waste saving fact sheet
Managing waste in
the dairy processing
industry
Introduction
n reducing environmental impacts associated with waste
If you operate a small to medium sized dairy company, then this
fact sheet could help you to:
n improving the reputation of your business and employee
disposal and consumption of limited resources
n reduce input and waste disposal costs
n improve your environmental performance
n be more competitive!
This fact sheet provides practical and cost effective waste
management options that managers can apply to activities such
as: processing; cleaning; monitoring and testing; packaging;
and warehousing.
Some actions offer immediate savings and associated benefits
while others may involve an upfront cost that can be recovered
within a few months or years.
Major waste generating activities
Manufacturers of dairy products generate both solid waste and
waste water, including water (milk water), wash down water,
packaging, waste water treatment sludges and caustic solutions.
Plastic pallets 2%
General (recyclable) 9%
Metal (recycled) 11%
Total plastic (recycled) 13%
Cardboard and paper 64%
Other 0.1%
Wooden pallets 1%
Fig 1 Solid waste generation breakdown – manufacturers of
dairy products
(Source: Dairy Australia, Australian Dairy Manufacturing Industry Sustainability
Report 2007/08)
Benefits of reducing waste
Improving waste management can benefit your business and
the environment by:
n reducing the cost of purchasing materials through improved
efficiency (e.g. avoiding disposal of damaged materials)
n minimising waste treatment and disposal costs (and possibly
generating alternative income streams by finding secondary
markets for recyclable products)
satisfaction through promoting an environmentally
responsible image
n providing a safer workplace through process improvements
and reducing waste handling.
Things to consider when improving
waste management practices
Implementing waste management improvements may require
forward planning and some changes to the way your business
operates. For example:
n Proposed actions, such as adjustments to machinery
settings or recycling systems that change the way wastes
are managed, may need to be discussed with managers,
workplace safety representatives, unions, insurers, investors,
suppliers and customers. This is needed to check that they
suit existing Cleaning-In-Place (CIP) systems and cycle times
and will not impact negatively on food hygiene, safety and
other standards.
n Employee training and awareness may be required to
successfully implement actions and support the introduction of
new equipment or processes (e.g. better segregation of wastes).
n Special licences or permits may be required by your business or
contractors to handle hazardous wastes or to compost on-site.
Monitoring waste generation and disposal, such as checking
collection contractors’ invoices or benchmarking production
against raw material purchases, is important for environmental
compliance, stock control and to measure (and reward!)
improvements.
The costs, savings and payback periods for the waste reduction
options provided below are a rough guide only. They include
estimates of up front costs such as capital, labour and installation,
but do not include ongoing costs unless these are fundamental to
the option itself (e.g. improved maintenance regimes).
The suitability and benefits of each option depend on the
nature and size of your business and the scale of application.
You should also check that they comply with local environment,
safety and other requirements. The waste hierarchy provides a
framework for managing waste: avoid; reduce; reuse; recycle;
and dispose. Waste avoidance generally delivers the best
financial and environmental outcomes.
Managing waste in the dairy processing industry
waste saving fact sheet
$ up to $1,000
$$ $1,000 - $10,000
Process change
$$$ $10,000 - $50,000
Maintenance
Option
Use less water in the wash down process (e.g. use
squeegee mops instead of continuous hosing) to
minimise waste water and control run-off.
$$$$ $50,000+
Equipment / plant upgrade
Cost
$
Payback
Waste
period
hierarchy
Water use,
treatment and
disposal
0-1 year
Avoid
Saving
Recover and treat caustic, surfactants and other
cleaning chemicals for reuse until spent.
$$$
Chemical use
>5 years
Avoid/
Recycle
If CIP is used, the caustic solution may be suitable for
reuse after topping up with caustic, and the final CIP
rinse can be collected and reused for the first flush.
$$$
Caustic use
and waste water
2-3 years
Recycle
Water use
2-4 years
Recycle
Implement a management plan to conserve water and install
water collection and recycling systems for rain and grey water.
$$$$$
Treat waste water for use in irrigation (depending on
the application and salt level) as reuse in the factory
may not be permitted due to food safety regulations.
Consider collecting and treating non-CIP waste
water separately as it is may contain less salt.
$$
Waste water
treatment and
disposal
2-5 years
Recycle
Check if waste water treatment sludge can be composted
at an approved off-site facility. Trial if necessary.
$
Waste disposal
n/a
Recycle
Collect food residues from pasteurising tanks, spill trays
and wash down process for use (and sale?) as animal
feed, in consultation with relevant authorities. Dry waste
may also be suitable for animal feed or composting.
$$
Waste disposal
1-2 years
Recycle
Donate off-spec products suitable for human consumption
(e.g. packaging is unsuitable for sale) to charity. Off
spec food that is unsuitable for human consumption
may be suitable for stock feed or composting.
$
Waste disposal
n/a
Reuse
Collect and recycle shrink wrap, aseptic film packaging and other
freight packaging types via contractors. Purchase raw materials
in returnable, reusable or recyclable packaging where possible.
$
Waste disposal
n/a
Avoid/
Recycle
Keep floor areas dry so that you can use dry cleaning
methods or sweep dry areas before wet washing.
nil
Water use,
treatment and
disposal
n/a
Avoid
Use pressurised water hoses and washing angles
up to 60 degrees to wash down surfaces.
$$
Water use,
treatment and
disposal
2-3 years
Avoid
Install temperature sensors and controls to optimise
temperatures in cool rooms and refrigerators to suit the
various products stored in order to minimise spoilage.
$$
Product use
1-3 years
Avoid
Further information
If you would like further information, or to talk to someone who can help get you started, please contact
Ai Group’s Energy and Sustainable Business Helpdesk on 1300 733 752 or at [email protected]
or visit the Ai Group website at www.aigroup.com.au.
AIG8603