Water and Process Treatment Solutions For the Food and Beverage Industry
WATER TECHNOLOGIES
For more than a century, Veolia has provided sustainable solutions to help customers around the globe address some of the world’s most pressing challenges. And today, the Water Solutions & Technologies business of Veolia continues that commitment. We are a forward- thinking and thoughtful leader in developing water reuse, wastewater treatment, and water process solutions our customers need to operate more efficiently and profitably while reducing their environmental footprint. Our goal is to help industries thrive and communities prosper.
Addresing Today’s Challenges Water is one of the most widely used raw materials in the food and beverage industry. Maintaining its quality is a critical task at every stage of production, including cleaning, boiling, washing, cooking, fermenting, evaporating, sterilizing and pasteurizing. Processing operations also require special attention to control problems like deposits, corrosion, foaming and bacterial growth, and to facilitate dewatering, clarification, off-line cleaning, and other procedures. Strict government regulations apply to water quality throughout the plant, and treatment products need to be approved for primary and secondary direct food contact applications. At the same time, compliance with increasingly stringent effluent discharge regulations must be maintained. Veolia understands that the food processing and beverage industry has a diverse range of water treatment needs which require treatment programs to help ensure that expensive capital equipment runs troublefree and at peak efficiency, to reduce operating costs through water and energy conservation, and to comply with federal, regional, and local government regulations.
Driving Financial and Environmental Performance We understand the challenges and recognize the opportunities of the food and beverage industry. As a strategic business partner, Veolia can provide a complete set of chemical and equipment solutions to help manage and improve water resources. From reduced water usage to increased productivity, we deliver the results to drive your performance—financially and environmentally.
Technology and Solutions Veolia is one of the world’s premier suppliers of water and process treatment programs for both large industrial plants that produce sugar, starch, and ethanol in bulk quantities, and food manufacturing plants involved in processing, canning, freezing, and bottling operations. Our expertise is derived from the depth and breadth of our advanced chemical and equipment technology, our systems and applications expertise, and extensive industry experience. These plant-wide water and process treatment resources are brought to food and beverage plants worldwide: •
Utilities solutions that include advanced chemical technology for boiler and cooling systems to improve plant productivity, safeguard assets and improve energy efficiencies.
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Ingredient water solutions – from microfiltration to reverse osmosis, Veolia’s membrane technology can ensure consistent quality standards are met to protect your brand. Veolia’s membrane chemicals and On-Point services keep your membrane system functioning optimally.
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Complete suite of on-line and off-line monitoring solutions and knowledge management systems, such as TrueSense* and PaceSetter Platinum, to optimize performance and conserve resources.
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A complete portfolio of food process chemicals to improve operations such as deposit and corrosion control, biocides, foam control, improved solids recovery, viscosity modifiers, enhanced clarity and products specially designed for offline cleaning.
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Veolia’s mobile water fleet—the largest in the world—meets demand for on-site water treatment through emergency, short-term leases, and long term outsourcing.
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Wastewater management and water reuse: Integrated wastewater management and water reuse solutions for water recovery, treatment and recycling. Veolia is a world leader in Membrane BioReactor solutions for the food industry.
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Food process membranes and electrodialysis provide advanced solutions for food process separation, concentration, purification, acidification or deacidification.
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Sterilizer and pasteurizer treatments to keep food packages and process equipment free of deposits, provide microbiological control, and protect equipment from scale and corrosion.
Food and Beverage Industry Case Studies Case Study Veolia and Frito Lay work together to reduce environmental footprint Frito Lay’s Casa Grande Facility in Arizona was one of 40 chosen by Frito Lay in 2007 to demonstrate a “Net Zero” environmental footprint. Built in 1984, the 188,000-square-foot manufacturing facility produces Lay’s potato chips, Fritos corn chips, Tostitos tortilla chips, Doritos tortilla chips, and Cheetos cheese-flavored snacks. The company’s goal to “leave no trace” means that energy primarily must come from renewable power—solar, in this case—and that water is primarily reused. The plant began commissioning in the summer of 2009. The solution for the Casa Grande Facility was Veolia’s ZeeWeed* membrane bioreactor and reverse osmosis system. ZeeWeed-immersed ultrafiltration (UF) membrane technologies are engineered for specific applications to ensure a highly cost-effective system, enhanced to meet customer needs. They form a physical barrier against common contaminants, minerals, bacteria and viruses. The systems are simple to operate, offer the highest solids tolerance and small footprints, which reduce capital costs. The UF membranes also produce an ideal reverse osmosis (RO) feed that improves RO membrane reliability, performance and service life. At Casa Grande, ZeeWeed* technologies treat and recycle 648,000 gallons per day of wastewater from the potato chip manufacturing process for reuse as rinse and wash water, as well as for irrigation. Other aspects of the system include solar power, a biomass boiler, and zero landfill. This solution helped the plant achieve renewable energy and recycled water goals, including a 90 percent reduction in water and electricity usage. The plant has the unique distinction of being the first existing food manufacturing site in the United States to achieve LEED EB Gold Certification. It also is one of the few in the United States where wastewater is biologically treated and the treated wastewater is directly reused in a food application. In 2010, Veolia and Frito Lay received the Environmental Contribution of the Year Award from Global Water Intelligence for the Casa Grande Facility.
Case Study Veolia maximizes water efficiency for major bottler A major bottler of carbonated soft drinks and bottled water, located in the Northwest United States, has trusted Veolia for many years to provide them with high-quality water treatment solutions, such as ultrafiltration and reverse osmosis systems. With such large volumes of water required for their product, this bottler wanted to decrease the ratio of gallons of feedwater required per gallon of product manufactured. Veolia designed a recovery system that could treat effluent from numerous unit operations, and recycle the treated water back to the feed into the water treatment system. By incorporating this water recovery system into their water room operations, the bottler was able to realize greater than 90% overall water usage efficiency. Veolia successfully implement the solution for this customer to realize their water efficiency goals on their finished products.
