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8/22/2019 Guidance for Dairy and Milk Processing Sector-ippc_s6_13
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www.environment-agency.gov.uk
Sector Guidance Note IPPC S6.13
General Guidance for the Dairy and
Milk Processing Sector
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Guidance for the Dairy and Milk Processing Sector IPPC S6.13 | Issue 1 | Modified on26 October, 2003 i
Commissioning Organisation
Environment Agency
Rio House
Waterside Drive
Aztec West
Almondsbury
Bristol BS32 4UD
Tel 01454 624400 Fax 01454 624409
Environment Agency
First Published 2001
ISBN 0 11 3101740
This document is Environment Agency copyright . We specifically allow the following: Internal business or personal use. You may use this document for your own private use or for use within your
business without restriction. Giving copies to others. You may do this without restriction provided that you make no charge.
If you wish to use this document in any way other than as set out above including in particular for commercial gain,for example by way of rental, licence, sale or providing services you should contact:
Liz Freenland
Data and Information Exploitation Manager
Environment AgencyRio House
Waterside Drive
Aztec West
Almondsbury
Bristol
BS32 4UD
This is an uncontrolled document. To ensure you are using the latest version please check onany of the websites listed within the references.
Written comments or suggested improvements should be sent to Mark Maleham at the Environment Agency byemail at [email protected] or at:
Environmental Protection National Service
Environment Agency
Block 1
Government Buildings
Burghill Road
Westbury-on-Trym
Bristol.
BS10 6BF
Telephone 0117 914 2868
Table 0.1: Record of changes
Version Date Change Template Version
Issue 1 October 2003 V5
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Guidance for the Dairy and Milk Processing Sector IPPC S6.13 | Issue 1 | Modified on26 October, 2003 ii
Executive summary
This guidance has been produced by the Environment Agency for England and Wales with the Scottish
Environment Protection Agency (SEPA) and the Northern Ireland Environment and Heritage Service
(EHS). Together these are referred to as the Regulator throughout this document. Its publication
follows consultation with industry, government departments and non-governmental organisations.
What is IPPC Integrated Pollution Prevention and Control (IPPC) is a regulatory system that employs an integrated
approach to control the environmental impacts of certain industrial activities. It involves determining the
appropriate controls for industry to protect the environment through a single Permitting process. To
gain a Permit, Operators will have to show that they have systematically developed proposals to apply
the Best Available Techniques (BAT) and meet certain other requirements, taking account of relevant
local factors.
This Guidance and the
BREF
This UK Guidance for delivering the PPC (IPPC) Regulations in this sector is based on the BAT
Reference document BREF (see Ref. 1) produced by the European Commission. The BREF is the
result of an exchange of information between member states and industry. The quality,
comprehensiveness and usefulness of the BREF is acknowledged. This guidance is designed to
complement the BREF and is cross-referenced to it throughout. It takes into account the information
contained in the BREF and lays down the indicative standards and expectations in the UK (England
and Wales, Scotland and Northern Ireland). The reader is advised to have access to the BREF.
The aims of this Guidance The aims of this Guidance are to:
provide a clear structure and methodology for Operators to follow to ensure they address all aspects
of the PPC Regulations and other relevant Regulations
minimise the effort by both Operator and Regulator in the permitting of an installation by expressing
the BAT techniques as clear indicative standards
improve the consistency of Applications by ensuring that all relevant issues are addressed
increase the transparency and consistency of regulation by having a structure in which the Opera-
tor's response to each issue, and any departures from the standards, can be seen clearly and whichenables Applications to be compared
To assist Operators in making applications, separate, horizontal guidance is available on a range of
topics such as waste minimisation, monitoring, calculating stack heights and so on. Most of this
guidance is available free through the Environment Agency, SEPA or EHS (Northern Ireland) websites
(see References)
key environmental issues The key environmental issues for this sector are:
Water use
Effluent management
Waste handling
Accident risk
Hygiene
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Contents
1 Introduction ..............................................................................................1
1.1 Understanding IPPC .............................................................................................2
1.2 Making an application ...........................................................................................51.3 Installations covered .............................................................................................6
1.4 Timescales ............................................................................................................71.4.1 Permit review periods ............................................................................................ 71.4.2 Upgrading timescales for existing plant ................................................................. 7
1.5 Key issues .............................................................................................................9
1.6 Summary of releases ..........................................................................................11
1.7 Technical overview ..............................................................................................12
1.8 Economics ...........................................................................................................131.8.1 Sector costs ........................................................................................................ 14
2 Techniques for pollution control ..........................................................16
2.1 The main activities and abatement .....................................................................172.1.1 In-process controls .............................................................................................. 172.1.2 Materials handling, unpacking, storage ............................................................... 202.1.3 Pasteurisation, Sterilisation and UHT .................................................................. 212.1.4 Evaporation ......................................................................................................... 222.1.5 Drying .................................................................................................................. 232.1.6 Centrifugation and Bactofugation ........................................................................ 252.1.7 Membrane Separation ......................................................................................... 262.1.8 Ion Exchange ...................................................................................................... 272.1.9 Filtration .............................................................................................................. 282.1.10 Churning ............................................................................................................ 292.1.11 Cooling and Chilling .......................................................................................... 302.1.12 Freezing and Blast Cooling ............................................................................... 31
2.1.13 Mixing, Blending and Homogenisation .............................................................. 322.1.14 Filling ................................................................................................................. 342.1.15 Fermentation/Incubation Process ..................................................................... 352.1.16 Cleaning and sanitation ..................................................................................... 36
2.2 Abatement of point source emissions .................................................................412.2.1 Abatement of point source emissions to air ........................................................ 412.2.2 Abatement of point source emissions to surface water and sewer ..................... 462.2.3 Abatement of point source emissions to groundwater ........................................ 612.2.4 Control of fugitive emissions to air ...................................................................... 622.2.5 Control of fugitive emissions to surface water, sewer and groundwater ............. 652.2.6 Odour .................................................................................................................. 67
2.3 Management techniques .....................................................................................69
2.4 Raw materials .....................................................................................................722.4.1 Raw materials selection ...................................................................................... 722.4.2 Waste minimisation ............................................................................................. 742.4.3 Water use ............................................................................................................ 77
2.5 Waste handling ...................................................................................................82
2.6 Waste recovery or disposal .................................................................................83
2.7 Energy .................................................................................................................852.7.1 Basic energy requirements (1) ............................................................................ 862.7.2 Basic energy requirements (2) ............................................................................ 872.7.3 Further energy-efficiency requirements ............................................................... 89
2.8 Accidents .............................................................................................................90
2.9 Noise ...................................................................................................................94
2.10 Monitoring .........................................................................................................962.10.1 Emissions monitoring ........................................................................................ 962.10.2 Environmental monitoring (beyond installation) ................................................ 99
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2.10.3 Monitoring of process variables ...................................................................... 1002.10.4 Monitoring standards (Standard Reference Methods) .................................... 101
2.11 Closure ............................................................................................................103
2.12 Installation issues ............................................................................................105
3 Emission benchmarks .........................................................................106
