Seiberling, a Haskell Company presented on water reduction last week at the FPSA (Food Processing Suppliers Association) annual conference in March 2015. Presentation was given by Bob Price, Senior Project Manager.

1. www.seiberling.com
Water Reduction in Food Processing Facilities
Water Reduction in Food Processing Facilities
Economics | Feasibility | Impact

2. Water Facts
www.seiberling.com
69% of the Fresh water that is
on earth is unavailable in
Glaciers and permafrost.
66% of the Earth is covered by water.
97.5% of that water is saltwater.

3. Water Facts
http://cnx.org/contents/f7706968-c97f-4337-8a3f-2d48ecc84495@2/Nutrient_Cyclesechnical Offerings
www.seiberling.com

4. Water Facts
www.seiberling.com
source: www.CSWS.ca

5. Why Is Water Conservation Important to Us?
According to the United Nations, water use has grown at more
than twice the rate of population increase in the last century. By
2025, an estimated 1.8 billion people will live in areas plagued
by water scarcity, with two-thirds of the world's population
living in water-stressed regions as a result of use, growth, and
climate change.
The number of people
with access to clean water
has doubled in the last 20
years.
1.1 billion people in the
world still do not have
access to safe water. This
is nearly 20% of the
population.
www.seiberling.com

6. Why Is Water Conservation Important to Us?
The World’s fresh water supply has remained relatively
constant throughout history, but…us?
Conservation Important to us?
Humans have not been the best stewards of the land. A
majority of industrial water is returned to the environment but
is contaminated.
http://www.filterwater.com
www.seiberling.com

7. Why Is Water Conservation Important to Industry?
www.seiberling.com
It’s expensive!

8. How much does water cost?
$0 $100 $200 $300 $400 $500 $600 $700
Chicago
New York
Los Angeles
Columbus
Atlanta
Seattle
Santa Fe
$ per 10,000 Gallons
$ per 10K
http://www.circleofblue.org/waternews/2013/world/the-price-of-water-2013
www.seiberling.com

9. How much water are we talking about?
Final
Processing -
1.2 – 3.0
Gallons H2O/
Gal Milk
Overall - 880
Gallons
H2O/Gal Milk
www.seiberling.com

10. Dairy Product Consumption in the United States
www.seiberling.com
198.8
13
5.6
36
36
36
23.9
11.6
2012 US Per Capita Consumption (lbs.)
Fluid milk and cream
Yogurt
Butter
Cheese
Cottage Cheese
Sour Cream/Dips
Frozen dairy products
http://www.ers.usda.gov/data-products/dairy-data.aspx#48505

11. How much milk is consumed?
10,000,000,000 gal. of milk!
15,000 miles of tankers
bumper to bumper.
33,000 football fields
covered with gallon jugs!
www.seiberling.com

12. Final Processing 10 Billion Gallons of Milk
Takes Over 21 Billion Gallons of Water!
www.seiberling.com

13. How much water to CIP clean 1,300 US Dairies?
Over 21 Billion Gallons of Water!
Fluid Milk Plant Water Use
Ratio 2.1 gal H2O / Gal Output
50%
16%
6%
5%
5%
4%
3%
3%
2%
2%
4%
CIP
Cooling Tower
Homo Cooling
Filler Rinse/Spray
Separators
Case Washer
Conveyor Lube
Enviro / Sanitary
Central Sanitizing
Boiler
Misc
Ecolab 2014 OSU CIP Course
www.seiberling.com

14. Common Sense Water Reduction | Good Housekeeping
www.seiberling.com

15. Reduced Water Consumption by Optimization
New Plants - Proper Design . . . Up front.
– Properly size CIP Supply/Return and Process Lines to minimize volumes
– Train Production and CIP Personnel.
– Automate CIP Systems with the proper controls to provide for water
optimization.
– Consider Product Recovery Systems to minimize residual product in lines
prior to CIP … double payback.
– Optimize CIP Operating Parameters during commissioning.
– Strategically locate CIP Room central to cleaning loads.
www.seiberling.com

16. Centralized CIP Design
Centrally Located CIP Rooms
– Multiple CIP Rooms
based upon plant size
– Locate centrally to
cleaning loads
Raw Side
CIP
Pasteurized Side
CIP
www.seiberling.com

17. Example 1
– Relocating Pasteurized Side CIP Skids closer to use point
– 11,500 circuits per year affected
– Average piping savings per circuit – 240 feet
0
50000
100000
150000
200000
250000
300000
2" Piping 2 1/2"
Piping
Piping Volume (Gal)
Gallons
www.seiberling.com
Centrally Located CIP Room

