Water flow within beverage preparation process
The ADUE research team in cooperation with the University of Bologna had undertaken a study aimed to deepen the industrial beverage water flow and qualitatively and quantitatively map out the potential water recovery points at the Customer’s plant.
Three customers of ADUE, different one from each other due to various product typologies, accepted to be subject to the survey conducted under NIAGARA project including the water and the waste water sample taking from its plants.
CUSTOMER 1 produces fruit juices, tomato sauce and frozen vegetables; CUSTOMER 2 produces tomato sauce, soups, tea and fruit juices; while CUSTOMER 3 produces Carbonated Soft Drinks. All customers are interested in water consumption optimising and saving.
The research team analyzed the following aspects:
- inlet water (taken either from well or from aqueduct, either demineralized or osmosized ), its consumption and the respective applicability (cooling, boiler, production, etc…);
- potential water discharge points;
- drainage points for sample collection;
- the operative phase during which the sample is to be collected at a discharge point;
- average quantity of the discharged water, both total daily quantity and flow rate;
- current use of the discharged water: either sewer or organic purifier;
First of all, the project team identified the following water cycles at the customers’ production sites:
see the water cycle at the Customer 1 production plant.
see the water cycle at the Customer 2 production plant.
see the water cycle at the Customer 3 production plant.
The analysis of the above water cycle diagrams revealed several potential water recovery points:
- Reverse osmosis concentrate discharge;
- Sand and coal filters washing water discharge;
- Evaporator cooling circuits water (blowdown water);
- CIP washing water discharge;
- Initial and final water-product phases during the pasteurization;
- Water discharge from pump mechanical seals flushing;
- Homogenizer cooling water;
- Water for PET bottles rinsing prior to the filling process;
- Other possible water discharging points depending on the specificity of the production of the certain customer.
But what really matters is the fact that NIAGARA study emphasized an extremely high water consumption at the beverage plant: from of 1.300.000 m3 H2O to 2.400.000 m3 H2O per year!