1 University Microfilms International, Annarbor, Michigan48ioe 1977
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il ;i 78-5820 CARAWAN, Roy Eugene, 1943- EFFECT OF PROCESS MODIFICATIONS ON THE REDUCTIONOOF WATER USE AND WASTE IN A CASE STUDY DAIRY PLANT. The Ohio State University, Ph.D., 1977 Food Technology I' 1 University Microfilms International, Ann Arbor, Michigan 48ioe @ c°Pyright by Roy Eugene Carawan 1977 EFFECT OF PROCESS MODIFICATIONS ON THE REDUCTION OF WATER USE AND WASTE IN A CASE STUDY DAIRY PLANT DISSERTATION Presented In Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Roy Eugene Carawan, B.S., M.S. ******* The Ohio State University 1977 Reading Committee: Approved By Dr. W. J. Harper Dr. 0. L. Blaisdell Dr. T. Kristoffersen Advis< Depa nent of Food Science and Nutrition DEDICATION I wish to dedicate this dissertation to the following individ uals: DR. FREDERICK G. WARREN, DR. VICTOR A. JONES AND DR. W. JAMES HARPER, who have most influenced my university career over the last several years as an undergraduate and a graduate student in the hope that this work in some small way will compensate and reward them for their time, effort, motivation and knowledge they have given to me. ii ACKNOWLEDGEMENTS The author wishes to express appreciation to the many individuals who provided consultation, information, guidance and review throughout this study. Special gratitude is expressed to Dr. W. James Harper who provided interest, encouragement, expertise and a working entree with the dairy industry throughout the author's graduate program and research. The author is deeply indebted to the North Carolina Agricul tural Extension Service which provided him with an Educational Leave to assist in the completion of his graduate work. The support of the Water Resources Center at The Ohio State University is acknowledged and appreciated. Without the financial support of these two organizations, these studies would have been impossible. The invaluable time, expertise, suggestions and criticisms of Drs. Francis E. Walker, David H. Hahn, E. Earl Whitlatch, John L. Blaisdell, Robert C. Stiefel, T. Kristoffersen, Jean R. Geisman and C. C. Chipley were important to the author and the successful con clusion of this research. The information, assistance and records of the many dairies and dairy equipment manufacturers who have cooperated in this study greatly facilitated the development of this work. Particularly, the author would like to thank Dale A. Seiberling, former Vice President of Economics Laboratories-Equipment Engineering Division m• « ■ and now with Siberling Associates, whose searching mind, intimate knowledge of the dairy industry, and vigorous pursuit of all is hopefully reflected throughout this study. Also, Mr. Bob Elliott formerly associated with CREPACO, Inc. was very generous in giving of his time and knowledge of the dairy industry. Appreciation is extended to both Ms. Judy Fulp and Ms. Marie Walton who helped in preparing the manuscript of this dissertation. Finally, my thanks to my family. First, to my Mother and Father who encouraged and supported my university studies. Last, but not least, to my children, Russ and Ashley, who did without a father while he studied and prepared this dissertation and to my wife, Debbie, for her encouragement, sacrifice, love and under standing throughout my graduate program. VITA June 9, 1943..................... Born - Southport, North Carolina 1961........................... Diploma, Junius H. Rose High School, Greenville, North Carolina 1966........................... B.S. - Food Science, North Carolina State University, Raleigh, North Carolina 1966-68 ........................ Research Assistant, Food Science Department, North Carolina State University, Raleigh, North Carolina 1968-Present..................... Extension Specialist (Food Engineering), Food Science Department, North Carolina State University, Raleigh, North Carolina 1970........................... M.S. - Food Science with Civil Engineering (Sanitary) minor, North Carolina State University, Raleigh, North Carolina 1974-75 ........................ Educational Leave - The Ohio State University PUBLICATIONS Water and Waste Management Educational Program for Dairy Processing. 1977. Carawan, Roy E. and V. A. Jones. J. Dairy Science 60(7). pp. 1192-1197. v PUBLICATIONS (Continued) Water and Waste Management in Poultry Processing. 1974. Carawan, Roy E., W. M. Crosswhite, J. A. Macon and B. K. Hawkins: U. S. Environmental Protection Agency, EPA-660/2-74-031, Washington, D.C. 223 pgs. Water and Wastewater Management in Dairy Processing. 1972. Carawan, R. E., V. A. Jones and A. P. Hansen. Water Resources Research Institute, Report No. 79. The University of North Carolina, Raleigh, N. C. 132 pgs. Proceedings Workshop on Poultry Processing Plant Water Utilization and Waste Control. 