Water Usage and Total Waste(Solid and Liquid)1a(2)

Design Document

Waste Generation, collection and Treatment PROJECT: FFF

Document Title

Fauji Fresh n Freeze Lahore Trade Centre 11-Shahrah-e-Aiwan-e-Tijarat,Lahore

FFF-DD-101-01

Document Number

SCBS Pvt. Ltd Project: Frozen Fruits & Vegetables Plant

Page : 1/1 Date: 21.04.2014 Customer: Fauji Fresh n Freeze Site: SWL

Data for the Design of

Waste Management System

Design Document


Document Title


FFF-DD-101-01

Document Number



Contents

1. Introduction ... 3

2. Process Water Usage and Solid Waste . 3

2.1. French Fries Line 3

2.2. Fruits and Vegetable Line ..... 5

3. Utilities ... 6

3.1. Boiler .... 6

3.2. RO Plant .. 6

3.3. Condensers .. 6

4. Water for Sanitation . 7

4.1. Offices and Industrial Usage Including Food Preparation in Kitchen ..... 7

4.2. Future Requirements ...... 8

5. Washing and Cleaning .... 8

5.1. Processing Facility and IQF Hall .... 8

5.2. Kitchen, offices and Change Rooms 8

5.3. Water for Laundry ..... 8

6. Quality of Influent and Effluent Water ... 8

7. Local Laws to be Implemented . 9

Design Document


Document Title


FFF-DD-101-01

Document Number



1. Introduction

In order to design the waste treatment plant, 3W Systems requested the data regarding the waste

(liquid and solid). The data required includes the quantities of waste (solid and liquid), type of solid

wastes and their generation points along with various operations being performed in process halls.

The Sanitary water from offices and industrial buildings, Master layout of the plant along with road

network and existing or proposed sewer network. Keeping in view the environmental effects, final

specification of water and any local or national laws to be implemented.

2. Process Water Usage and Solid Waste

Like a typical food processing industry, water is being used to wash and clean vegetables and fruits

before further processing to avoid any contamination of pollutants which can affect the end user if

go untreated. Hygiene is most important factor in food processing industries. Various operations are

being performed on vegetables and fruits and water requirement for each step varies accordingly.

Water after being used contains stones, particles of dust and starch and plant sugars and must be

disposed of.

The process of French Fries (FF) line and water usage along with organic solid waste is as follows.

2.1. French Fries line Water Usage (Capacity 2 ton/hr) (Reference: JBT Manual)

Design Document


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FFF-DD-101-01

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Process Water Usage (m/day)

Solid Waste (kg/day)

TS (kg/day)

1 Pre Washing/De-stoning (For removal of Stones and dirt) 5.8 380 0

2 Abrasive Peeling + Sorting (To Remove the skin of Potato + Reject the undesired potatoes)

52 11560 2320

3 Trimming (For Peeled Potato Inspection) 0 1080 0

4 Cutter (To cut potato in strips of specified Length and thickness)

22.4 2280 460

5 Blancher (To remove Reducing Sugars and Ascorbic acid) 22 440 80

6 Frying 0 0 0

Total 102.2 15740 2860

IQF (FS1) Freezer

Defrosting (FF line)

Water required is 2.25m/day.

Rinsing

Freezer belt is rinsed with 1 m/day water.

Cleaning with Chemicals and Rinsing.

Evaporator is rinsed after defrosting with 0.750 m/day clean water. Then a 5% of Diverclean VF7 or

equivalent chemical detergent in water is applied. The water used in foam making is 125 liters and

air 2125 liters. Composition of detergent can be obtained by material safety data sheet given in

annexure 1. After 5 minutes freezer is rinsed with 750 liters clean water. The belt is rinsed with 1 m

water. Then a 5% of Diverclean VF7 detergent in water is applied. The water used in foam making is

125 liters and air 2125 liters. Then a disinfectant of 1% Divosan VS1 (Quatdet SU 321) or equivalent

chemical foam is applied. The water used in foam making is 125 liters and air 2125 liters. The

composition of disinfectant can be obtained by annexure 2. The belt is rinsed with 1 m clean water

again.


Water Rinse 0.750

Detergent Application 0.125

Design Document


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Water Rinse 0.750

Belt rinse 1.000


Water Rinse 1.000

Disinfectant Application 0.125

Water Rinse 1.000

Floor Wash 0.500

(Reference: Freezer Manual)

2.2. Fruit and vegetable (FnV) Line (Capacity 3 ton/hr) (Reference: JBT Manual)

Process Water Usage (m/day) Solid Waste (kg/day)

1 Pre Washing/Destoning 4

2 Peeling 24 36000

3 Trimming and Sorting 0 6000

4 Cutting + Hydro Transport 8 0

5 Blanching 16 0

6 Cooler 10 0

Total 62 42000

IQF (FS2) (FnV line)

Defrosting

Water used in defrosting is 4.5m/day.

Rinsing

The belt is rinsed with 1 m/day water.

Cleaning using Chemicals and Rinsing

Design Document


Document Title


FFF-DD-101-01

Document Number



Evaporator is rinsed after defrosting and 0.750 m clean water is used. Then a 5% solution of

Diverclean VF7 or equivalent chemical in water is applied to belt. Water used is foam formation is

125 liters. Composition of detergent can be obtained by material safety data sheet given in annexure

1. After 5 minutes freezer is rinsed with 0.75 m of water. The belt is rinsed with 1 m water. . Then a

5% solution of Diverclean VF7 in water is applied to belt. Water used is foam formation is 125 liters.