3.1 Emissions inventory ..........................................................................................106
3.2 Emission benchmarks .......................................................................................1083.2.1 Emissions to air associated with the use of BAT ............................................... 1083.2.2 Emissions to water associated with the use of BAT .......................................... 1093.2.3 Standards and obligations ................................................................................. 1093.2.4 Units for benchmarks and setting limits in permits ............................................ 1103.2.5 Statistical basis for benchmarks and limits in permits ....................................... 1113.2.6 Reference conditions for releases to air ............................................................ 111
3.3 Biochemical oxygen demand ............................................................................112
3.4 Chemical oxygen demand .................................................................................114
3.5 Halogens ...........................................................................................................115
3.6 Heavy metals ....................................................................................................116
3.7 Nitrogen oxides .................................................................................................117
3.8 Nutrients (phosphates and nitrates) ..................................................................1183.9 Particulate and suspended solids .....................................................................120
3.10 Sulphur dioxide ...............................................................................................121
3.11 Volatile organic compounds ............................................................................122
4 Impact ..................................................................................................123
4.1 Impact assessment ...........................................................................................123
4.2 Waste Management Licensing Regulations .....................................................125
4.3 The Habitats Regulations ..................................................................................126
References ...............................................................................................................127
Abbreviations ...........................................................................................................130
Appendix 1: Some common monitoring and sampling methods .............................131
Appendix 2: Equivalent legislation in Scotland & Northern Ireland .........................135
Appendix 3: Groundwater Regulations 1998 Sechdule of listed substances and recom-mendations for List I (DEFRA) .......................................................................137
List of figures
Figure 1.1: Overview of the activities within the milk processing sector ............................................. 12
Figure 2.1: Cleaning-in-place chemical recovery membrane system ................................................. 76
Figure 2.2: Example of four-stage counter-flow system based on pea cannery ................................. 81
List of tables
Table 1.1: Specific timescale improvements ......................................................................................... 8
Table 2.1: Process monitoring and control equipment ........................................................................ 19
Table 2.2: Abatement options for specified pollutants ........................................................................ 44
Table 2.3: Abatement options information .......................................................................................... 45
Table 2.4: Water treatment for the Food and Drink sector .................................................................. 57
Table 2.5: Summary of aerobic and anaerobic treatment processes ................................................. 58
Table 2.6: Membrane bio reator (MBR) - activated sludge (AS) comparison ..................................... 60
Table 2.7: Raw material substitutions ................................................................................................. 74
Table 2.8: Potential use for waste ....................................................................................................... 84
Table 2.9: Example breakdown of delivered and primary energy consumption ................................. 86
Table 2.10: Example format for energy efficiency plan ....................................................................... 88
Table 2.11: Monitoring of process effluents released to watercourses ............................................... 97
Table 2.12: Monitoring of process effluents released to sewer ........................................................... 98
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Table 2.13: Monitoring substances released from sources ................................................................ 98
Table 2.14: Monitoring of process variables ..................................................................................... 100
Table 3.1: Biochemical oxygen demand: water quality objectives in England, Wales and NorthernIreland ............................................................................................................................. 112
Table 3.2: Biochemical oxygen demand: water quality objectives in Scotland ................................. 112
Table 3.3: Halogen standards ........................................................................................................... 115
Table 3.4: Benchmark emission values ............................................................................................ 115
Table 3.5: Heavy metal standards .................................................................................................... 116
Table 3.6: Heavy metal benchmark emission values ........................................................................ 116
Table 3.7: Nitrogen oxides benchmark emission values ................................................................... 117
Table 3.8: Nutrients:water quality objectives in England, Wales and Northern Ireland .................... 118
Table 3.9: Nutrients:water quality objectives in Scotland .................................................................. 118
Table 3.10: Particulate and suspended solids in water ..................................................................... 120
Table 3.11: Particulate and suspended solids: benchmark emission values .................................... 120
Table 3.12: Sulphur dioxide: benchmark emission values ................................................................ 121
Table 3.13: Volatile organic compounds: benchmark emission values ............................................ 122
Table 4.1: Measurement methods for common substances to water ............................................... 131
Table 4.2: Measurement methods for other substances to water ..................................................... 132
Table 4.3: Measurement methods for air emissions ......................................................................... 134
Table 4.4: Equivalent legislation ....................................................................................................... 135
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Introduction Techniques Emissions Impact
Understand-ing IPPC
Making anapplication
Installationscovered
Timescales Key issues Summary of releases
Technicaloverview
Economics
Introduction
Guidance for the Dairy and Milk Processing Sector IPPC S6.13 | Issue 1 | Modified on26 October, 2003 1
1 Introduction
The status and aims of
this Guidance
This Guidance has been produced by the Environment Agency for England and Wales, with the
Scottish Environment Protection Agency (SEPA) and the Environment and Heritage Service (EHS) in
Northern Ireland - each referred to as the Regulator in this document. Its publication follows
consultation with industry, Government departments and non-governmental organisations.
It aims to provide Operators and the Regulators officers with advice on indicative standards of
operation and environmental performance relevant to the industrial sector concerned, to assist the
former in the preparation of applications for PPC Permits and to assist the latter in the assessment of
those Applications (and the setting of a subsequent compliance regime). The use of techniques quoted
in the guidance and the setting of emission limit values at the benchmark values quoted in the guidance
are not mandatory, except where there are statutory requirements from other legislation. However, the
Regulator will carefully consider the relevance and relative importance of the information in the
Guidance to the installation concerned when making technical judgments about the installation and
when setting Conditions in the Permit, any departures from indicative standards being justified on a
site-specific basis.
The Guidance also aims (through linkage with the Application Form or template) to provide a clear
structure and methodology for Operators to follow to ensure they address all aspects of the PPC
Regulations and other relevant Regulations, that are in force at the time of writing. Also, by expressing
the Best Available Techniques (BAT) as clear indicative standards wherever possible, it aims to
minimise the effort required by both Operator and Regulator to apply for and issue, respectively, a
Permit for an installation.
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Understand-ing IPPC
Making anapplication
Installationscovered
Timescales Key issues Summary of releases
Technicaloverview
EconomicsUnderstandingIPPC
Introduction
Guidance for the Dairy and Milk Processing Sector IPPC S6.13 | Issue 1 | Modified on26 October, 2003 2
1.1 Understanding IPPC
IPPC and the Regulations Integrated Pollution Prevention and Control (IPPC) is a regulatory system that employs an integratedapproach to control the environmental impacts of certain listed industrial activities. It involves
determination by the Regulator of the appropriate controls for those industries to protect the
environment, through a single permitting process. To gain a Permit, Operators have to demonstrate in
their Applications, in a systematic way, that the techniques they are using or are proposing to use, are
the Best Available Techniques (BAT) for their installation, and meet certain other requirements, taking
account of relevant local factors.
The essence of BAT is that the techniques selected to protect the environment should achieve an
appropriate balance between environmental benefits and the costs incurred by Operators. However,
whatever the costs involved, no installation may be permitted where its operation would cause
significant pollution.
IPPC operates underThe Pollution Prevention and Control Regulations(for equivalent legislation in
Scotland and N Ireland see Appendix 2). The three regional versions of the PPC Regulations
implement in the UK the EC Directive on IPPC (96/61/EC). Further information on the application of
IPPC/PPC, together with Government policy and advice on the interpretation of the English & Welsh
Regulations, can be found in IPPC: A Practical Guide published by the Department for Environment,
Food and Rural Affairs (Defra). Equivalent guidance on the Scottish Regulations is provided in PPC
Regulations: A Practical Guide (Part A Activities), published by the Scottish Executive and SEPA.
