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Reference project
Dairy factory in Italy installed multiple technologies from Mellifiq for both odor control and upgrading CIP
Introduction.
Dairy factory clears odor problems and upgrades CIP process with Mellifiq advanced treatment solutions
This time, we are helping out a dairy factory that was founded in 1931 in the northern Italian region of Lombardy.
It has been producing dairy products continuously for the past 90 years, even during the Second World War. Continuous improvement is one of the core values of the company: it was the first dairy factory in Italy to incorporate UHT pasteurization into their production process.
The problem.
As the factory was built not far from the current city center, it is surrounded by a relatively dense residential area. Dairy products may involve lactic fermentation among other processes and these processes result in residues emitting odorous compounds. The residues are discharged into the factory’s process water and the odorous compounds enter the ventilation system. Then, they are subsequently released into the surrounding environment.
In this case, the odor problem resulted in both the neighbors and the municipality filing complaints against the dairy factory.
The complaints made the company management determined to start looking for an efficient odor control solution. As a company with strong sustainability values, they were aiming for a solution that could solve the odor problem and lower the environmental impact of the production at the same time.
In addition to solving the environmental issue caused by odors, the company also decided to look for a way to reduce the use of fresh water. They were hoping to be able to reuse the wastewater for their equipment clean-in-place (CIP) process by treating it.
The solution.
Since the dairy factory required a sustainable, effective and innovative solution, they chose us at Mellifiq for this project. In our turn, we delivered a system consisting of an Ozonetech RENA Pro B4 turn-key ozone system and two Nodora ADS A-series.
The system is connected to the factory’s ventilation system, where it treats the air in two stages before releasing it into the environment.
In the first step, ozone is injected into the ventilation duct, breaking down most of the odorous compounds. Afterwards, the remaining air passes through the Nodora adsorption modules, where remaining odorous compounds are adsorbed by the activated carbon.
As mentioned before, the Italian dairy factory was also looking to improve their clean-in-place process by reusing their treated wastewater for it. Ozone treatment can decontaminate wastewater from the dairy production to the point that it can be reused to clean the production equipment.
For that reason, the company also placed a second order, going for an Ozonetech RENA Vivo B4 ozone system from Mellifiq, accompanied by automation equipment (Ph sensor, ORP sensor). Our solution is fully compatible with the EU initiative Industry 4.0, possessing a high level of automation and several possibilities for remote monitoring.
Odor control
Nodora ADS A-series: 1 160 x 760 x 2 070 mm
Ozonetech RENA Pro: B4: 800 x 600 x 1800 mm
Closed cooling system: 450 x 490 x 720 mm
Water reuse system
Ozonetech RENA Vivo B4: 270 x 120 x 80 cm
Mellifiq delivery
Ozonetech RENA pro B4 ozone system, 2 Nodora ADS A-series cabinets and closed cooling system (odor control solution); Ozonetech RENA Vivo B4, along with automation (pH and ORP sensors) and closed cooling system (CIP water treatment solution)
Capacity
11,000 m3/h for the odor control solution, up to 300 m3/h for the CIP solution.
Evaluation.
In the preliminary evaluations, our odor control solution achieved a removal rate of 90% when it came to odorous compounds after the installation. In addition, we achieved over 90% lower organic contamination and disinfection levels in the water reuse system.
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