INTERNATIONAL
CLEANER
PRODUCTION
INFORMATION
CLEARINGHOUSE
INTERNATIONAL
CLEANER
PRODUCTION
INFORMATION
CLEARINGHOUSE
CASE STUDY #36 1. Headline: Improving technology in soft drink manufacturing 2. Background: Aire and Calder: Source reduction at river catchment in the UK The Aire and Caldor Project was the United Kingdom's first major cleaner production project. Most of the initiative for the project took place between May 1992 and March 1993, and involved 11 companies from a wide range of industries located in the catchment of the Aire and Calder rivers in Yorkshire. Initiated by the Centre for Exploitation of Science and Technology (CEST), the project aimed to demonstrate the benefits of a systematic approach to waste minimization, by identifying ways of reducing effluent discharge at the source rather than by applying treatment methods. Funding for the initiative, which totalled oe400 000, was provided by Her Majesty's Inspectorate of Pollution (HMIP), the National Rivers Authority (NRA), Yorkshire Water Services, the BOC Foundation for the Environment, and the participating companies. By September 1994, two and a half years after launching, 671 opportunities for savings had been identified, with a value of oe3.3million a year. Ten per cent of the measures were evaluated as cost-neutral; a further 60 per cent had a payback period of less than one year. The Aire and Caldor initiative was followed by the Project Catalyst, which ran between January 1993 and May 1994. Sponsored by the UK Department of Trade and Industry and the BOC Foundation for the Environment, the project aimed to demonstrate how planned management of processes and systems can lead to financial and environmental benefits. By April 1994, the 14 participating companies had achieved savings of oe2.3million, from 399 options identified for improving efficiency. Thirty per cent of the measures were evaluated as cost-free; a further 30 percent had payback periods of one year or less. With a consumption of 7 500 m3 of water per day, CCSB is one of the largest users of mains water in theYorkshire region of the UK. A total of 237 cleaner production opportunities were identified at CCSB's Wakefield facility, in ares including water, liquid waste, raw material, and energy. Of particular interest is the improvement to conveyor technology. Conveyor lubrication technology in the canning industry has remained static for the last 15 years. Line speeds have been developed to the point at which present state-of-art equipment is capable of producing filled cans in excess of 2 00 cans per minute. 3. Cleaner Production Principle: Process modification 4. Description of Cleaner Production Application: The aims of this project were to: - remove the need for slat lubrication onto the line, whilst maintaining excellent can handling properties - leading to less load on the effluent treatment plant - improve the hygiene standards on the line through the alternative belting - reduce the energy consumption of the conveyor drives, by means of reduction in the coefficient of friction between belt and wear strips - improve safety in the production area - the floor can be kept much drier by removing the slipping hazard - maintain critical handling characteristics both en masse and at varying line speeds - allow the cans to pass in single file at high speed through the can inspection systems. Enabling technology: A different type of belt - in the form of an acetal belt of full conveyor width - was fitted, requiring the development of a new tracking system to maintain can handling properties at the conveyor crossover points. The drive systems were also modified with a new style of driver sprockets and fitted with stainless steel to reduce wear on the sprockets. Initially, one belt was trailed on line for one month to assess the can handling properties and wear characteristics. After assessment, a further 50 per cent of the lines were retrofitted, with the total line performance monitored to eliminate unforeseen problems. After a further two months' trial, the remaining lines were converted to the new type of conveyor belting. The project took six months from start to finish. 5. Economics: For all 237 projects: Cost saving (per year) oe1 491 100 Capital investment oe507 500 Payback period 4 months For the conveyor belt project: Cost saving (per year) oe27 000 Capital investment oe30 000 Payback period 18 months 6. Advantages: The total elimination of slat lubrication has significantly improved the environmental performance of the canning lines. The lubricant contained a biocide - isothiazoline - and its elimination has benefited the operation of the anaerobic effluent treatment plant to which the biocide is discharged in the washing from the process area. Emissions to sewer have reduced by 112 000 m3/year. 7. Constraints: N/A 8. Contacts:Mr C. Ord CCSB Kenmore Road Wakefield 41 Business Park Wakefield West Yorkshire WF2 OXR United Kingdom Tel: +44 1924 82 99 66 Fax: +44 1924 82 55 90 Mr J.R. Watt March Consulting Group Telegraphic House Waterfront 2000 Salford Quays Manchester M5 2XW United Kingdom Tel: +44 161 872 3676 Fax: +44 161 848 0181 9. Keywords:UK, United Kingdom, food processing, soft drink, process modification, conveyor belt, lubricant, Aire and Calder, canning 10. Reviewer comments: This case study was originally published in the UNEP IE document "Cleaner Production Worldwide", Volume II. In the process of preparing the document the case study underwent a technical review.