CLEANER PRODUCTION CASE STUDY
PORT LINCOLN TUNA PROCESSORS
SUMMARY Port Lincoln Tuna Processors is the single largest user of potable water in Port Lincoln. A detailed investigation into its water usage and wastewater generation identified strategies, in conjunction with the services of Eyre Peninsula Water Treatment, to minimise water usage. Since mid-1999 the company has implemented these strategies and is saving 22,000 kL or 20% of mains water annually - a direct saving of $20,000, even with a significant increase in production.Water use for canning tuna has been reduced by over 50% on a per tonne basis. Ongoing improvements to waste treatment infrastructure will result in significant reductions in trade waste treatment costs.
DEPARTMENT FOR environment and heritage CASE STUDY CASE STUDY CASE STUDY CASE STUDY PORT LINCOLN TUNA PROCESSORS
Business profile
Port Lincoln Tuna Processors (PLTP) is currently the only operating tuna cannery in Australia. Its primary products are canned tuna and sashimi tuna.The facility employs 200 people and has an economic value of approximately $50 million to South Australia.
Financial assistance provided
Flinders University of South Australia carried out the consultancy with a grant of $15,000 from the EPA and funding through the Coast and Clean Seas scheme.The consultancy covered eight major processing facilities in Port Lincoln
Technology Implemented
A detailed investigation of water usage and wastewater generation (both quality and quantity) identified areas where major savings could be made.Waste reverse osmosis (RO) water and vacuum pump wastewater is now used for washdown.Thaw tank efficiency has been improved significantly. All washdown hoses are fitted with flow trigger nozzles. An improved cooling conveyer system is now used for cooling hot fish fillets.
Cleaner production motivators
Major increases in production following the closure of the New South Wales cannery at Eden would have increased water usage and associated costs. In addition, the implementation of a new marine discharge policy by the SA EPA in 2001 will require PLTP to instigate new waste treatment practices at significant cost. Waste minimisation was considered important for continuing economic operation of the facility.The Coast and Clean Seas project was also an important driver for this study.
TRADITIONAL APPROACH
Water usage at PLTP has been increasing annually up to a high in March 2000 when the facility had used 109,855 kL in the previous 12 months. Previous attempts at reducing water usage had not been implemented fully. Incentives to minimise wastewater and waste generation were not pressing, as discharge of wastewater through a marine outlet was allowed.
#1 CASE STUDY CASE STUDY CASE STUDY CASE STUDY
CLEANER PRODUCTION INITIATIVES
Benefits recommended and implemented
Monitoring A thorough review of all water usage and wastewater generation on site was instigated in the program, identifying opportunities for minimisation.The investigation also identified possibilities for waste stream separation to reduce future waste treatment costs.
Waste treatment/separation Mesh baskets and silt traps were installed and employees trained in new waste removal procedures. A range of options being investigated by PLTP management includes the use of screens and membranes, with the main barrel screen separator to be upgraded.
AUTOCLAVE FOR STERILISING CANS
CANNING PROCESS LINE
#2 BENEFITS
ENVIRONMENTAL Water usage • Water use has been reduced by 20% in a wide range of processes Waste water usage • PLTP has invested a considerable amount of water storage tanks and wash down systems throughout the the processing line. Washdown is now achieved using 85% recycled treated water Waste reduction • Reductions in nutrient load in wastewater will have significant benefits for the re-use of wastewater treatment plant effluent being implemented in the Coast and Clean Seas initiative Waste separation • Investigations into waste stream separation should allow high nutrient, low volume wastewater and separated solids to be used beneficially, e.g. for composting ECONOMIC Productivity • Productivity and cost efficiency have increased significantly Water usage costs • Cost of water usage per tonne of processed fish in the cannery has reduced by over 50% Future waste • Future trade waste discharge fees to sewer will be based on both volume and strength; treatment costs savings in charges through waste minimisation and separation of high nutrient streams, use of screens etc. will result in significant future savings Payback period • Most improvements have been instigated through changes in operational procedures and use of existing infrastructure. • Equipment upgrade—e.g. installation of a new cooling conveyer primarily to increase processing efficiency—has been accompanied by significant cost savings in water usage. • Payback period for measures aimed directly at waste minimisation is estimated to be less than two months.
WHERE TO FIND ADDITIONAL INFORMATION
Eco-efficiency Team Mr Stephen Visic Environment Protection Agency Chief Engineer GPO Box 2607 Port Lincoln Tuna Processors Adelaide SA 5001 Proper Bay Road Port Lincoln SA 5606 Phone (08) 8204 2027 www.epa.sa.gov.au Phone (08) 8682 1255
Totally Chlorine Free TCF Recycled R Content