FOOD PROCESSING FLUID TREATMENT APPLICATIONS
For all types of food processing, when a Triangular Wave Deposit Control System is installed, every water molecule becomes a cleaning agent. The water molecules are free of other contaminants and can do a better job with less chemicals, labor, and dwell time.
Food Processing Applications
|Application||Triangular Wave Technologies Benefits|
packaged use and food service
|Dairy products include liquid milk, butter, condensed whey, cottage cheese, ice cream, condensed & dry milk, dry whey, fluid and cultured products, natural and processed cheese. Typical processes include: refrigerated storage, pasteurization/sterilization, separation and packaging.|
water and fluids are used and what their state is throughout the process
volumes of water are needed for cleaning, sanitary, cooling and production
The pasteurization/sterilization process requires significant heat generation capacity. Many large dairy facilities have on site boilers to meet these high temperature requirements.
|Stock water||Deposit control and better taste for hard water used for cow watering. Many cows are "fussy" about the water they drink. The more water they drink the more milk they produce. Deposit control means waterers do not scale up and leak and the lines are clean.|
|Clean-up water||Treated water
usually requires less chemical additives. Iron in the water is bound
up with the scale minerals and taken out of the "chemistry"; the
result is easier clean-up with fewer chemicals to deal with the iron.
Experience has shown that water supplies that had E. coli contamination now show a zero count after treatment by the Triangular Wave System. More tests are underway to further verify this.
|Milk processors and cheese manufacturing|
|Cooling System||Deposit control on cooling tower and condensers for refrigeration units and process cooling|
|Process water||Deposit control in brine tanks, pumps, valves and pipes.|
|Storage tanks and pipes||Deposit control
of milk stone, reducing need for chemicals (particularly
acids or caustics for cleaning of pipelines and vessels), reducing energy needed to
produce hot water, and shortening the cleaning cycle for dissolving the
milk stone and sanitizing the equipment.
Typical storage vessels may include the following: bulk storage tanks, caustic and acid tanks and fuel oil tanks; tank farm (multiple tanks) containing finished product; and tanks of assorted additives, caustics, disinfectants, detergents and cleaning agents.
|Other equipment||Deposit control in vats, extruders, fermentation tanks, slicers, shrink-wrap packaging machines, pumps, and aeration equipment.|
packaged use and food service
|Processes include the slaughter and butchering of animals, the subsequent preparation of meat into a range of products, and the processing and use of non-meat materials, such as blood, bone, hide and horn. Auxiliary operations include steam generation in large boiler plants, refrigerated storage, ovens/smoking facilities, sterilizing and pasteurizing lines, and wastewater treatment|
in boiler tubes, pumps and pipes, and hot water heater tanks and heating
Deposit control on cooling tower fill, pipes, pumps, valves, and condensers.
Meat processing plants will usually have large cold storage facilities. The release of ammonia into the atmosphere, due to leaks from cooling equipment, is a health and safety concern.
TWT Deposit Control Systems help maintain plumbing, piping, cooling, heat exchangers, and all HVAC/R systems in a clean and efficient state, avoiding bio-corrosive conditions which often lead to such leaks.
|Packaging machines||Softening effect on water to prevent pitting of water channels in aluminum headers that cool shrink-wrapped packages.|
|Ovens||Deposit control on spray nozzles that douse the cooked meat product with cooling water. Ovens are cleaned with high pressure hot water jets and chemicals. TWT Deposit Control will extend the life of the cleaning equipment and reduce the time needed to service the equipment.|
|Energy savings||Reduced deposits in pipes, condensers, and cooling towers means reduced pumping costs and greater heat exchange efficiency.|
|Wastewater discharges||Abattoirs traditionally use large volumes of water to maintain clean and hygienic conditions. Water may be used to hose down or pressure wash floors, machinery and containers. Waste can include blood, skin, bone, hair, salt solutions. TWT Deposit Control can reduce clogging of spray and hose equipment, and aid in the re-use of water.|
packing uses basic equipment like grinders, extruders, slicers, and
mechanical devices for packaging. All equipment needs continuous
cleaning and disinfecting.