Then a disinfectant of 1% Divosan VS1 (Quatdet SU 321) or equivalent chemical foam is applied.

Water used is foam formation is 125 liters. The composition of disinfectant can be obtained by

annexure 2. After 10 minutes belt is washed with 1 m water again.

Process Water Usage(m/day)

Water Rinse 1.500


Water Rinse 1.500

Belt rinse 1.000


Belt rinse 1.000


Belt rinse 1.000

Floor Wash 0.500

(Reference: Freezer Manual)

Gyro Freezer

Defrosting

Gyro freezer is defrosted and cleaned once a day. 2.175 m/day water is used for defrosting.

Rinsing

Gyro is rinsed with 0.5 m clean water.

Cleaning using Chemicals and Rinsing

Gyro is rinsed using 0.725 m clean water. . Then a 5% solution of Diverclean VF7 or equivalent

chemical in water is applied to belt. Water used is foam formation is 125 liters. Composition of

detergent can be obtained by material safety data sheet given in annexure 1. After 5 minutes freezer

is rinsed with 0.725 m clean water. Then a disinfectant of 1% Divosan VS1 (Quatdet SU 321) or

equivalent chemical foam is applied. Water used is foam formation is 125 liters. The composition of

Design Document


Document Title


FFF-DD-101-01

Document Number



disinfectant can be obtained by annexure 2. After belt disinfection belt is again washed with 0.5 m

clean water.


Water Rinse 0.725


Water Rinse 0.725

Belt Rinse 0.500


Water Rinse 0.500


Water Rinse 0.500

Floor Wash 0.500

(Reference: JBT CIP Manual and working time is assumed)

3. Utilities

3.1. Boiler

The water being sent to drain is 0.1478 m/day. The TDS are 2500 PPM.

Water Blow down (m/day) TS (PPM)

0.1478 2500

3.2. RO Plant

408 m/day of rejected water is being sent to drain. Total solids are given as follows.

Water Type Flow (m/day) TS (PPM)

Inflow 1608 3850

Treated Water 1200 200

RO Water Reject 408 14585

3.3. Condensers

12 m/day of water is lost to drain from condensers.

Design Document


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Water Sent to drain (m/day) TDS (PPM)

12 1000

(Reference: Taylors Technologies Inc.)

4. Water for Sanitation

4.1. Offices and Industrial Usage including Food Preparation in Kitchen

The basis of this number is maximum number of people present in one shift and that is for

pomegranate. The basis of water per capita comes from hygiene uses and cooking water

requirements as given by Kochi University Japans Survey in Pakistan.

Population Category

Number of Persons

Liter/Capita/ Shift

No. of shifts/day

Water Usage (m/day)

1 Industrial 900 30 3 81

2 Office 100 25 1 2.5

Total 83.5

(Reference: A Survey Conducted by Kochi University Japan)

4.2. Future Requirements

For future expansion of plant, a similar facility of current capacity is expected.

5. Washing and Cleaning

5.1. Processing, receiving and IQF Hall.

Washing of food processing hall is required in order to avoid any contamination of foreign

matter that is detrimental to food quality. In case of no washing mold and biofilm formation are

big problems which harbor the bacteria that pollute the food. One cleaning per day is must for

these halls. Detergent is used in this water and concentration of detergent is 5%.

Total Water Usage = 4.725 m/day

(Reference: Calculated from nozzle size and pressure of water being used)

5.2. Kitchen, Offices and Change Rooms

Design Document


Document Title


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Document Number



The kitchen and change rooms are required to be cleaned once a day at least. The required

water is 1.5 m/day for kitchen and 1.5 m/day for change rooms cleaning. A 5% solution of

detergent with water is used. Common detergents are used. (Reference: Calculated)

5.3. Water Required for Laundry

No. of Persons Water Use (liter/capita) Water Usage (m/day)

900 30 27

Detergents are used for laundry purpose. The detergent is 0.5% solution in water i.e. 50 grams of

detergent in 10 liters of water. (Reference: Soaps and Detergents by K.R Janardhanan)

6. Quality of Influent and Effluent Water

Water which will be used in food processing must be potable water. The parameters of potable

water are acquired by EPA Pakistan for drinking water.

Influent Water Quality

Parameters for influent are given above and 3W team will calculate the parameters from data

above.

Effluent Stream Water Quality

The parameters are in accordance with EPA Pakistan standards.

Effluent Stream

Parameters Quantity (mg/l)

COD 150

BOD 80

TSS 150

VSS To be obtained from EPA Pakistan

TKN 30-100

Phosphorous 1

Alkalinity To be obtained from EPA Pakistan

pH 6.0-10.0

Temperature 40 C

Design Document


Document Title


FFF-DD-101-01

Document Number



7. Local Laws to be implemented

Waste and Treatment Plant

a) The industries shall ensure management / disposal of effluents after required treatment as

per EPA/FDA regulations at their own cost.

b) The liquid waste from industries will be so rendered so as to be equivalent to normal

domestic sewerage. It shall be connected to the municipal sewer only after the quality and

quantity has been tested and certified to be within the permissible limits by the TMA.

All industrial managements shall be responsible for the disposal of solid waste themselves.

TDS 3500

Water Usage and Total Waste(Solid and Liquid)1a(2)

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