IMPEL FOOD PROJECT

QUESTIONNAIRE

IMPEL FOOD PROJECT [Integrated pollution control, compliance and enforcement of EU Environmental legislation to Industries (IPPC and non IPPC) of the food production/processing sector]

QUESTIONNAIRE QUESTIONNAIRE
PART IIa:: MILK INDUSTRY PART IIa MILK INDUSTRY
1.

Data of the person completing Part IIa of the questionnaire (IF THE SAME PERSON AS FOR
PART I, DO NOT COMPETE ALL THE DATA; JUST WRITE NAME & DATE AND SIGN): __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ Date:

Name: Position: Institution: Address: Phone: Fax: e-mail: Country

Signature: General Notes: i) Throughout the Questionnaire, if and when applicable, please indicate clearly the source of the information provided, using the following initials:

E: Estimation (personal opinion, based on experience/expertise) R: Data from official Record (e.g., Registry, Departments Database, Official Publication, etc.) D: Available Data from any other source (e.g., an internal report, a project, your files, etc.) PC: Personal Communication with a competent person (a colleague, a consultant, etc.) Also, where applicable, and especially in questions where your comments are solicited (e.g.,6i., 6ii, 9) use one of the two following initials: PO: Personnal Opinion OP: Official Position. This should not be seen too formally, i.e., it does imply a formal national position. It should simply be used when the comments or suggestions expressed by the person completing this form are in line with existing official documents of any type (e.g. guidelines, reports, results of a project, Ministerial decisions or circulars, etc.). The Guidelines developed for the Milk Industry by The World Bank Group have been used as a general reference document in the preparation of this part of the Questionnaire. Ref.: Industry Sector Guidelines: Dairy Industry, The World Bank Group, 1998 [http://wbln0018.worldbank.org]. Also: The World Bank Technical Background Document "Pollution Prevention and Abatement: Dairy Industry", the World Bank, Environment Department, 1996. ii) Industry description: The milk industry involves processing raw milk into products such as consumer milk, butter, cheese, yoghurt, condensed milk, dried milk (milk power), and ice cream, using processes such as chilling, pasteurisation, and homogenisation. Typical by-products include buttermilk, whey, and their derivatives. PART-IIa (MILK) - 1

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QUESTIONNAIRE

2.
i.

Overview of the Milk Industry sector in your country

Please fill in the table below (annual production of milk products, etc.) 1:
Total annual production (million lt or million kg) Total value of product (million EURO/year)
TO BE FILLED ONLY IF DATA ARE READILY AVAILABLE

PRODUCTS

Number of plants (the total should be filled only if there are no data for the first 2 columns) IPPC Non-IPPC Total (or large)1 (or SME)

Consumer milk* Condensed Milk* Dried milk (milk powder)** Cheese** Yoghurt** Butter** Ice cream*
TOTAL***

* Unit to be used: million lt, ** Unit to be used: million kg; IF DIFFERENT, PLEASE, SPECIFY THE UNITS USED. *** The total number of plants in the country should generally be less than the sum of the individual lines above. This is because one plant may be producing more than one product(s)2. The total number of IPPC and non-IPPC milk industries in the country should have been reported in Table 3.a of Part I. However, if a different threshold/categorisation is used the above table, so different total number of plants for IPPC (or large) and non-IPPC (or SME) apply here, please fill in the last row here too. Year for reported data:

Source for reported data: If a different threshold than IPPC (200 lt milk received/day) is used, please specify that threshold: ..

3. Water use - Quantities of waste produced Waste characteristics

i. Water use (total consumption of water in the plant)
According to the bibliography, relatively large amounts of water are used in the milk industry (ranging from 0.7 to 4.5 lt water/lt of processed milk). If such data are available for your country (e.g. from permits granted to industries or from another source, such as report, registry data, etc.) please complete the following table. In the case that no data are available but there are rules of thumb used in the permitting of the milk industry, please use the latter to fill in the table. Product (operation) Condensed milk (Milk bottling) Cheese Ice cream Butter Other Other Other * Tick in one of the 2 boxes: Water used (lt water/lt of processed milk)* Mean value (e.g. 2.2) Range (e.g. 1.0 - 4.3)

a) Reported data (from record, studies, etc.)

or, b) Rule of thumb used in permitting

Comments (if any): . ...

