i

Table of contents

TITLE PAGE

Table of contents i
List of Tables ii
List of Figures iii
List of Abbreviations iv

1. Introduction 1
2. Description of dairy industry 1
2.1 Production statistic 1
2.2 Importance of the industry 4
2.3 Presentation of production process 4
3. Environmental issues of dairy industry 6
3.1 Main pollution sources in dairy products 7
3.2 Characteristics of pollution 8
4. Conventional end of pipe treatment and inline treatment system 11
4.1 Conventional end of pipe treatment 11
4.2 Inline treatment system 12
5. Possible process modification & cleaner production aspects 12
5.1 Waste minimization 12
5.2 Process control 13
6. Case study Meiji dairy industry 17
6.1 Waste segregation 17
6.2 Waste sampling and monitoring 17
6.3 Waste treatment plant layouts 18
6.4 Typical cost information 20
6.5 Simple unit process material balance calculation 21
6.6 Major O & M issues related to wastewater treatment plant 25

Reference 26


ii

List of Tables

Table Title Page

Table 2.1 Input and output of dairy industry 5
Table 2.2 Classification of packaging and distribution systems 5
Table 3.1 Wastewater characteristic for the dairy industry 8
Table 3.2 The air emissions from gas-oil combustion and cleaning process 9
Table 3.3 Industry benchmark of energy and resource consumption 10
for dairy processing facilities 10
Table 3.4 Typical noise limits in effected residential areas (dBA) 10
Table 4.1 Air emission control Efficiency of Venturi Scrubber 12
Table 5.1 Waste minimization strategies 13
Table 5.2 Cleaner Production Assessment and Techniques in Liquid milk production 15
Table 6.1 Monitoring plan of air pollution 17
Table 6.2 Monitoring plan of wastewater 18
Table 6.3 Typical cost of milk production process 20
Table 6.4 Unit operation and construction cost 20
Table 6.6 Major O & M issues related to wastewater treatment plant 25





















iii

List of Figures

Figure Title Page

Figure 2.1 Milk production growth between 2000 and 2013 2
Figure 2.2 Per capita milk consumption versus development in world population 2
Figure 2.3 Major World Dairy Exporters 2
Figure 2.4 Composition of dairy products 2
Figure 2.5 The demand for milk and dairy products in Asia 3
Figure 2.6 Where will dairy production gains be located over the next decade 3
Figure 2.7 The import and export of dairy products of Thailand in 2010 3
Figure 2.8 After a downward correction prices continue rising in nominal terms 4
Figure 2.9 Basic diagram for milk process 6
Figure 3.1 Environmental pollution sources 8
Figure 4.1 Components of a conventional dairy processing wastewater treatment 11
Figure 6.1 Solvent recovery in CIP process 17
Figure 6.2 Wastewater treatment plant layout 19
Figure 6.3 Mass balance for whole process 21
Figure 6.4 Mass balance for separator and standardization 22
Figure 6.5 Mass balance for tie compound (fat) 19





















iv

List of Abbreviations

BMP Butter Milk Powder
BOD Biological Oxygen Demand
COD Chemical biological Oxygen Demand
CIP Clean In Place
COWI
International consulting group, specializing in engineering, environmental
science and economics, based in Lyngby, Denmark.
DAF Dissolved Air Flotation
DLD Department of Livestock Development
DPO Dairy Farming Promotion Organization
FAO Food and Agriculture Organization
GDP Gross Domestic Product
IFC International Finance Corporation
LDC Least Developed Country
OECD Organization for Economic Co-operation and Development
SMP Skim Milk Powder
UN United Nations
UNEP United Nation
UNIDO United Nations Industrial Development Organization
USDA United States Department of Agriculture
US EPA US Environmental Protection Agency
WMP Whole Milk Powder
WWTP Waste Water Treatment Plant








1

1. Introduction

The dairy sector plays an economically important part in the agricultural sectors in most
industrialized and also many developing countries. Global demand for dairy is continuing to
grow because of population growth, rising incomes, urbanization and westernization of diets.
Asia continues to be the major growth market globally accounting for 34 per cent of all dairy
imports in 2011. Asia accounts for 53 per cent of the worlds SMP (Skim Milk Powder) and
40 per cent of the worlds WMP (Whole Milk Powder) imports. Consumer products include
branded dairy products, such as fresh milk, flavored milk, nutritional milk powders, cheese,
yoghurt, butters, creams and ice cream. Consumer products are produced either from domestic
milk supply or imported dairy ingredients.

Today, industry consolidation and the shift toward mega-farms continue. Sustainability and
traceability remain top-of-mind concerns. The overall consumption of dairy products has risen
but the consumers tend to choose competitive beverages, such as protein and energy drinks
and plant-based products almond, soy and rice milk.

Like any other industrial activities, dairy processing inevitably leads to the production of
wastes. In this paper, the critical link between milk processing operations and waste
generation is examined and suitable waste reduction and management options are discussed.
The case of a hypothetical skimmed milk factory is presented to provide specific examples of
application of waste abatement and management strategies.