Case Study Water reuse helps white energy save over $200,000 per year White Energy’s Russell, Kansas plant has been producing about 40 million gallons (151,000 m3) of ethanol per year since 2001. The plant plays an important role in helping the United States achieve its 2007 “Twenty in Ten” goal, which aims to replace 20 percent of the nation’s gasoline use with ethanol over the next decade. White Energy’s plant, like most ethanol facilities in the United States, is located in the nation’s mid-west where it is in close proximity to the milo, sorghum and corn plants that provide the primary ingredients for ethanol production. But in addition to the feedstock, a large amount of water is also needed to convert the biomass into ethanol. White Energy’s Russell, Kansas plant draws as much as 600,000 gallons (2,271 m3) of water per day from the municipal supply—about a third of the total daily water requirements for this small community of 4,200 people. As the city confronted an extended drought during 2006, White Energy, along with the City of Russell, began working together to find ways to reuse water and reduce the plant’s use of increasingly limited municipal water supplies. Veolia’s broad portfolio offered White Energy the opportunity to create an integrated water reuse and chemical treatment strategy that could not only help the ethanol producer recycle water, but also reduce operating costs and yield environmental benefits. Veolia’s team proposed a water reuse solution that would recover wastewater from the ethanol production process and recycle the treated effluent as makeup water for the plant’s cooling towers. Within nine months, the team had completed pilot testing, design, construction and commissioning of the water reuse system, and by August, 2006 the system was fully operational. The multi-step process incorporated ultrafiltration pretreatment to first remove virtually all suspended solids from the waste stream. Next, Veolia’s reverse osmosis (RO) membranes filter dissolved contaminants; producing high quality effluent that is reused within the plant’s cooling towers. A second Veolia RO system was also installed to produce high quality boiler feedwater.
Case Study Veolia diagnoses root to pasteurizer corrosion problem A major European dairy company used hydrostatic autoclaves to sterilize bottles and cans of condensed milk at its manufacturing plant. However, these relatively large autoclaves had developed serious corrosion and other water conditioning problems. The equipment was at risk of completely deteriorating, and would cost millions to replace. A competitive water treatment company had tried to solve the problem with applications of a corrosion inhibitor based on Zinc phosphate. That treatment proved unsuccessful, resulting in expensive retrofits on one of two autoclaves. Unless the problem was resolved in the second autoclave, similar retrofits would be necessary. Veolia worked closely with the dairy company team to collect baseline data, which helped identify the corrosion’s root cause and mechanism. Data showed that water pH variances caused the original treatment to fail, leading to corrosion. When pH was high, it caused uncontrolled deposit formation and loss of active corrosion inhibitors. A low pH caused protective layers to dissolve and unprotected metal surfaces to corrode. Steam condensate was diluting the water during the sterilization process, slowly reducing the water’s alkalinity. Leaking milk bottles also contributed to a drop in the water’s pH. Veolia’s treatment strategy combined a change to a FoodPro corrosion inhibitor with pH and alkalinity adjustment of the feedwater with caustic. Veolia incorporated a blend of surfactants to help keep the metal surfaces free of organic debris, causing sticky walls. Veolia’s special polymer chemistry solution stabilized the phosphate and allowed higher effective PO4 levels in the water.
Commitment to Sustainability At Veolia, we imagine new models, new technologies, new solutions, to secure a resourceful future for all. We engage in the resource revolution to reinvent the way we manage resources in the new circular economy.
Double investment in clean research and development • In 2009, Veolia invested $1.5 billion on R&D, reaching the commitment to double our annual investment by 2010 one year ahead of schedule. Veolia continues to be committed to unleashing new technology. Therefore, in 2010 Veolia is introducing a new commitment to invest an additional $10 billion in research and development by 2015.
Increase Revenues from Products • In 2009, Veolia R&D revenues grew six percent to $18 billion even in a challenging global environment. Veolia is now committing that this revenue will grow at twice the rate of total company revenue in the next five years, making Veolia R&D an even larger proportion of total company sales.
Reduce its greenhouse gas (GHG) emissions and improve the energy efficiency of its operations • Veolia reduced its GHG emissions by 22 percent compared to 2004. Veolia improved its energy intensity 34 percent compared to 2004, surpassing the goal of 30 percent in 2012. And Veolia has reduced its GHG intensity 39 percent compared to 2004. By 2015, Veolia will improve the energy intensity of its operations by 50 percent, and will reduce its absolute GHG emissions by 25 percent (both using the 2004 baseline).
Reduce water use and improve water reuse • Veolia reduced water consumption 30 percent compared to a 2006 baseline, surpassing the original goal of 20 percent by 2012.
Keep the Public Informed • Veolia is continuing ongoing discussions, dialogues and communications to engage with the public on our R&D efforts.
A Trusted Business Partner A name synonymous with quality around the world, Veolia is a trusted global partner for food and beverage companies large and small. With a broad range of products and services, Veolia’s integrated solutions and unique expertise help manage and overcome important challenges in an ever-evolving industry, while ensuring the responsible and sustainable resource savings our customers across the globe have come to expect. Through innovation, breakthrough technology, and dedicated teams of global experts, we help you successfully compete—and win—in today’s food and beverage industry. We can help food and beverage customers to: • Meet environmental compliance
• Ensure asset protection
• Provide safe, healthy workplaces
• Drive down product costs
• Optimize production
• Improve and/or maintain product quality
• Maximize yield
• Recover value products
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