RECOWATER PROJECT
Retort Water Recycling

Dissemination via retorts manufacturers
24th & 30th of July 2013

Participants

Christophe Crouzet : Composite project leader
Gebhard Kregel :Global R&D, responsible for dissemination

Philippe Frickert :ERN chief Engineer, local project leader

Christophe Mathey : ERN maintenance manager

Yann Weissgerber : Steriflow
Jean Patrick Roumagnac : Steriflow
Gerd Werner :Scholz (Separate meeting 30/07/2013)

Frank Funke :Scholz (Separate meeting 30/07/2013)2

Agenda of the day

12:00 – 12:30

Welcome on Site and a first introduction

Philippe Frickert

12:30 – 13:30

Lunch in the cafeteriaAll

13:30 - 14:00

Retort Process Steam Air and the special requirements

Gebhard Kregel

14:00 – 14:45

Detail technical presentation of the RWR

Christophe Crouzet

14:45 – 15:00

Break

15:00 – 16:30

intensive and detailed factory tourAll

16:30 – 17:00

Quality requirements for a successful operation

Philippe Bernard

17:00 – 17:30

Question & Answer Session

Gebhard, Christophe and Philippe

17;30

Return to the Hotel Petite France in Strasbourg3

Content of this presentation

1) History2) Dissemination
3) Technical description
4) Results & challenges

4History & context- 2009 : We commissioned in VDN a innovative Retort cooling Water Recycling System based onfine filtration, UV light, ozone, saving 95% water and keeping water quality on potable level-Early 2010 : Based on this success, we decided to roll out to European factories equipped withsteam air retorts : ERN & GAR with the support of European Union (MEL & BRK stepped out for
strategic & economical reasons)- October 2010 : Contract with EU was signed to get subsidies from them to help us
implementing the replications, as far as will disseminate this project outside.

5

Dissemination-> From the initial contract, we were asked to disseminate via the following channels :MARSCommercial → Subcontractor

Europeanfoodindustry/
public-> Due to time & resources constraints we downscaled the scope to retorts manufacturers only-> Therefore we would need your help to fulfil the contract terms :(We have)...”also approached the major European retort and filter producers and currently discusses theoption of including information on the project e.g. in their newsletters. That way, approximately 60% of all
food producing companies within Europe could be reached”

6Principle of the RWR
Here is the principle :Weekend cleaning system

Raw Water
Tank
RetortCoarseFilter

Water check &rejectstation

Police disinfection
Clean Water Tank

Fine
FilterUV Treatment•

Coarse filter to remove solids, avoid debris build up & reduce COD level•

Online checking station for incoming water, with rejection of water > 10 NTU•

Raw-water buffer tank and pumps•

Self cleaning filter (size 20-30µm) to prevent that any debris or build-up of substances in thesystem becomes nutrients for bacterial growth.

•

UV light for water disinfection, as it will not impact the water chemistry nor require special
safety protections/training of operators deal with hazardous substances.

•

Ozone police disinfection via ozone injection to keep the system clean after the UV treatment
and provide verification of chemical sanitation•

Clean water buffer tank and pumps•

Automatic CiP system to provide weekly cleaning and sanitation of the whole recycling system
7

Pouch sterilisation in Steam/Air retortStart
empty retort

Cold
water

V2

PT100

Heatexchanger
2x

Controlvalve

Condensat

T

V3

VD1
Pump 2x

P2A
P2B

8

V7

Pouch sterilisation in Steam/Air retort
Condensate(C.U.T and Sterilisation)
Venting
CP2
CP1

Flow direction away from the vanFlow direction to the van

Cold
water

PT100

V2

PS1

Heatexchanger
2x

Pressureair

Condensat
Steam
N3

V3
N1

N0

VD1
Pump 2x

P2A
P2B

9

V7

Condensate(300 - 350 ltr.)

T

100 mm ∑300 - 350 ltr.

Pouch sterilisation in Steam/Air retort
Pre-Cooling waterfrom 125°C to ~95°C
Flow direction away from the vanFlow direction to the van
Cold
water

Pre-Cooling
valve

V2

V1

Heatexchanger
2x

Cold water
injection
Condensat

N3

V3
N1

250 mm ∑1.300 ltr

N0

VD1
Pump 2x

P2A
P2B

10

V7

Pre-Cooling water(1.000 ltr.)