The ovens, curing booths, smokers, aging racks, pressure cookers, vacuum seal packaging equipment, cutting tables, saws, and conveyors all have a cleaning crew. It is very time consuming and costly to stay within the guidelines of the sanitary code. For every ten hours of processing there are eight hours of cleaning. When a Triangular Wave Deposit Control System is installed, every water molecule becomes a cleaning agent. The water molecules are free of other contaminants and can do a better job with less chemicals, labor, and dwell time.
Important new product news with impact
on the meat packing industry: TWT
is proud to announce the introduction of the BSR Series, a breakthrough in
comprehensive bacterial reduction, designed to solve problems for meat and
poultry processors. For more information on this exciting product
packaged use and food service
|Common examples of processed fruit products include: fruit juices (apple, orange, tomato etc.); grading and packing of fresh fruit for market; canned peaches and pears; dried fruits (apricots, prunes, dates, raisins etc.); wine and fruit purees for food industry use. Typical processed vegetable products include: canned sweetcorn, carrots, peas, beans etc.; frozen peas and beans; concentrated tomato paste; vegetable soup; potato chips (french fries); pickled mixed vegetables; dried tomatoes; dried onion flakes; vacuum packed beetroot etc.|
water is used and what its state is throughout the process
How TWT fluid treatment systems can help
Sources of process and potable water - municipal, abstraction wells, boreholes. Water from these sources many times needs treatment before and during processing in order to avoid the effects of colloid and particulate buildup on the process equipment and throughout the piping and fluid delivery systems.
Large volumes of water are needed for washing raw materials, factory cleaning purposes, and in the transport of materials within the factory.
Pollutants in wastewaters include detergents, pesticides, suspended solids, dissolved solids, nutrients, and microbes.
Seasonality of production can place heavy demands on treatment/disposal systems during the peak seasons.
TWT Deposit Control can render the effects of particulates reduced, minimal, or harmless, both in the process water, and in the processed fruit in its state of liquefication. It can also allow for reduced use of detergents for cleaning, and make other liquid formulas used in processing work more efficiently, also reducing the amounts needed for their purposes. TWT Filtration can provide a second level of protection. These TWT systems will help ensure reduced maintenance needs throughout the process and highest quality end-products. Systems are modular for easy expansion and upgrades during peak processing times and expanded production.
|Processing and post-processing||
Need to separate solid from liquid waste by screening, sedimentation, flotation etc.
TWT Deposit Control will keep particulates in suspension, flowing through and out of the process system, instead of adhering to piping and equipment, which provides a habitat for biofilm, bacteria, and odor, and which causes equipment degradation and shortened lifecycle, and which exposes an operation to health regulation compliance issues. TWT Filtration products make post-processing easier and cleaner in the wastewater stream, also making re-use of water for irrigation, wash, and transport more readily accomplished.
|Refrigerants||Fruit and vegetable processing plants will usually have large cold storage facilities. The release of ammonia into the atmosphere, due to leaks from cooling equipment, is a health and safety concern. TWT Deposit Control Systems help maintain plumbing, piping, cooling, heat exchangers, and all HVAC/R systems in a clean and efficient state, avoiding bio-corrosive conditions which often lead to such leaks.|
|Storage||Storage may include the following: underground storage tanks (UST), bulk storage oil tanks, fuel oil tanks, tanks of food additives, caustics, disinfectants and detergents. TWT Deposit Control can help reduce the impact of particulate build-up on these vessel surfaces, providing control in recirculating equipment, clean-in-place (CIP) equipment, tank cleaning equipment, storage tanks, feed lines, pumps, and valves.|
-Reduced water consumption
-Reduced energy consumption
-Reduced chemical, detergent, and formula consumption
Ensure thorough cleaning of equipment to maintain high standards of hygiene and compliance with food safety regulations. Remnants of processed foods have reduced or no ability to adhere to surfaces and remain behind when scale and biofilm provide no pits or cavitation and no biological "bed" on those surfaces. Further, since equipment and heat transfer will work more efficiently as a result, energy savings can be more readily achieved.