2. Description of dairy industry

2.1 Production statistic

2.1.1 The world dairy industry situation

The growth of world milk production slowed down in 2013. Compared to last year it increased
by only 1.5% to 781 million tones. This rate is rather small in comparison to 2011 versus 2010
(2.8%) and much lower than the compound annual growth rate (2.4%) observed during the
period from 2000 to 2009 (Figure 2.1). Poor return from milk production and high input cost
seemed to have discouraged farmers in many parts of the world.

Based on the UN world population can estimate population which amounting more than 7.1
billion people, global per capita consumption of milk in 2012 was 109.1 kg. Because of the
continuous growth in world population, the global per capita milk consumption in the period
between 2005 and 2013 grew by no more than 8% (Figure 2.2). Over the last decade,
consumer eating habits have gradually shifted toward single-serve portion (that can be eaten
on-the-go) as well as healthier food choices. This trend has given rise to new dairy products
such as Greek yogurt, which is lower in fat and sugars than traditional yogurt and is available
in single serving.


2


































2.1.2 Dairy industry in Asia

The Organization for Economic Co-operation and Development (OECD) and the Food and
Agriculture Organization (FAO) project that the strongest gains in dairy production and
consumption over the coming decade will take place in Asia. Increasing incomes and a
continuation in changing consumption patterns are expected to translate into a nearly 120
million tones increase in world milk production, up to 20 percent to 803 million tons by 2017.
Over half of the output gains, or 63 million tones, will be produced in Asia, particularly China
and India, two countries which are expected to account for a respective 16 and 20 percent of
the global increase (FAO, 2009).




Figure 2.1 Milk production growth between
2000 and 2013 (Source: The World Dairy
Situation, 2013)
Figure 2.2 Per capita milk consumption
versus development in world population
(Source: The World Dairy Situation, 2012)
Figure 2.3 Major World Dairy Exporters
(Source: U.S.DA FAS)
Figure 2.4 Composition of dairy products
3
















2.1.3 Dairy industry in Thailand

Thai dairy farming was initially run as a project by the Ministry of Agriculture for the Royal
Thai Government. The Department of Livestock Development (DLD), the Dairy Farming
Promotion Organization of Thailand (DPO) and the Nongpo Dairy Cooperative have been
responsible for intensively promoting dairy farming and the dairy sector ever since.

The total amount of raw milk production in 2012 was 1,064,270 tons. About 95-97 percent
of this production was processed for drinking milk. The remaining 3-5 percent was
processed for cheese. Thailand also imports other milk products, especially skimmed milk
powder, which in 2010 was valued at 59,357 tons. Thailand also exports milk products, such
as sweetened condensed milk, sterilized drinking milk and evaporated milk, to Cambodia,
Singapore, Philippines, Myanmar, Laos, Indonesia and other neighboring countries (DLD,
2012).

















Figure 2.5 The demand for milk and dairy
products in Asia (Source: FAO)
Figure 2.6 Where will dairy production
gains be located over the next decade
(Source: OECD, FAO)
Figure 2.7 The import and export of dairy products of Thailand in 2010 (Source: DLD, 2012)
4

2.2 Importance of the industry

Dairy industry is a highly labor intensive industry and it provides a lot of employment hence
widely contributing to the GDP of the nation. Moreover, westernization of diets has resulted in
the increasing market of the dairy industry. The dairy sector is one of the fastest growing
sector and over the next 10 years, world milk production is projected to increase by 153 Mt, of
which major portion is anticipated to be contributed by developing countries. The average
growth rate for the projection period is estimated at 1.9%, slightly below the 2.1% level
witnessed in the last decade (OECD and FAO, 2011)
















Figure 2.8 After a downward correction prices continue rising in nominal terms
(Source: OECD and FAO Secretariats, 2011)

Dairy products have a strong market in developing nation like North Africa, Middle East and
East Asia and in the mature markets like European Union, United State and Russia. There is a
huge disparity of the per capita consumption pattern of the milk product among LDC (50
kg/person/year), developing countries (kg/person/year) and developed nation (200
kg/person/year) which further increases the investment potential and future opportunities for
both the domestic and global dairy sectors (OECD and FAO, 2011).


2.3 Presentation of production process

Products
There are many categories from dairy industry, based on raw material. The USDA
identifies four basic classes of milk use:
Fluid milk products
Cream products, cottage cheese, ice cream, and other food uses
Hard and spreadable cheeses
Butter and dried milk products
5

Raw material
Raw fluid milk is collected from individual dairy farms where milk is temporarily
stored until transport. The raw milk is delivered to the processing plant by truck. The
incoming tanker milk delivered to the processing/production facility is routinely checked for
quality and safety factors, including biological, chemical, and physical contaminants: odors,
temperature, appearance, acidity, bacterial counts, drug residues, antibiotics, herbicides, and
pesticides.

Inputs and outputs
Inputs and outputs associated with milk production are shown in the table below. Data
are provided per kg of milk product at the dairy's gate without packaging. Table 2.1 shows the
input and output of dairy industry.

