1 Food, drink and milk BREF Tallinn - 27 and 28 March 2007 Rosemary Campbell

2 BREF scope (Annex 1) 6.4. (b) Treatment and processing intended for the production of food products from: -animal raw materials (other than milk) with a finished product production capacity greater than 75 tonnes per day -vegetable raw materials with a finished product production capacity greater than 300 tonnes per day (average value on a quarterly basis) 6.4. (c) Treatment and processing of milk, the quantity of milk received being greater than 200 tonnes per day (average value on an annual basis)

3 BREF scope veryvery wide scope large number of FDM sectors large number of processes similar products processed differently different products processed similarly advantages many common environmental issues – also with other BREFs many common BAT – also with other BREFs learning from sharing - first opportunity at European level (develop for revision) disadvantages large document amount of information and detail varies between sectors difficult to address all the key issues

4 Information submitted/exchanged 258 references BREF pages some general, some detailed BREF outline and guide - structure late, even at the final TWG meeting data compared where consistent units used Estonia

5 Key environmental issues for processing for washing raw materials, product for cleaning packaging, equipment, installation for transport of product from drying of FDM material - then to the WWTP! Water consumption/contamination drinks manufacture - in the product

6 Key environmental issues Energy processing - mechanical/heating/cooling/drying maintaining freshness/food safety - refrigeration, freezing

7 Key environmental issues Solid waste trimmings, peelings spills leaks overflow off-specification inherent loss heat deposited waste residues in equipment

8 Other driving forces at FDM installations food safety/hygiene –public health –shelf life quality –taste –appearance –nutrition customer preferences/market forces –regional eating habits of consumers –downstream industry requirements

9 BREF structure EXECUTIVE SUMMARY PREFACE SCOPE Chapter 1GENERAL INFORMATION Chapter 2APPLIED PROCESSES AND TECHNIQUES Chapter 3CURRENT CONSUMPTION AND EMISSION LEVELS Chapter 4TECHNIQUES TO CONSIDER IN THE DETERMINATION OF BAT Chapter 5BEST AVAILABLE TECHNIQUES Chapter 6EMERGING TECHNIQUES Chapter 7CONCLUDING REMARKS Chapter 8REFERENCES GLOSSARY

How BAT are presented 5.1 General BAT for whole FDM sector Environmental management Collaboration with upstream and downstream activities Equipment and installation cleaning ADDITIONAL BAT for some processes and unit operations Minimisation of air emissions Waste water treatment (contains some sector specific BAT information) Accidental releases 5.2 ADDITIONAL BAT for some individual FDM sectors ADDITIONAL BAT for some processes and unit operations where those processes and unit operations are applied (these processes and unit operations are widely applied in the FDM sector, but not in every sector) ADDITIONAL BAT for the meat sector ADDITIONAL BAT for the fish and shellfish sector ADDITIONAL BAT for the fruit and vegetable sector ADDITIONAL BAT for the vegetable oils and fats sector ADDITIONAL BAT for the dairy sector ADDITIONAL BAT for the starch sector ADDITIONAL BAT for the sugar sector ADDITIONAL BAT for the coffee sector ADDITIONAL BAT for the drinks sector ADDITIONAL BAT for milk powder ADDITIONAL BAT for buttermaking ADDITIONAL BAT for cheesemaking ADDITIONAL BAT for ice-cream manufacturing ADDITIONAL BAT for winemaking ADDITIONAL BAT for brewing General BAT for whole FDM sector Additional BAT for some individual FDM sectors

11 BAT for whole FDM sector Many BAT are concerned with “in-process” managementoperation management and operation of FDM processing involving low investment in technology require training and supervision provide significant protection of the environment as a whole

12 General BAT for whole FDM sector General processes and operations environmental management system training design/select equipment maintenance apply and maintain a methodology to minimise consumption of water and energy and the production of waste

13 Apply and maintain a methodology

14 General BAT for whole FDM sector Apply and maintain a methodology obtain management commitment (financial benefit!), organise and plan analyse process steps to identify opportunities for reduction (mass balance) – possibly use external benchmarks assess objectives (initial) identify prevention and minimisation options evaluation and feasibility study implement prevention and minimisation programme monitor by measurement and visual inspection

15 General BAT for whole FDM sector landspreading MAY be BAT - consider –Nitrates Directive (Council Directive 92/46/EEC) –nutritional value to plants –geographic (soil, climatic, hydrologic, may affect food or livestock) –traceability – origin and destination of spread substances –monitoring, e.g. soil and groundwater implement a system for monitoring and reviewing consumption and emission levels for individual processes and at site level –e.g. emissions to water and air; product and by-product yield transport solid FDM materials dry segregate outputs to optimise use, re-use, recovery, recycling and disposal (and minimise waste water contamination)

16 Segregation of outputs Achieved environmental benefits reduced water consumptionreduced water consumption reduced volume of waste water reduced wastewater contaminationreduced waste water contamination energy consumptionreduced energy consumption (to heat water, for WWTP) reduced wastereduced waste and can dispose of appropriately increased recovery/recycling of materials reduced use of detergents