Pouch sterilisation in Steam/Air retort
Additional water to reach thecorrect level for circulation pump

Cold
water

V2

V1

Heatexchanger
2x

Condensat

N3

V3
N1
N0

VD1
Pump 2x

11

Cold
water

V7

P2A
P2B

Additional water(few hundred ltr.)∑1.500 ltr

Pouch sterilisation in Steam/Air retort
Start cooling over heat exchanger
from 95°C to 35°C

Cold
water

V2

V1

Heatexchanger
2x

Condensate
recycling

Condensat
N3

V3
N1
N0

VD1
Pump 2x

P2A
P2B

12

V7

Pouch sterilisation in Steam/Air retort
Empty the retort(Drain the water)A) to the drain water andwaste it
or
Cold
water

B) send the water to the
RWR system for reuse
PT100

V2
Heatexchanger
2x

Condensat

N3

V3
N1

Drain

N0

VD1
Pump 2x

P2A
P2B

13

V7

DN 65

14

P

P

9

LSA16

ProMinent®

DN 100UV-Lamp20

Fine filtration
10 µm
dP
P

P

P

Flushing tank
P

P

16

DN 50
DN 100P

P

P

Emptying pipes

treated coolingwater

14

PSpectral
Absorption

18 Coefficient

FT

P2

13

CIP-Base 50 %to Waste Water

LSA16

P4

Zirculation pipe to
avoid switch off the UV-lamps

21

Level

Flow
QIS
10

FU

10 DN 50

DN 50

pH
09

FIC

11

P

15

P1

P

P

LSA15

FT

SAC
08

P

12

P3

8

P

to the Retorts
56 m3/h

pH

19

P

FIC

24

Ozon-Injection

CIP- Pipe

DN 50
DN 40

DN 40

Flushing Air

14

27

P

13

Level
LIC
06

DN 40

12

6

TI
11

Temperature

Process watertank

QIS-

optional

P

DN 50

Catalytic
remaining ozon annihilator

ProMinent ®

ProMinent ®

LIC

rH

4

3

Failure Indication
Ozon

P

Ozon

25

Level
05

Flow

23

7

DN 40

DN 50

P

ProMinent ®

P

26

DN 40

P

Redox

Failure Indication
Berkefeld-Filter

2

DN 65

Potable water conn.

Ozone

P

P

5

From the Retorts
45 m3/h

TI
03

FI
04

Störungsmeldung
UV

QIS
02

min. 1 m infeed lenght
DN 100Temperature

Flow

1

Lf
00

ProMinent®

Turbidity

PD Coarse Filter > 1 mm
01

Raw watertank

Conductivity

ProMaqua®

Retort Recirculation Cooling Water
Treatment System

22

Agenda of the day

12:00 – 12:30

Welcome on Site and a first introduction

Philippe Frickert

12:30 – 13:30

Lunch in the cafeteriaAll

13:30 - 14:00

Retort Process Steam Air and the special requirements

Gebhard Kregel

14:00 – 14:45

Detail technical presentation of the RWR

Christophe Crouzet

14:45 – 15:00

Break

15:00 – 16:30

intensive and detailed factory tourAll

16:30 – 17:00

Quality requirements for a successful operation

Philippe Bernard

17:00 – 17:30

Question & Answer Session

Gebhard, Christophe and Philippe

17;30

Return to the Hotel Petite France in Strasbourg

15

Content
1 - General project overview
2 – From idea to pilot
3 – Technical overview & deep dive on key elements
4- Reco summary
5- Achieved results

16

1- Project Charter• OBJECTIVE : Recycle retort cooling water (steam air retorts) to reduce dramaticallypotable/softened water usage, and keep water quality on Q&FS standards• SCOPE :• 11 retorts in ERN (300m3 water/day) , 21 retorts in GAR (500m3 water/day)• Conversion to “water through process” in ERN, and full emptying in GAR• PROJECT KEY DATA :• 1 turnkey supplier for the core treatment system• Local suppliers for environing systems/interfaces• ERN : 0,8 M€ project, actual commissioning July 2011
• GAR : 1,6 M€ project, actual commissioning October 2011
• KEY SUCCESS FACTORS :KPIMeasureRetort fresh water consumption reduction-90% on basis of equivalent portofio/volume

CFU at system outlet<100 bacts/ml

Coliforms & enterococci at system outlet

0

Impact on retort cycle time0

Workload
17 to operate & maintain the system

Max 4h/week
Standalone for 1 week

2 - Why such a system ?
The project started from blank sheet and different options were studied for water treatment :1) Physical treatment : RO/Ultra filtration

