2.3.4.1 Proper selection of cleaning chemicals and/or disinfectants Description
Avoidance or minimisation of the use of cleaning chemicals and/or disinfectants that are harmful to the aquatic environment, in particular priority substances considered under the Water Framework Directive. When selecting the substances, hygiene and food safety requirements are taken into account.
Technical description
Chemicals such as chlorine, quaternary ammonium compounds, bromine- or iodine-based products are routinely used to maintain the hygiene of food manufacturing sites. However, these are often potentially hazardous in combination with organic residues. Moreover, to work safely and effectively, such chemicals typically require large volumes of water and often high temperatures. Then, when cleaning is complete, further treatment with a significant associated environmental impact is often needed to clean up any effluent.
Avoiding or minimising the production of harmful residues can include the following measures:
use of less harmful cleaning chemicals (e.g. ozone);
reduce the use of cleaning chemicals (e.g. EDTA, halogenated biocides, acids).
Ozone (O3) in water solution can destroy the cell membrane of pathogens by oxidising the
phospholipids and lipoproteins and has the advantage of itself quickly breaking down into harmless oxygen. Ozone is effective against a wide range of microbes including bacteria, yeasts, moulds, viruses and spores. The incorporation of ozone-rich water in CIP and other cleaning processes has the advantage over traditional disinfectants that no residues are left and the ozone is applied cold. This reduces the volume of water necessary to rinse detergents from the plant and the energy use associated with heating the water. Ozone can also be used in dry settings. Using products with an EU Ecolabel is a voluntary commitment to a sustainable environment. From raw materials to production, packaging, distribution and disposal, EU Ecolabel products have been evaluated by independent experts to ensure that they meet the criteria that reduce their environmental impact. Detergents that meet the criteria of the European Ecolabel are readily biodegradable and are not toxic to the environment.
Achieved environmental benefits
Reduction in consumption of cleaning agents and detergents.
Environmental performance and operational data
No information provided.
Cross-media effects
No information provided.
Technical considerations relevant to applicability
No technical restrictions in relation to the applicability of this technique.
Economics
Driving force for implementation
No information provided.
Example plants
This technique is implemented in multiple FDM installations [ 193, TWG 2015 ].
Reference literature
[ 107, COM 2017 ], [ 193, TWG 2015 ]
2.3.4.2 Reuse of cleaning chemicalsin cleaning-in-place
Collection and reuse of cleaning chemicals in cleaning-in-place (CIP). When reusing cleaning chemicals, hygiene and food safety requirements are taken into account.
See also Section 2.3.3.2.4.
2.3.4.3 Dry cleaning
See Section 2.3.3.2.1.
2.3.4.4 Optimised design and construction of equipment and process areas
See Section 2.3.3.2.6.
2.3.4.5 Use of refrigerants without ozone depletion potential and with low global warming potential
Description
Prevention of emissions of substances that deplete the ozone layer or have a high global warming potential by using alternative refrigerants, such as water, carbon dioxide or ammonia.
Technical description
Refrigerants are widely used in the FDM sector in cooling, refrigeration and freezing operations. The interaction of halogen refrigerants with ozone in the air has resulted in the progressive prohibition of the placing on the market and use of ozone-depleting substances and of products and equipment containing those substances. These compounds are being substituted by other refrigerants such as carbon dioxide, ammonia, glycol or, in some cases, by chilled water.
The leakage rate for industrial HFC refrigeration systems has been estimated at around 8 %, compared to > 20 % for HCFC-containing equipment. The overall consumption of HFC refrigerants for the first fill of new equipment and the refill in existing equipment is estimated to grow significantly in the future [ 25, COM 2011 ].
Hydrochlorofluorocarbons (HCFCs), hydrofluorocarbons (HFCs), chlorine and ammonia are frequently used if the temperatures are below -10 °C. HCFCs have the disadvantage of depleting the ozone layer when released to the atmosphere. They also show considerable GWP. The use of HCFCs is generally prohibited [ 140, EC 2009 ]. HFCs have the disadvantage of possessing a much higher GWP than alternative refrigerants such as ammonia, carbon dioxide, chlorine and water. There are provisions aiming at containing, preventing and thereby reducing emissions of HFCs [ 137, EC 2014 ].
Food, Drink and Milk Industries 129 Achieved environmental benefits
Reduced risk of ozone depletion and global warming.
Cross-media effects
The risk of ammonia and glycol leaks, which can cause health and safety problems.
Environmental performance and operational data
The use of substances that deplete the ozone layer can be prevented or minimised by [ 35, Germany 2002 ]:
using substitutes for such substances;
when ozone-depleting substances are used, using closed-circuit systems;
enclosing systems in buildings;
encapsulating parts of systems;
creating a partial vacuum in the encapsulated space and preventing leaks in systems;
collecting the substances during waste treatment;
using optimised waste gas purification techniques;
proper management of the recovered substances and the waste.
Ammonia (R717) has been used for industrial refrigeration for a long time. Ammonia refrigeration systems are more costly, especially in the low-capacity range. Since the year 2000, HCFC-22 has been replaced in new equipment by the HFC refrigerant R404A, first in Europe, then in other industrialised countries. In recent years, a number of cascade systems with ammonia and CO2 have been installed in the food industry [ 25, COM 2011 ].
For example, a Norwegian ice cream plant is using a transcritical CO2 cooling and freezing
system with heat recovery and hot gas defrost capabilities [ 107, COM 2017 ].
Economics
Substitution of refrigerants is energy-efficient for industrial cooling systems. Examples of individual abatement costs for the alternative option ammonia (R717) are given in the preparatory study for a review of Regulation (EC) No 842/2006 on certain fluorinated GHG [ 25, COM 2011 ].
For a small system with 270 kW cooling capacity at three temperature levels:
Cost of HFC system: EUR 425 000.
Additional cost of similar NH3 system: EUR 132 000 (+31 %). Electricity consumption: 1 800 000 kWh/year.
NH3: -27 % electricity consumption.
Operation cost for F-gas system: EUR 100 000 per year. For a large system with 5 MW cooling capacity:
Cost of HFC system: EUR 6 million.
Additional costs for similar NH3 system: between 0 and 20%. Electricity consumption: between -10 % and -30 %.
Operating cost for the large system: EUR 1 million per year.
Driving force for implementation
There are low-impact alternatives available in the FDM sector and promoted by the Regulation (EU) No 517/2014. For some gases, e.g. HFOs (hydrofluoroolefins), there is no ban in Regulation (EU) No 517/2014 but only a reporting obligation. In addition, this Regulation’s rules related to equipment aim to minimise leakage, not to prevent the use of all such gases. Moreover, the quota system refers to total tonnes of CO2 equivalent and does not mention
Example plants
This technique is implemented in multiple FDM installations [ 193, TWG 2015 ].
Reference literature
[ 25, COM 2011 ], [ 35, Germany 2002 ], [ 107, COM 2017 ], [ 137, EC 2014 ], [ 140, EC 2009 ], [ 193, TWG 2015 ]