The Department of the Environment, Northern Ireland has published equivalent guidance on its
Regulations.
Installation based, NOT
national emission limits
The BAT approach of IPPC differs from regulatory approaches based on fixed national emission limits
(except where General Binding Rules or Standard Permits are issued). The legal instrument that
ultimately defines BAT is the Permit, and Permits can only be issued at the installation level.
Indicative BAT Standards Indicative BAT standards are laid out in national guidance (such as this) and, where relevant, should be
applied unless a different standard can be justified for a particular installation. BAT includes the
technical components, process control, and management of the installation given in Section 2, and the
benchmark levels for emissions identified in Section 3. Departures from those benchmark levels can
be justified at the installation level by taking into account the technical characteristics of the installation
concerned, its geographical location and the local environmental conditions. If any mandatory EU
emission limits or conditions are applicable, they must be met, but BAT may go further (see BAT and
EQS below).
Some industrial sectors for which national guidance is issued are narrow and tightly defined, whilst
other sectors are wide and diffuse. This means that where the guidance covers a wide variety of
processes, and individual techniques are not described in detail, the techniques (and their associated
emission levels) which might constitute BAT for a particular operation, are more likely to differ, with
justification, from the indicative BAT standards than would be the case for a narrow, tightly-defined
sector.
BAT and EQS The BAT approach complements, but differs fundamentally from, regulatory approaches based on
Environmental Quality Standards (EQS). Essentially, BAT requires measures to be taken to prevent
emissions - and measures that simply reduce emissions are acceptable only where prevention is not
practicable. Thus, if it is economically and technically viable to reduce emissions further, or prevent
them altogether, then this should be done irrespective of whether or not EQSs are already being met.
The BAT approach requires us not to consider the environment as a recipient of pollutants and waste,
which can be filled up to a given level, but to do all that is practicable to minimise emissions from
industrial activities and their impact. The BAT approach first considers what emission prevention can
reasonably be achieved (covered by Sections 2 and 3 of this Guidance) and then checks to ensure that
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Understand-ing IPPC
Making anapplication
Installationscovered
Timescales Key issues Summary of releases
Technicaloverview
EconomicsUnderstandingIPPC
Introduction
Guidance for the Dairy and Milk Processing Sector IPPC S6.13 | Issue 1 | Modified on26 October, 2003 3
the local environmental conditions are secure (see Section 4 on page 123 of this Guidance and also
Guidance NoteIPPC Environmental Assessments for BAT). The BAT approach is therefore the
more precautionary one because the release level achieved may be better than that simply required to
meet an EQS.
Conversely, if the application of indicative BAT might lead to a situation in which an EQS is still
threatened, a more effective technique is required to be BAT for that installation. The Regulations allow
for expenditure beyond indicative BAT where necessary, and, ultimately, an installation will only be
permitted to operate if it does not cause significant pollution.
Further advice on the relationship between BAT, EQSs and other related standards and obligations is
given in IPPC: A Practical Guide, its Scottish equivalent, and also in Section 3.
Assessing BAT at the
sector level
The assessment of indicative BAT takes place at a number of levels. At the European level, the
European Commission issues a BAT reference document (BREF) for each main IPPC sector. It also
issues horizontal BREFs for a number of general techniques which are relevant across a series of
industrial sectors. The BREFs are the result of an exchange of information between regulators, industry
and other interested parties in Member States. Member States should take them into account whendetermining BAT, but they are allowed flexibility in their application. UK Sector Guidance Notes like this
one take account of information contained in relevant BREFs and set out current indicative standards
and expectations in the UK. At national level, techniques that are considered to be BAT should
represent an appropriate balance of costs and benefits for a typical, well-performing installation in the
sector concerned. They should also be affordable without making the sector as a whole uncompetitive,
either within Europe or world-wide.
Assessing BAT at the
installation level
When assessing applicability of sectoral indicative BAT standards at the installation level, departures
may be justified in either direction. Selection of the technique which is most appropriate may depend
on local factors and, where the answer is not self-evident, an installation-specific assessment of the
costs and benefits of the available options will be needed. The Regulators guidance IPPC
Environmental Assessments for BAT and its associated software tool may help with the assessment.Individual installation or company profitability (as opposed to profitability of the relevant sector as a
whole) is not a factor to be considered, however.
In the assessment of BAT at the installation level, the cost of improvements and the timing or phasing of
that expenditure, are always factors to be taken into account. However, they should only be major or
decisive factors in decisions about adopting indicative BAT where:
the installations technical characteristics or local environmental conditions can be shown to be so
different from those assumed in the sectoral assessment of BAT described in this guidance, that the
indicative BAT standards may not be appropriate; or
the BAT cost/benefit balance of an improvement only becomes favourable when the relevant item of
plant is due for renewal/renovation (eg. change to a different design of furnace when the existing
furnace is due for a rebuild). In effect, these are cases where BAT for the sector can be expressed
in terms of local investment cycles; or
a number of expensive improvements are needed. In these cases, a phasing programme may be
appropriate - as long as it is not so drawn out that it appears to be rewarding a poorly performing
installation.
In summary, departures by an individual installation from indicative BAT for its sector may be justified
on the grounds of the technical characteristics of the installation concerned, its geographical location
and the local environmental conditions - but not on the basis of individual company profitability, or if
significant pollution would result. Further information on this can be found in IPPC: A Practical Guide
and IPPC Part A(1) Installations: Guide for Applicants, or the equivalent Scottish Guidance.
Innovation The Regulators encourage the development and introduction of innovative techniques that advanceindicative BAT standards criteria, ie. techniques which have been developed on a scale which
reasonably allows implementation in the relevant sector, which are technically and economically viable
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Understand-ing IPPC
Making anapplication
Installationscovered
Timescales Key issues Summary of releases
Technicaloverview
EconomicsUnderstandingIPPC
Introduction
Guidance for the Dairy and Milk Processing Sector IPPC S6.13 | Issue 1 | Modified on26 October, 2003 4
and which further reduce emissions and their impact on the environment as a whole. One of the main
aims of the PPC legislation is continuous improvement in the overall environmental performance of
installations as a part of progressive sustainable development. This Sector Guidance Note describes
the indicative BAT standards at the time of writing but Operators should keep up-to-date with
improvements in technology - and this Guidance note cannot be cited as a reason for not introducing
better available techniques. The technical characteristics of a particular installation may also provide
opportunities not foreseen in the Guidance, and as BAT is determined at the installation level (except in
the case of General Binding Rules (GBRs)), it is a requirement to consider these even where they go
beyond the indicative Standards.
New installations Indicative BAT standards apply, where relevant, to both new and existing installations, but it will be
more difficult to justify departures in the case of new installations (or new activities in existing
installations) - and for new activities, techniques which meet or exceed indicative BAT requirements
should normally be in place before operations start.