1971. Carawan, Roy E. (Editor). Water Resources Research Institute, Report No. 59. The University of North Carolina, Raleigh, N. C. 92 pgs. Effect of Preheating On the Ultra-High Temperature Inactivation of Bacillus Subtil is A Spores. 1970. Carawan, Roy E. M. S. Thesis, Department of Food Science, N. C. State University, Raleigh, N. C. 107 pgs. FIELDS OF STUDY Studies in Food Processing Water and Waste Control - Professor W. James Harper Studies in Linear Programming - Professors E. E. Whitlatch and F. F. Walker Studies in Food Engineering - Professor J. L. Blaisdell . TABLE OF CONTENTS Page DEDICATION............. ...................... 11 ACKNOWLEDGEMENTS ................................. 111 VITA .......................................... v LIST OF TABLES .................................. x1v LIST OF FIGURES ................................. xxii GLOSSARY....................................... xxiv INTRODUCTION . 1 LITERATURE REVIEW ............................... 6 Introduction ............................... 6 Dairy Processing Wastewater Characteristics .......... 8 Introduction ............................ 8 Sources and Nature of Wastewater .............. 9 Dairy Wastewater Parameters ............... ^ Variability of Dairy Wastewaters .............. ^ 3 Water and Waste Monitoring .................. Waste and Wastewater Coefficients ............ Waste L o a d .............................. Water Use and Wastewater Discharge . 20 Coefficients for Areas, Processes and E q u i p m e n t .............................. 25 Control of Dairy Wastes ........................ 27 Introduction ............................ 27 vii TABLE OF CONTENTS Continued) Page Plant Records Versus Losses ................... 29 In-Plant Control Measures ..................... 33 Municipal Discharge of Dairy Wastewaters ............. 52 Municipal Charges ........................... 52 Industrial User Ordinance ................... 54 Systems Analysis............................. 55 Operations Research ........................ M o d e l i n g ................................. 57 Linear Programming ........................ 59 OBJECTIVES AND SCOPE OF INVESTIGATION .................. 65 EXPERIMENTAL PROCEDURES AND METHODOLOGY . ............... 68 Introduction ................................. 58 Case Study Plant ............................ 69 L o c a t i o n ............................... 72 Product Availability ...................... 73 Plant Operating Assumptions .................. 73 Processes and Equipment ........................ 73 Process Alternatives ........................... 96 Selection of Process Alternatives ............. 96 Evaluation of Process Alternatives ............ 97 Initial Cost and Annual Budgets ............... 99 Management Reduction Practices..................... H I Process Alternatives for Water Reduction ............. 113 vin• * • TABLE OF CONTENTS (.continued) Page Mater Related Process Alternatives ............ 113 Process Alternatives for Waste Reduction.. .......... 114 Waste Related Process Alternatives ............ 114 Dairy Processing as a Linear Analysis Model ......... 115 Formulation of Linear Programming Model ....... 117 Model Development ........................ 118 Linear Programming Format .................. 120 Dairy Plant Parameters ........................ 122 Waste, Water and Wastewater Coefficients ....... 124 Relationship of Product and Product Losses ....... 128 Linear Analysis Inputs ..................... 132 RESULTS AND DISCUSSION ............................ 133 Introduction ............................... 133 The Case Study P l a n t ......................... 133 Benchmark Coefficients ...... 134 Management Action Coefficients ............... 136 Fluid Milk Processing Coefficients ............ 139 Cottage Cheese Processing Coefficients ......... 143 Ice Cream Processing Coefficients ............ 147 Ancillary Processes ...................... 148 B e n c h m a r k.................................. 153 Water Use ............................ I53 E f f l u e n t s .............................. I55 ix TABLE OF CONTENTS (continued) Page Wastewater Characteristics . , ........... 155 Waste L o a d ............ ................. 156 Operating Characteristics ................. 156 Monthly Water and Waste Related Costs ......... 156 Management Action Levels ...................... 157 Water Use . ...................... 157 E f f l u e n t s ......... .................... 159 Wastewater Characteristics .................. 159 Waste L o a d .............................. 159 Monthly Water and Waste Related Costs ......... 160 Initial and Annual Costs ............ ....... 160 Water Related Process Alternatives ............... 163 Collective Evaluation .