Eco-efficiency for the Dairy Processing Industry, 2019 edition Eco-efficiency for the Dairy Processing Industry, 2019 Edition Prepared for: Mr Ian Olmstead Program Manager - Manufacturing Innovation & Sustainability - Trade & Industry Strategy Dairy Australia, Level 3, HWT Tower, 40 City Road, Southbank, Victoria, 3006 2019 Update Prepared By: The Ecoefficiency Group Pty Ltd Penny Prasad, Jane Gaffel, Nicole Price www.ecoefficiencygroup.com.au 2004 Edition Prepared By: The UNEP Working Group for Cleaner Production in the Food Industry Environmental Management Centre, The University of Queensland, St Lucia Penny Prasad, Robert Pagan, Michael Kauter and Nicole Price Sustainable Business Level 9, 121 Walker Street, North Sydney Patrick Crittenden Publication by: Dairy Australia 2019 Disclaimer: While every attempt has been made to ensure that the information in this publication is correct at the time of printing, errors can occur. The information is provided as general information only. Specific issues relevant to your workplace should be considered in light of this and on an individual basis. You should consult with professional advisers familiar with your particular factual situation for further advice. Page ii Eco-efficiency for the Dairy Processing Industry, 2019 edition Contents 1.0 Introduction ...................................................................................................... 1 2.0 Industry profile ................................................................................................. 3 3.0 Sustainability Frameworks and Targets ........................................................... 6 4.0 Environmental Challenges ............................................................................... 9 4.1 Compliance and legislation ..................................................................................... 9 4.2 Water security and cost .......................................................................................... 9 4.3 Wastewater discharge ............................................................................................ 9 4.4 Energy security and cost ....................................................................................... 10 4.5 Carbon Emissions ................................................................................................. 11 4.6 Solid waste management ...................................................................................... 12 4.7 Packaging ............................................................................................................. 12 4.8 Circular Economy.................................................................................................. 13 4.9 Biodiversity ........................................................................................................... 13 4.10 The Digital Economy ......................................................................................... 14 5.0 Achieving Sustainability Goals ....................................................................... 16 5.1 All about eco-efficiency ......................................................................................... 16 5.1.1 Origins ........................................................................................................... 16 5.1.2 Carrying out an assessment .......................................................................... 16 5.1.3 Barriers .......................................................................................................... 17 5.2 Achieving best practise in dairy processing ........................................................... 18 5.2.1 Characteristics of a company that is aiming for best practise ......................... 18 5.2.2 Future or emerging technologies .................................................................... 20 5.3 Effecting Change .................................................................................................. 21 5.3.1 Avenues for supporting implementation ......................................................... 21 5.3.2 Building the business case............................................................................. 22 5.3.3 Stakeholder engagement ............................................................................... 22 5.3.4 Supplier performance contracts ..................................................................... 25 6.0 Water ............................................................................................................. 27 6.1 Overview of water use .......................................................................................... 27 6.1.1 Water use in dairy factories ............................................................................ 27 6.1.2 The true cost of water .................................................................................... 29 6.1.3 Measuring water consumption ....................................................................... 31 6.1.4 Process Models ............................................................................................. 32 6.2 Reducing demand for water: processing ............................................................... 33 Page iii Eco-efficiency for the Dairy Processing Industry, 2019 edition 6.2.1 Optimising rate of water flow .......................................................................... 33 6.2.2 Efficient process control ................................................................................. 33 6.2.3 Leaks ............................................................................................................. 33 6.3 Reducing demand for water: cleaning ................................................................... 34 6.3.1 Dry cleaning ................................................................................................... 34 6.3.2 Trigger-operated controls for hoses ............................................................... 35 6.3.3 High-pressure cleaning systems .................................................................... 35 6.3.4 Clean-in-place systems .................................................................................. 35 6.3.5 Scheduling or modifying product changeovers ............................................... 38 6.3.6 Crate washers ................................................................................................ 39 6.4 Reducing demand for water: utilities ..................................................................... 39 6.4.1 Cooling tower operation ................................................................................. 39 6.4.2 Blowdown in cooling towers and boilers ......................................................... 39 6.4.3 Equipment sealing water ................................................................................ 40 6.5 Ancillary water use ................................................................................................ 40 6.6 Stormwater ........................................................................................................... 40 6.7 Water recycling and reuse .................................................................................... 41 6.7.1 Condensate recovery ..................................................................................... 42 6.7.2 Use of membranes for water recovery ........................................................... 44 6.8 Wastewater ........................................................................................................... 46 6.8.1 Treatment of wastewater ............................................................................... 46 6.8.2 Selection of a wastewater treatment system .................................................. 48 6.8.3 Management of saline waste streams ............................................................ 49 6.8.4 Reuse of treated wastewater for irrigation ...................................................... 50 7.0 Energy and Carbon Emissions ...................................................................... 53 7.1 Overview ............................................................................................................... 53 7.1.1 The cost of energy ......................................................................................... 55 7.1.2 Carbon emissions .......................................................................................... 56 7.2 Energy management ............................................................................................. 58 7.2.1 Real time energy monitoring .......................................................................... 59 7.2.2 Demand management ................................................................................... 59 7.2.3 Power factor correction .................................................................................. 60 7.2.4 Voltage optimisation....................................................................................... 61 7.2.5 Process models ............................................................................................. 61 7.3 Reducing thermal energy demand ........................................................................ 61 7.3.1 Evaporation ................................................................................................... 61 7.3.2 Membrane concentration ............................................................................... 63 Page iv Eco-efficiency for the