Existing installations -
standards
For an existing installation, it may not be reasonable to expect compliance with indicative BAT
standards immediately if the cost of doing so is disproportionate to the environmental benefit to beachieved. In such circumstances, operating techniques that are not at the relevant indicative BAT
standard may be acceptable, provided that they represent what is considered BAT for that installation
and otherwise comply with the requirements of the Regulations. The determination of BAT for the
installation will involve assessment of the technical characteristics of the installation and local
environmental considerations, but where there is a significant difference between relevant indicative
BAT and BAT for an installation, the Permit may require further improvements on a reasonably short
timescale.
Existing installations -
upgrading timescales
Where there are departures from relevant indicative BAT standards, Operators of existing installations
will be expected to have upgrading plans and timetables. Formal timescales for upgrading will be set
as Improvement Conditions in the Permits. See Section 1.4.2 on page 7 for more details.
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Understand-ing IPPC
Making anapplication
Installationscovered
Timescales Key issues Summary of releases
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EconomicsMaking anapplication
Introduction
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1.2 Making an application
A satisfactory Application is made by: addressing the issues in Sections 2 and 3 of this guidance;
assessing the environmental impact described in Section 4 (and in England and Wales Environ-
mental Assessment and Appraisal of BAT (IPPC H1));
demonstrating that the proposed techniques are BAT for the installation.
In practice, some Applicants have submitted far more information than was needed, yet without
addressing the areas that are most important - and this has led to extensive requests for further
information. In an attempt to focus application responses to the areas of concern to the Regulator,
Application forms (templates) have been produced by the Environment Agency, by SEPA and by EHS
in N Ireland. In addition, as the dates for application have approached, the operators in most industrial
sectors in England and Wales have been provided with Compact Discs (CDs) which contain all relevant
Application Forms, technical and administrative guidance, BREFs and Assessment tools, hyper-linkedtogether for ease of use.
For Applicants with existing IPC Authorisations or Waste Management Licences, the previous
applications may provide much of the information for the PPC application. However, where the
submitted Application refers to information supplied with a previous application the Operator will need
to send fresh copies - though for many issues where there is a tendency for frequent changes of detail
(for example, information about the management systems), it will be more appropriate simply to refer to
the information in the Application and keep available for inspection on site, up-to-date versions of the
documents.
For further advice see IPPC Part A(1) Installations: Guide for Applicants (for England and Wales)
orPPC Part A Installations: Guide for Applicants (for Scotland) or the equivalent Northern Irelandguide for Applicants.
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Understand-ing IPPC
Making anapplication
Installationscovered
Timescales Key issues Summary of releases
Technicaloverview
EconomicsInstallationscovered
Introduction
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1.3 Installations covered
This Guidance relates to installations containing the activities listed below, as described in Part A(1) ofSchedule 1 to the The Pollution Prevention and Control Regulations. The schedules of listed
activities are slightly different in Scotland and Northern Ireland so for their equivalent Regulations see
Appendix 2
Section 6.8
(e) Treating and processing milk, the quantity of milk received being greater than 200 tonnes per
day (average value on an annual basis).
The installation includes the main activities as stated above and associated activities which have a
technical connection with the main activities and which may have an effect on emissions and pollution.
They include, as appropriate:
Raw milk reception Pasteurisation
Cheesemaking
Butter
Yogurt production
Packing
Cleaning
Refrigeration
the control and abatement systems for emissions to all media;
the power plant
The installation will also include associated activities which have a technical connection with the mainactivities and which may have an effect on emissions and pollution, as well as the main activities
described above. These may involve activities such as:
the storage and handling of raw materials;
the storage and despatch of finished products, waste and other materials;
the control and abatement systems for emissions to all media;
waste treatment or recycling.
Environment Agency advice on the composition of English or Welsh installations and which on-site
activities are to be included within it (or them) is given in its guidance document The Pollution
Prevention and Control Regulations (SI 2000 No. 1973) (www.hmso.gov.uk).. Operators are
advised to discuss the composition of their installations with the Regulator before preparing their
Applications.
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Understand-ing IPPC
Making anapplication
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Timescales Key issues Summary of releases
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1.4 Timescales
1.4.1 Permit review periods
Permits are likely to be reviewed as follows:
for individual activities not previously subject to regulation under IPC or Waste Management Licens-
ing, a review should be carried out within four years of the issue of the PPC Permit
for individual activities previously subject to regulation under IPC or Waste Management Licensing,
a review should be carried out within six years of the issue of the IPPC Permit
However, where discharges of Groundwater List I or List II substances have been permitted, or wherethere is disposal of any matter that might lead to an indirect discharge of any Groundwater List I or II
substance, a review must be carried out within four years as a requirement of the Groundwater
Regulations.
These periods will be kept under review and, if any of the above factors change significantly, they may
be shortened or extended.
1.4.2 Upgrading timescales for existing plant
Existing installation
timescales
Unless subject to specific conditions elsewhere in the Permit, upgrading timescales will be set in the
Improvement Programme of the Permit, having regard to the criteria for improvements in the following
two categories:
1 Standard good-practice requirements, such as, management systems, waste, water and energy
audits, bunding, housekeeping measures to prevent fugitive or accidental emissions, good waste-
handling facilities, and adequate monitoring equipment. Many of these require relatively modest
capital expenditure and so, with studies aimed at improving environmental performance, they
should be implemented as soon as possible and generally well within 3 years of issue of the Permit.
2 Larger, more capital-intensive improvements, such as major changes to reaction systems or the
installation of significant abatement equipment. Ideally these improvements should also be com-pleted within 3 years of Permit issue, particularly where there is considerable divergence from rele-
vant indicative BAT standards, but where justified in objective terms, longer time-scales may be
allowed by the Regulator.
Local environmental impacts may require action to be taken more quickly than the indicative timescales
above, and requirements still outstanding from any upgrading programme in a previous permit should
be completed to the original time-scale or sooner. On the other hand, where an activity already
operates to a standard that is close to an indicative requirement a more extended time-scale may be
acceptable. Unless there are statutory deadlines for compliance with national or international
requirements, the requirement by the Regulator for capital expenditure on improvements and the rate
at which those improvements have to be made, should be proportionate to the divergence of the
installation from indicative standards and to the environmental benefits that will be gained.
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The Operator should include in the Application a proposed programme in which all identified
improvements (and rectification of clear deficiencies) are undertaken at the earliest practicable
opportunities. The Regulator will assess BAT for the installation and the improvements that need to be
made, compare them with the Operators proposals, and then set appropriate Improvement Conditions
in the Permit
All improvements should be carried out at the earliest opportunity and to a programme approved by the
Regulator. Any longer timescales will need to be justified by the Operator.
The Applicant should include a proposed timetable covering all improvements.
Table 1.1: Specific timescale improvements
Improvement By whichever is the later of:
Activities under Section 6.8di
(see Section 1.3) Animal raw
materials
Activities under Section 6.8dii
and 6.8e (see Section 1.3)
Vegetable raw materials and
milk
Waste minimisation audit in
accordance with Section 2.4.2
on page 74
31 August 2005
or one year from the issue of
the Permit
31 March 2006
or one year from the issue of
the Permit
A review of water use (water
efficiency audit) in accordance
with Section 2.4.3 on page 77
31 August 2005
or one year from the issue of
the Permit
31 March 2006
or one year from the issue of
the Permit
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1.5 Key issues
An assessment of the issues indicates that there are no areas where there is a fundamental clashbetween good environmental practice and good business practice. However the implementation of
pollution prevention and control measures represents a balance between environmental protection and
costs incurred by the operators and will not always result in cost savings for the operator.