1

Data or estimation. If you use a different threshold for implementing IPPC or, if you currently have a different system for categorising milk industries as large and Small & Medium (Enterprises) for permitting and data reporting purposes (see also Table 4a, quest. b of Part I), use the latter, but specify the threshold at the bottom of the table. If one installation/company is producing more than one of the listed milk products, it should be counted in all applicable product types. 2 For instance, if there are only 2 plants in the country that fall under the scope of IPPC, and one of them produces the three types of milk and ice cream and the other produces consumer milk, cheese and yoghurt, the first 7 rows of the IPPC column will have the values: 2, 1, 1, 1, 1, 0, and 1. If the last (eighth) row must be filled, it should have a value of 2. PART-IIa (MILK) - 2

IMPEL FOOD PROJECT QUESTIONNAIRE ...

PART-IIa (MILK) - 3

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QUESTIONNAIRE

ii.

Liquid effluent characteristics (before treatment)

Milk effluents have relatively high organic load. Bibliographical data are available for the typical values of the key effluent parameters in the milk effluent (e.g. WHO/REP/GETNET/93.1-A, Economopoulos, 1993). Please fill in the table below with the data that are applicable for your country (either from record, or as a rule of thumb)*: Uncontrolled source ** Receiving station - cans - bulk Fluid products Cultured products Butter Cottage cheese with whey recovery Cheese with whey recovery Cheese without whey recovery Ice cream Condensed milk Powder production Yoghurt Other Other: .. Generic estimation (tn milk equivalent) * Tick in one of the 2 boxes: a) Reported data (from record, studies, etc.) or, b) Rule of thumb used in permitting ** As used in the Model for Liquid Waste Inventory for Milk Industries of WHO, 1993; leave blank the rows for which no data is available (and add new sources in the other .- if necessary). Volume of effluent (m3/tn product) BOD COD TSS Tot-N Tot-P (kg/tn product) [tn product = metric tons of product] or (ppm = mg/l) [please delete the unit that is not applicable]

4a.

Emission limit values [Art. 9.3 of IPPC Directive]: Liquid effluent

Please fill in the table to indicate what are the typical quality requirements for the treated effluents of the milk industry (before discharge to municipal sewers or receptors). If the relevant permit conditions are set on a case by case basis, give either typical values (that are most commonly used), or a range or fill in more than one column (if applicable): Parameter Effluent limit value (mg/l) TO BE FILLED ONLY IF NECESSARY (in that case, please specify) Effluent limit Alternative Alternative Alternative value range3 effluent limit effluent limit effluent limit (mg/l) value3 value3 value3 (mg/l) (mg/l) (mg/l)

PH BOD5 COD (Cr or Mn)* Total suspended solids Oil and grease Total nitrogen Total Phosphorus Temperature increase (oC) Coliform bacteria (total count, or /100ml, .)* Other . * Circle the appropriate parameter or unit or specify the appropriate units.
3

If applicable (i.e., if more than one set of effluent limits are used in your country). For instance, you may want to give the effluent limits for discharges in water receptors in the first column and the corresponding limits for discharge in a sewerage system in one of the last three columns (alternative). Or, you may give typical Regional limits, if significantly different. PART-IIa (MILK) - 4

IMPEL FOOD PROJECT

QUESTIONNAIRE

4b.

Emission limit values: Air emissions

With the exception of milk powder production, where a limit may be set for particulate matter (dust), no special air emissions are associated with the milk industry. Of course, the general emission limits for boilers will be applicable for any burners used in the installations. Please fill in the table below, with the air emission limit values that are applicable in your country (please fill in the appropriate unis, in the second row; e.g. mg/Mm3 or mg/tn product): PM* %CO2 O2 Units mg/Nm3 Milk powder .. .. Any milk industry/ Boilers * PM = Particular Matter (Total Suspended Particles) CO NOx SO2 Shoot Odour

5. Treatment technologies
Treatment technologies used in the milk industry are generally limited to: treatment of liquid effluent (pre-treatment and biological treatment), odour control in some cases (where cheese is stored or melted) and dust control at milk powder plants. Please fill in the table shown below, based on the situation in your country: Please check (tick) here, if widely applicable Please check (tick) here, if it is normally included as mandatory in permit conditions IPPC* Non-IPPC Please check here if problems are associated with the use of this technology in your country (e.g. malfunction) IPPC* Non-IPPC

Treatment technologies a) Liquid effluent treatment Pre-treatment - screening - flow equalization - neutralization - air flotation (fats & solids removal) - other . - other . Biological treatment - Extended aeration activated sludge - Activated sludge treatment. - Land treatment or pond systems - Trickling filters - Rotating biological contactors - Anaerobic digestion - other - other b) Odour control - Ventilation - Scrubbing - other . - other . c) Dust control - fabric filters (at milk powder plants) - other . d) Other .. - other .

