Evaluation of the application of Cleaner Production techniques in a dairy industry in Southern Bahia

Santos, Fábio Ferreira; Queiroz, Rita de Cássia Souza de; Almeida Neto, José Adolfo de

doi:10.1590/0104-530X2234-16

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Articles • Gest. Prod. 25 (1) • Jan-Mar 2018 • https://doi.org/10.1590/0104-530X2234-16 copy

Evaluation of the application of Cleaner Production techniques in a dairy industry in Southern Bahia

Authorship SCIMAGO INSTITUTIONS RANKINGS

Abstract:

Dairy products are of great importance to the South of Bahia, as they contribute to its development and economic diversification. However, it is necessary to pay attention to the possible environmental impacts caused by the corresponding activities. Thus, the adoption of Cleaner Production (CP) techniques can contribute to improving production processes, as well as providing economic benefits, environmental protection and better working environment. This study aims to identify the techniques adopted and opportunities for CP in a dairy industry in southern Bahia. For this, we carried out a literature review, technical visits and a questionnaire in order to obtain characterization information of the company, CP and environmental management, environmental aspects and impacts related to the production processes. The study revealed that dairy industries are potential polluters, mainly due to their lack of structured environmental programs. Nevertheless, the dairy industry in question was already adopting certain environmental practices and showed interest in learning about others that could contribute to minimizing their impacts and propitiate economic gains. Thus, we successfully identified and presented opportunities for CP.

Keywords:
Environmental management; Cleaner Production; Environmental sustainability

		Environmental Aspect
		Water	Energy	Effluents	Waste	Emissions
	Opportunity
1	Receiving control of raw materials and auxiliary products	*		*	*
2	Control of stored materials			*	*
3	Reduction in loss of milk			*	*
4	Sludge separation in the clarification			*	*
5	Use of continuous system for milk pasteurization		*
6	Heat energy recovery		*
7	Using buttermilk			*
8	Whey utilization			*
9	Dry elimination of salt from cheese after salting			*	*
10	Control and recovery from brine	*			*
11	Dry cleaning of surfaces	*		*	*
12	Use of pressurized water for surface cleaning	*		*
13	Use of foam system for surface cleaning	*		*	*
14	Use of CIP (clean in place)	*		*
15	Use of single-use detergents	*		*
16	Recovery of cleaning products	*		*
17	Periodic control of the boiler emissions					*
18	Condensate recovery	*
19	Safe storage and handling of dangerous and hazardous goods			*	*
20	Minimizing packaging waste				*
21	Solid waste segregation and resource recovery				*
22	Wastewater neutralization	*		*
23	Cogeneration		*
24	Best practices for reducing water consumption	*		*
25	Best practices for reducing energy consumption		*
26	Best practices for the reduction of air gaseous					*
27	Best practices for waste management				*

Product	Raw materials and ingredients	Packing	Machinery and equipment
Bagged milk	Milk	Plastic film and plastic returnable box for transportation	Milk filling
Yogurt	Milk, sugar, yeast, pulp, flavorings and colorings.	Plastic jars, plastic labels and corrugated boxes for transportation.	Yogurt Maker and filling
Cheese	Milk, yeast, salt, calcium chloride and rennet.	Heat shrinkable plastic film and corrugated cardboard box for transportation.	Two double walled tanks, vacuum forming, vacuum package (only the provolone) and polishing machine packaging.
Butter	Milk cream, salt and other additives.	Plastic jars, plastic labels, stamps of aluminum and corrugated boxes for transportation.	Butter churn
Cream cheese	Mass of mozzarella, cream and water.	Plastic jars, plastic labels, stamps of aluminum and corrugated boxes for transportation.	Tub with swizzle stick and double wall.
Milk caramel sauce	Milk, sugar and glucose.	Plastic jars, plastic labels, stamps of aluminum and corrugated boxes for transportation	Tub with swizzle stick and double wall.

Actions implemented	Level	Environmental Benefits	Economic Aspects
Control of incoming raw material, establishing acceptance criteria, operating procedure, training and qualification of personnel.	Source reduction	-Reduces waste and the consumption of water and energy.	-Reduced costs of raw materials, waste disposal/treatment and/or rejected products, -Investments in human resources, the costs of equipment for testing.
Control of materials stored with adoption of the FIFO system	Source reduction	-Reduction of losses of materials and waste generation and/or effluents.	-Cost reduction
Preventive Maintenance	Source reduction	-Reduction in the amount of waste and polluting load;	-Avoids shutdowns costs, production and quality losses.
Whey for animal feed	Recycling	-Reduction in volume and organic and inorganic charge of final effluent.	-Reduction in effluent treatment costs, gains from the sale.
CIP cleaning	Source reduction	-Lower water consumption; reduction in volume of the final effluent.	-Reduction in water consumption and materials detergents and sanitizers; additional energy costs;
Adjusting storage of sulfuric acid	Source reduction	-Prevention of accidents and associated impacts.	-Additional costs for neutralization.
Use of rainwater and Yogurt Maker	Reuse and source reduction	-Reduction in water consumption;	-Reduction in water bill;
Turn off the machines between the 18:00 and 21:00 of the night.	Source reduction	-Reduction in energy consumption.	- Reduction in energy bill

Aspect	Opportunity	Environmental and economic aspects
Environment and workplace safety	-Isolate the pasteurizer; -Install more wind extractors; -Monitoring and control of temperature, noise and vibration; -Follow the standard NR 17 (ergonomics).	-More safety and comfortable workplace; -Quality and productivity gain; -Employee more satisfied with the work; - Need more investment.
Water resource	-To develop a monitoring and control program of water management; -Train and educate employees to reduce consumption; - Use of pressurized water and foam system for surface cleaning; - Use of dry cleaning (removal of waste by sweeping or compressed air).	-Reduction of water consumption; -Reduction of effluent generation; -Reducing of treatment costs; -Additional costs of waste management; -Investment in equipment and training.
Energy resource	- To develop a monitoring and control program of electrical and thermal energy consumption; -Personal training; - Energy recovery and maintenance of steam pipes; -To develop cogeneration projects; -Firewood storage in suitable place.	-Reduction of energy consumption and costs; -Reduction of air emissions; -Use of cleaner fuels (natural gas, for example); -Additional costs for project development, implementation and maintenance.
Effluents, emissions and wastes	-To develop a monitoring and control program of waste, effluents and air emissions; -To use the whey/buttermilk; -Properly disposal of laboratory waste; -Solid Waste Management; -To offer training courses to employees; -To treat for reuse the sludge; -Wastewater neutralization.	-Reduction of waste, air emissions, effluents; -Reduction treatments costs; -Investment and additional in equipment and training -Reduction of losses; -Sludge storage costs; -Business opportunities with the sale of coproducts; -Cost reduction of environmental liability and accident with the laboratory waste.

Universidade Federal de São Carlos Departamento de Engenharia de Produção , Caixa Postal 676 , 13.565-905 São Carlos SP Brazil, Tel.: +55 16 3351 8471 - São Carlos - SP - Brazil
E-mail: gp@dep.ufscar.br

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[1] Source: CETESB (2008)Companhia de Tecnologia de Saneamento Ambiental – CETESB. (2008). Guia técnico ambiental da indústria de produtos lácteos (Série P+L). São Paulo: CETESB. 95 p. Apostila..