Waste minimisation
Commercial considerations mean that the controls of parameters such as process yield and product
wastage are usually understood. These parameters are also key pollution prevention issues as product
loss accounts for a significant proportion of the sectors environmental impact.
Water use
The sector is a significant water consumer, the vast majority of which is used for cleaning, both
manually and in CIP (cleaning in place) systems, which are widely used throughout the industry. In
addition to minimising the use of a raw material, measures to optimise water use will be important
pollution prevention measures relating to effluent management. There are a number of opportunities to
either reuse water (for example low-grade wash waters) or to recycle water from for example
membrane systems (also see Hygiene and Food Safety).
Releases associated with energy use
The industry is a major energy user. There remain significant opportunities for reduction of emissions
caused by energy use and choice of energy source (CO2, SOx, NOx, etc. contributing in particular to
global warming and acidification). The dairy industry has entered into a Climate Change Levy
Agreement with the Government, dated the 6th March 2001. The applicability of techniques and
standards for IPPC is explained in Section 2.6.
Emissions to air
It is an inherent factor within the food, drink and dairy industries that emissions of VOC and odour arise,
for example from drying and other processes, including effluent treatment. Emissions of dust and
particulate material can also be a factor from milk powder drying and the transfer of materials. Odour
emissions can be problematic, not only because of the sometimes subjective nature of the problem, but
as emissions tend to be fugitive. Other fugitive emissions considerations include those potentially
arising from refrigeration, cooling and effluent treatment systems.
Effluent management
The composition of the effluent within the dairy industry is very highly variable, dependant on the
activity, working patterns, product wastage and cleaning systems. Of these the most important iskeeping raw materials, intermediates, product and by product out of the wastewaters, by controlling
product wastage and cleaning processes.
Accident risk
All types of milk, cream and most other dairy products have a very high oxygen demand and spills and
leaks into the water environment are serious events. In addition to normal spills and process leaks,
they typically arise from for example, overfilling of vessels and failure of containment, wrong drainage
connections and blocked drains.
Hygiene and food safety
Health and safety and product quality issues apply to industry as a whole, but hygiene and food safetyis of fundamental importance to the dairy sector. Consequently particular attention must be given to
these considerations when specifying particular techniques, especially in relation to pollution prevention
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Guidance for the Dairy and Milk Processing Sector IPPC S6.13 | Issue 1 | Modified on26 October, 2003 10
measures, in for example measures relating to water use, cleaning and reuse and recycling of water.
Industry experience of managing risk in relation to hygiene and food safety issues is a sound basis for
environmental management issues.
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1.6 Summary of releases
Note:
1. Most of the other releases to water pass through the effluent treatment plant (ETP). Included here
are only those which arise as a direct result of the operation of the ETP.
2. Releases to air usually result in a subsequent, indirect emission to land and can therefore affect
human health, soil and terrestrial ecosystems.
3. Releases identified above to water can all also appear in the effluent treatment sludge (see Section
2.5 on page 82).
Storagean
dhandlingofraw
Cuttingand
Mixingand
blending(powdersand
Mixing,
blen
dingandhomogenisation(solid/liquid
)
Pasteurisationandsterilisation
Dryingand
evaporation
Cleaninga
ndsanitisation
Storagean
ddispatchoffinished
Coolingan
drefrigeration
Boilerand
Combustionplant
Effluentplant(Note1)
Oxides of sulphur - - - - - - - - - A -
Oxides of nitrogen & car-
bon
- - - - - - - - - - -
Particulate/TSS AW W AW W W AW AW AW - A W
COD/BOD W W - W W W W W - - W
Odour A AW W A AW A A A - A A
Biocides - W - - - - W - - - W
Dispersants & sur-
factants
- - - - - - W - - - -
Phosphates & nitrates - - - - - W - - - -
Refrigerants
Ammonia, HCFC, Glycol
- - - - - - - AW W W
Sludges - - - - - - - - L
KEY A Release to Air, W Release to Water, L Release to Land
SOURCE
RELEASES
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1.7 Technical overview
Figure 1.1: Overview of the activities within the milk processing sector
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1.8 Economics
The food and drink industry is an important part of the manufacturing industry in the UK. It is the largestindustrial sector in turnover terms: with a market value in excess of 90 billion. . It is a large and
diverse sector and accounts for about 9% of manufacturing output and a commensurate fraction of the
jobs available in UK manufacturing. Table 1-1 shows a breakdown of the main activities by SIC code
and it is clear that a wide range of activities is represented.
Almost half of the milk sold to first-hand buyers under wholesale contract is used to supply the liquid
market, with the remainder being processed into a widening range of milk products. Much of the this
manufactured product is sold to consumers (e.g. as cream, butter or cheese) but large quantities are
also used by food manufacturers as ingredients in the production of a vast range of foods.
At one time, much of the by-product (such as skim milk and whey) was of minimal value and was fed to
livestock, particularly at times of seasonal surplus. However, such end-uses have diminished as the
industry has sought to extract the maximum value from each litre of milk produced and as quotas have
sharply reduced milk output. As a result, the vast majority of milk leaving the farm is now destined for
human consumption. However, as the table below suggests, there is a mix in size of the dairy
companies within England and Wales, with around 38% of them processing in excess of 30 million
litres/year, although many more smaller companies processing up to 30 million litres/year.
The dairy industry is extremely complex and can be characterised as follows:
there are a wide range of unit operations
some of the unit operations such as pasteurisation, are not well known outside of the immediate
industry
the consumer market is becoming more sophisticated and demanding
there is a continual need for process innovation
plant and equipment needs to be flexible to respond to changes in demand
quality of production is paramount (and is matched only by pharmaceutical standards)
These factors contribute to making the plant and equipment of dairy food production increasingly
complex. Associated abatement equipment needs to be equally flexible and adaptable. There is a
potential reluctance to invest in large capital abatement plant when it may be made redundant by a
change in the production process, however, changes in the process are opportunities for environmental
investment.
The food and dairy market-place is characterised by:
Short time-to-market and competitiveness, where the time between product conception and deliver-
ing the product to the market-place is continually reducing; against a background of increasing com-
petitiveness and reduced margins, the emphasis during product development is on the production
process itself.
Size Band
(million litres/year)
No. of Companies
processing milk
Percent of Total
1 and under 15 13.3%
Between 1 and 10 35 31.0%
Between 10 and 30 19 16.8%
Between 30 and 100 23 20.4%
Over 100 21 18.6%
TOTAL 113 100%
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Product innovation with more and more product variations available now to the consumer; this
implies that existing products face stiffer competition and product lifetimes become shorter, with the
result that manufacturing processes and production lines require change more frequently.
Product complexity with the introduction of new flavours, mixtures and combinations of products,
pre-prepared products, new packaging, etc..
The production runs also become shorter as tastes change more frequently.
Raw materials are generally natural and are therefore more variable than other sectors.
