INDUSTRIAL WASTE MANAGEMENT OF A MILK PROCESSING INDUSTRY

HARKRISHAN SINGH M. TECH (ENVIRONMENTAL SCIENCE & TECHNOLOGY) 601101008

INTRODUCTION

Industrial activity involves the transformation of raw materials into value added products

Transformation involves:
Input of energy, water and chemicals Involvement of man-power Use of space, buildings, machinery and equipment Generation of byproducts

INTRODUCTION
All these activities involve waste generation because transformation process has to be supported by:
Material Inputs require procurement, storage, processing and supply as and when required Intermediates may require storing Products & byproducts require storage, packing & shipment Wastes need proper collection, handling (storage, processing/treatment and transportation) and disposal Machinery and equipment, and facilities require repair and maintenance Employees require proper working environment (water supply and sanitation, canteen and other amenities)

INTRODUCTION

Industrial Activities are divided into two major divisions:

Core Activities: Activities directly associated with the transformation of raw materials into products. These vary from industry to industry Support Activities: Activities meant to support the core industrial activities. These include water treatment & supply systems, Electrical power and steam systems, storage facilities, maintenance of machinery & equipment, Packaging, Water supply & sanitation, Waste collection, handling & disposal

INTRODUCTION

The Environmental Concerns of these activities are identified and henceforth modification are suggested

The modifications and measures to be taken are suggested on the basis of:
Technical Feasibility Practical Feasibility Economical Feasibility

INTRODUCTION

The Punjab State Cooperative Milk Producers Federation Limited popularly known as MILKFED Punjab, came into existence in 1973 Its Objectives:
To provide remunerative milk market to the Milk Producers in the State To provide technical inputs to the milk producers for enhancement of milk production on the other hand

PRODUCTS
Processed Cheese

Cheese Spread
Sweetened flavored milk Paneer

Dahi
Kheer Lassi Packaged Milk Cream (for catering purpose only) Khoya (for catering purpose only)

RAW MATERIAL

Raw material used is Milk Milk is procured from:

69 Milk Chilling plants installed in different villages in trucks with chilling units installed
Local dairy farms in 80lb containers

CORE ACTIVITIES
Milk procurement Filtration Cream Separation

Pasteurization
Homogenization Fat Percentage and SNF (solid-not-fat) ratio adjustment

Milk Supply to Different Sections of Production

Paneer, Kheer, Dahi, Lassi, Cheese, Packaged Milk & Flavored Milk Production

Packaging
Storage

SUPPORT ACTIVITIES
Washing of Bottles, Milk Cans and Trays Chilled water plant & circulating chilled water system Boiler & Steam distribution system Quality Testing Lab Storage for Chemicals In-house Fuel Filling Station Convenience Facilities Transport Vehicle Garage and Repair Centre DG sets (2 of 250KVA each) and Transformer

Milk from Tankers Fat & SNF Milk in 80lb cans

Conveyor Belt

Milk Collection

Chilled Water Chilled Water

Storage Tank

Suspended Solids

Filtration

Cream

Centrifugal Cream Separator

Feed Lines

Paneer & Kheer

Dahi

Flavored Milk

Lassi Packaged Milk

Steam H.E Steam Condensate

Temperature based Sensor

Chilled Water

H.E Pasteurization

Chilled Water

2000 psi

Homogenizer
Compressed Air

800 psi

Pasteurization & Homogenization

Pump

Pump

Milk from Storage

Steam

Rice & Sugar Kheer for Packaging Steam Condensate

Feed Tank
Steam Condensate Chemical addition container
Coagulated Proteins

Steam Vessel

Citric acid

Dye Press Whey Chilled Water

Dye Boxes

Dye Boxes Whey

Chilled Water Tub

Paneer for Packaging

Chilled Water

Paneer & Kheer Section

Milk from Storage

Microbial Culture

Feed Tank

Chilled Water Storage Room F.D Fan Automatic Cup Filling and Packing Steam fed Radiator Incubation Room for Cups

Chilled Water

Dahi Section

Milk from Storage

Sugar & Flavor

Feed Tank

Washing Chemicals

Bottles

Washing of Bottles

Bottle Checking

Automatic Filling

Manual Filling

Manual Capping

Wastewater

Water Spilling Milk Spilling Cooled to Room Temperature & Branding

In-bottle Sterilizer

Flavored Milk Section

Milk from Storage

Microbial Culture

Feed Tank

Chilled Water Storage Room

Chilled Water

Sugar/Salt

Motor

Mixing

Automatic Packaging

Lassi Section

Milk from Storage

Packing Material Automatic Packaging Under Vacuum Caustic Steam Condensate

Packaged Milk put in Trays

Trays

Tray Washing

Trays

Spilling Wastewater Chilled Water Storage Room Chilled Water

Loading into Trucks

Packaged Milk Section

Wood Steam

Flue gases to atmosphere through stack

F.D Fan

External Boiler Furnace

Fire Tube Boiler Fly ash

Flue Gas

Blowdown to drain

Burnt Wood

Boiler Feed Water Pumps

Soft water from Ion Exchanger

Boiler Feed Water Tank

Boiler

Return Chilled Water

Heat Exchanger Heat Exchanger Heat Exchanger

Brine Water
Refrigerant Vapors

Ice bank Tank

Pump
Liquid Refrigerant

Chilled Water

Compressor Cooling Water

Condenser

Refrigerant reservoir Cooling Water

Chilled Water Plant

ENVIRONMENTAL CONCERNS
Conveyor belt system requires frequent oiling and greasing Filtered out substances from milk which are mainly suspended solids and have high BOD Hydraulic Systems in milk packaging requires maintenance The steam condensate from Heat Exchangers

The whey from Paneer production which is high in BOD

Chilled water Washing of bottles which contains chemicals

Spilling of milk
Waste heat

ENVIRONMENTAL CONCERNS

Electricity Consumption Flue gases from boiler

Burnt wood Ammonia gas for chilling plant

Boiler blowdown containing TDS

Resin Backwash & Regeneration water Regeneration Chemicals Fly ash from the boiler

Sludge disposal
Rejected products Noise Pollution CIP chemicals

EFFLUENT TREATMENT PLANT

Collected in two equalization tanks (10ft X 6ft X 8ft) Transferred to aerated lagoon (14ft X 28ft)

Transferred to Sludge Settling Tank (14ft X 5ft)

Pumped and transferred to two sludge drying beds (15ft X 15ft)

The treated water is used for irrigation of green belt within the industry premises.

Inlet of Wastewater Equalization Tank-1 10ft X 6ft X 8ft Equalization Tank-2 10ft X 6ft X 8ft Pump Aerator (10 HP)

Aerated Lagoon 14ft X 28ft Sludge Drying Bed-1 15ft X 15ft

Aerator (10 HP)

Sludge Drying Bed-2 15ft X 15ft

Settling Tank 14ft X 5ft

V-notch Chamber

Effluent Treatment Plant

Fine Treated Effluent used for Irrigation

SUGGESTED MODIFICATIONS

Reuse of steam condensate

Counter-current washing of trays APCD for flue gases from the boiler

Vapor Absorption Systems can be used for Chilling Water System

REFERENCES
http://www.epa.gov/osw/hazard/tsd/mercury/pdf/njac726g1.pdf http://www.scribd.com/doc/46379519/Industrial-WastewaterManagement-System-Overview Based upon the Lectures of Dr. A.S Reddy on Industrial Waste Management http://www.scribd.com/doc/25462830/Supporting-IndustrialActivities-and-Environmental-Concerns