Waste learnings from a major food processor on a local and national scale

Nigel PriceTechnical Project Manager (KP Teesside)

Masum A Patwary (Research Student, University of Teesside)

Environmental Composer (KP Teesside)

Aims and Objectives• To give you an idea about how a food

processor deals with waste & by-products.• To describe the potential opportunities to

minimise waste & maximise revenues within a food industry (i.e. NISP)

• To show how waste is managed within an environmental, legislative & business framework.

• To explore a justification of the economics of good manufacturing practices.

• To recognise the operation on a local and national scale.

Introduction to a food processor

•KP Foods which is itself part of the United Biscuits group•Year of Establishment – 1969 with 168 employees

and producing 500 tonnes products/annum•Land area – 33.5 acres (perimeter = 1 mile)•Products – McCoys, Snacks, Frisps, Crisps•Number of employees – 900 – 1000 (at present)•Average potato usage is – 460 tonnes/day, or 2300 tonnes/week

Factory StatisticsFactory Statistics• Average ingredient usage :

• Potatoes 500 tonnes/day

• Potato Flake 30 tonnes/day

• Flavour 10 tonnes / day

• Water 0.6 million gallons/day

(3million litres/day)

• Gas £1900k ( 2.8 million Euro) /yr

• Electricity £1200k ( 1.7 million Euro) /yr

Production Portfolio in Production Portfolio in TonnesTonnes

McCoys62%

KP Crisps5%

Tesco11%

M&S2%

Sticks2%

6%

11%

4%Others

1%

KP Input and Output (Waste/By-product)

OutputCrisp/snacksPeelPaperWaste oilStarchSand/mudMetalReel CoresWoodCans/cupsGeneral

InputPotato

Packaging filmCardboard Box

FlavourOil

WaterEnergy

Canteen OperationsOffice operations

Eco-friendly Waste Management as a Resource

Separation at source -RecycleCollection and transportationA systematic management likeCompostingand safe disposal like Landfill

KP mud and sand recycled as a compost

Sand and Mud mixing Final Product - Compost

Cabbage Willow

KP peels recycled as a livestock feed

Animal feed recipe: KP peelings, Vegetable Protein, Crushed Barley

Life is good being fed recycled KP Peelings

Plastics and cardboard recycling

The economics- a justification

£ 4,926142 tonnesGeneral Waste

£ 22.50

£ 39

90 kg230 kg227 kg570 kg

Canteen/office- Cans- Cups- Paper

£ 2456.56 tonnesMetal by-products£ 1043 tonnesReel Cores£ 137839.37 tonnesCardboard

-£ 156£ 336

111 tonnes156 tonnes336 tonnes

Potato Peelings- Steam Peeling- Peeled potatoes- Screen Waste

£ 5,28977.84 tonnesPotato starch- Recovery

Cost avoidance & Value to KP

WeightMaterial

Re th!nk About WasteWhat can YOU do?

You can utilize all materialsYou can minimize waste Think again before throwing material into any BINDo you know the correct use of bins?

Material in RED BINS is a personal cost

Material in GREEN BINS generates REVENUE ££££££££££££££££ FOR ALL

What Can You Do?

•Utilise recycling facilities.

•Use the correct colour bins.

•Stay briefed on new recycling initiatives.

What Can You Do?Thank you for your assistance in recycling waste product through the correct bin OR re-working into production, you are POSITIVELY affecting;

•Your Environment•The Business Performance•The External Environment

Environmental Teamwork at KPAre you aware that in YOUR role you can influence?Your working Environment –

» Individual and business benefit

Business profitability –» Individual and business benefit

The wider Environment –» Individual and business benefit

Need YOUR help to make this work

UB Waste Business for the 21st Century

•UB is 11 Manufacturing sites across the Country and support site•Aiming to work with one waste partner to add value to the

whole business

•Provide benefits and practice waste solutions on local,

regional and/or national scale•Using good manufacturing practices meeting all legal

requirements.