All of these factors contribute to the dynamic and complex nature of dairy food production. While this
can imply the potential for more frequent upgrade of processing equipment, it has the drawback of
providing a degree of instability. With the end of the end of the Milk Marketing schemes in 1994, the milk
market in the UK was opened up for greater competition, both for producers selling their milk and for the
processors buying the milk. However, the price ex. farm has dropped significantly over the past few
years, as the table below shows:
N.B.: Data from Dairy Facts and Figures see Ref. 8. 2000 data based on January to November only
This highlights the drop in revenues experienced by the farmers, which has also resulted in a drop in
milk prices at the supermarkets. The current (December 2001) cost of a 4-pint polybottle (2.27 Litres) is93pence, which equates to a cost of c. 40 pence per litre to the consumer.
This means that the simple milk processing companies, those who take farm milk for liquid consumption
in either polybottles for the supermarkets or glass for the declining doorstep delivery market operate at
low margins. This requires them to be very efficient in all manner of production, not least in wastage of
raw materials. The most successful companies are therefore the most efficient. Considering the
manufacturing companies, there is more scope for adding value to their products and hence profit
margins are greater.
1.8.1 Sector costs
Costs, both capital and revenue, for effluent treatment at dairy plants are site specific, and can vary
markedly depending on effluent volumes and loadings, as well as ancillary items such as:
Landscaping, fencing or planting requirements
Access roadways
Ground conditions (e.g., piling requirements)
However, in order to provide some specific information, some example projects and costs are provided
below.
YEAR UK Farm Gate Prices, pence per litre
(including bonus payments)
1995 24.94
1996 25.02
1997 22.12
1998 19.37
1999 18.35
2000(1) 16.89
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N.B.: Costs assume 2001 base, with inflationary increases of 5%pa.
In all cases, it is recommended that competent professional assistance is sought to provide a detailed
design specification, against which prospective contractors can quote. This provides for competitive
quotations on a like-for-like basis.
For revenue costs, again the actual costs will be site specific but as a guideline, the following figures
provide a reference:
Conventional Activated sludge = 16pence/kgCOD treated
Conventional filtration plants = 12pence/kgCOD treated
MBR activated sludge = 19pence/kgCOD treated
These costs are based on electricity and sludge disposal only.
As a comparison, the average cost of discharging dairy effluent to sewer for treatment at a local sewage
works by the Water Service plc will be 56 pence/kgCOD, assuming 3,000 mg/l COD and 800 mg/l TSS.
This is based on the standard Trade Effluent Charging tariffs and does not include the Scottish water
companies.
Project Total Cost
at 2001 prices
Crude Effluent Final Effluent Plant Outline
Volume
m3/day
Loading
kgCOD/
d
A 660,000 300 1,000 40:60 Primary screening,
4,800m3 HDPE-lined
lagoon, 8.5m diameter
settlement tank
B 2.8 million 1,230 5,240 20:30:5 Anoxic tank, 13,000m3
concrete tank, 15m diam
settlement tank and sand
filters
C 1.0 million 1,800 6,720 25:25 Retrofit to existing plant,
including 3,000m3 aera-
tion tank, 1,000m3 bal-
ance tank, 2 settlement
tanks
D 200,000 500 2,000 25:40:25 Retrofit to remove old
technology filter plant,
replace with activated
sludge
E 160,000 1,000 N/A N/A Pump sump and fat trap,300m3 balance and 50m3
divert tank and control
equipment
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Introduction Techniques Emissions Impact
The mainactivities andabatement
Abatement ofpoint sourceemissions
Managementtechniques
Rawmaterials
Wastehandling
Wasterecovery ordisposal
Energy Accidents Noise Monitoring Closure Installationissues
Economics
Techniques for pollution control
2 Techniques for pollution control
BAT Boxes to help in
preparing applications
To assist Operators and the Regulators officers in respectively making and determining applications for
PPC Permits, this section summarises the indicative BAT requirements (i.e. what is considered to
represent BAT for a reasonably efficiently operating installation in the sector). The indicative BAT
requirements may not always be absolutely relevant or applicable to an individual installation, when
taking into account site-specific factors, but will always provide a benchmark against which individual
Applications can be assessed.
Summarised indicative BAT requirements are shown in the BAT boxes, the heading of each BAT box
indicating which BAT issues are being addressed. In addition, the sections immediately prior to the
BAT boxes cover the background and detail on which those summary requirements have been based.
Together these reflect the requirements for information laid out in the Regulations, so issues raised in
the BAT box or in the introductory section ahead of the BAT box both need to be addressed in
any assessment of BAT.
Although referred to as indicative BAT requirements, they also cover the other requirements of the PPC
Regulations and those of other Regulations such as the Waste Management Licensing Regulations
(see Appendix 2 for equivalent legislation in Scotland and Northern Ireland) and the Groundwater
Regulations, insofar as they are relevant to PPC permitting.
For further information on the status of indicative BAT requirements, see Section 1.1 on page 2 of this
guidance orGuidance for applicants.
It is intended that all of the requirements identified in the BAT sections, both the explicit ones in the BAT
boxes and the less explicit ones in the descriptive sections, should be considered and addressed by theOperator in the Application. Where particular indicative standards are not relevant to the installation in
question, a brief explanation should be given and alternative proposals provided. Where the required
information is not available, the reason should be discussed with the Regulator before the Application is
finalised. Where information is missing from the Application, the Regulator may, by formal notice,
require its provision before the Application is determined.
When making an Application, the Operator should address the indicative BAT requirements in this
Guidance Note, but also use the Note to provide evidence that the following basic principles of PPC
have been addressed:
The possibility of preventing the release of harmful substances by changing materials or processes
(see Section 2.1 on page 17), preventing releases of water altogether (see Section 2.2.2 on page
46), and preventing waste emissions by reuse or recovery, have all been considered, and
Where prevention is not practicable, that emissions that may cause harm have been reduced and
no significant pollution will result.
This approach should assist Applicants to meet the requirements of the Regulations to describe in the
Applications techniques and measures to prevent and reduce waste arisings and emissions of
substances and heat - including during periods of start-up or shut-down, momentary stoppage, leakage
or malfunction.
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Introduction Techniques Emissions Impact
The mainactivities andabatement
Abatement ofpoint sourceemissions
Managementtechniques
Rawmaterials
Wastehandling
Wasterecovery ordisposal
Energy Accidents Noise Monitoring Closure Installationissues
The mainactivities andabatement
Techniques for pollution control
2.1 The main activities and abatement
(includes directly associated activities in accordance with the PPC Regulations)
2.1.1 In-process controls
Improved process control inputs, conditions, handling, storage and effluent generation will minimise
waste by reducing off-specification product, spoilage, loss to drain (for example, fitting a level switch,
float valve, or flow meter will eliminate waste from overflows), overfilling of vessels, water use and other
losses.
Product loss or wastage is a significant benchmark for the dairy industry and is a useful guideline for an
operator to assess the performance of the installation against industry standards. In assessing the
wastage efficiency of milk processing sites, two co-efficients are used to measure milk loss and water
usage:
%COD (or milk) loss to effluent (measured as COD)
Effluent:Milk Intake Ratio (or Water:Milk Intake Ratio)
These techniques have been used for many years, and have proven themselves much more accurate
than trying to assess %milk loss using yield calculations or mass balances, which are used by the
majority of the dairy companies in the UK. Mass balance or yield figures often give negative variances
(milk is gained instead of lost which is clearly impossible), whereas this never occurs when actually
measuring the loss to effluent using %COD loss techniques.
