Green Business case study
Sector: Food and Drink
Name: Wexford Creamery Ltd
Location: Rocklands, Wexford
Aims of this project
The aim of the project was to reduce waste, to increase awareness of waste and to recycle and reuse where possible. The primary objective was to recover suspended solids from the wastewater mainly produced in removing plant and product residues by plant cleaning and by accidental losses. Other objectives included energy usage reduction, staff training to increase awareness of waste and its concomitant cost, to reduce water consumption mainly by substitution, where possible with condensate /distillate from the evaporation plant and by good housekeeping. Water costs €1.20/1000 litre to the company, the provision of water evaporate from whey processing on the site to replace water purchased from the local authority would be environmentally and economically acceptable to Wexford Creamery.
Project description
White whey is a particular stream of whey derived from cheese manufacture but tends to be of poorer quality than the vast bulk of the standard. After much experimentation on the effects of pasteurisation of white whey it was concluded that it’s quality was brought to an acceptable level without pasteurisation for addition to the general whey stream instead of being discarded as a waste product for land spread.
Chlorine dioxide treatment of the condensate has been successfully introduced in order to improve its bacteriological quality and the treated condensate is now also used for chemical make-up in the effluent treatment plant; to feed the cooling towers on site and to clean milk tankers.
The introduction of an energy monitoring system to monitor energy, steam and water usage on site has been introduced, in order to bring about savings in these target areas. Year to date savings on electricity are 4% through good housekeeping and the company is satisfied that a further saving of 7% can be achieved in all areas. Expected savings of 7% are also anticipitated on water consumption.
Achievements and lessons
Staff were trained by site personnel regarding nature and sources of waste on site. The attendance included production operatives, maintenance staff, laboratory technicians, administration staff and management staff.
The economic benefits will become more apparent in the longer term and will act as a catalyst for ongoing emphasis on reducing waste. The reduction in the waste removal costs of sludge derived from white whey which is now processed has resulted in savings of approximately €26,000/annum (2000tonne @ €13/tonne). Reductions in water, steam and electricity usage have significance in containing service costs.
More information
For more information on this project please contact Joe Costello, Wexford Creamery Ltd, Rocklands, Wexford, telephone 00 353 (0) 53 917 1110 or fax 00 353 (0) 53 914 3321. Email: joe.costello@wexford-creamery.com
Source: Cleaner Greener Production Programme