|Processed mixes and formulas for canned and bottled drinks delivered to market||
The process of mixing ingredients with water to produce a finished product. It is assumed that ingredients are simply mixed and receive little or no on-site processing. Once mixed, the drink is usually carbonated and then canned. The canning procedure is typically fully-automated and comprises the following: Pre-formed and printed cans that have no lid are put onto a conveyor; The product is poured into the can, and the lid is put on and fixed in place.
|Water use and product contamination||Most canning operations use large amounts of water, added to small amounts of concentrate and essences, all of which have to be fit for human consumption. Water treatment is widely used and often relies on high specification technologies such as TWT activated carbon filtration. However, care must be taken to ensure that the treatment process itself does not introduce contaminants such as cleaning agents into the water. When TWT Deposit Control is in place, chemical cleaning agents for vessel surfaces, delivery tubes and piping, and process equipment are less necessary.|
Cans are often required to be washed before the product is packaged. In addition to this, other equipment in the plant will also require washing. TWT Deposit Control keeps parts and can washing equipment working efficiently with little or no scale build-up and allows the detergent formula to better complete itself (using less detergent to do the same job, and allowing the detergent that is used to be more easily removed from the process and end-product).
Wastewater from the food process may be high in sugar content and may also be impacted by food coloring formulas. Fruit juices in untreated wastewater increase the COD (Chemical Oxygen Demand), solids and acidity and could also contain pesticide residue.
Cleaning agents, such as sodium hydroxide and detergents are typically used in a Clean-In-Place (CIP) process, or in batches. Cleaning agents discharged with wastewater are typically alkaline and contain surfactants.
Due to the large volume of water treated, some systems may require the continual or intermittent discharge of concentrated blowdown waters. High salt content is a characteristic of this wastewater stream.
Potentially hazardous wastes may include sludge from either the cleaning of the CIP facilities or wastewater treatment plants; waste oil and solvents; and waste chemicals from the quality control laboratory.
These substances must be properly controlled during the discharge treatment process, but just as importantly, they must also be removed from the earlier processing infrastructure, leaving behind as little residual trace as possible. TWT Deposit Control reduces or eliminates the scale and biofilm that build up from the water used in these processes, also reducing the opportunities for particulates from the other fluids (processed foods and cleaning agents) involved in the processes to find a home in which to further build up.
Local regulators may place limits on the quantity and quality of wastewater discharged from the facility. The quality of wastewater can be improved by minimizing process spills and overfills and minimizing the amount of conveyor lubricant and cleaning chemicals used. TWT Deposit Control can keep fill nozzles from clogging, lessening the occurrence of inconsistent fill, reducing spills, overfills, and the need for cleaning them up as well as reducing process downtime to clear the fill nozzles.
Cleaning water may be heated in a boiler prior to use. Air emissions may result from the operation of the boiler. Local regulators may place limits on air emissions from boilers, therefore boiler operations must be optimized and efficient. TWT Deposit Control will allow the boiler to heat water more quickly and efficiently, using less energy, requiring less time to reach proper operating conditions, and using less chemicals.
Energy is also consumed by refrigeration units and the canning lines. Efficient, optimized operation with TWT Deposit Control again reduces this energy consumption.
The main energy consumer on canning lines is friction caused by moving parts. Pumps are a prime candidate for energy usage reduction by improving their operating efficiency with TWT Deposit Control.
Printing: Following filling, cans are typically printed with product information, using a solvent based ink. While quantities are small, storage of the ink and disposal of waste ink is both an environmental and a maintenance issue.
Fuels and oils: Fuels and oils may be stored at the facility for fueling and maintenance of a transportation and delivery fleet. Vessel corrosion and leakage is a concern.