•Utilizing principles practiced at KPKP Teesside

The Food Technology Centre

4 October 2006

Dr Leo V. Guevara

Presentation Outline

• Mission• Vision• Background• Food Technology Centre - Expertise• Services offered• Case studies• Conclusions

The Food Technology Centre

A business unit undertaking consultancy assignments, training, research projects and teaching in the application of food science and technologies for the food chain.http://www.foodtechnologycentre.com

Mission

• To continue to provide the food and drink industry in the North East with technical and business support through technical assistance, training, knowledge transfer and applied research.

Vision

To be the premier provider of training, technical support, applied research and innovation to companies in the North East.

Background• An business unit in SST • Established in March 1999 - one of five National

Food Technology Transfer Centres (FTTC).• First FTTC established in the North of England• Only FTTC to receive follow on funding from

DEFRA.• Funded by ERDF, ESF, Tees Valley Single

Programme, Food Standards Agency, DEFRA, University of Teesside and Private Income.

People at the FTC

• Dr Leo Guevara - Centre Head• Eleanor Nicholls – Food Technologist• Sian Fergusson – Food Technologist• Andrea Bassett - Training Co-ordinator / Food

Technologist • Rebecca Buckingham – Project Administrator

USP – Food Expertise and R&D

1. Technical expertise, practised in industry2. Access to academic knowledge and

expertise within the University for example in Marketing, Market Research, and Operations Management.

Services Offered

1. Training2. Consultancy3. Knowledge Transfer Partnerships4. Research projects – M.Sc.5. Innovation audit, product development and

business systems agreement workshops

Services Offered – 1. Training

In-house training and open coursesAccredited coursesWorkshops

Food Labelling Sensory EvaluationInternal AuditingMicrobiology

Services Offered - 2. ConsultancyHACCP BRC Quality Management Systems Product Development Process Development

Health and Safety

http://www.foodtechnologycentre.com

Case Study – Acorn Diaries

• Family run farm.• Producing organic milk,

cream and butter.• Secured contract to

supply Darlington Memorial hospital with organic milk.

• FTC assisted them to gain BRC Certification.

Services Offered - 3. Research

Knowledge Transfer Partnerships (KTP’s)Research Projects: Undergraduates & M.Sc.

Innovation audit, product development audit, business systems agreement, planning and implementation

KTP Case Study – Zeina Foods

• Family run pistachio & nut processor.

• Main market: selling roasted nuts in bulk.

• KTP with University of Teesside via FTC.

• Aim: “To develop product development processes strengthening product quality and technical support and to launch new products to achieve increased market share and profits”.

M.Sc. Project - KP Foods

• Momodou Ujie• M.Sc.Food Technology

student• Project at KP Foods.• Industrial supervisor:

Nigel Price• Project: Food processing

waste minimisation

Summary

• The FTC: serving the Food & Drink Sector in the North East with technical and business advise, training and applied research.

http://www.foodtechnologycentre.com

ETTC EVENTEncycleEncycle

Food Waste To Food Waste To EnergyEnergy

Phil StokesManaging Director NEL

Power

4th October 2006

EnCycle Joint Venture

“Quality by design”

E n C y c l efoodwastetorenewableenergy

January 2006 – Aim – To Develop Food Waste To Energy Projects

Food Waste

UK Estimate• Waste from food production• Pre-packaged meals• Supermarket waste• Domestic food waste

6,000 tonnes per day

Causes Of Waste

Causes Of Waste:

• Not sold within date

• Discarded from the process

• Discarded by the purchaser

Options for Disposal:

• Composting processes

• Landfill• Conversion to fuel

SyntheticGas

BiomassFuel

INETEC UNIT

Tonnes To Batch process

GEMUNIT

GAS ENGINES

Waste Food

Raw FoodCooked Food

PlasticGlassPaper

Power

Waste Water Start-upGas

Char Heat For Client’s Process

Overall the basic process takes waste food at a gate fee and converts the waste into a biomass fuel which is used to produce power and earn ROCs.

