Water and Wastewater Treatment in the Beverage Industry

Water and Wastewater Treatment in the Alcoholic Beverage IndustryDoroy Huyo Pinili Tantengco

1BeerDistilled SpiritsWine

2Beer

Also called malt beveragesProduced from grain fermentationCommonly used grains include: BarleyRiceRyeCornWheatProduction is comprised of FOUR main steps:Brew house operationsFermentationaging or secondary fermentationPackaging

3Distilled SpiritsIncludes:VodkaGinRumWhiskyBrandyPotatoes, sugarcane, molasses and agave are usedWhiskies are produced from fermented grain mashes and aged.Vodkas are produced from fermented grain mashes, but are not aged.Gins are produced from the fermented product, grain neutral spirits (GNS), to which either botanical extracts and/or flavors are added to the GNS and bottled, or dried botanicals (e.g., juniper berries) are added to the GNS to extract their oils and then distilled.Rums are made from fermented sugar cane products, such as molasses.Brandy is an alcoholic distillate or mixture of distillates obtained from the fermented juice, mash, or wine from grapes or other fruit (e.g., apples, apricots, peaches, blackberries, or boysenberries.

4Figure 2. General Production of Distilled Spirits (adapted from Kentucky Bourbon Trail)

Production of Distilled Spirits is comprised of SIX main steps:MillingMashingFermentationDistillationAging or MaturationBottling

Distilled Spirits5Wine

Produced by fermentation of sugars in fruit juices, primarily grape juice.Basic steps in wine production include:HarvestingCrushingPressingFermentationClarificationAgingFinishingBottling

6Table 1. Types of alcoholic beverages

7Alcohol Industry Water Quality8BEVERAGE RAW MATERIALSAGRICULTURAL Ingredients(grains, rye, barley, grapes)CHEMICALS(flavorings, sweeteners)WATERWater is the largest ingredients in beverage products.

In most industrial water, the hardness and the concentrations of chloride or other substances that may cause corrosion are low. Bacteriological, color, disssolved oxygen requirements are minimal.9WATER in Beverage IndustryPOTABLE WATERAlkalinityColorMineral contentPathogensAcidityWATER is treated mainly with granular activated carbon for the removal of chlorine by-products. Reverse Osmosis, separate bed deionizers or mixed bed deionizers may be required to keep water quality consistent for product quality.10It should be clean, clear, and free from bad-tasting impurities such as iron. Water high in lime or iron can interfere with the fermentation process and discolour the final product.Table 2. Recommended quality parameter for treated water (NPCS Board of Consultants & Engineers, 2008)

11Water TreatmentThe food and beverages processing industry:- requires a huge amount of water wherein it uses water for many purposes. - the quality and purity of the water is of primary concern since it is used to make products that will be consumed. - potable water is first treated to soften it and to remove additional minerals.

Water is also used to clean and sanitize floors, processing equipment, containers, vessels, and the raw food products prior to their processing. Hot water, steam, cooling, and refrigeration also require source water.

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Eight major water-using activities in the food- and beverage-manufacturing sector (Alliance for Water Efficiency, 2014):

cleaning and sanitation thermodynamic processes (water is inthe production of steam, hot water and in cooling towers) transportation and cleaning offood products equipment cleaning container (bottles, cans, cartons, etc.)cleaning lubricating can and bottle conveyor belts can and bottle warming and cooling product ingredients

14Sources of Water in Alcoholic Beverage ProductionThe water used in the production of alcoholic beverages is municipal and raw water. Municipal water such as the Metropolitan Cebu Water District (MCWD) is treated to meet drinking water standards . Raw water can either be surface or ground water that is directly taken from the source and has not undergone treatment.

15Sources of Wastewater in Alcoholic Beverage ProductionSince water is mainly used for the cleaning of containers, process equipment and washing, major portion of water used results as wastewater from different sections of the processing plant. The common sources of wastewater in the brewery, winery and distillery are as follows:wastewater from sanitary and employee facilitiesrainwatercooling waterproduction wastewaterwash water (from rinsing and cleaning of process equipment)water from the cleaning of packaging material (bottles)condensatescleaning water (floors)fruit waste (grapes)