Essences: Essences can be both corrosive and flammable. Storage adjacent to incompatible materials, or near heat/flame sources is an environmental/safety risk.
Cleaning agents: Sodium hydroxides and other corrosive materials may be used in cleaning.
Laboratory chemicals: Most facilities are equipped with a quality control laboratory. Small amounts of laboratory reagents are used in tests to determine the quality of the products and raw materials.
The manufacturer of alcoholic
beverages includes brewing to produce beer; and fermentation to produce wines and cider.
Beer production:Beer is produced from malted barley, hops, yeast and water. Possible additional ingredients include caramel as coloring and various enzyme preparations. The key process stages are:
Wine making:The key process stages for wine-making (cider making process stages are similar) are:
Water supply and wastewater management
|The quality of water used in beverage production is critical. It must be: potable; free from contaminants (such as chlorine, sulfides, iron and nitrates); of an appropriate hardness or softness or be free of the negative effects of hardness and of the sodium and chemical softening processes; free of suspended solids (these can be removed by coagulation and filtration); sterilized or disinfected.|
Wastewater from typical alcoholic beverage production
Presents a pollution risk due to:
high levels of organic matter, which will reduce the oxygen concentration in water courses; high acidity or alkalinity, depending on the type of cleaning detergents used; other contaminants, such as pesticides from the initial washing of fruit and biocides from cleaning.
Issues to consider:
Cost, quality and security of water supply are key factors in the production of beer and wine. Large quantities of water are required both for the product and for plant cleaning.
Contamination of water supply or variable water quality may cause disruption to production processes and give rise to product quality problems. Groundwater from on-site wells is often used to produce ales. The volume and quality of the groundwater used are critical factors, as is the potential for groundwater contamination from both on-site and off-site sources. Abstracted water may require pre-treatment before it can be used in the production process.
Brewing and wine making may generate significant volumes of wastewater including waste product and cleaning water. While this effluent is unlikely to contain toxic materials, its high organic content may present a pollution risk if discharged is left untreated.
|Hygiene||Hygiene standards within process areas must be maintained to a high level to prevent product contamination.|
If groundwater is used in production, the quality and volume are critical issues which can determine the viability of the business.
Water supply and wastewater treatment may constitute a significant proportion of operating costs.
Pre-treatment of water used for the production of beverages may require considerable capital investment in water pre-treatment or investment in alternative sources of water.
As environmental standards and enforcement measures become stricter the operating costs associated with environmental performance such as waste disposal, water abstraction and pre-treatment and discharge of treated wastewater will also increase.
Energy costs, particularly for generation of steam and hot water, may be significant.
TWT Deposit Control offers a highly effective and cost-efficient alternative to previously used methods of fluid management and water treatment. The comparative cost of a TWT Deposit Control System can range from somewhat to less to less than half of the cost of a commercial water softener for the same application. TWT Deposit Control offers control of water quality throughout the production process, enables traditional wastewater treatment to be more done more effectively and safely, and offers significant reduction in energy consumption by keeping process and HVAC/R equipment running clean and efficiently. Combined TWT Deposit Control with TWT Ultraviolet Disinfection, Filtration, and Purification systems, for a comprehensive solution for all your process needs.
|Roasts, grinds and liquids for drinks||
For purposes of this
discussion, non-alcoholic beverages can be categorized into three main
types: carbonated and fruit based drinks; tea and coffee; mineral/spring water.
The processes involved may include the mixing of various ingredients, carbonation (if appropriate) and packaging (cartons, bottles). Processing of tea and coffee includes additional processes such as heating, roasting and decaffeination.
Ancillary activities may include boilers, bottle cleaning operations, wastewater treatment and blow molding of plastic bottles.
|Water quality||The quality of the water used in the production of non-alcoholic beverages is a critical issue.|
main ingredients for fruit based drinks include fruit juices, sugars,
additives, preservatives, etc. Other items on site may include bulk
storage of carbon dioxide (for carbonation) and caustic (sodium hydroxide)
for cleaning returned bottles.