Food Waste to Fuel- Overview Of The Process

The Inetec ProcessThe Inetec Process

The Basic SynopsisThe Basic Synopsis

GEM Gas Converter

GEM Process

Engine Exhaust

Feed Reception

BagOpener

Iron Recycled

AluminiumRecycled

Granulation

Storage

LiquidStorage

Carbon Ash

Blast Cooler

Scrubber(If Required)

Generator Engine

ElectricalEnergy

GasConverter

Dryer

Gem Hall – 9 Units

Sites

Encycle is looking at 7/8 sites in the UKNorthNorth EastNorth WestSouth WestSouth East

The object is to process1,500 tonnes a day

Typical Site - Immingham

Plant Diagram

To Sum Up – Make Use Of Food Waste

Encycle:• To make a fuel• To make power• To make heat• To reduce CO2 emissions• To SOLVE a major problem

PDM Group

Environmentally sustainable Environmentally sustainable recycling and renewable energy recycling and renewable energy services for the Food Industry.services for the Food Industry.

An OverviewAn Overview

PDM Group’s operations

• One of the largest privately owned animal by-products processing businesses in Europe.

• Service the entire meat production chain; from farm gate to supermarket shelf.

• Handle over 1 million tonnes of raw materials per annum.

• Established over 80 years, still under founding family ownership.

• 11 UK processing plants.• ~£200 Million turnover, 1,100 staff

PDM Group’s operations

• Five key operating divisions:– Food Production– Food Services– Petfood Production– Recycling & Bio-fuel production– Renewable Energy

• Food is at the heart of our operations

Waste Food Waste Food -- OptionsOptions

• Options for future–Do nothing – continue landfill.– Introduce own recycling facilities–Pursue ‘novel’ technologies–Utilise existing tried & tested

infrastructure – low risk option

Waste Food Recycling

• Challenges– Legal– Sustainable– Cost effective– Minimum impact on own operation – allow

to focus on core business– Maximum environmental benefit

ByBy--Product ProcessingProduct Processing• Four large-scale plants;

South West, London, Midlands and North West.

• In-house capacity to handle all grades of animal by-products from every stage of the meat industry

• Premier service provider to the UK supermarkets for ABP processing.

PDM Retail CollectionsPDM Retail Collections

• 3,000 “traditional” butcher shops and over 8,500 supermarkets and C & C sites serviced.

Combustion to Energy

At PDM plant

De-packaged

Landfill

Biodegradable waste generated from store or

Factory

Conditioned & blended

Combustion & green power to grid

Packaging Raw Feed Stock

Recycling Markets

Cleansing & Disinfection

Collected by PDM Group

PDM Renewable Energy PlantsPDM Renewable Energy Plants

Widnes, Cheshire Rushden, Northants

Both plants fully operational.

New plants planned for Nuneaton and London

PDM Food Waste ServicesPDM Food Waste Services

• Unique ‘one-stop shop’ service for all food wastes (including meat, oils and fats) with complete coverage across the UK.

• Wide range of service options to cover customer requirements.

• Dedicated 24/7 customer support helpdesk.• Secure, fully documented audit trail with

sustainable disposal route to “green” energy.• Service available today

PDM Oils & FatsPDM Oils & Fats

• UK’s largest collectors and processors of used oils and fats.

• Fully integrated operations – trucks, processing plant and end-use applications to minimise cost.

• R & D continuing into new bio-diesel systems.

• Long term partnership for bio-diesel with Oil ‘majors’.

Renewable EnergyRenewable Energy• Generate ‘green’ electricity

from food wastes for the National Grid using Combined Heat & Power plants.

• Producers and suppliers of bio-fuels to Industry, also recycled vegetable oil for bio-diesel production.

Service OfferingService Offering

• Fully integrated service provider• Capacity to handle all food wastes; liquids

and solids• Nationwide coverage• Renewable energy and recycling• Long-standing operator, financially secure• On-going R & D

Further information:

www.pdmwww.pdm--group.co.ukgroup.co.uk