Elgin Fruit Juices (Pty)(Ltd)

Grabouw, Western Cape,

South Africa

Company Structure Shareholding

• Elgin Fruit Juices is a wholly owned subsidiary of the Two-a-Day Group.

• Two-a-Day is own by 55 apple and pear producers.

• Only current producers of apples and/or pears can be shareholders of Two-a-Day.

• Shareholders farm 2500 ha of apples and 500 hectares of pears

Company Structure

Producers/Shareholders

100%

Two-a-Day Group Ltd

100%

Elgin Fruit

Juices (Pty) Ltd

50%

Tru-Cape Fruit

Marketing (Pty) Ltd

20%

APL Cartons (Pty) Ltd

20%

Link SCM (Pty) Ltd

Company structure

Volumes handled

• EFJ handles roughly 75 000 tons of apples and 15 000 tons of

pears annually, 70% of this volume is from shareholders.

• Production is about 9 000 000 litres of apple concentrate (AJC)

• PJC production 1,65 million litres

• Pomace is sold to the local dairy industry (12 000 tons)

• Apple aroma is also produced

Capital spend 2017/18

• Roughly R105m spend on plant upgrades

• New infeed line

• Fully automated process, linked to Scada for data collection and

analysis

• Press control upgrade

• New second pressing line

• New Ultra filtration plant

• New absorber plant (No more charcoal and gelatin in factory)

• New 70 ton/h evaporator

Problems encountered

• Volume of waste water generated put our effluent plant under

pressure

• COD values to high for effluent plant

• Water use to high in the factory-Drought in the Western Cape

• Price of water increase 400%

• Got in contact with the NCPC through Green Cape

• Appoint Darrin McComb to do a water budget

Process flow

Water Balance

Water Balance

Water Cost

Water saving opportunities

Evap

Absorber

UF 1&2

PW tanks

UF tanks 50°C

100 kl tank

Second pressin

g Sweet water 50°C

Sanitizer

Recovered

caustic

Juice push water

Caustic

recovery

Retentate tank

Juice push water

Product displacement

Caustic

Sanitizer

Sanitizer

Sanitizer

Caustic

Caustic

Caustic tank

Pomace screw

In feed and general cleaning

Flush water, when evaporator goes from product to water and again from water to product. This all goes to 2nd pressing tank Switching to “sweet water tank”/”sanitiser tank” will be according conductivity (flexible parameter), above 400uS to the “sweet water tank”, below 400uS to the drain, below 200uS to the “sanitiser tank”. Spent caustic, after the caustic cycle of CIP must go to spent caustic tank Switching to “caustic tank”/”drain” will be according conductivity (flexible parameter), above 400uS to the “caustic tank”, below 400uS to the drain, below 200uS to the “sanitiser tank”,.

Sanitizer water after the CIP cycle must go to the sanitizer tank See above

Rinse water after sanitizer and caustic to drain See above

Evaporator

Evaporator

Modified sealing water recycling see drawing of Deon van Straaten and P&ID Install a seal water recovery system

UF 1 & 2

Product displacement, to the retentate tank This is already the procedure No, product displacement due to low flow goes to drain

Spent caustic, after the caustic cycle of CIP must go to spent caustic tank

Sanitizer water after the CIP cycle must go to the sanitizer tank

Rinse water after sanitizer and caustic to drain

UF Plants

Switching to “caustic”/”sanitiser tank”/”drain” will be according conductivity (flexible parameter) and status of the filtration unit, when it I was in “cleaning 1” above 400uS to the “caustic tank”, below 400uS to the drain, below 200uS to the “sanitiser tank”.

Additionally there will be an vale beside the permeate drain valve V491, which sends the approx. 1m3 clear water out of the permeate tank into the sweet water tank during each start up. Note 1: If there is no “batch tank cleaning” (is not standard process) all the water geos to the drain. Note 2: approx. 1-1.5m3 of water which is in the modules during stand still won’t be collected during start up.

Absorber

Flush water, when absorber goes from product to water and again from water to product. This all goes to 2nd pressing tank, Juice push water.

Spent caustic, after the caustic cycle of CIP must go to spent caustic tank

Sanitizer water after the CIP cycle must go to the sanitizer tank

Rinse water after sanitizer and caustic to drain

Absorber (not in Bucher scope)

Switching to “caustic”/”sanitiser tank”/”drain”/”sweet water” will be according conductivity (flexible parameter) and status of the Adsorber.

Process water

T1 30t

New 100kl tank will act as a buffer tank, when process water tank is full, water will go to this tank. When process water tanks is empty it will first fill from this tank, then from municipal supply.

Ozone system will be installed in the Process water tanks, two circulation pumps maintain pressure in the line

Service spray balls, mills, UF plants

Water in the UF Tanks is heated to 50°C through HE. Two circulation pumps maintain pressure in the line

Process water

Process water

T2 30t

Clear condensate from evaporator

Raw condensate from evaporator

Municipal water Absorber T2

Absorber T1

UF Water

T2 45t

UF Water

T1 45t New

100kl tank

Absorber tanks supply the Absorber Installed in the area of the adsorber

2nd pressing tank

Sweet water tank

Supply from evaporator and Absorber and UF plants

Top up from process water tanks (clear condensate connection 8 in the P&ID, via spray ball)

Supply leach water to presses and water to 2nd pressing tank

Pump to circulate through heat exchanger to heat water to 50°C

New 60kl 2nd pressing tank

Note: Depending on the amount of water, this water may also be used for diafiltration on both UltraStar units, For now lets leave this option

Recovered caustic tank

Supply from evaporator, UF 1 & 2 and Absorber The lines from the press are also included with 3 x2 manual valves, since each press delivers 1500l of caustic once a week after cleaning. Noted agreed

Overflow to drain

Recovered caustic tank

Caustic recovery system

Won’t be included in the Bucher system. Except signals

of communication

Agree

Caustic tanks at absorber

Sanitizer tank

Supply from evaporator, UF 1 & 2 and Absorber

Overflow to drain

Sanitizer tank

Infeed line

Ring main in factory, for general cleaning

Retentate tank

Supply from UF 1 & 2

Overflow to drain

Retentate tank

Pomace discharge line

Flow meter inline

Top-up from process water if it is below approx. 10% via spray ball with water

Note: On the P&ID the option to send the retentate from the UF-units “direct”/”via pump 3121PCE05” to the anaerobic plant is still in. Do you like to keep this option or should we take it off? Keep it for the moment

Conclusion, way forward

• Municipal water volumes reduce 20-30%

• Effluent volumes reduced 15%

• COD levels are under control

• Caustic recovery plant will be commissioned

• Absorber water handling improved

• Looking to install a borehole to ensure water quality