gedney foods company - mntap€¦ · water & salt conservation gedney foods company ryan...
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Water & Salt Conservation Gedney Foods Company
Ryan Venteicher
Advisor: Paul Pagel
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Company Overview
• Pickling Plant
− Fermented
− Fresh Pack
− Relish, Condiments, Preservatives
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Motivations for Change
• Doubled production in past two years
• Conserve well water
• Limited capacity wastewater disposal
system
GEDNEY
A
B
C
MN River
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Reasons for MnTAP Assistance
• Audit water usage
• Investigate water/salt conservation
methods
• Evaluate costs and be a part of
implementation processes
• Investigate impact of salt on wastewater
system
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Approach
• Understand
processes
• Talk with staff
• Discuss with other
companies
• Monitor Processes
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Pasteurizers
• A-line: Hot Water
• B-line: Steam
A - line B - line
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Pasteurizers (cont.)
• Opportunity
− Large amount of hot overflow water from
B-line
• Solution
− Redirect B-line overflow to be used as
makeup water for A-line
• Savings
− 22,000 therms $10,600/year
− 3,085,000 gallons water
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Fermentation Tank Farm
• ~150 tanks/year
• 360,000 lbs. salt & 360,000 gallons
of water sent to waste stream
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Fermentation Tank Farm:
Reuse
• Opportunity − Fresh brine made for each tank
• Solution − Reuse brine
• Savings – 213,400 lbs. salt
– 214,500 gal. water
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Reuse Brine
Cucumbers
Fermentation
& Storage
Cucumbers
Waste Brine
Waste
Production
Current
Fermentation
& Storage
Cucumbers Cucumbers
Fresh Brine
Lixate
Waste
Production
Waste Brine
Reuse
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Fermentation Tank Farm:
Reduce • Opportunity
− Stored at a 12% salt level
• Solution
− Modify tanking procedures
so product can be stored at
a 7% salt level
• Savings
– 364,500 lbs. salt
– 537,000 gal. water
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Recommended Changes
Recommendations Annual energy saved
Lbs. of salt reduced
Water savings (gpy)
Annual Savings
B-line past. overflow to A-line
22,000 therms
N/A 3,085,000 $10,600
Reuse brine N/A 213,400 214,500 $21,340
Reduce final salt in brine
N/A 364,000 383,000 $36,400
Total 22,000 therms
460,500 543,200 $56,650
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Additional savings
• Water leaks
− 2,220,000 gallons/year
• Water conservation culture
− Sections in “The Crunch”
− Communication
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Personal Benefits
• Free pickles on Thursdays
• Real-world engineering experience
• Wastewater tests in lab
• Environmental regulation
• Data analysis
• Cost/benefit analysis
• Communication with staff
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Questions?