Energy and water efficiency in the gelatine production plant

Janusz Wojdalski; Magdalena Krajnik; Piotr F.  Borowski; Bogdan Dróżdż; Adam Kupczyk; Janusz Wojdalski; Magdalena Krajnik; Piotr F.  Borowski; Bogdan Dróżdż; Adam Kupczyk

doi:10.3934/geosci.2020027

AIMS Geosciences

2020, Volume 6, Issue 4: 491-503. doi: 10.3934/geosci.2020027

Previous Article Next Article

Research article Special Issues

Energy and water efficiency in the gelatine production plant

1.
National Institute of Rural Culture and Heritage in Warsaw, Poland
2.
Institute of Mechanical Engineering, Department of Production Engineering, Warsaw University of Life Sciences, Poland

Received: 03 September 2020 Accepted: 09 November 2020 Published: 17 November 2020

Nexus water-energy-food can be represented on a micro scale using the example of gelatine production in a rendering plant. The article presents the results of research on the variability of energy and water consumption in a rendering plant producing food gelatin. Monthly production was 565.2–631.3 Mg of gelatin and on average 18.89 Mg of gelatin was produced per day. The power of the installed electrical devices was 1150 kW. The average unit consumption of water was 18.97 m³/Mg, heat energy 22.39 GJ/Mg and electricity 1174.76 kWh/Mg. The influence of gelatine production on energy and water consumption was determined. It has been shown that in the examined plant there is an increased by about 20–30% non-production consumption of energy and water, which in the future should be reduced by introducing technological innovations. Moreover, it has been shown that there is a possibility of increasing production efficiency. The obtained energy efficiency and unit consumption indicators can be used to define environmental standards as well as eco-efficiency and production costs important for management of the enterprise.
- rendering industry,
- food industry,
- production energy consumption,
- energy efficiency,
- water consumption,
- energy consumption,
- mechanical properties
Citation: Janusz Wojdalski, Magdalena Krajnik, Piotr F. Borowski, Bogdan Dróżdż, Adam Kupczyk. Energy and water efficiency in the gelatine production plant[J]. AIMS Geosciences, 2020, 6(4): 491-503. doi: 10.3934/geosci.2020027

Related Papers:

Abstract

Nexus water-energy-food can be represented on a micro scale using the example of gelatine production in a rendering plant. The article presents the results of research on the variability of energy and water consumption in a rendering plant producing food gelatin. Monthly production was 565.2–631.3 Mg of gelatin and on average 18.89 Mg of gelatin was produced per day. The power of the installed electrical devices was 1150 kW. The average unit consumption of water was 18.97 m³/Mg, heat energy 22.39 GJ/Mg and electricity 1174.76 kWh/Mg. The influence of gelatine production on energy and water consumption was determined. It has been shown that in the examined plant there is an increased by about 20–30% non-production consumption of energy and water, which in the future should be reduced by introducing technological innovations. Moreover, it has been shown that there is a possibility of increasing production efficiency. The obtained energy efficiency and unit consumption indicators can be used to define environmental standards as well as eco-efficiency and production costs important for management of the enterprise.