16SourceOperationCharacteristicsMash TunRinsingCellulose, sugars, amino acids, ~3000 ppm BODLauter TunRinsingCellulose, sugars, spent grain. SS~3000 ppm, BOD ~10000 ppmSpent GrainLast running and washingCellulose, nitrogenous material. Very high in SS (~30000 ppm). Up to 100000 ppm BODBoil KettleDewateringNitrogenous residue. BOD ~2000 ppmWhirlpoolRinsing spent hops and hot tubProteins, sludge and wart. High in SS (~35000 ppm). BOD ~85000 ppmFermentersRinsingYeast SS~6000 PPM, BOD up to 100000 ppmStorage TanksRinsingBeer, yeast, protein. High SS (~4000 ppm). BOD ~80000 ppmFiltrationCleaning, start up, end of filtration, leaks during filtrationExcessive SS (up to 60000 ppm). Beer, yeast, proteins. BOD up to 135 000 ppmBeer SpillsWaste, flushing1,000 ppm BODBottled washerDischarges from bottle washer operationHigh pH due to chemical used. Also high SS and BOD, esp. thru load of paper pulpKeg washerDischarges from keg washing operationLow in SS (~400 ppm). Higher BODMiscellaneousDischarged cleaning and sanitation materials. Floor washing, flushing water, boiler blow-down Relatively low on SS and BOD. Problem is Ph due to chemicals being used.Table 3. Main Areas of Wastewater Generation (taken from Brewers Association)Treatment of Alcohol Industry Wastewaters18Alcohol industries generate huge amounts of acidic, recalcitrant and colored wastewaters with high organic contentAnaerobic treatment is one of the most commonly applied technologies for alcohol industry effluents with a high treatment efficiency and bioenergy recoveryExamples of Anaerobic reactors:Upflow Anaerobic Sludge Blanket (UASB) ReactorExpanded Granular Sludge Bed (EGSB) ReactorUpflow Anaerobic Filter (UAF)Upflow Fixed Film Column (UFFC)Upflow Fluidized Bed (UFB)Down-flow Fluidized Bed (DFB)Anaerobic Hybrid Reactor

19Parameters to Monitor Wastewater Effluent QualityChemical ParametersSolids content (TS, VS, FS, TSS, VSS, TDS)pH (hydrogen-ion concentration in water)DO (the higher the DO is, the better the water quality is)Oxygen Demand (BOD/COD)Nitrogen & Phosphorus (TN, TKN, TP)Total Organic CarbonHeavy MetalsWastewater Characteristics

Table 4. Wastewater Characteristics of Alcoholic Beverages21Treatment of Brewery Wastewater

22Treatment of Winery Wastewater

23Distillery Wastewater or stillageAnaerobic digestion is widely accepted as first treatment step in distilleries.Typical BOD/COD ratio of 0.8-0.9 indicates suitability of distillery wastewaters for biological treatment and biochemical energy recovered is 85-90% as biogas(Mohana et al., 2007).A list of common types of anaerobic reactors used for distillery effluent treatment is shown in Table 5. Table 5. Anaerobic methods employed for distillery effluent treatmentTreatment of Distillery Wastewater

Parameters that affect the quality of water and wastewaterThe main parameters to be evaluated in the assessment of water quality are as follows:Appearance and taste. Good quality water is clear, colourless, tasteless, and free from turbidity and soluble solidsNitrates. Fertilizers and decaying animal matter can cause nitrates to be present in water. Nitrates should be kept to a minimum in potable waters.Chloride. High level of chloride in water, i.e. 100 mg/L, may be an indication of pollution by sewage, or contamination by sea water.Organic content. Various acids, e.g. humic acid and fulvic acid, polysaccharides and microbial contaminants, can be present in water in very small amounts.Microorganisms. Microorganisms of all types can be found in water from all natural sources. High bacterial counts indicate polluted water, and the presence of coliform bacteria indicates faecal contamination.Phosphates and Silicates. The phosphate of water is representative of the residues of the decomposition of sewage or vegetation, and should not be present in good quality water levels greater than 0.05 mg PO4/L.Trace metals. Water that is polluted by industrial effluents may contain small amounts of various metals. Although they may not be toxic at the levels found, they can cause problems such as brown deposits.Chlorinated substances. Water from the main supply is generally treated with chlorine prior to entering the supply steam, as a means of maintaining sterility. Chloramines give water a medicated taste.Pollution indicators. It is totally impractical to check water for every potential pollutant. However, the presence of certain parameters can give an indication of the type and sources of pollution present

25 Indicators for pollutants in water IndicatorPollutantColiform bacteria especially E. ColiIntestinal pathogens due to faecal contaminationYellow/brown colourInorganic chemicals, organic debrispH lower than 6.5Free CO2pH higher than 8.5Carbonates and bicarbonatesFree ammoniaSewage and/or decaying vegetable matterNitritesSoil bacteria, sewage or manureNitratesFertilizers, decaying animal matterHigh levels of chloride e.g. 100 mg/LSewage or seawaterTrace metalsIndustrial effluent26Wastewater Statutory RequirementsChemical oxygen demand: maximum of 200 ppmBiochemical oxygen demand: maximum of 100 ppmSuspended solids: maximum of 150 ppmpH: 6-9

Referenceshttp://www.formatex.info/microbiology2/988-999.pdf?_360safeparam=315193828http://www.westfalia-separator.com.sg/v2/applications/fluids-water/brewery-waste-water.htmlhttp://www.westfalia-separator.com.sg/v2/applications/fluids-water/waste-water-in-wineries.htmlhttps://repositorium.sdum.uminho.pt/bitstream/1822/6012/1/Brewery_and_Winery_Wastewater_Treatment%5B2%5D.pdfhttp://extension.psu.edu/food/enology/beer-and-spirits/distilled-spirits/notes-from-the-kentucky-bourbon-trailhttp://environmentclearance.nic.in/writereaddata/Form-1A/HomeLinks/TGM_Distillery_010910_NK.pdfhttp://www.brewersassociation.org/attachments/0001/1517/Sustainability_-_Water_Wastewater.pdfhttp://www.ghd.com/PDF/Wastewater%20Treatment%20for%20Wineries.pdf

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