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Minimizing product wastage and water consumption in juice concentrate production at Kiviks Musteri AB

Causevic, Ariana LU and Rosenqvist, Johanna LU (2017) KBT820 20171
Biotechnology
Department of Chemistry
Abstract
Kiviks Musteri AB has a vision to maintain a good environmental profile with a sustainable production. To achieve this, the aim is to decrease the product wastage and water consumption. Apart from the increased sustainability, this also leads to an increased income and is essential for the growth of the company. The main aim with this master thesis is to identify and chart the product wastage and water consumption in one production line, line 10, and provide suggestions to how it can be improved.

The studied product categories were juice and still drink concentrates, due to their high product value. The work was conducted according to four steps. The first step included observation and information gathering about the production... (More)
Kiviks Musteri AB has a vision to maintain a good environmental profile with a sustainable production. To achieve this, the aim is to decrease the product wastage and water consumption. Apart from the increased sustainability, this also leads to an increased income and is essential for the growth of the company. The main aim with this master thesis is to identify and chart the product wastage and water consumption in one production line, line 10, and provide suggestions to how it can be improved.

The studied product categories were juice and still drink concentrates, due to their high product value. The work was conducted according to four steps. The first step included observation and information gathering about the production process, the second step focused on the quantification of the product wastage and water consumption while the purpose of the third and fourth step was to evaluate the results and possible implementation of technical solutions.

The results obtained showed that the mixing department contributes to the total product wastage with 8 %, the pasteurization phase with 65 % and the filling department with 27 %. To decrease the product wastage, the main focus should be to minimize the wastage from the pasteurization phase and filling department. In the pasteurization phase the heat exchanger wastage can be minimized by implementation of a refractometer, enabling more product to reach the filling machine. If 70 % of the total wastage from the pasteurization phase for all products in line 10 could be saved, the yearly income would increase with 1.4 MSEK. The total product wastage from the filling machine has a value of 1.04 MSEK/year pointing at the importance of reintroducing this wastage. This can be performed either manually or by implementation of an opening machine.

The specific water consumption for the most commonly produced batch sizes, 10 000-15 000 kg, is 1.66 L/L for a 1+9, 1.82 L/L for a 1+6 and 1.75 L/L for a 1+4 concentrate. The main contributor to the water consumption is the cooling water which adds 1.05 L/L to the specific water consumption. The second largest source is the rinsing and cleaning water which are batch size dependent. The result was that larger batch sizes results in a lower specific water consumption and percental product wastage. The main suggestion to decrease the water consumption is to reuse the cooling water in cleaning and recirculate the cooling water.

The production planning was found to have a great impact on the product wastage and water consumption due to fewer rinsing times and an increased reintroduction of product wastage. The obtained perception is that awareness and knowledge about the environmental impacts could be increased at KM, which could result in decreased wastage and water consumption. A method to raise the awareness is to increase the documentation along the production process.

From the results in this master thesis, KM can take a step further towards reaching their environmental goals. (Less)
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author
Causevic, Ariana LU and Rosenqvist, Johanna LU
supervisor
organization
course
KBT820 20171
year
type
H2 - Master's Degree (Two Years)
subject
language
English
id
8916953
date added to LUP
2017-06-19 15:23:24
date last changed
2017-06-19 15:23:24
@misc{8916953,
  abstract     = {Kiviks Musteri AB has a vision to maintain a good environmental profile with a sustainable production. To achieve this, the aim is to decrease the product wastage and water consumption. Apart from the increased sustainability, this also leads to an increased income and is essential for the growth of the company. The main aim with this master thesis is to identify and chart the product wastage and water consumption in one production line, line 10, and provide suggestions to how it can be improved. 

The studied product categories were juice and still drink concentrates, due to their high product value. The work was conducted according to four steps. The first step included observation and information gathering about the production process, the second step focused on the quantification of the product wastage and water consumption while the purpose of the third and fourth step was to evaluate the results and possible implementation of technical solutions. 

The results obtained showed that the mixing department contributes to the total product wastage with 8 %, the pasteurization phase with 65 % and the filling department with 27 %. To decrease the product wastage, the main focus should be to minimize the wastage from the pasteurization phase and filling department. In the pasteurization phase the heat exchanger wastage can be minimized by implementation of a refractometer, enabling more product to reach the filling machine. If 70 % of the total wastage from the pasteurization phase for all products in line 10 could be saved, the yearly income would increase with 1.4 MSEK. The total product wastage from the filling machine has a value of 1.04 MSEK/year pointing at the importance of reintroducing this wastage. This can be performed either manually or by implementation of an opening machine. 

The specific water consumption for the most commonly produced batch sizes, 10 000-15 000 kg, is 1.66 L/L for a 1+9, 1.82 L/L for a 1+6 and 1.75 L/L for a 1+4 concentrate. The main contributor to the water consumption is the cooling water which adds 1.05 L/L to the specific water consumption. The second largest source is the rinsing and cleaning water which are batch size dependent. The result was that larger batch sizes results in a lower specific water consumption and percental product wastage. The main suggestion to decrease the water consumption is to reuse the cooling water in cleaning and recirculate the cooling water. 

The production planning was found to have a great impact on the product wastage and water consumption due to fewer rinsing times and an increased reintroduction of product wastage. The obtained perception is that awareness and knowledge about the environmental impacts could be increased at KM, which could result in decreased wastage and water consumption. A method to raise the awareness is to increase the documentation along the production process. 

From the results in this master thesis, KM can take a step further towards reaching their environmental goals.},
  author       = {Causevic, Ariana and Rosenqvist, Johanna},
  language     = {eng},
  note         = {Student Paper},
  title        = {Minimizing product wastage and water consumption in juice concentrate production at Kiviks Musteri AB},
  year         = {2017},
}