Table 2.1 Input and output of dairy industry

Unit
Quantity
Skimmed
milk
Low fat
milk
Full milk Minimilk
Inputs Raw Milk kg 1.12 1.08 1.02 1.11
Electricity Whr 54.00 54.00 54.00 54.00
Heat Whr 50.00 50.00 50.00 50.00
Water L 0.70 0.70 0.70 0.70
Outputs Milk kg 1.00 1.00 1.00 1.00
Cream kg
0.12 0.08 0.02 0.11
(Source: Material/Food from industry/ from dairies)

Packaging materials
The package selection will have to satisfy the requirements dictated by existing
economic limits, production and distribution efficiency, retailing objectives, consumer
considerations and ecological aspects. The classification of packaging and distribution systems
of liquid milk is shown in table 2.2.

Table 2.2 Classification of packaging and distribution systems
Liquid milk
Returnable containers Single service containers Dispatch by
tankers to vending
machines
Glass
bottles
Plastic
bottles
Cans Cartons Sachets
Plastic
bottles
Pasteurized
Sterilized
UHT
(Source: http://www.fao.org/DOCREP/003/X6511E/X6511E01.htm)

6

Production process (refer to appendix A for explanation)





































3. Environmental issues of dairy industry

As many food processing, dairy processing industries associate with some major
environmental issues: (1) large amount of water consumption, (2) high volume of wastewater
produced, (3) high energy consumption, (4) air emissions from drying operations and (5) solid
waste production. In addition, odors from wastewater treatment plant operations and noise
from equipment may also be concerned. (Please refer to Appendix B)

Separation and
Standardization

Pasteurization
Milk receipt, filtration and clarification
Cream
Skimmed milk
Storage
Homogenization
Deodorization
Packaging and cold storage
Distribution
Butter
churning
Packaging and freezing
Skimmed milk
Storage
Cream
Buttermilk
Butter
Butter
Cream
Skimmed milk
Figure 2.9 Basic diagram for milk process (Source: COWI, 2000)
7

3.1 Main pollution sources in dairy products

Milk receiving
Wastewater is from tank, truck and storage tank washing, pipe line washing and
sanitizing. It contains milk solids, detergents, sanitizers and milk wastes.

Whole milk products
Wastewater is mainly produced during cleaning operations. Especially when different
types of product are produced in a specific production unit, clean-up operations between
product changes are necessary. In developing countries, the main problem is pollution through
spoilage of milk.

Cheese/Whey/Curd
Wastewater results mainly from the production of whey, wash water, curd particles etc.
Cottage cheese curd for example is more fragile than rennet curd which is used for other types
of cheese. Thus the whey and wash water from cottage cheese may contain appreciably more
fine curd particles than that from other cheeses. The amount of fine particles in the wash water
increases if mechanical washing processes are used.

Butter/Ghee
Butter washing steps produce wash water containing buttermilk. Skim milk and
buttermilk can be used to produce skim milk powder in the factory itself or itself or these
materials may be shipped to another dairy food plant by tank truck. The continuous butter
production process materially reduces the potential waste load by eliminating the buttermilk
production and the washing steps (Harper et. al., 1971).

Milk powder
Environmental problems are caused by high energy consumption (emission of CO
2
,
CO etc.), by cleaning and by emission of fine dust during the drying process.

Condensed milk/Cream/Khoa
Environmental problems related to the production of condensate are mainly caused by
the high energy consumption during the evaporation process. The main suspended solids
mentioned in the literature are coagulated milk and fine particles of cheese curd.
Major waste generation in the processes includes:
Washing, cleaning and sanitizing of pipelines (metals), pumps, processing
equipment, tanks, tank, trucks and filling machines.
Start-up, product change over and shut down of HTST and UHT pasteurizers
Breaking down of equipment and breaking of packages resulting in spilling during
filling operations
Lubrication of casers, stackers and conveyors




8























3.2 Characteristics of pollution

Wastewater

Wastewater contains high amounts of organic loading, oil and grease, suspended solids,
nitrogen and phosphorus content. The pH depends on the chemical or detergent use in
cleaning operations and pathogens from contaminated materials or production processes.

Table 3.1 Wastewater characteristic for the dairy industry
Parameter Average
COD (mg/L) 2000
BOD (mg/L) 1500
Fat (mg/L) 150
Nitrogen (mg/L) 100
Phosphorus (mg/L) 30
(Source: Danish EPA, 1971)

From Table 3.1, it is inevitable that the dairy industry produces biodegradable waste that
consist high amount of BOD and fat (oil and grease). (Details on appendix C)




Figure 3.1 Environmental pollution sources
9

Solid waste

Main sources of the wastes were from production processes and product losses (e.g. milk
spillages liquid whey and buttermilk), grid and filter residues, sludge from centrifugal
separators and wastewater treatment, and packaging waste (e.g. discarded cuts, spent ripening
bags, wax residues from cheese production).

The amount of sludge production in an aerobic process is about 0.5 kg per kg of removed
COD and in an anaerobic process is about 0.1 kg per kg of removed COD. (US EPA, 1971).

Air pollution

Exhaust Gases emissions from the combustion of gas and fuel oil or diesel in
turbines, boilers, compressors and other engines for power and heat generation. The
characteristics of air emissions from a dairy industry would depend on the type of fuel.
Emissions of dust during dairy processing activities include fine milk powder residues
in the exhaust air from the spray drying systems and bagging of product and type of fuel.
The major sources of odor emissions in dairy processing facilities are related to on-
site wastewater treatment facilities, in addition to fugitive odor emissions from filling /
emptying milk tankers and storage silos.

