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CGPP Report 2004/13

AT A GLANCE
Acid casein is a high-protein food ingredient
derived from milk and used in the production
of many food and drink products including
nutritional drinks, cream liqueurs and dessert
toppings. All acid casein processing plants use
a certain amount of food grade hydrochloric
acid (HCl) to facilitate the precipitation of
casein from skim milk: this is a standard part
of the production process.
As part of its involvement in the Cleaner
Greener Production Programme (CGPP),
Lakeland Dairies at Killeshandra, Co Cavan
decided to review its usage of HCl and assess
whether it would be possible to modify, or
reduce its level of usage.
Using theoretical models established by dairy
researchers, the results of the study carried
out by the companys CGPP project team
suggested that the amount of HCl used could
potentially be reduced by up to 20%.
Laboratory trials carried out at the plant
showed that a 15% HCl reduction would also
decrease the protein content of the casein
curd by up to 100 tonnes per year.
Decreasing the protein content by this
amount was not an option for the company:
therefore the issue of modifying HCl usage
required further detailed study. Following an
audit, which was carried out as part of the
CGPP project, Lakeland Dairies achieved a
number of cost savings in milk processing and
on-site wastewater treatment.

LAKELAND DAIRIES

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Lakeland Dairies is Irelands second largest

dairy processing co-operative. It has an
annual turnover in excess of 411 million.
The Group operates in fifteen counties, on a
cross-border basis, and processes more than
700 million litres of milk annually at several
major facilities in the Republic of Ireland and
in Northern Ireland. It produces a complete
portfolio of dairy foodservice products and
highly functional food ingredients, which
are used by manufacturers of leading food
brands throughout the world. As well as
supplying dairy products for the Irish
market, Lakeland Dairies also exports dairy
products to the UK, Europe, North and
South America, Asia and Africa. The
processing facility at Killeshandra is involved
in the production of UHT products, casein
and whey protein concentrate and in the
manufacture of ice cream.

A REDUCTION IN HCL USAGE LEADS TO

SAVINGS FOR DAIRY
AIMS OF THIS PROJECT
Acid casein is a high-protein food
ingredient derived from milk and used in
the production of many food and drink
products including nutritional drinks, cream
liqueurs and dessert toppings. All acid
casein processing plants use a certain
amount of food grade hydrochloric acid
(HCl) to facilitate the precipitation of
casein from skim milk: this is a standard
part of the production process.
The main aims of this project were to:
Set up a monitoring programme
designed to quantify Lakelands existing
usage of HCl per tonne of casein
produced.
Compare Lakeland Dairies usage
figures with the theoretical levels that
have been suggested by dairy
researchers.

was designed primarily to yield

environmental benefits.
Finally, the CGPP project team set out
to explore the feasibility of using a wide
range of new, cleaner technology
options in all other aspects of its food
processing and on-site waste treatment
operations.

PROJECT DESCRIPTION
In order to quantify the exact amount
of HCl being used during the production
process, flow meters were installed on
pipelines, and levels of flows were
recorded. The results of this monitoring
procedure were then fed into a
computer programme, which calculated
the precise quantities of HCl being used
during each stage of the production
process.

Modify the companys existing

manufacturing processes in order to
reduce its HCl requirement, and bring it
into line with the lowest theoretical
requirement.
As well as standing to gain significant
savings as a result of reducing expenditure
on the purchase of HCl, the company also
set out to achieve a reduction in the level
of chloride ions which are part of the
typical waste stream handled by the onsite wastewater treatment plant: this move

Fig 1. Milk storage silos at Casein Plant.

BETTER BUSINESS IN A BETTER IRELAND

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The next stage of the CGPP project involved correlating HCl

usage rates and comparing those figures with theoretically
ideal usage rates. Based on the theoretical models
established by dairy researchers, it was proposed that the
amount of HCl used by the company could, potentially, be
reduced by up to 20%.
An extensive range of laboratory trials then began in order
to:
Determine the effects of varying levels of HCl usage on
the end-product.
Observe and analyse the effects that occur when levels
of HCl are reduced, and assess the impact of that
reduction on the ability to process the curd, and on the
composition of the end-product.
Determine the optimum amount of HCl required for
commercial operations.
This stage of the project also involved carrying out a
comprehensive programme of chemical analysis on the
casein produced: the results of these analyses and
assessments were then studied in depth.

SECONDARY AIM
A secondary objective of this project was to carry out an
assessment of overall operations at Lakeland Dairies, with a
view to ensuring that a cleaner greener approach to
processing was implemented across the entire operation
and, in particular, in relation to the reduction of waste from
product/water interfaces and from Cleaning in Place (CIP)
interfaces.

OBSERVATIONS
The project teams laboratory experiments showed that it
was feasible to produce a casein curd of the correct texture
at a higher pH, (i.e. if reduced quantities of HCl were used).
By adjusting the coagulation temperature, it was possible to
obtain a suitable curd at a pH range of between 4.4 and
5.2. The precise temperature level required to achieve this
varied depending on the composition of the milk. The
teams laboratory trials also indicated that when HCl usage
rates were reduced by approximately 15%, the amount of
protein recovered decreased by approximately 1%-2%.
This issue of protein recovery was critical: any reduction in
protein recovered would have a negative effect on the
economic viability of the casein process, as it would reduce
the yield recovery. It was essential therefore to establish
where the protein was being lost during the production
process and how it might be recovered.
In order to address this particular issue, a new batch of
laboratory trials began, which involved taking the
chemical/physical characteristics of casein samples produced
in a laboratory setting and comparing them with everyday
production samples from the Killeshandra casein plant. The
researchers also carried out tests to identify what had
caused the decreased protein content and how this might
have been prevented. Work in this area is ongoing.

