Post on 30-Apr-2020
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Elgin Fruit Juices (Pty)(Ltd)
Grabouw, Western Cape,
South Africa
Company Structure Shareholding
• Elgin Fruit Juices is a wholly owned subsidiary of the Two-a-Day Group.
• Two-a-Day is own by 55 apple and pear producers.
• Only current producers of apples and/or pears can be shareholders of Two-a-Day.
• Shareholders farm 2500 ha of apples and 500 hectares of pears
Company Structure
Producers/Shareholders
100%
Two-a-Day Group Ltd
100%
Elgin Fruit
Juices (Pty) Ltd
50%
Tru-Cape Fruit
Marketing (Pty) Ltd
20%
APL Cartons (Pty) Ltd
20%
Link SCM (Pty) Ltd
Company structure
Volumes handled
• EFJ handles roughly 75 000 tons of apples and 15 000 tons of
pears annually, 70% of this volume is from shareholders.
• Production is about 9 000 000 litres of apple concentrate (AJC)
• PJC production 1,65 million litres
• Pomace is sold to the local dairy industry (12 000 tons)
• Apple aroma is also produced
Capital spend 2017/18
• Roughly R105m spend on plant upgrades
• New infeed line
• Fully automated process, linked to Scada for data collection and
analysis
• Press control upgrade
• New second pressing line
• New Ultra filtration plant
• New absorber plant (No more charcoal and gelatin in factory)
• New 70 ton/h evaporator
Problems encountered
• Volume of waste water generated put our effluent plant under
pressure
• COD values to high for effluent plant
• Water use to high in the factory-Drought in the Western Cape
• Price of water increase 400%
• Got in contact with the NCPC through Green Cape
• Appoint Darrin McComb to do a water budget
Process flow
Water Balance
Water Balance
Water Cost
Water saving opportunities
Evap
Absorber
UF 1&2
PW tanks
UF tanks 50°C
100 kl tank
Second pressin
g Sweet water 50°C
Sanitizer
Recovered
caustic
Juice push water
Caustic
recovery
Retentate tank
Juice push water
Product displacement
Caustic
Sanitizer
Sanitizer
Sanitizer
Caustic
Caustic
Caustic tank
Pomace screw
In feed and general cleaning
Flush water, when evaporator goes from product to water and again from water to product. This all goes to 2nd pressing tank Switching to “sweet water tank”/”sanitiser tank” will be according conductivity (flexible parameter), above 400uS to the “sweet water tank”, below 400uS to the drain, below 200uS to the “sanitiser tank”. Spent caustic, after the caustic cycle of CIP must go to spent caustic tank Switching to “caustic tank”/”drain” will be according conductivity (flexible parameter), above 400uS to the “caustic tank”, below 400uS to the drain, below 200uS to the “sanitiser tank”,.
Sanitizer water after the CIP cycle must go to the sanitizer tank See above
Rinse water after sanitizer and caustic to drain See above
Evaporator
Evaporator
Modified sealing water recycling see drawing of Deon van Straaten and P&ID Install a seal water recovery system
UF 1 & 2
Product displacement, to the retentate tank This is already the procedure No, product displacement due to low flow goes to drain
Spent caustic, after the caustic cycle of CIP must go to spent caustic tank
Sanitizer water after the CIP cycle must go to the sanitizer tank
Rinse water after sanitizer and caustic to drain
UF Plants
Switching to “caustic”/”sanitiser tank”/”drain” will be according conductivity (flexible parameter) and status of the filtration unit, when it I was in “cleaning 1” above 400uS to the “caustic tank”, below 400uS to the drain, below 200uS to the “sanitiser tank”.
Additionally there will be an vale beside the permeate drain valve V491, which sends the approx. 1m3 clear water out of the permeate tank into the sweet water tank during each start up. Note 1: If there is no “batch tank cleaning” (is not standard process) all the water geos to the drain. Note 2: approx. 1-1.5m3 of water which is in the modules during stand still won’t be collected during start up.
Absorber
Flush water, when absorber goes from product to water and again from water to product. This all goes to 2nd pressing tank, Juice push water.
Spent caustic, after the caustic cycle of CIP must go to spent caustic tank
Sanitizer water after the CIP cycle must go to the sanitizer tank
Rinse water after sanitizer and caustic to drain
Absorber (not in Bucher scope)
Switching to “caustic”/”sanitiser tank”/”drain”/”sweet water” will be according conductivity (flexible parameter) and status of the Adsorber.
Process water
T1 30t
New 100kl tank will act as a buffer tank, when process water tank is full, water will go to this tank. When process water tanks is empty it will first fill from this tank, then from municipal supply.
Ozone system will be installed in the Process water tanks, two circulation pumps maintain pressure in the line
Service spray balls, mills, UF plants
Water in the UF Tanks is heated to 50°C through HE. Two circulation pumps maintain pressure in the line
Process water
Process water
T2 30t
Clear condensate from evaporator
Raw condensate from evaporator
Municipal water Absorber T2
Absorber T1
UF Water
T2 45t
UF Water
T1 45t New
100kl tank
Absorber tanks supply the Absorber Installed in the area of the adsorber
2nd pressing tank
Sweet water tank
Supply from evaporator and Absorber and UF plants
Top up from process water tanks (clear condensate connection 8 in the P&ID, via spray ball)
Supply leach water to presses and water to 2nd pressing tank
Pump to circulate through heat exchanger to heat water to 50°C
New 60kl 2nd pressing tank
Note: Depending on the amount of water, this water may also be used for diafiltration on both UltraStar units, For now lets leave this option
Recovered caustic tank
Supply from evaporator, UF 1 & 2 and Absorber The lines from the press are also included with 3 x2 manual valves, since each press delivers 1500l of caustic once a week after cleaning. Noted agreed
Overflow to drain
Recovered caustic tank
Caustic recovery system
Won’t be included in the Bucher system. Except signals
of communication
Agree
Caustic tanks at absorber
Sanitizer tank
Supply from evaporator, UF 1 & 2 and Absorber
Overflow to drain
Sanitizer tank
Infeed line
Ring main in factory, for general cleaning
Retentate tank
Supply from UF 1 & 2
Overflow to drain
Retentate tank
Pomace discharge line
Flow meter inline
Top-up from process water if it is below approx. 10% via spray ball with water
Note: On the P&ID the option to send the retentate from the UF-units “direct”/”via pump 3121PCE05” to the anaerobic plant is still in. Do you like to keep this option or should we take it off? Keep it for the moment
Conclusion, way forward
• Municipal water volumes reduce 20-30%
• Effluent volumes reduced 15%
• COD levels are under control
• Caustic recovery plant will be commissioned
• Absorber water handling improved
• Looking to install a borehole to ensure water quality