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newsletter winter 2003 |
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Site Visit—Extra Set of Eyes Cuts
Product Loss
Story: The Dairy Farmers of America,
Inc. (DFA) Zumbrota plant produces cheese and whey, shreds
cheese and has a spray dryer. Like many dairy plants, DFA
was losing product down the drain and was paying the wastewater
treatment plant to remove it.
John Polanski, MnTAP food processing specialist,
worked with the plant to help solve the problem. “After
working with John, our waste reduction team focused on an
area we knew was losing product to the drain in the cheese
manufacturing area,” said Jim McIntire, superintendent
at the Zumbrota plant.
DFA lost product during startup and shutdown
when flows through its equipment were switched between milk
for production and water for cleaning. Flows needed to be
directed and timed to maximize the amount of milk going to
production and keep it from the sewer, while preventing too
much water from entering the production vat during cleaning.
The plant needed an extra set of eyes to
watch the flow and divert it at precisely the right time.
Results: The plant installed an optical
sensor in the cheese manufacturing area to be that extra set
of eyes. An optical sensor uses a light beam to detect how
much solids are in the flow. Based on the amount of solids,
the sensor’s program automatically shifts a valve to
send the flow to the production vat or the sewer.
Optical sensors cost about $4,500 plus $200
to $300 for installation. “It was a small investment
for the amount of product we have saved. We saw the results
almost immediately,” said McIntire.
DFA installed the optical sensor in October
2002. The plant has not yet calculated the amount of product
saved from the sewer or the amount of money saved, but it
has documented reduced BOD for its wastewater.
“John was very helpful. We wouldn’t
have gotten this going on our own, he was the driver for it,”
concluded McIntire.
Prevention tips: Don’t send
valuable product down the drain. Examine what you are sending
to the sewer and develop a strategy to reclaim lost product.
Request a visit from a MnTAP engineer or
scientist to get suggestions customized to your operation,
call 612.624.1300.
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