To calculate the %COD loss to effluent, the procedure is to use effluent loadings and compare this
against the milk intake, converted to kgCOD, as follows:
To do this we usually consider the COD equivalent of milk as 220 kgCOD/m3, or 220,000 mg/l, although
this can vary depending on butterfat content, SNF ratios, etc. As an example, consider a site with a the
following conditions:
Milk intake:650,000 lpd
Effluent volume:1,200 m3/day
Indicative BAT requirements:
1 See each subsection of this section 2.1.
Effluent Load, kgCOD
Milk Intake, as kgCOD
%COD loss = x 100
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Introduction Techniques Emissions Impact
The mainactivities andabatement
Abatement ofpoint sourceemissions
Managementtechniques
Rawmaterials
Wastehandling
Wasterecovery ordisposal
Energy Accidents Noise Monitoring Closure Installationissues
The mainactivities andabatement
Techniques for pollution control
Effluent loading:3,650 kgCOD/day
The effluent:milk ratio (or water:milk ratio) is simply a ratio between the amount of effluent or water used
compared against milk or product intake. Again, this allows for comparison across similar processing
sites. Using the example above, the effluent:milk ratio would be 1,200/650 or 1.84:1.0, which means
that 1.84 litres of effluent are generated for every litre of milk processed.
Good wastage co-efficients for simple milk processing sites would be c. 1.5% milk loss to effluent and c.
1.5:1 effluent:milk ratio. Some sites with excellent wastage management can (and do) achieve less
than 1% milk loss to effluent and an effluent:milk ratio of 1:1, or less. Sites with poor wastage
management, or inefficient processing profiles, can have losses in excess of 5% milk loss.
Clearly, these figures can only be a guide as actual wastage performance depends on many other
factors including product type and mix, processing profiles, plant utilisation efficiency, age of processing
equipment and control systems, and effluent pressure. Using these techniques as part of the wastage
monitoring for the site will allow the operator to demonstrate historical wastage performance and
highlight improvements as part of an overall wastage control campaign
The factors that influence wastage control on a dairy include, but are not limited to the following:
Management awareness and motivation to improve wastage
Operator awareness
Measurement of losses
Constraints on the effluent disposal route
Process design of the CIP systems
Plant utilisation efficiency and downtime
Willingness to invest time money and effort
For example, consider a small traditional cheese-making factory, with a high desire to implement
wastage control to reduce Trade Effluent Charges, and having a committed management team.
Despite the oldest of equipment and processes within the dairy, they achieved losses measured at
0.88% COD loss and an effluent:milk ratio of 0.89.
Consider, also a very large multiproduct dairy with a milk intake capacity of over 1,000,000 li tres/day,
but only handling around 380,000 litres/day. This plant has a large effluent plant (due to its maximum
capacity) but with little pressure to monitor losses as the effluent discharge is well within specification.
The losses here are 8.44% COD loss and 3.85 effluent:milk ratio.
Finally, consider a another large manufacturing dairy, with a very focussed management team, with
effluent pressure due to an old, not very efficient effluent plant discharging into a trout river. The factory
was equipped with simple but effective wastage monitoring, including individual drain lines to enable
checking on CIP systems, etc., and achieved 0.77% COD loss and a 1.21 effluent:milk ratio. Despite
these figures, further on-site survey work highlighted savings of 149,000 pa in product, water and
effluent costs.
To successfully tackle wastage control and maintain impetus within a factory requires a consideration of
all the points detailed above. In addition, a systematic approach is essential for action to be effective,
and the one outlined below will provide some guidance:
%COD loss =3,650 kgCOD
650m3 x 220
x 100
%COD loss = 2.55
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Introduction Techniques Emissions Impact
The mainactivities andabatement
Abatement ofpoint sourceemissions
Managementtechniques
Rawmaterials
Wastehandling
Wasterecovery ordisposal
Energy Accidents Noise Monitoring Closure Installationissues
The mainactivities andabatement
Techniques for pollution control
Determine the size of the problem - this requires effluent monitoring to be set up to provide information
on wastewater loadings (kgCOD and volume). This information can be converted into product or
money equivalents, and the loss co-efficients mentioned above can be calculated. If youre not
monitoring it.you cant manage it
Set targets/objectives/KPIs - this could be a reduction in daily kgCOD or volume, a percentage
reduction in Trade Effluent Charges, or any other specific objective. As with all objectives, the target
should be measurable, realistic and agreed by those who are going to implement it and achievable.
Investigate/isolate high loss areas - this is often where factory personnel provide the best input for
suggestions and information. Specific machines or departments can be assessed or a complete factory
effluent audit conducted, itemising the effluent loadings from all manufacturing and cleaning processes.
Catching people doing things RIGHT can be key to ensuring their commitment and interest.
Action - this stage may mean an input of capital or revenue expenditure for pipework or recovery
systems, but this can be offset against the potential savings. All financial input should have a return on
investment, and following completion this should be audited to prove the savings. Often changes in
working practices or techniques will provide savings without the need for any additional expenditure.
Continue monitoring and review - has the action worked? Have we reached target? Do we re-set our
target for further improvements?
Selection of process techniques also has a bearing on product loss. While selection is primarily based
on product requirements, it will also have implications for pollution. Operators should consider this
trade off when implementing BAT. .
It is important that process monitoring and control equipment selected is designed, installed, calibrated
and operated so that it will not interfere with hygiene conditions in the production process and itself lead
to product loss and waste. Measures, which should be implemented as appropriate, include:
Table 2.1: Process monitoring and control equipment
Technique Application Outcome
Temperature
measurement
Storage and processing ves-
sels, transfer lines, etc.
Reduced deterioration of materials and out-of-
specification products
Pressure Meas-
urement
Indirect control of other
parameters, for example flow
or level
Minimise waste from material damaged by
shear friction forces
Level measure-
ment
Storage and reaction vessels Prevent storage overflow of materials and asso-
ciated wastage from storage or reaction tanks;
minimise waste from transfer losses in inaccu-
rate batch recipes in vessels; and minimise out-
of-date stock or production losses due to insuffi-
cient material
Flow measure-
ment
Transfer lines Accurate addition of materials to processing
vessels and minimise excessive use of materi-
als and formation of out-of-specification prod-
ucts
Steam supply Maintain correct operating temperature and min-
imise waste from underheated or overheated
materials and products
Cleaning systems Control and optimise water use, and minimise
effluent generation
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Introduction Techniques Emissions Impact
The mainactivities andabatement
Abatement ofpoint sourceemissions
Managementtechniques
Rawmaterials
Wastehandling
Wasterecovery ordisposal
Energy Accidents Noise Monitoring Closure Installationissues
The mainactivities andabatement
Techniques for pollution control
The most accurate way of measuring milk intake into most sites is the use of a weighbridge, although
this is sometimes not the most convenient approach. Weighbridges are normally very accurate with
measurement errors typically less than 0.05%. The move within the UK dairy industry to the use of in-
situ tanker flow meters has introduced significant errors into milk loss measurement, as it is now
generally accepted that unless the flow meter error on the tanker meter is greater than 60 litres, this
discrepancy is acceptable. An error of 60 litres on a volume of say 15,000 litres equates to 0.4%, which
falls well below the level required for accurate measurements of factory losses, particularly when using
yield or mass balance calculations.