IPPC*

Non-IPPC

* If a different threshold than IPPC (200 lt milk received/day) is used, please specify that threshold: .. Comments (if any): . PART-IIa (MILK) - 5

IMPEL FOOD PROJECT

QUESTIONNAIRE

6.

Pollution Prevention and Control Practices

i) Good practices for pollution prevention. The table below presents some good pollution prevention practices (World Bank, 1998). Based on your experience and on the situation in your country, please comment on those practices and also include any other practice(s) that you believe to be important [see also related question 8.ii.] Please rank the practices by priority (i.e. 1, 2, ; 1 being the most important from your point of view. Please check here (tick) if the practices are generally applied by the milk industry in your country Please check here (tick) if the practices are mandatory for the milk industry in your country For industries For falling under the Non-IPPC scope of IPPC* (or, generally, large installations)

Good pollution prevention practices

a) World Bank, 1998: 1. Reduce product losses by better production control. 2. Use disposable packaging (or bulk dispensing of milk) instead of bottles where feasible. 3. Collect waste product for use in lowergrade products such as animal feed where feasible without exceeding cattle feed quality limits. 4. Optimize use of water and cleaning chemicals. Recirculate cooling waters. 5. Keep effluents from sanitary installations, process, and cooling (including condensation) systems segregated. This facilitates recycling of wastewater. 6. Use condensates instead of fresh water for cleaning. 7. Recover energy by using heat exchangers for cooling and condensing. 8. Use high pressure nozzles to minimize water usage. 9. Avoid the use of phosphorus-based cleaning agents. 10. Continuous sampling and measuring of key production parameters in order to allow production losses to be identified and reduced, thus reducing the waste load. b) Other (please specify, below): 11. Use of CHP (Combined Heat Plants) 12. 13. 14. 15. 16. * If a different threshold than IPPC (200 lt milk received/day) is used, please specify that threshold: ..

IF NECESSARY, ADD LINES IN THE TABLE (if filled electronically) or AN EXTRA PAGE!
PART-IIa (MILK) - 6

IMPEL FOOD PROJECT

QUESTIONNAIRE

ii) Product losses

a) The following table presents product losses that could be considered as target production losses in a well-run milk installation (World Bank, 1998). Based on your experience and on the situation in your country, please comment on the reported values and propose any additions or modifications that you consider to be appropriate. Do you consider the values on the left as appropriate? If YES, check (tick) in the boxes below; If NO, please write the values that you would suggest as more appropriate Milk Fat Whey

Product losses (%)*

Operation Milk Fat Whey Butter/transport skimmed milk 0.17 0.14 N/A Butter + skimmed milk 0.60 0.20 N/A powder Cheese 0.20 0.10 1.6 Cheese + whey evaporation 0.20 0.10 2.2 Cheese + whey powder 0.20 0.10 2.3 Consumer milk 1.9 0.7 N/A Full cream milk powder 0.64 0.22 N/A Other. Other. Other. Other. Other. * Expressed as percentage of volume of milk, fat or whey processed. N/A = Not Applicable.

Do permit conditions normally include provisions for product losses?

a) For IPPC installations? (or, generally, large) b) For non-IPPC installations (small & medium)? YES YES NO NO

7.

Problems encountered (for IPPC and non-IPPC)

IPPC* Non-IPPC Clarifications/Comments (if any)

i) Which is the frequency of inspections in the milk installations in your country? (Please check tick- as appropriate) Frequency: Monthly? Annually? Other? (please specify) ..

* If a different threshold than IPPC (200 lt milk received/day) is used, please specify that threshold: .. Does the competent authority have an annual programme of inspections? YES NO

ii) What are the main problems identified during inspections? Please check if applicable, and rank them by order of incident frequency. [i.e., 1, 2, 3, ; 1 being the problem most frequently encountered] YES 1. Non compliance with effluent discharge limit values? 2. Illegal connections to sewerage system? 3. Non compliance with air emission limit values? 4. Inadequate solid waste management? 5. Pollution of the environment locally? 6. Noise (from activities within the installation) 7. Local traffic problem (and related noise) 8. Other, please specify .. 9. Other, please specify .. 10. Other, please specify .. Rank# Clarifications/Comments (if any)

PART-IIa (MILK) - 7

IMPEL FOOD PROJECT iii) Complaints made by the public against milk industry installations a) Is there a written record kept with complaints of the public to the competent authority?