The decaffeination of coffee involves the use of the solvent, methyl chloride. If handling and storage of solvents is poor there is a risk of soil and groundwater contamination.
Non-alcoholic beverage production plants will usually have facilities to chill the product at various stages in the process. Ammonia, which has no such restriction, is also used as a refrigerant. The release of ammonia into the atmosphere, due to leaks from cooling equipment, is a health and safety concern.
Effluent arises from tank cleaning operations, washing of returned bottles, and spillages.
TWT Deposit Control Systems help maintain plumbing, piping, cooling, heat exchangers, and all HVAC/R systems in a clean and efficient state, avoiding bio-corrosive conditions which often lead to such leaks. Storage tanks, washing equipment, and process equipment are protected as well.
Screening of raw materials and water used in the process for potential contaminantsScreening of finished products for contaminants
Potential for reuse of wastewater within processing, thus minimizing final wastewater volumes
Ensuring the proper non-chemical maintenance of storage areas, for example of fruit juice and solvents, and of production areas to prevent leakages from corrosion and biocorrosion.
Use of recirculating chilled water systems where practical.
TWT Deposit Control, Filtration, UV Disinfection, and IonGuard Systems all provide reliable solutions, and allow more efficient use of resources in ways not practical before. TWT integrated fluid control solutions can offer comprehensive solutions, from small and intermediate scale systems for disinfection to Total Water Control for cooling systems.
|Candy-making||Confectionery manufacturing comprises a wide range of sweet products including chocolate, toffee and boiled sweets. The manufacturing process will vary depending on the nature of the product but the main elements of the process may include: shelling, grinding and roasting of cocoa beans; processing of cocoa granules or taking delivery of pre-processed liquid chocolate; mixing with other raw materials including milk powder, sugar, cocoa butter, gelatin, glucose, gum arabic and fat, and mixed nuts; cooking the ingredients by heating and extruding, pressing or cutting mixture into shape prior to drying on racks to reduce water content; packaging by hand or automatically; storage, often in cold storage facilities, and distribution.|
Water supply and wastewater management
Reduction of effluents
Sources of water: mains or via direct abstraction. Large volumes of water are likely to be required for manufacturing, cooling and cleaning.
Wastewater from chocolate production presents a pollution risk due to: effluent with a high organic content notably fats; high alkalinity, depending on the type of equipment cleaning materials used; solvents and oils used in maintenance and operation of equipment. TWT Deposit Control Systems can reduce the amounts of cleaners, solvents, and oils used in the production process by helping keep process and manufacturing equipment clean, and its operation optimized
|Effluent treatment and discharge||
Liquid raw materials and effluent produced during the confectionery manufacturing process are likely to have high sugar content, giving potential for water pollution through spillage of raw materials or product or insufficient treatment of effluent.
|Handling and storage of materials||
Storage facilities may include bulk storage of raw materials in tanks and drums, silos.
Pollution risks to watercourses and soil may arise from spillages of: chemicals used for water treatment or cleaning such as hydrochloric acid, caustic soda and ethylene glycol; raw materials including sugar, colors and flavorings; product; oils and fuels.
Steam ovens, proofers, bagel making, any
water-fed equipment including hot water heaters, boilers, HVAC
Coffee and other beverage equipment
Protection from scale build-up extends the lifecycle of this equipment and protects your capital investment. Equipment works more efficiently and lasts longer with TWT Deposit Control.
Effects of hard and soft water on baked goods
Taste, moisture content, "fluffiness", appearance
Corrective actions are often taken by bakers to counteract existing water conditions. These actions usually involve the adjustment of ingredients or other factors, since the introduction of softeners and/or chemical treatment are considered to be very undesirable for many reasons, not the least of which is the effect on product taste. TWT Deposit Control Systems offer a completely non-chemical way to accept the positive effects of hard water on baked goods and avoid the negative effects of softening, allowing you to bake as you intend to.