Packing line efficiency
Poorly designed and operated packing lines cause many companies to lose as much as 4% of their
product and packaging. To improve efficiency and productivity and to reduce wastage, individual
machines should be correctly specified so that they work together as part of an efficient overall design.
2.1.2 Materials handling, unpacking, storage
Summary of the activities Materials handling applies to the receipt, storage and internal conveying of raw materials, intermediate
products and final products.
Solid materials are commonly delivered in bags on pallets. They are transported with forklift trucks, and
stored in a store. The same holds for liquid ingredients in containers. Larger amounts of solid raw
materials and powders are mostly delivered in bulk trucks. These are off-loaded directly for processing
or stored in silos. Solid raw materials can be conveyed by water (vegetables, roots, tubers), by air
(solid particles, powder) or by conveyer belts and elevators.
Conveyor systems include:
gravity systems (direct flow to receptacle)
mechanical systems (belts, screw conveyors or buckets)
pneumatic systems (positive or negative pressure systems)
fans
Liquid raw materials are normally delivered in bulk tankers and then pumped into storage tanks. Internal
transport of liquid is carried out by pumping through, sometimes extensive and complex, piping
systems.
Environmental impact Water: Leakages, for example from pipework or flume systems. Effluent from cleaning. Results in the
release of suspended solids (both organic and/or inorganic) and soluble compounds (both organic and/
or inorganic) to water, which leads to a considerable biochemical oxygen demand and turbidity.
Air: Potential emissions from vessel vents whilst filling, which could consist of particulates, gases and
odours. Dust and particulate from conveyor systems.
Land: Deposition from emissions to air and contamination from leaking pipework.
Waste: Residues from vessels and other material handling equipment. Reworked for sale as animal
feed where possible.
Flow control Constant flow valves Control flow rate to water ring vacuum pumps
Flow regulators Control process water flow rates for specific
processes
Table 2.1: Process monitoring and control equipment
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Introduction Techniques Emissions Impact
The mainactivities andabatement
Abatement ofpoint sourceemissions
Managementtechniques
Rawmaterials
Wastehandling
Wasterecovery ordisposal
Energy Accidents Noise Monitoring Closure Installationissues
The mainactivities andabatement
Techniques for pollution control
Energy: Materials handling is almost exclusively electrically driven.
Accidents: Spillage from, for example, flume systems or cleaning activities or transfer of materials, for
example containers being dropped. Overfilling of storage vessels.
Noise: No issue from vessels and static conveying equipment, but there might be noise from certain
types of vehicle-mounted blowers used to discharge solids and liquids from road vehicles into silos and
other vessels. Safety horns on forklift trucks may also be a factor.
2.1.3 Pasteurisation, Sterilisation and UHT
Summary of the activities Heat treatment of products is one of the main techniques used in the food industry for conservation.
Within the dairy industry, heat treatment kills all micro-organisms capable of causing disease as well as
improving the keeping quality of the end product. In heat treatment various time/temperature
combinations can be applied, depending on product properties and shelf life requirements.
In pasteurisation generally a heating temperature below 100 C is applied (72 to 75oC for 15 seconds
for High Temperature Short Time pasteurisation), this means a reduction of enzyme and bacterial
activity and a stable shelf life. Sterilisation commonly means a heat treatment over 100oC for such
times that a longer shelf life is achieved. UHT means Ultra High Temperature treatment, usually 135 to
140oC during very short times; and was pioneered on milk products to produce extended shelf life.
Generally for sterilisation the milk product is canned or bottled and then heat-treated in a retort in hot
water (under overpressure) or steam. Sterilising retorts may be batch or continuous in operation.
Environmental impact
Indicative BAT requirements for storage and handling of materials:
1 The main control issues are:
cleaning techniques see Section 2.1.16 on page 36
air emissions from conveyors see Section 2.5 on page 82
accidents, for example overfilling of storage silos see Section 2.8 on page 90
2 No further issues are identified.
Air: Potential for fugitive losses from refrigeration systems.Water: Once-through cooling post heat treatment requires substantial quantities
of cooling water. Fouling of heat transfer surfaces requires cleaning.
Land: No direct impacts.
Waste: Product residues and concentrated flushes can be collected for recovery
or animal feed.
Energy: Energy required in the form of steam or hot water treatment and for cool-
ing. Cooling can be accomplished by once-through cooling or with a recir-
culating chilled water system. The latter will involve a mechanical
refrigeration system. Most dairy pasteurisers now use a regenerative
heat exchangers which can be up to 96% energy efficient
Accidents: Not applicable.
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Introduction Techniques Emissions Impact
The mainactivities andabatement
Abatement ofpoint sourceemissions
Managementtechniques
Rawmaterials
Wastehandling
Wasterecovery ordisposal
Energy Accidents Noise Monitoring Closure Installationissues
The mainactivities andabatement
Techniques for pollution control
BAT for pasteurisation etc.
2.1.4 Evaporation
Summary of the activities Evaporation is the partial removal of water from liquid food by boiling. Milk or milk products can be
evaporated to produce concentrated, condensed, or evaporated products. Water is usually removed
from liquid milk in an evaporator prior to drying. Milk products are normally condensed from an initial
solids content of 9 to 13% to a final concentration of 40 to 50% total solids before drying.
Steam or vapour is usually used as heating medium. The latent heat of condensation is transferred to
the liquid to raise its temperature to the boiling point and evaporate the water. The vapour is then
removed from the surface of the boiling liquid.
Evaporation systems may be single-stage or multi-stage (also called effects) with 2, 3 or more
evaporator or vacuum units. In multi-stage evaporators the effects operate at decreasing pressure as
the product moves through the stages. These stages are usually under vacuum so that evaporation and
boiling temperatures are lower than at atmospheric pressure, so as to reduce heat input and damage to
the products.
Other options to reduce energy consumption by re-using heat contained in vapours include:
vapour recompression;
preheating using the vapour to heat incoming feedstock or condensed vapour is used to raise steam
in a boiler.
Periodical chemical cleaning is carried out in order to ensure clean surfaces and an efficient heattransfer. The cleaning frequency is, depending on product and evaporator type, from 8 to more than 48
hours.
Environmental impact
Noise: Not applicable.
Indicative BAT requirements for heat treatment processes:
1 The main control issues are:
water use see Section 2.5 on page 82 the operator should justify why the reuse of once through cooling waters is not possible.
cleaning techniques see Section 2.1.16 on page 36
fugitive emissions to air (refrigerants) see Section 2.8 on page 90
energy efficiency see Section 2.8 on page 90 for use of regenerative heat exchangers
2 No further issues are identified.
Air: Odour and particulate arising from incondensable gases vented to ensure
efficient heat transfer and entrainment, where a fine mist of concentrate is
produced during violent boiling.
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Introduction Techniques Emissions Impact
The mainactivities andabatement
Abatement ofpoint sourceemissions
Managementtechniques
Rawmaterials
Wastehandli