Filtration Capabilities
Flow Direction

Reverse Osmose (RO)No pores

Nanofiltration (NF)

Ultrafiltration (UF)

Mikrofiltration (MF)Highly molecular org.substances
Org. Substances with medium size

Bacteria, parasites
anorganic substances

Low molecular org. Substances
Polyvalent ions
Univalent ions

Viruses+ : bacteria avoidance, chemical-free, no impact on material/product- : Low efficiency (less savings), prefiltration needed to cope with pollution, possible re-infection after system18

2- Why such a system ?
2) Thermal treatment+ : No add-ons or chemicals required, Sterile water after cycle , no impact on material- : Energy usage, Pre-filtration for particles necessary3) Chemical treatment (Chlorine, Bromine, Hydrogen peroxide)+ : Strong disinfection agent, easy to operate-: Possible creation of by products, risks on material / product if not correctly handled

For these reasons we had to design a fit-for-purpose specific water treatment system19

3- Principle
Here is the principle :•Coarse filter to remove solids, avoid debris build up & reduce COD level•

Online checking station for incoming water, with rejection inappropriate of water•

Raw-water buffer tank and pumps to “transform” a batch process to a continuous process•

Self cleaning filter (size 20-30µm) to prevent that any debris or build-up of substances in thesystem becomes nutrients for bacterial growth.

•

UV light for water disinfection, as it will not impact the water chemistry nor require special
safety protections/training of operators deal with hazardous substances.

•

Ozone police disinfection via ozone injection to keep the system clean after the UV treatment
and provide verification of chemical sanitation•

Clean water buffer tank and pumps•

Automatic CiP system to provide weekly cleaning and sanitation of the whole recycling system20

3- Deep dive : Checking station
1) Theory : role of the checking station
Aperture
Lamp

Lens

Glas Cuvette

90° scattered Light

Photo Cell-> Temperature control : filters out water >45°C (damage to turbidity/UV light devices)-> Conductivity control : water quality (condensate vs softened)-> Turbidity control : filters out polluted water2) Lessons learned on turbidity-> VDN : On line measurement -> Not working because of air bubbles from emptying pumps-> ERN/GAR : Measurement in bypass and bubble removal with ultrasonic bath -> Working better,but too long time between measurement & rejection (too late), bacteria buid-up in bath21

3 -Deep dive : Checking station
3) Recommendation for future project•

By pass solution•

Need to reduce the time between taking the water and measuring as much as possible•

Turbidity meter to be placed far enough from tank1 to allow possibility to reject batches•

Commissioning with involvement of manufacturer•

Rejection limit =4 NTU

22

3- Deep dive : Filters
Basics of Filtration
2001) Theory : role of the filter

20.000100.000

Pharma- Macroceuticals molecules
pesticides

Colloids

Particle
B

V

Ions

Molecular weightP

0,1B – 2 bar
Microfiltration (MF)0,1 – 5 bar
Ultrafiltration (UF)3 – 10 bar
Nanofiltration (MF)5 – 100 bar

B

Reverse Osmose (RO)

V

0,1

1

P

10
100
Particle size (nm)1000

10.000Here the goal is not to filter out all particles/bacts, but just to remove “big” particles (>10-30 microns)
which could prevent the UV light to work properly (shadow effect) or create a nest for bact growth.
To fulfil its role the filter must be as well :-Automatic self washable (backwash) and able to remove bacts/ biofilm-

Withstand CIP conditions-

Several units in parallel to allow continuous operation23

3- Deep dive : Filters2) Results from VDN pilot
Techno : Disk filter 20 µm Beckerfeld

Working

Works fine for ½ week (biofilm)
Low water usage

Challenges

Suitable only up to 50°C (plastic)
Not able to work continuously 1 week24

3- Deep dive : Filters3) Implementation ERN/GAR-> Stainless filter 30 micron (hot CIP 85°C) from Wolftechnik-> Problems we faced :•Mesh destruction : solved after changing design to 3 layer & setting
proper operational conditions•Blockages by biofilm : solved by manual cleaning 3/week and local
CIP by mid-week

Working

Filters water @ 30 microns

Challenges

Long time to find the solution
Manual cleaning 3/week and mici CIP mid week
Still blockages in GARgzdai25