QUESTIONNAIRE

YES

NO

b) If YES, what is the update rate (i.e. how often is it updated)? . c) What was the number of complaints during the last 5 years? (or any other recent period of time for which data exist; in that case, specify period; approximate number or estimate is OK; no need for exact figures): .... c) What are the main reasons for complaints? Please check if applicable, and rank them by order of incident frequency. YES 1. 2. 3. 4. 5. 6. Emissions to water receptors? Emissions to air? Noise? Odour problems? Non conformity with compliance notices and warnings? Local environmental pollution due to geographical location of the plant in combination with the local environmental conditions (e.g., coastal areas)? 7. Local traffic (because of the industry fleet of vehicles transporting raw material and products) 8. Other? (please specify) 9. Other? (please specify) . d) What percentage of the complaints is shown to be justified? iii) a) Sanctions What is the range of possible fines, in case of non-compliance with the (environmental) conditions of the permit? [i.e., range of fines foreseen by legislation].(give amounts in EURO) Rank# Clarifications/Comments (if any)

b) What is the range of typical fines, in case of non-compliance with the (environmental) conditions of the permit? [i.e., of fines imposed in practice; for instance, use records of fines imposed to milk industries over the last 5 years, if available, to determine actual typical fines; do not distinguish by type of offence]....(EURO) c) What other sanctions are normally imposed to milk installations for non-compliance? [in practice!] .. iv) What is the expected impact (if any) of the implementation of the IPPC Directive on the Milk industry of your country, with respect to: [do not repeat information already covered, directly or indirectly, in Part I ; e.g., sections 4b, 7] a) Permitting b) Inspections. .. c) Monitoring of compliance.. .. d) Enforcement . .. Special issue: How are discharges to municipal sewers taken into account in the integrated approach required by IPPC? .. .. Comments (if any): . .. .. .. ..

PART-IIa (MILK) - 8

IMPEL FOOD PROJECT

QUESTIONNAIRE

8. Production processes - Key issues Suggestions

i. Typical Milk industry processes If readily available, please attach to the questionnaire Flow Charts of the Production Process that show schematically the various stages of one or more Milk Industry processes that are typical for your country (e.g., condensed milk production, cheese production, yoghurt production, production of more than one milk products in a single plant, etc.). ii. Keys issues with respect to production processes/parameters Please indicate the Milk industry production stages or parameters that you consider to be important (key stages or key parameters) for any reason that relates to pollution control, compliance and enforcement of EU Environmental legislation to Milk industries (IPPC and non IPPC). For instance, suitability of or need for implementation of Best Available Techniques (BATs) may be one of the criteria. The list of production stages shown below is indicative rather than exhaustive (and processes that are similar for more than one milk products, e.g., for milk production and butter production) are only shown once. Please add any other stage or parameter in an extra line (or use an extra sheet if necessary). Production stage or Production parameter a) Milk production Receiving station Storage of milk received Homogenisation Cream separation Milk powder drying Condensing Pasteurisation Packaging Standardisation/additives packaging Chilling Sterilisation Storage of products Distribution of products b) Butter Mixing Neutralisation of cream Washing Fat content regulation Buttermilk removal Kneading .. c) Yoghurt Milk clearing Fermentation - straining Additives . d) Cheese Thickening Whey removal Maturing Separation Hardening Molding Heating Mixing straining .. .. Tick here Key issue related to the stage/parameter and comments/remarks

PART-IIa (MILK) - 9

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QUESTIONNAIRE

9.

Additional Comments (if any)

Write here any comments or remarks that you might have on any of the issues that have been addressed in this part of the questionnaire (Part IIa). Furthermore, please comment if there are any issues that were not addressed here but you consider them to be important and you feel that they should be addressed in the Workshop to be held in Athens. ..

Contact persons (for questions/clarifications): Natasha Kotronarou: fax./tel.: +301-3490154, e-mail: natasha@env.meteo.noa.gr Katerina Iacovidou, fax./tel.: +301-8652493 PLEASE RETURN TO Natasha Kotronarou NOT LATER THAN 16/2/2001, THANK YOU!

PART-IIa (MILK) - 10