In dairy industries, air pollution is mainly caused by the energy consumption. The main
discharged gasses are CO
2
, CO, NO
x
and SO
2
.

Table 3.2 The air emissions from gas-oil combustion and cleaning process
Process
Air emission
(kg/ton processed milk)
Heating by burning gas or oil CO 0.03
CO
2
92
NO
x
0.1
SO
2
0.05
Producing milk powder Fine dust 0.39
Cleaning VOC 0.05
(Source: FAO, 1996)

Energy consumption

Electricity is used for the operation of machinery, refrigeration, ventilation, lighting and the
production of compressed air. Like water consumption, the use of energy for cooling and
refrigeration is important for ensuring good storage quality of dairy products and storage
temperatures as specified by regulation. Thermal energy, in the form of steam, is used majorly
for heating.

Dairy industry utilizes fossil fuel for the purpose of energy generation which leads to the air
pollution and emission of greenhouse gasses, making dairy industry vulnerable cause of global
warming.
10

Table 3.3 Industry benchmark of energy and resource consumption
for dairy processing facilities
Milk Product
Resource and energy consumption
Water
(L/L processed milk)
Energy
(kWh/ L processed milk)
Wastewater
(L/L processed milk)
Market milk and cultured
products
1.0-1.5 0.1-0.2 0.9-1.4
Cheese and whey 1.4-2.0 0.2-0.3 1.2-1.8
Milk powder, cheese, and
(or) liquid products
0.8-1.7 0.3-0.4 0.8-1.5
Ice cream 4.0-5.0 0.8-1.2 2.7-4.0
(Source: IFC-World Bank, 2007)

Noise

Generally, most milk processing plants are located in country areas where there are no
residential statutory requirements for industry but EPA may set noise targets based on the
State Environment Protection Policy and guidelines and may use discretion in each particular
case. In addition, there may be local government regulation on industrial noise. The principle
causes of continuous noise are: air discharges from drier stacks, heater fans, ventilation,
boilers, pumps, cooling towers, refrigeration units, and aerators on aerated lagoons.
Truck movements to and from the site or in streets are a source of noise, as are refrigeration
compressors on trucks. Intensity of the noise increases during the night transportation shift.
Noise operations at dairy plants include milk drying which requires high airflows and the
movement of transport vehicles to and from the site. Depending on the distance to sensitive
receptors such as residential areas, suitable noise suppression or abatement measures such as
noise silencers on equipment, enclosure of outdoor equipment, concrete housing for
mechanical plant, and mufflers on transport vehicles may be required.

Table 3.4 Typical noise limits in effected residential areas (dBA)
Time of day (hours)
Day
(6am 10pm)
Evening
(6pm 10pm)
Night
(10pm- 7am)
Mainly residential 50 54 44 48 39 43
Residential
Commercial or
Industrial
54 59 48 52 39 43
Commercial 56 59 52 57 47 52
Industrial 63 68 57 71 52 - 56
(Source: The State Environmental Protection Policy (Control of Noise from Commerce,
Industry and Trade, No. N-1)



11

4. Conventional end of pipe treatment and inline treatment system

4.1 Conventional end of pipe treatment

Solid Wastes Disposal:

Solid waste generated by dairy plants included packaging waste such as cardboard, cartons,
paper and plastic, and organic waste such as sludge and reject product (UNEP, 2004).
However, the main solid waste produced by the dairy industry is the sludge resulting from
wastewater purification. In aerobic systems the sludge production is about 0.5 kg per kg of
removed COD and in anaerobic systems about 0.1 kg per kg of removed COD (US EPA,
1971). Conventional solid waste management approach deals with the collection of waste
without any source separation and finally disposing it to the landfill using municipal collection
system. Sludge cake are also sent to the landfill after reducing the moisture out of it.

Wastewater Treatment:

In dairy industry different water intensive manufacturing processes produces a large amount of
effluents which consist of high organic load. This organic load is basically constituted by milk
(raw material and dairy products), reflecting an effluent with high levels of COD, BOD, oils
and grease, nitrogen and phosphorus. Moreover, CIP (automated) - discards rinse waters with
pHs varying between 1.0 and 13.0, further complicating the question of treatment (Brio,
2000). BOD is directly related to milk wastes (90% to 94% of the effluent BOD), and in some
cases losses can reach 2% of the volume processed by the industry (UNIDO, 1999).