3- Deep dive : Filters4) Recommendation for future projects•

Ability to clean automatically the pollution including bio film for 1 full week•

Withstand CIP conditions 85°C with caustic•

Hygienic design•

Mesh size as small as possible (20 µm max)•

Water usage limited as much as possible26

3- Deep dive : UV light1) Theory : role of the UV light
Ultraviolet radiation causes damage to organic cells by modifying their vital enzymes and the DNS. Because ofthat, the metabolic process and cell replication will be stopped. The microorganisms will then die shortly- The disinfection effect of the light is in a range of 240 to 290 nm wave length with a maximum at 254 nm.
- Water has to be clear water with low absorption within the UV range-2 types of lamps : low pressure and the medium pressure lamps

Medium pressure discharge lamps have a higher specific electric power in W/cm, produce a lower
percentage
27 of UV at 254 nm , but emit a wider spectral range of microbial effective radiation

3- Deep dive : UV light2) Results from VDN pilot
1 medium pressure lamp from Prominent-> 2kW power-> over designed power (3000J/m2 whereas 450J/m2 are enough in theory)

28

Working

Killing bacteria
0 bacts after UV and ozone

Challenges

Still some bacts after UVEnergy usage

3- Deep dive : UV light3) Results from ERN/GAR
On supplier recommendation, we decided to go for low pressure lamps from Wedeco (more homogeneousenergy flow due to higher number of lamps, better efficiency at 254 nm, lower consumption…)-> 10 -16 lamps in 1 housing 3-5 kW-> Over designed power (3000J/m2 instead 450J/m2 )Working

Killing bacteria, efficiently as in VDN (medium pressure)

Challenges

Still some bacts after UV
Killing rate around 1:100 to 1000 (vs 1:100.000 promised by supplier)
Measured power is only 80W/m2 (Design=220W/m2) due to water quality
Issues on commissioning29

3- Deep dive : UV light4) Recommendation for future projects•

No bacteria after UV•Overdesigned•

Involve supplier for commissioning•

Automatic emitter tube wiping system (based on time/ actual power)•

Withstand CIP conditions when Off•

Withstand up to 45°C in normal operations•

Equipped with a intensity sensor (W/m2 or %)30

3- Deep dive : Ozone system
1) Theory : role of the Ozone
Role :-> Keeps the water sustainably clean (avoid re-infection after UV)->Traceability (presence of ozone in water = no bacteria)-> Target 0,3-0,7 ppm in water after tank 2 (clean water)
It is composed of different equipments :-> Ozone generator-> Ozone dosing & mixing devices-> Online concentration measurement-> Gas warning system (safety)

31

3- Deep dive : Ozone system
2) Results from VDN pilot• From Prominent• Designed on 1,5g/m3/hour• Compressed air inlet -> ozone/air outlet• Online dosing in main water pipe before tank 2• Static mixer

32

Working

Ozone is injected and measured on line

Challenges-

3- Deep dive : Ozone system
3) Results from ERN/GAR
On supplier recommendation, we used a different technology :• From BWT• Designed 1,5-2 g/m3/h• Water by pass 6m3/h from the main water flow to tank 2• Ejector sucking air by venturi effect• After analyse of gaps between dosed and measured quantities, we
implemented 2 additional static mixers

Working

Ozone in fresh water concentration after injection at target

Challenges

Long investigations to find out the dilution problem (mixers)
Still not enough ozone in water to cope with pollution33

3- Deep dive : Ozone system
4) Recommendation for future projects•

Recommendation for the VDN solution with compressed air and no bypass(more simple)•

Cruise dosing 2g/m3/h•

2 Ozone mixers•

Connexion to both tanks to avoid bacteria growth in tanks•

Ozone measurement online based on VDN solution but after tank 2•

Involvement of manufacturer for commissioning•

Gas detector as in ERN/GAR

34

3- Deep dive : CIP system
1) Theory : role of the CIP system•Bring the overall system 100% clean once a week
• Cleaning via caustic soda solution (0,5-2%)• Disinfection with Chlorine• Must include as well the inlets/outlets from/to retorts

2) Results from VDN pilot• Only local CIP (Treatment system)• Cold CIP
WorkingCore system is clean after CIP

Challenges

Dirtiest point of the system (pipe from retorts) not cleaned
Limited efficiency (cold)
Need manual mechanical / chemical cleaning several times/year35