ACHIEVEMENTS
Because of the financial consequences that would accrue
from casein protein loss, it was not possible to implement
acid optimisation across the full-scale production process
within the 12-month timeframe allotted to this project.
However, work is still ongoing, and the project team is
continuing to advance its original research and to overcome
the issue of protein loss.
A number of benefits have accrued as a result of Lakeland
Dairies participation in this project. They are as follows:
A conductivity probe installed on the dilute acid line has
improved control of dilute acid strength. This has
eliminated the incidence of process failures due to acid
dosage miscalculations, thereby saving the company
approximately 11,000 a year.

Fig 2. Extensive laboratory work was an important element

of the project.

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The team carried out an intensive investigation of all

product/water/Cleaning in Place (CIP) interfaces, with
the aim of reducing waste. Significant waste reduction
has been achieved, and this has proved to be very
successful both in terms of economic savings and in
terms of its effect on staff motivation and workplace
morale.
In the UHT plant, emissions to the wastewater treatment
plant have decreased by 30% through improved
management.
An advanced system entitled CHEMTRACK was installed
in the UHT plant: this system uses modern telemetry to
monitor usage of detergents. As a result of analysing the
data provided by CHEMTRACK, Lakeland Dairies has
achieved year-on-year savings of 65,000 in detergent
usage in the Killeshandra UHT plant.
The company has installed an on-line product-loss
detection system to monitor all material being sent to the
wastewater treatment plant: this measure is aimed at
investigating whether it is possible to reduce the volume
of material being disposed of in this way.

LESSONS
The involvement of a dedicated, cross-functional project
team with a wide range of expertise worked well for
Lakeland Dairies. In particular, individual team members
benefited from exposure to the experience and skills of
colleagues. The project also increased overall awareness of
the importance of controlling waste and implementing
cleaner production practices across all aspects of on-site
operations.
The research work relating to casein production was far
more complex than had been anticipated at the outset. The
team believes that if this were to be repeated at some
future date, the involvement of a professional research body
would be beneficial. In addition, the CGPP team believe
that a pilot project (as opposed to laboratory trials) would
be a more suitable methodology for this type of research.

MORE INFORMATION
For more information on this project contact:
Rory Farrell
Group Environmental Co-ordinator
Lakeland Dairies
Killeshandra
Co Cavan
Tel: 049-436 4200
Fax: 049- 436 4215
E-mail: rory.farrell@lakeland.ie
Website: www.lakeland.ie

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CLEANER GREENER
PRODUCTION IS
the application of integrated preventive environmental
strategies to processes, products, and services to increase
overall efficiency and reduce risks to humans and the
environment.
Production processes: conserving raw materials and
energy, eliminating toxic raw materials, and reducing the
quantity and toxicity of all emissions and wastes
Products: reducing negative impacts along the life cycle
of a product, from raw materials extraction to its
ultimate disposal.
Services: incorporating environmental concerns into
designing and delivering services.

CLEANER GREENER
PRODUCTION REQUIRES
new attitudes, better environmental management, and
evaluating available technology options. We need to take
good environmental practice to the stage where it is an
inherent part of any business operation.

HOW IS CLEANER GREENER

PRODUCTION DIFFERENT?
Much of the current thinking on environmental protection
focuses on what to do with wastes and emissions after they
have been created. The goal of cleaner, greener production
is to avoid generating pollution in the first place.
This means:

Better efficiency
Better business
Better environmental protection
Lower costs
Less waste
Less emissions
Less resource consumption

WHY IS THE CLEANER

GREENER PRODUCTION
PROGRAMME BEING RUN?

The long-term goal is to ensure that cleaner, greener production

becomes the established norm in Ireland. The programme seeks to
promote environmentally friendly business through increased
resource productivity, waste reduction, recovery of materials,
improved efficiency in a product value chain, energy management,
and a change of culture within organisations.
The programme aims are focussed on avoiding and preventing
adverse environmental impact rather than treating or cleaning up
afterwards. This approach brings better economic and
environmental efficiency.

PROGRAMME MANAGERS:
The Clean Technology Centre (CTC) at Cork Institute of
Technology was appointed to manage the programme in
association with OSullivan Public Relations Ltd, and Energy
Transport Actions Ltd, (ENTRAC).
The CTC was established in 1991 and is now nationally and
internationally regarded as a centre of excellence in cleaner
production, environmental management and eco-innovation across
a range of industrial sectors.

WHERE CAN I GET

FURTHER INFORMATION?
This case study report is one of 29 reports
available from the organisations that
participated in the first phase of the Cleaner
Greener Production Programme. A summary
of all the projects and CD containing all the reports
are also available. More information on the Programme
is available from the Environmental Protection Agency
Ms. Helen Walsh,
CGPP,
Environmental Protection Agency,
Richview, Clonskeagh Road, Dublin 14, Ireland.
Tel. 01 2680100
Website

Fax. 01 2680199

www.epa.ie

select link to cleaner production.

Email. ertdi@epa.ie
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The Irish Government, through the National Development

Plan 2000 - 2006, has allocated funds to a programme for
Environmental Research, Technological Development and
Innovation (ERTDI).

The Department of the Environment and Local Government asked

the Environmental Protection Agency (EPA) to run the CGPP as
part of the ERTDI programme. With the programme continuing to
2006 about 60 businesses will be supported to implement cleaner
greener production and to demonstrate their achievements to the
rest of Ireland.