Typical end of pipe treatment of the dairy waste water consist of the waste water treatment
plant designed to meet the effluent standard. A typical or conventional WWTP consist of the
screen to remove coarse milk solid followed by Parshall flow meter to measure the flow of
wastewater, equalization and neutralization tank to balance the flow and pH; oil and grease
removal mechanisms such as Dissolved Air Flotation (DAF)to remove the oil and grease;
anaerobic or aerobic activated sludge process to reduce the BOD, tertiary treatment unit like
wetland, polishing pond, facultative lagoon, etc. and finally Sludge thickening and
Sludge dewatering to convert the sludge into solid waste which can either be sent to the
landfill or can be incinerated. The industries need to comply with the effluent standard before
discharging it to the stream. (Effluent standard of different countries: appendix D)












Screening
Oil and
Grease
Removal
Aerobic or
Anaerobic
Treatment
Discharge
Equalization/
Neutralization
Tank
Figure 4.1 Components of a conventional dairy processing wastewater treatment
12

Air Emission Control:

Conventional end of pipe treatment of the air emission for the dairy are either by increasing
the stack height and using pollution control equipment like cyclone, electrostatic precipitators
and scrubbers. Venturi Scrubber is one of the control equipment generally used in dairy
industry for the control of dust and gaseous pollutants. Caustic soda is used for the spray
which removes the gaseous pollutants. Cyclone with demister follows the scrubber. Removal
efficiency is shown below. The main conventional source of pollutant in the dairy industry is
boiler for which a huge amount of energy is consumed in the form of combustion of biomass
or coal (traditionally used) resulting in the production of SOx, NOx, PM and CO
2
as major
pollutant and VOC and minor pollutant. However, dairy accounts less air pollution in
comparison to other industries.

Table 4.1 Air emission control Efficiency of Venturi Scrubber




(Source: Design of Air Pollution Control Systems by Dr. N. T. Kim Oanh)


4.2 Inline treatment system

The inline system is suggested considering the use of low-waste technology, use of less
hazardous substances, recovery and recycling of waste, low pay back period, principle of
precaution and prevention and occupational health of the workers. (Detail of possible inline
treatment method: Appendix E)


5. Possible process modification & cleaner production aspects

Cleaner Production is a proactive approach to industrial pollution management. When applied
to processing, cleaner production implies minimization of raw materials and energy use, the
elimination of toxic raw materials, and the reduction in the quantities and toxicity of wastes
and emissions. In the dairy industry, milk production typically consumes large quantities of
water and energy and discharges significant loads of organic matter in the effluent stream.
Toxicity elimination is irrelevant in dairy industry. Thus, successful application of cleaner
production procedure in the production will contribute to use of water and energy resources,
increasing the production yield, and reduction of effluent discharge and solid wastes
generation. This can be accomplished through waste minimization and process control.

5.1 Waste minimization

Waste minimization is the:
1. Reduction in the generation of waste.
2. Reuse of waste materials/by-products.
3. Recycling of waste materials.
Pollutant Type Efficiency
Gaseous SO
2
, NO
2
, HC 30 - 60%
PM PM
10
90 - 99%
13


The driving force for waste minimization for industry is improved yields of product, reduced
effects on the environment and lower wastewater treatment costs. Best practice management
options for waste in decreasing order of preference are given as following:



Strategies for minimizing waste in a dairy plant are suggested in Table 5.1:

Table 5.1 Waste minimization strategies
Plant Planning area and layout for works
Processes Prevent spillages and purge lines
Automate CIP systems
Maintenance of equipment
Recover and recycling of waste (membrane technology)
Monitor processes (alarms, interlocks)
New technology
Personnel Waste management program and training
Staff training


5.2 Process control

Sources of waste

Dairy configuration and the products may affect the nature and concentration of dairy wastes.
The amount of product lost depends on design and operational factors including:
- The range of process technologies in use
- The availability of adequate process monitoring, and plant and procedure
alarms/interlocks
- The availability of automated operation especially automated Clean-In-Place (CIP)
systems and procedures
- The level of management and operator commitment, training and efficiency
- The level of routine equipment maintenance

Most site losses come from activities associated with liquid handling and, to a lesser extent,
with the discharge of air and solid waste. Some examples of avoidable losses are:
- Leaking valves, pumps, pipelines or other fittings the volume lost may not be large
but the pollution load may be great
Avoid Reduce
Reuse &
Recycle
Treatment Disposal
14

- Spills from overflows, malfunctions and poor handling procedures spills usually
happen over a short period but the amount and the high concentration of milk or
product lost may be a significant increase in the pollution load
- Losses from processing and cleaning during the normal operation of plant and
equipment this includes the deliberate discharge of unwanted materials such as whey,
spent cleaners and diluted product not thought to be worth recovering

Suggested measures for reducing waste

Liquid milk production may lead to the generation of odor, wastewater, noise and solid waste.
Best practice involves processing the predominant by-products such as whey, buttermilk into
high value products like, buttermilk powder (BMP), whey powder, whey protein concentrate
and casein, rather than being used as low value animal feed/fertilizer or being dumped as
waste.

The techniques listed below in Table 5.2 is based on the following techniques for
implementing cleaner production
1) Improved housekeeping practices
2) Process optimization
3) Raw material substitution
4) New technology
5) New product design


15

Table 5.2 Cleaner Production Assessment and Techniques in Liquid milk production
Process Inputs and Outputs Description Environmental Issue
Cleaner
Production Focus
Techniques
Receipt
and
storage of
milk