3- Deep dive : CIP system
3) Results from ERN/GAR• Hot CIP 85°C
• Includes pipes from / to retorts including individual & main pipes• Reutilisation of the caustic mix (tank)• Possibility to make local CIP wihin the week, without stopping production

Working

System fully cleaned

Challenges

Long commissioning phase36

3- Deep dive : CIP system

4) Recommendation for future projects•

Based on ERN/GAR overall –> RWR + retort main + retort pipes•

Hot CIP, but with bypass if disk filters•

For automated factory, based on ERN solution•

For semi automated based on GAR solution (CIP needs manual validation before starting,problem on retort during CIP handled differently, light management)

37

4- Reco basis
As a summary, here is the lessons learned recap from VDN/ERN/GAR installations which
could be used to setup a reco. However, future investigations may be needed

Item

38

Top line SpecBase

Coarse filter

0,2mm

ERN/GAR

Check station

Turbidity by pass

ERN/GAR + relocation

Tanks & pumps

Hygienic design, 1h

ERN/GAR

Fine filtration

Disks 20µm

VDN stainless steel

UV

Medium or low

Test needed

Ozone

2g/h, compressed air

VDN

CIP system

Including full piping

ERN/GAR

Controls

Just fit for purpose &interface

Functions ERN/GARTechno VDN

5 - What have we achieved initially
From the beginning (commissioning summer 2011) we achieved-> Water savings >90%-> No impact on the rest of the factory-> Good hygienic design & very efficiency CIP system
But :-> Quick build up of biofilm-> generating bacteria over limit after 3 days in ERN and 1 day in GAR (higher pollution)-> and blockage of the filter generating installation stop.

39

5- What have we achieved finally
After months of optimisation on :-> Filters (3 layers design, operating conditions)-> Ozone dilution (adding mixers)-> Controls (filter cleaning, rejection dirty batches...)-> Implementation of mid week local CIP-> Setting up proper supervision procedures
We managed to reach the required quality of water and signed the HO2 in July 2012 for
ERN and in June 2013 for GAR

40

Quality requirements
12:00 – 12:30

Welcome on Site and a first introduction

Philippe Frickert

12:30 – 13:30

Lunch in the cafeteriaAll

13:30 - 14:00

Retort Process Steam Air and the special requirements

Gebhard Kregel

14:00 – 14:45

Detail technical presentation of the RWR

Christophe Crouzet

14:45 – 15:00

Break

15:00 – 16:30

intensive and detailed factory tourAll

16:30 – 17:00

Quality requirements for a successful operation

Philippe Bernard

17:00 – 17:30

Question & Answer Session

Gebhard, Christophe and Philippe

17;30

Return to the Hotel Petite France in Strasbourg

41

ERN Achieved quality today

42

Conclusion : ERN meets expectations on KPIs as far as a good
maintenance & supervision is carried out

ERN operational procedure to fit R&D requirements
1) Preventive maintenance-> Systematic CIP &system emptying at weekend & verification of effectiveness (CIP report)-> Systematic mini CIP on Wednesdays/Thursdays-> Filter cleaning systematically 3 times/ week2) Supervision & corrective actions-> Control of key parameters daily (Ozone, UV, pollution ultrasonic bath...) by key user-> Automatic alarm if problem with the system (filter blockages, water rejection too high, UV transmission too
low, stopped ozone generator....)
In case of deviation the key user put the system back in good function. If pollution is suspected, the system will be
emptied, a mini CIP will be run and 1 ATP control will occur within 24h. As emergency solution, the system is switchedto softened water until the root cause is found. Further punctual treatment with biocide is possible in addition-> Supervision of production defects (which could pollute the system) by sterilisation operator
In case of production defect, the system will be stopped immediately-> Systematic water analyse (system outlet) on Friday
In case of deviation, the following procedure will take place :43

ERN operational procedure to fit R&D requirements
3) Escalation procedure in case of excessive bacteria countFrom the Friday analyse, the results are available
4.1 If total bacteria count is between 100 and 10000 UFC/ml : System is switched off
 Analyse root causes and implement corrective actions
 mini CIP and ATP control every day until the results of bacteria count. Biocide treatment possible

4.2 If total bacteria count is above 10000 UFC/ml or another parameter is above 1 : System is switched off
 PRIMP process is started
 Analyse root causes and implement corrective actions (System cleaning with biocide is possible/required) restart only after a validation with microbiological analysis
 ATP controls every day during 2 weeks

44