18. Summing up Pre-rinse, Alkali Wash,
Post-rinse, and Sanitize steps – 1.6
Million gallons/yr. Reduction.
What does this cost?
Example 1
– Relocating Pasteurized Side CIP Skids closer to use point
– 11,500 circuits per year affected
– Average piping savings per circuit – 240 feet
0
50000
100000
150000
200000
250000
300000
2" Piping 2 1/2"
Piping
Piping Volume (Gal)
Gallons
www.seiberling.com
Centrally Located CIP Room

19. Time Savings:
330 Hours/Year!
$0
$10,000
$20,000
$30,000
$40,000
$50,000
$60,000
Savings per Year
$ per Year
Cost Savings:
$124,000/Year!
www.seiberling.com
Centrally Located CIP Room

20. Properly Sized Process Piping
Example 2
– Ice Cream Facility, Pasteurized Mix Lines from Storage
Tanks to Freezer Centers.
– 18 Storage Tanks to 8 Freezer Centers.
– 6,500 Feet of Piping.
0
500
1000
1500
2000
2500
2"
Piping
2 1/2"
Piping
3"
Piping
Piping Volume (Gal)
Gallons
www.seiberling.com

21. What’s the big deal?
The pipes aren’t that
much bigger.
Example 2
– Ice Cream Facility, Pasteurized Mix Lines from Storage
Tanks to Freezer Centers.
– 18 Storage Tanks to 8 Freezer Centers.
– 6,500 Feet of Piping.
0
500
1000
1500
2000
2500
2"
Piping
2 1/2"
Piping
3"
Piping
Piping Volume (Gal)
Gallons
www.seiberling.com
Properly Sized Process Piping

22. 770K
420K
4,620K
2,520K
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
4,500,000
5,000,000
3" Piping 2 and 2.5"
Piping
Volume
Product
(Gal/Yr.)
Water
(gal/Yr.)
• Annually, about 2.1 Million gallons of
additional water are required to clean
lines that were installed too large.
$52,000.
• Initial Piping installation costs
increased by $105,000.
www.seiberling.com
• It takes an additional 350,000 gallons of
product every year to fill lines. Assuming
that air blows or flushing can be used to
recover 90%.
• Over 35,000 gallons worth of profits
down the drain! At $3 for a 1.5 qt.
container and 80% overrun, that’s only a
bit over $250,000 per year!!
Properly Sized Process Piping

23. • Products such as milk and juices
can be recovered effectively with
air blows and water flushes.
• More viscous products, however,
and usually more costly products
(ice cream, sour cream, yogurt),
require product recovery systems
to recover substantial amounts of
product.
Product Recovery – Product to Filler, Not the Drain
www.seiberling.com

24. Conductivity/Resistivity Sensors –
Determine CIP solution/water
interfaces during post rinse and final
rinse steps.
Automation of Process and CIP Functions
Turbidity Sensors – Effectively monitor
product/water interfaces and transitions in
CIP pre-rinses .
Flow Meters - Automate rinse and
recirculation steps based upon
volume instead of time.
Turbidity
Flow
Conductivity
Turbidity
Air Blow
Air Blows - Chase product or
detergent from pipelines.
www.seiberling.com

25. Optimize CIP Parameters during Commissioning
40%
10%
15% 15%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
Turbidity
Sensors -
Product
Flushes, CIP
Transition
Conductivity
Sensor - CIP
Transition, Final
Rinse
Rinse Recovery
- Re-using rinse
water
Burst Rinse -
Minimizing Pre-
rinse
Potential Water Savings by using
Water Savings
Ecolab 2014 OSU CIP Course
www.seiberling.com

26. Optimize CIP Parameters during Commissioning
• CIP Unit Matrix Charts
• CIP Circuit Recipe Parameters
• Valve Sequencing Chart
• PLC Code
www.seiberling.com

27. Reduced Water Consumption by Optimization
– Develop cost estimate identifying key improvements/anticipated ROI
resulting from:
– Reduced product lost
– Reduced water, chemical, steam, and electricity usage
– Reduced waste treatment costs
– Monitor existing operations, develop GAP assessment.
Existing Plants – Design Upgrades and Optimization
– Recommend equipment/piping and programming modifications.
www.seiberling.com
– Optimize CIP operating parameters during commissioning.
– Train Production and CIP personnel.