- Raw milk is received at
processing plants in milk tanker
- At the central collection facilities,
mik is measured its quality and fat
content.
- The milk is filtered and/or
clarified by cenfigures to remove
dirty particles as well as udder
and blood cells
- The milk then is cooled and
storaged in insulated vessels until
required for production
- Empty tanks are washed for the
next batch.
- High organic load to
the effluent stream
- Associated
downstream
problems
- Reducing the
amount of milk
lost to effluent
stream
- Reducing amount
of water used for
cleansing
- Avoiding milk spillage when
disconnecting pipes and hose
- Equipped tank with level
control to prevent overflow
- Using clean-in-place systems
for internal cleansing of
tankers and milk storage
vessels
- Improving cleansing regimes
and training staff
- Reuse final rinse water for
initial rinses in the CIP
operation
Separation
and
standardiz
ation

- Milk is separated to remove fat
from raw milk (e.g. milk with
cream contain 40% fat whereas
skimmed milk has only 0.5% fat)
- Standarization is process to ensure
that the milk product has
consistent composition.
Standardaztion is achieved by
remixing cream with skimmed
milk
- High organic load of
effluent stream
- Wastewater contain
milk solid and
cleaning agents
- Reducing the
generation of
separator sludge
- Optimizing its
collection and
disposal
- Reducing the frequency with
which the centrifugal
separators cleaned by
improving milk filtration at the
receiving stage or clarification
of raw milk
- Collecting sludge and
disposing of it along with
other solid waste
16

Pasteuriza
tion and
homogeni
zation

- Pasteurizartion is process that
milk is heated up to 65
o
C for
bacth process and 78
o
C for
continuous pasteurization process
for at least 15seconds. Then, the
milk is cooled to below 10
o
C
immediatedly after heating.
- Homogenization is process to
break up the butterfat globules to
a size that keep it in suspension.
- High level of energy
consumed for the
heating and cooling
of milk
- Wastewater contain
milk solid and
cleaning agents
- Increasing the losses
of milk and organic
load into effluent in
batch process
- Improving energy
efficiency
- By changing heat
exchange for
better heat
transfer
- Replacing batch pasteurizers
with continuous process
incorporating plate heat
exchanger (PHE) pasteurizers.
- Install new manufacturing
equipment
- Avoiding stops in continuous
processes
- Reducing the frequency of
cleaning of pasteurizers
Deodoriza
tion

The odor substances are drawn-off
by injectecting steam into the
system under vacuum. If the odor is
only mild, a vacuum alone may be
used.
Large volume of water
used to operate water
seals on the vacuum
pump
Reducing the use
of water
Re-circulate the water used in
vacuum pump to reduce or
eliminate the necessity of
discharge it
Storage
and
packaging

- Milk is bottled and/or packaged in
a number of types of containers,
including glass, plastic, paper
carton, etc. Normally, filling of
containers is highly automated.
- After filling, the packaged milk
products are usually packaged and
transported in wire and or plastic
crates.
- Loss of milk
products from spills
and packaging
mistakes
- Generation of
wastewater from
cleaning process
- Carton creates solid
waste during the
process of
packaging.
Preheating the
heating plate of
packaging machine
- Make continuous process
- Using high grade carton so it
not break

17

6. Case study Meiji dairy industry

6.1 Waste segregation

Three type of waste results from the dairy industry which are liquid waste (Leaked milk, waste
water, and refrigerant loss), solid waste (Clarification solid, spent filter, packaging materials,
and rejected packaging) and gas (Condensate, odor, air emissions like VOC). However the
waste type in milk industry is liquid in nature. The nature of the waste water (acidic or
alkaline) mainly depends on the cleaning process which utilizes both acid and base for
cleaning in different batch. (Please refer to appendix F for detailed description of the waste)



















In CIP process, alkali and acidic solvents are used to clean the tank in the dairy production
process before a new batch operation, the concept of solvent reuse is applied in this step to
recover ~80% of the solvents back to the CIP process.


6.2 Waste sampling and monitoring

6.2.1 Monitoring of emissions to air

Table 6.1 Monitoring plan of air pollution
SN Unit Parameter Method Frequency
1 Boiler Stack Emission SO
2
, NO
x
, CO, PM10 Manufacturing Instruction Annual
2 Boiler Combustion Efficiency Manufacturing instruction Annual
3 Drier, filter PM10 Isokinetic sampling Annual
4 Conditioning Unit PM10 Isokinetic sampling Annual
5 Factory Odor Olfactory (sniff) assessment Daily

Figure 6.1 Solvent recovery in CIP process
18

6.2.2 Monitoring of aqueous emissions

Table 6.2 Monitoring plan of wastewater
SN
Monitoring Point Parameter Method Frequency
1 Before Screening Flow Parshall flow meter Real time
2 Before Equalization BOD Azide modification method 1 time/week
pH pH meter Real time
TSS Gravimetric method 1 time/week
TKN Micro Kjedahl method 1 time/week
TP Ascobic method 1 time/week
Temperature Thermometer Real time
3 Activated Sludge COD Automatic Sampler Real time
4 Effluent BOD Azide modification method 1 time/week
pH pH meter Real time
TSS Gravimetric method 1 time/week
TKN Micro Kjedahl method 1 time/week
Temp Thermometer Real time


6.2.3 Monitoring of solid waste

The recording in a register types, quantities, date and manner of disposal/recovery of
all wastes.
Leachate testing of sludge and other material as appropriate being sent for landfill.
Annual waste minimization report showing efforts made to reduce specific
consumption together with material balance and fate of all waste materials.