17 General BAT for whole FDM sector Collaboration with upstream and downstream activities minimise storage times manage on-site vehicle movements selection of less harmful materials, e.g. cease use of pesticides ahead of supply supply fresh, but not over-ripe raw materials high quality fish

18 General BAT for whole FDM sector Equipment and installation cleaning remove raw material residues asap after processing provide and use catch-pots optimise the use of dry cleaning

19 Dry cleaning Achieved environmental benefits reduced water consumptionreduced water consumption reduced volume of waste water reduced wastewater contaminationreduced waste water contamination energy consumptionreduced energy consumption (to heat water, for WWTP) reduced solid wastereduced solid waste increased recovery/recycling of materials reduced use of detergents

20 General BAT for whole FDM sector Equipment and installation cleaning pre-soak before wet cleaning manage the use of water, energy and detergent operate CIP optimally - measure turbidity, conductivity or pH - automatically dose chemicals minimise the use of EDTA

21 General BAT for whole FDM sector Additional BAT for some unit operations –freezing and refrigeration avoid keeping aircon and refrigerated areas colder than necessary minimise transmission and ventilation losses from cooled rooms and coldstores

22 General BAT for whole FDM sector Additional BAT for some unit operations –compressed air systems review the pressure level and reduce it if possible optimise the air inlet temperature fit silencers at air inlets and exhausts, to reduce noise levels

23 General BAT for whole FDM sector Additional BAT for some unit operations –steam systems maximise condensate return avoid losses of flash steam from condensate return isolate unused pipework improve steam trapping repair steam leaks minimise boiler blowdown

24 General BAT for whole FDM sector Waste water treatment waste water arises from water consumption during processing and cleaning and from the drying of FDM materials. apply process-integrated BAT to minimise consumption and contamination of water apply end-of-pipe treatment waste water treatment techniques

25 General BAT for whole FDM sector Waste water treatment BAT not concluded on whether it is better to treat waste water from FDM installations on-site or off-site, except some primary on-site techniques, i.e. –apply an initial screening of solids –remove fat using a fat trap, if the waste water contains animal or vegetable FOG

26 Waste water treatment - BATAELs TWG supported BATAELs for whole diverse FDM sector –no sector-specific BATAELs –some sector-specific evidence of low achievable levels available –no lower level concluded for COD, BOD 5, oil and grease or total nitrogen (low levels achievable at some installations)

27 Waste water treatment - BATAELs Parameter Concentration (mg/l) BOD 5 <25 COD<125 TSS<50 pH6 – 9 Oil and grease<10 Total nitrogen<10 Total phosphorus0.4 – 5 Better levels of BOD 5 and COD can be obtained. It is not always possible or cost effective to achieve the total nitrogen and phosphorus levels shown, in view of local conditions. SPLIT VIEW

28 Additional BAT for meat and poultry thaw meat in air avoid using flake ice, by mixing chilled and frozen raw materials dose spices and other solid ingredients from a bulk container, not plastic bags stop water flow to sausage fillers during production breaks

29 Additional BAT for the fruit and vegetable sector E.g. where storage of fruit and vegetables and by- products cannot be avoided, minimise storage time and, subject to weather, store outdoors in clean covered area after blanching fruit and vegetables, pass through cold water before freezing optimise the re-use of water, whilst maintaining hygiene

30 Additional BAT for dairies E.g. replace batch pasteurisers with continuous ones maximise the recovery of diluted, but otherwise uncontaminated, product from CIP initial rinses, HTST start-up, shut-down and change-over and from the rinsing of other equipment and pipework

31 BAT - dairies BATACLs and BATAELs for market milk milk powder production ice-cream addressing energy consumptionenergy consumption water consumptionwater consumption waste water volumewaste water volume

32 BAT – dairies BATACLs and BATAELs – ranges indicative of levels achievable by in-process BAT energy consumption levels vary due to, e.g. production volumes warm climates may use more energy for cooling and vice versa various product portfolioswater consumption and waste water emission levels vary due to, e.g. various product portfolios, batch sizes and cleaning waste water emission levels may be lower than water consumption levels if dairies measure intake of cooling water, often from their own wells, but then discharge it unmeasured warm climates - water may be lost due to evaporation

33 Additional BAT for drinks manufacturing E.g. if CO 2 is used in the installation, use CO 2 which is either recovered from the fermentation process or as a by-product of another process, to avoid the production of CO 2 directly derived from fossil fuels especially for use in the installation recover yeast after fermentation

34 Recommendations for future work olive oil extraction – more information NO x from coffee roasting (techniques/levels) EDTA – avoiding use – existing information! exploration of wider applicabilities of techniques economic data, including payback times

35 Suggested topics for future R&D projects composition and harmfulness of odours reducing NO x emissions from coffee roasting EDTA – avoiding use reverse osmosis – economic and cross-media effects