28. Optimization of Existing Facilities
CIP System – Not the “Sexy” Part of Processing
– Major user of water in a Food processing facility.
– Typically considered a “Utility” and not given proper attention.
– Operators are not trained well on how the systems are to operate and how
to troubleshoot problems.
– System parameters are “excessive” in most installations….some is good,
more is Better.
– Is the major reason for loss of production time on equipment.
Production Is the Number One Priority in Processing Plants
– Unfortunately many plants do not realize how much production time is lost
due to non-optimized CIP systems.
www.seiberling.com

29. Case Study – Existing Plant Optimization
22,500 Annual CIP Circuits in Dairy A
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Cleaning Events
Cleaning Events
www.seiberling.com

30. Circuit Name
Post Rinse Set
point (Gal)
Actual Gal.
Needed Circuits/Yr.
Excess
Rinse
Vol./yr.
(Gal)
HTST1 Discharge 800 590 352 73,920
SK1/2 250 145 136 14,280
PT25 350 158 104 19,968
PT6 350 175 88 15,400
Freezer Center 6 800 525 78 21,450
Tankers Bay 1/2 250 150 1,729 172,900
Tankers Bay 3/4 250 150 960 96,000
Past. VG 2 850 455 288 113,760
Past. VG 4 850 490 169 60,840
Total Yearly 3,904 588,518
About 150 gallons per circuit just on Post Rinse!
www.seiberling.com
Case Study – Existing Plant Optimization
22,500 Annual CIP Circuits in Dairy A

31. 73,920
14,280
19,968
15,400
21,450
172,900
96,000
113,760
60,840
Excess Rinse Vol./yr. (Gal)
HTST1 Discharge
SK1/2
PT25
PT6
Freezer Center 6
Tankers Bay 1/2
150 gallons/circuit avg. reduction – 3.3 Million gallons water
$82,000, 680 hours @ 80 GPM
20% - 136 hours filler runtime @ 80 cpm and 5% profit, $4 per carton
$130,000 lost profit per year!
www.seiberling.com
Case Study – Existing Plant Optimization
22,500 Annual CIP Circuits in Dairy A

32. Case Study - Cost of Leaving Product in Lines
Annual Costs related to dumping 1,000 Gal.
Alkali Tank (Cost per Re-use CIP System):
# of drops – (2 per day)(5 days/wk.)(52 wks./year) = 520 drops
per year or 520,000 gallons alkali solution per year.
BTUs –390,000,000 btus @ approximately $10 per
1,000,000 btus - $3,900
Chemical Costs – Approximately $0.07 per gallon of
solution - $36,400
Water/Waste Treatment Cost – $26,000
Electrical Cost - 15 HP Pump - $547
Product Loss – 10.5 Gal, about 90 15 oz. bottles –
Retail at $4.49 - $404/day - $105,000
Lost Time –1040 hours per year @ $13 per hour -
$13,520
www.seiberling.com

33. Case Study - Cost of Leaving Product in Lines
Annual Costs related to dumping 1,000 Gal.
Alkali Tank (Cost per Re-use CIP System):
# of drops – (2 per day)(5 days/wk.)(52 wks./year) = 520 drops
per year or 520,000 gallons alkali solution per year.
BTUs –390,000,000 btus @ approximately $10 per
1,000,000 btus - $3,900
Chemical Costs – Approximately $0.07 per gallon of
solution - $36,400
Water/Waste Treatment Cost – $26,000
Electrical Cost - 15 HP Pump - $547
Product Loss – 10.5 Gal, about 90 15 oz. bottles –
Retail at $4.49 - $404/day - $105,000
Lost Time –1040 hours per year @ $13 per hour -
$13,520
$370,000 loss
per year!
www.seiberling.com

34. Other Areas of Water Consumption in Dairies
50%
16%
6%
5%
5%
4%
4%
3%
3%
2%
2%
Water Use
CIP
Cooling Tower
Homo
Filler Rinsing
Separators
Case Washer
Misc
Conveyor Lube
Hoses, Footbath
Central Sanitizer
Boiler
www.seiberling.com

35. Summary
Water Reduction
• Have CIP Systems optimized and verified by qualified
partners who can provide long term support.
• Update existing controls to allow for CIP optimization.
• Design the System properly up front ... you get what you pay
for in equipment and engineering design.
• Properly train production staff to be experts … they are your
first line at water/waste reduction.
www.seiberling.com

36. Contact Information
www.seiberling.com
Bob Price
Senior Project Manager
Seiberling Associates, a Haskell Company
bob.price@seiberling.com
LinkedIn
Connect with Bob
Follow Seiberling