACTORY – JUNE 10 th 2014
Vapors compressor
MVR: HOW IT WORKS
Product heating pipes
Product steams inside separation
chamber
Product recovery tank
Separation chamber
Vapor suction duct
Vapor outlet duct
Tube bundle heat exchanger

19. SUSTAINABLE FACTORY – JUNE 10 th 2014
CFT’s APOLLO MVR EVAPORATORS INSTALLED
WATER REMOVAL
Cumulative Apollo water removal capacity installed over the last ten year

20. SUSTAINABLE FACTORY – JUNE 10 th 2014
RECENT MVR TECHNOLOGY INSTALLATIONS

21. SUSTAINABLE FACTORY – JUNE 10 th 2014
MVR RECENT INSTALLATIONS
Customer Country / year Application
Water
removal
FIT Portugal / 2003 Tomato 40 t/h
TRANSA Spain / 2004 Tomato 40 t/h
SUGAL Portugal / 2006 Tomato 40 t/h
CONXENTRA Italy / 2007 Whey 12 t/h
ACONCAGUA FOODS Chile / 2007 Tomato 40 t/h
CAMPIL Portugal / 2008 Tomato 40 t/h
EMPRESAS CAROZZI Chile / 2008 Tomato 40 t/h
TOMATO FARM Italy / 2008 Tomato 25 t/h
PROLIVER Belgium / 2008 FMP 12 t/h

22. SUSTAINABLE FACTORY – JUNE 10 th 2014
Customer Country / year Application
Water
removal
SUGALIDAL Portugal / 2009 Tomato 40 t/h
LAS MARISMAS Spain / 2010 Tomato 40 t/h
MUTTI Italy / 2010 Tomato 20 t/h
AGRAZ Spain / 2011 Tomato 40 t/h
EMPRESAS CAROZZI Chile / 2011 Tomato 40 t/h
ZOOGAMMA Italy / 2013 Milk 20 t/h
KAGOME Australia / 2013 Tomato 40 t/h
CONESA Spain / 2013 Tomato 40 t/h
MVR RECENT INSTALLATIONS

23. SUSTAINABLE FACTORY – JUNE 10 th 2014
Customer Country / year Application
Water
removal
ZOOGAMMA Italy / 2013 Milk 20 t/h
YEW TREE DAIRY UK / 2014 Milk 30 t/h
PRONAT Spain / 2014 Tomato 40 t/h
INGOMAR PACKING California / 2014 Tomato 40 t/h
MVR RECENT INSTALLATIONS

24. SUSTAINABLE FACTORY – JUNE 10 th 2014
SKYLINES
CALIFORNIA SKYLINE
MAY 19th
SPANISH SKYLINE
MAY 22nd
MVR EVAPORATORS ARE
6
TIMES MORE EFFICIENT THAN STANDARD TRIPLES

25. SUSTAINABLE FACTORY – JUNE 10 th 2014
THANK YOU ALL !
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