TWT Deposit Control offers:
|Energy and water savings||
and water savings are of ever-increasing importance to our communities and
to the profitability of bakery businesses.
Energy consumption can be reduced significantly because baking and infrastructure equipment operates more efficiently.
Water consumption can be reduced because "wetter" water works more efficiently, requiring less to do more.
Grain can be processed in many
different ways depending on the type of raw material and the end
product. Malting is a biological process which uses water to
extract the maltose.
The malting process involves wetting the grain and allowing germination to take place. This converts insoluble starch contained in the seed into a soluble and fermentable form (maltose). The germinated seeds are coarsely ground to produce grist from which the maltose is extracted by hot water solution. The residue is known as brewer's waste which can be sold as animal feed.
|Water supply and wastewater management||
Mills require water for cleaning purposes and for use in boilers. This may be obtained from municipal sources, or abstraction from rivers or boreholes.
A major source of wastewater within grain mills is cleaning water. Pollution may arise from:high alkalinity, depending on the type of cleaning materials used; solvent and oils used in equipment operation; oils, fats or molasses which may be used in blended products.
|Energy consumption is liable to account for a significant element of production costs.|
Machines - improves operating efficiency; improves appearance of ice
as well as of machine exterior without chemicals; aids filter operation;
reduced strain on machine means quieter operation; extends lifecycle of
Lobster steamers can benefit, also.
|Meat Department, Deli Department||Washing processes|
|Bakery||Steam ovens, proofers, bagel making|
|Produce Misters||Reduces frequency of need to clean nozzles, sprayers, water feed tubing, and mirrors and makes such cleaning much easier; generally eliminates need for acids and other glass and mirror cleaning formulas and chemicals to be used near produce - a quick wipe or squeegee and it's done.|
|Coffee bars, beverage & soup vending||Reduces scale, lime, and biofilm build-up in coffee, espresso, soda, and other beverage machine water feed tubes, brewers, and tanks, and improves the effectiveness of filters. Non-chemical treatment reduces odors, has no negative impact on (and possibly improves) taste. The need for scale removal is less frequent; breakdowns, leaks, and service calls are also less frequent and less costly, as parts are replaced less often. Less downtime = more sales.|
Reduces scale accumulation on the interior and
exteriors; reduces biofilm and its attendant bacteria growth; reduces spotting
and re-washes on glassware*, dishes, pots; improves life of gaskets,
seals, and packings; increases equipment lifecycle;
improves operating efficiency, saving water and energy, and reducing
detergent and formula consumption.
*Lead crystal may require special handling, check with TWT or your authorized TWT representative
|Food Court, Self-Serve Prepared Foods||Steamer tables - reduced scale and biofilm buildup that clogs water feed lines and inhibits steam generation; more efficient operation means less energy used.|
A/C, cooling towers, evaporative condensers,
chillers, condensers, compressors, reclamation units, boilers**, hot water
and refrigeration units can all function more efficiently, reducing corrosion,
and water consumption and waste. Resource-wasting scale and
bacteria-inducing biofilm build-up is kept under control, allowing
optimized heat transfer and operation, and reducing bacteria growth and
spread; blowdown frequency for cooling towers can be reduced.
Frequent chemical use can be reduced or possibly eliminated*, and cleaning
frequency is greatly reduced.
Hot water can be more easily and rapidly delivered to sinks and employee and public washrooms at the needed temperatures and within health code specified times.
**Boiler operation always requires the use of oxygen scavengers, regardless of method of water treatment, whether from TWT or other manufacturers; call TWT or your authorized TWT representative for more information on how to plan for proper chemical use reduction in HVAC and cooling tower environments.
For all types of food processing, when a Triangular Wave Deposit Control System is installed, every water molecule becomes a cleaning agent. The water molecules are free of other contaminants and can do a better job with less chemicals, labor, and dwell time