6.3 Waste treatment plant layouts

Waste generated in CP-Meiji Company Limited is divided into solid waste and effluent from
production process and office waste. For waste coming from production process i.e. solid
waste and effluent discharge are treated on-site of the factory whereas almost office waste
(organic and inorganic waste) that has characteristic of domestic waste is disposed to the
municipal collection system.

Solid waste management in the CP-Meiji plant comprises of different disposal and recycling
systems. Solid wastes from production process i.e. damaged package (glasses, paperboard,
plastic containers, etc.) and from non-production process i.e. food waste from canteen,
rubbish, scrap metals and office wastes will be disposed to municipal collection system. Boiler
ash and sludge from wastewater treatment will be disposed to a landfill. Finally waste from
paper packaging materials will be sold to recycling shops.

For wastewater treatment, this dairy industry treats 94 m
3
/day of wastewater, and the system
was designed to handle high organic loading (BOD ~2,000 mg/L) and suspended solid.
Effluent from milk production (i.e. mainly from cleaning process) is treated in a wastewater
19

treatment plant (Figure 6.2). Firstly, effluent is passed through the screening to remove dirty
particles release from empty tanker of raw milk. Wastewater is then held in an equalization
tank to avoid shock loading and pH adjustment for microorganisms in aeration tank. In the
next stage, the effluent is pumped into the DAF to remove suspended solids and fats, reducing
the organic load of the wastewater. FOG collected from DAF is then sent to landfill. An
activated sludge tank is used to degrade the remaining organic substance in the wastewater.
The treated water is held in a sedimentation tank to remove the sludge prior to discharge to a
wetland and finally to receiving stream. For the sludge from sedimentation tank, one is
returned to aeration tank in order to maintain the amount of microorganisms and the rest is
concentrated in a sludge thickener and dried in a filter press before disposal in a landfill. A
filtrate from filter press is returned to equalization tank to treat again. (Please refer to
Appendix G for WWTP diagram)


































Figure 6.2 Wastewater Treatment Plant Layout
20

6.4 Typical cost information

Typical capital and operation and maintenance cost of unit operations in the CP-Meiji Dairy
industry wastewater treatment plant.


Table 6.3 Typical cost of milk production process
Items
Total annual
expenditure
(USD)
Unit cost
(cent/liter)
Cost
(Percent)
Raw material 308,948.48 27.02 91.79
Reception of milk 2,392.87 0.21 0.71
Separation 4,785.76 0.42 1.42
Pasteurization/Standardization 2,630.75 0.4 1.34
Packaging 11,964.44 1.05 3.55
Storage 3,988.13 0.35 1.19
Overall 336,599.63 29.45 100
Total quality produced 1,407,398 liters per year
(Source: A Study on the Economics of Milk Processing in a Dairy Plant in Patiala, A.K.
Chauhan, K.K. Kalra)


Table 6.4 Unit operation and construction cost
Unit Operation
Capital cost
(USD)
Annual operation and
maintenance cost
(USD)
Screen 99,155.34 323.21
Grit Chamber 182,460.24 52.942.69
Equalization Tank 92,517.03 3,490.72
Dissolve Air Floatation system 535,567.05 32,340.88
Coagulation/Flocculation 425,450.38 13,201.44
Primary Sedimentation 83,712.65 9,909.77
Activated sludge system 304,468.41 15,837.53
Secondary Sedimentation 83,712.65 9,909.77
Sludge Thickener 30,705.41 2,811.97
Filter Press 141,471.15 12,960.92
Wetland 58,178.68 2,747.33
(Source: A Study on the Economics of Milk Processing in a Dairy Plant in Patiala, A.K.
Chauhan, K.K. Kalra)





21

6.5 Simple unit process material balance calculation

6.5.1 Mass balance for whole (micro scale) process
























Input L/d
Milk 105,000
Water 151,200
Total 256,200

Output L/d
Wastewater 151,200 x 0.8 = 120,960
Skimmed milk = 100,000
Cream [4% x 105,000 (0.5% x 100,000 +4% x 525] / 40% = 9,198
Milk loss 105,000 x 0.5% = 525
Total 230,683

Efficiency = (Output/Input) x 100

= (230,683 / 256,200) x 100 = 90.04 %
Loss = 100 - Efficiency
= 100 90.04 = 9.96 %

Cream 9,198 L/d
Milk 100,000 L/d
Wastewater 120,960 L/d
Milk loss 525 L/d
Fuel consumption (natural gas) 1,202 m3/day
Electricity 5,733kWh/d
Water 151,200 L/d
Raw milk 105,000 L/d
Milk production
Figure 6.3 Mass balance for whole process
Assumption:
Milk contains 4% fat
Milk after separation are skimmed milk (0.5% fat) and cream (40% fat)
Wastewater is generated about 80% of water input
Density of wastewater is 1.0 kg/L
Density of milk = 1.030 kg/L
Milk loss: 0.5%
22

6.5.2 Mass balance for one (micro scale) unit































Input kg/d
Raw milk (105,000 L/d x 1.036 kg/L) = 108,780
Water 13,230 L/d x 1.0 = 13,230
Detergents
(NaOH, HNO
3
)
= 134.93
Total 122,144.93

