Value from Beverage & Food Industry Wastes

UCD Institute of Food & Health

Environmental Science Association of Ireland

Food Processing Waste: Maximising Hidden Resources for Sustainable Food Processing

Michael Clancy 8th June 2015

AGENDA

• Intro – FDT Resource Efficiency

• Whiskey Co-Product & Waste Streams

• Improved Treatment of Distillery Co-Products

• PUReOPE

• A Little Water

• Ideal World

• Summary

FDT are a specialist Engineering Consultancy with strong Process Engineering Emphasis, operating in the Irish,

European, African and American markets. We have more than 300 man years of Beverage Industry

Experience in-house.

We help to make our client’s enterprise more competitive by efficient capital spend, optimisation of processes,

improving quality, reducing operational costs and meeting compliance requirements.

PHASE 1:

FDT Caustic Recovery Feasibility (2003)

PHASE 2:

Diageo Caustic Recovery Implementation

Galco Spent Pickle Acid Recovery

Feasibility

PHASE 4:

Galco Continuous Flux Treatment

Implementation

PHASE 5:

FDT Water Recovery Feasibility (2011/12)

FDT CO2 Recovery Feasibility (2011/12)

FDT Resource Efficiency History

Food Waste Opportunity

Nutraceuticals

Composting

Animal Feed

Improved Treatment of Distillery Co-Products

Irish Whiskey Renaissance

2015- Existing, New, Planned Distilleries

Dingle Distillery, Kerry

West Cork Distillers, Cork

Tullamore DEW, Offaly

O’Hara’s Distillery, Carlow

Walsh Whiskey Distillery, Carlow

Glendalough Distillery, Wicklow

Dublin Whiskey Company, Dublin

Teeling Whiskey Company, Dublin

Slane Castle Distillery, Meath

Great Northern Distillery, Louth

Niche Drinks Company, Derry Belfast Distillery Company

Echlinville & Portaferry Distilleries

Irish Fiddler Whiskey, Galway

Irish Distillers, Midleton

Cooley Distillery, Louth

Bushmills Distillery, Antrim

Kilbeggan Distillery, Westmeath

Burren Irish Whiskey, Clare

Nephin Irish Whiskey, Mayo

Connacht Irish Whiskey, Mayo

Duchas Distillery + 3, Cork

Kilmacthomas Distillery

Alltech Distillery, Dublin

Dublin Whiskey Distillery Co, Dublin

Sliabh Liag Distillery, Donegal

Unnamed project, Galway

Blackwater Distillery, Waterford

Kilkenny Whiskey Co, Kilkenny

Drumshambo, Leitrim

Merry’s Drogheda

Renegade Spirits, Waterford

Longueville House, Apple Highbank, Apple

St Patrick’s Distillery, Cork

Co-Product and “Waste” Streams

Energy

Cask Whiskey : Pot Ale

1 : 6.1-6.6

Whiskey : Spent Lees

1 : 1.1-2.1

Whiskey : Draff/ Grains

1: 1.8-3.4

Co-Product and “Waste” Streams

Multiple Considerations

Distillery Profiles Distillery Site activities Per annum

Malt Grain Draff Pot Ale/Stillage

Spent Lees

A

25,000 case

0.1 MLA 0.0 MLA 237 T 968 T 330 T

B

125K case

0.5 MLA 0.0 MLA 1211 T 4840 T 1648 T

C

1.5M case

1.0 MLA 5.0 MLA 7726 T 62721 T 10049 T

D

10.5M case

12.0 MLA 30.0 MLA 60886 T 434405 T 75564 T

Methodology

• Baseline Scenario = Animal Feed

• Impact of Transport Costs

• Look at on-site treatment options

• Calculate Best Option

– Financial

– Environmental

• Waste Hierarchy, Energy, Transport

Pig Population

Pigs Pot ale/y MLA equivalent

1 pig 1 1.7 0.00018

Average farm 845 1469 0.15

Big farm 10000 17381 1.80

Ireland 1425000 2476828 255.88

Capital Costs/m3 Feed - Processing

Specific Energy - Dewatering

Not effective with high DS

Effective with high DS

Pot Ale Conclusion

• <1MLA , on-site dewatering/treatment not practical

• Consider other routes to develop more value from resources and improve business case

Process for Upgrade and Recovery Of Polyphenol Extracts

Polyphenols are a complex group of antioxidant compounds found in the leaves, fruit, roots and bark of many plants.

What are Polyphenols?

Negative effects Positive effects

Haze in beer

Effluent Treatment Plant issues i.e.

high BOD, Antibiotic effect

Antioxidant

o Anti-Inflammatory

o Anti-Thrombotic

o Anti-Carcinogen

o Anti-Ageing

Antiseptic

Antiviral

Antibiotic

Antifungal (plants)

Natural Preservative

Natural Colorant

Examples

Project Description

Why PUReOPE? • Environmental Benefit from Recovery

• BOD ↓, Antimicrobial ↓, Bacteria ↑ • Technology Innovation - Recovery at source sites

rather than from virgin material. Potential for H20 recovery.

• IP around recovery & upgrade process and applications.

• High Value Reuse • Nutraceuticals, Supplements, Functional, Feed

Cosmetics, Other • USD 1,000M Market for Polyphenols by 2020

Follow PUReOPE

• Are you a Source or End-User Company?

• JOIN PUReOPE Group on 2 Degrees • https://www.2degreesnetwork.com/groups/pureope-

group/registration/refs/4bC/ • Twitter: @PUReOPE • Visit www.pureope.com

• +353-1-2960022 Michael Clancy • Michael.clancy@fdt.ie • www.fdt.ie

Water Recovery

EU Max

EU Avg

Ireland

Stress Testing of Payback

Membrane concentrate

Incoming Water Water Treatment Plant ProcessEffluent

Treatment Plant

UF & RO Plant

Water, Water?

WAT

ER

BARLEY YEAST

ENER

GY

RO

DISTILLERY

CO2

Waste Heat

Biogas

IDEAL WORLD

Summary

• Waste = Opportunity • Collaborate to Innovate • Business case should be made up of

multiple elements • Holistic Approach- Waste/Co-product,

Water, Energy, Route to Market? • Think outside your own network • Involve Engineers with practical experience • Challenge- Focus on Green Chemistry • Challenge-Consistency large v small industry

Contact Details

Michael.clancy@fdt.ie

M: +353-87-8264301

P: +353-1-2960022

www.fdt.ie

www.pureope.com

Speaker Background

• Process Engineer c.20 years experience in Beverage, Food, Dairy, Industry

• Involved in Resource Efficiency since 2001 – EPA & SEAI

• ISO 50001 Energy Management Systems Technical Assessor since 2007 – 51 Sites

• Energy Efficient Design Specialist- Irish standard IS399 & Guidelines • Background in Asset Care and Projects • Co-ordinator of PUReOPE – EUR1.6M Cip Eco-Innovation Project • FDT active in Brewery, Distillery & Food Projects in Ireland, and

overseas, with large & small companies

Michael Clancy