Output kg/d
Wastewater (13,230 kg/d x 80%) = 10,584
Discharged detergents (1 0.9) x 134.93 = 13.49
Skimmed milk (100,000 L/d x 1.036 kg/L) = 103,600
Cream (1 0.95 0.5%) x 108,780 = 5,125.61
Milk sludge 108,780 103,600 5,125.61 = 54.39
Total 119,364
Separation &
Standardization
Cream
5,125.6 kg/d
Skim milk
103,600 kg/d
Milk sludge
54.4 kg/d
Wastewater
10,584 kg/d
Raw milk
108,780 kg/d
Water
13,230 kg/d
Detergent
135 kg/d
Recycled detergents
121 kg/d
Discharged detergents
14 kg/d

Figure 6.4 Mass balance for separator and standardization
We assume:
Wastewater is generated about 80% of water input
Conversion efficiency is 0.95
Density of wastewater is 1.0 kg/L
Density of milk at 4.4 C= 1.036 kg/L
Recycled detergent efficiency is 90%
23

Efficiency = (Output / Input) x 100

= (119,364 / 122,144.93) x 100 = 97.72 %
Loss = 100 - Efficiency
= 100 97.72 = 2.28 %


6.5.3 Mass balance for a tie compound
































Input kg/d
Raw milk (105,000 L/d x 1.036 kg/L) = 108,780
Water 13,230 L/d x 1.0 = 13,230
Fat in raw milk 0.4 x 108,780 = 4,895
Total fat input 4,895
Centrifugal
separator
Fat in
cream4,351 kg/d
Fat in raw milk
4,895 kg/d
Fat in Wastewater
7.5 kg/d
Wastewater
10,584 L/d
(0.07%v/v of Fat)
Fat in skim milk 98
kg/d
Cream
(40% fat)
Skim milk 97,735
kg/d (0.1% Fat)
Raw milk 108,780 kg/d
(4% fat)
Figure 6.5 Mass balance for tie compound (fat)
We assume:
Wastewater is generated about 80% of water input
Conversion efficiency is 0.90
Density of fat is 1.0115 kg/L
Density of milk at 4.4 C= 1.036 kg/L
Fat in raw milk: 4%
Fat in cream: 40%
Fat in skimmed milk: 0.1%
Fat in wastewater: 0.07%v/v
24

Output kg/d
Wastewater (13,230 kg/d x 80%) = 10,584
FOG in wastewater 10,584 x 0.07% x 1.0115 = 7.494
Cream 108,780 x 0.1 = 10,878
Fat in cream 10,878 x 0.4 = 4351.2
Skimmed milk 108,780 10,878 7.494 / 4.5% = 97,735.5
Fat in skimmed milk 0.1% x 97,735.5 = 97.735
Total fat output 4,456.4

Efficiency = (Output / Input) x 100

= (4,456 / 4,895) x 100 = 91 %
Loss = 100 - Efficiency
= 100 91 = 9 %



25

6.6 Major O & M issues related to wastewater treatment plant

Table 6.6 Major O & M issues related to wastewater treatment plant
Unit Problems Remediation Remarks
Screen
Clogging of pump from solids particles
(large and small glasses, papers,
cardboards, milk solid )
Require coarse and fire screen before DAF -Coarse screen: prevent large particles.
-Fine screen: prevent small particles.
Equalization
Tank
- Overflows during peak storm water
loads
- Solids settling in bottom of equalization
tank
- Separate storm water from wastewater
- Send wastewater to other plant or CETP that
can treat diary wastewater
- Require screens for solid removal
Storm water will be discharged into
river
Dissolved Air
Floatation
(FOG removal)
Clogging of nozzles from suspended
matter
Shift to Cavitations Air Flotation method
Activated sludge
Tank
(BOD removal)
-DO concentration lower than 2-3 mg/L
from no adequate aeration
-Excessive foaming from high aeration to
make sludge settle down in a secondary
sedimentation tank
- Install probe to monitor DO concentration
> 2-3 mg/L
- Change aeration method to diffuse air overall
area of tank

Sedimentation
Tank
- Bulking sludge from a slight weight
sludge of fungi
- Rising sludge from large amounts of
sludge in tank
- Prevent the contamination from air into water
to prevent fungi
- Increase F/M ratio and return activated sludge
pumping rate and reduces sludge blanket depth
- The floc does not settle or compact and
discharge with effluent.
-There are nitrification and denitrification
that nitrogen gas make sludge rise
Sludge
Thickener
Low sludge settling efficiency Ensure adequate stirring with Pickets
Filter press
High energy consumption when sludge
contain low solid content
Use sludge thickener and sludge digester to
increase percentage of solid before sludge
dewatering by filter press
Improvement of more sludge treatment
facilities depend on the amount of
sludge and budget


26

Reference



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Djekic, I., et al. (2014). Environmental life-cycle assessment of various dairy products.
Journal of Cleaner Production.
DLD. (2012). Thailand Dairy Industry.
FAO. (2009). Smallholder dairy development: Lessons learned in Asia.
Krijger, A. (2012). The World Dairy Situation 2012. International Dairy Federation.
Krijger, A. (2013). The World Dairy Situation 2013. International Dairy Federation.