References

[1]	Ladha-Sabur A, Bakalis S, Fryer PJ, et al. (2019) Mapping energy consumption in food manufacturing. Trends in Food Sci Technol 86: 270-280. doi: 10.1016/j.tifs.2019.02.034
[2]	Borowski PF (2020) Zonal and Nodal Models of Energy Market in European Union. Energies 13: 4182. doi: 10.3390/en13164182
[3]	Giacone E, Mancò S (2012) Energy efficiency measurement in industrial processes. Energy 38: 331-345. doi: 10.1016/j.energy.2011.11.054
[4]	Prasad P, Pagan R, Kauter M, et al. (2004) Eco-efficiency for the Dairy Processing Industry. Environmental Management Centre, The University of Queensland, St Lucia, 43-48, 57-66.
[5]	Jayathilakan K, Sultana K, Radhakrishna K, et al. (2012) Utilization of byproducts and waste materials from meat, poultry and fish processing industries: a review. J Food Sci Technol 49: 278-293. doi: 10.1007/s13197-011-0290-7
[6]	Mariod AA, Fadul H (2013) Gelatin, source, extraction and industrial applications. Acta Sci Po Technol Aliment 12: 135-147.
[7]	Karim AA, Bhat R (2009) Fish gelatin: properties, challenges, and prospects as an alternative to mammalian gelatins. Food Hydrocolloids 23: 563-576. doi: 10.1016/j.foodhyd.2008.07.002
[8]	Poppe J (1992) Gelatin. In Imeson AP, Thickening and gelling agents for food. Springer, Boston, MA, 98-101.
[9]	Schieber A, Stintzing FC, Carle R (2001) By-products of plant food processing as a source of functional compounds—recent developments. Trends Food Sci Technol 12: 401-413. doi: 10.1016/S0924-2244(02)00012-2
[10]	Etxabide A, Leceta I, Cabezudo S, et al. (2016) Sustainable fish gelatin films: From food processing waste to compost. ACS Sustainable Chem Eng 4: 4626-4634. doi: 10.1021/acssuschemeng.6b00750
[11]	Senevirathne M, Kim SK (2012) Utilization of seafood processing by-products: medicinal applications. In Advances in food and nutrition research. Academic Press, 65: 495-512.
[12]	Wasswa J, Tang J, Gu X (2007) Utilization of fish processing by-products in the gelatin industry. Food Rev Int 23: 159-174. doi: 10.1080/87559120701225029
[13]	Abedinia A, Nafchi AM, Sharifi M, et al. (2020) Poultry gelatin: Characteristics, developments, challenges, and future outlooks as a sustainable alternative for mammalian gelatin. Trends Food Sci Technol 104: 14-26. doi: 10.1016/j.tifs.2020.08.001
[14]	Mirzapour-Kouhdasht A, Moosavi-Nasab M, Krishnaswamy K, et al. (2020) Optimization of gelatin production from Barred mackerel by-products: Characterization and hydrolysis using native and commercial proteases. Food Hydrocolloids 108: 105970. doi: 10.1016/j.foodhyd.2020.105970
[15]	Montero M, Acosta ÓG (2020) Tuna skin gelatin production: optimization of extraction steps and process scale-up. CyTA-J Food 18: 580-590. doi: 10.1080/19476337.2020.1801849
[16]	Meyer M (2019) Processing of collagen based biomaterials and the resulting materials properties. Biomed Eng Online 18: 24. doi: 10.1186/s12938-019-0647-0
[17]	da Trindade Alfaro A, Balbinot E, Weber CI, et al. (2015) Fish gelatin: Characteristics, functional properties, applications and future potentials. Food Eng Rev 7: 33-44. doi: 10.1007/s12393-014-9096-5
[18]	See SF, Hong PK, Ng KL, et al. (2010) Physicochemical properties of gelatins extracted from skins of different freshwater fish species. Int Food Res J 17: 809-816.
[19]	Gelatin Manufactureres Institute of America (2019) Gelatin Handbook. Available from: http://www.gelatin-gmia.com/uploads/1/1/8/4/118450438/gmia_gelatin_manual_2019.pdf.
[20]	Zhang XP, Ye TY, Meng XH, et al. (2020) Sustainable and Transparent Fish Gelatin Films for Flexible Electroluminescent Devices. ACS nano 14: 3876-3884. doi: 10.1021/acsnano.9b09880
[21]	Schrieber R, Gareis H (2007) Gelatine handbook: theory and industrial practice. Wiley-VCH, 96-97
[22]	Milovanovic I, Hayes M (2018) Marine Gelatine from rest raw materials. Appl Sci 8: 2407. doi: 10.3390/app8122407
[23]	EC (2005) Integrated Pollution Prevention and Control Reference Document on Best Available Techniques in the Slaughterhouses and Animal By-products Industries, 141-145. Available from: https://eippcb.jrc.ec.europa.eu/sites/default/files/2020-01/sa_bref_0505.pdf.
[24]	WS Atkins International (1998) Ochrona środowiska w przemyśle rolno-spożywczym. Standardy środowiskowe. FAPA, Warszawa, 32-36, 85-89,105-108.
[25]	Cavey A, Eyars R, Hill S, et al. (1998) Ochrona środowiska w przemyśle utylizacyjnym, Wyd. FAPA, Warszawa, 18-21.
[26]	Gündem A, Tarhan Ö (2020) Extraction of collagen and gelatine from animal wastes. Bull Biotechnol 1: 30-33.
[27]	Muller DCA, Marechal FMA, Wolewinski T, et al. (2007) An energy management method for the food industry. Appl Therm Eng 27: 2677-2686. doi: 10.1016/j.applthermaleng.2007.06.005
[28]	Cole C (2000) Gelatin. In Frederick FJ, Encyclopedia of Food Science and Technology, 2: 1183.
[29]	Ma Y, Zeng X, Ma X, et al. (2019) A simple and eco-friendly method of gelatin production from bone: One-step biocatalysis. J Cleaner Prod 209: 916-926. doi: 10.1016/j.jclepro.2018.10.313
[30]	Wojdalski J, Dróżdż B, Lubach M (2007) Factors influencing energy consumption in fruit and vegetable processing plants. TEKA Kom Mot Energ Roln-OL PAN 7: 277-285.
[31]	Abonyi J, Kulcsar T, Balaton M, et al. (2014) Energy monitoring of process systems: time-series segmentation-based targeting models. Clean Technol Environ Policy 16: 1245-1253. doi: 10.1007/s10098-014-0808-6
[32]	Wojdalski J, Dróżdż B, Grochowicz J, et al. (2013) Assessment of energy consumption in a meat-processing plant—a case study. Food Bioprocess Technol 6: 2621-2629. doi: 10.1007/s11947-012-0924-4
[33]	Wojdalski J, Grochowicz J, Dróżdż B, et al. (2015) Energy efficiency of a confectionery plant-Case study. J Food Eng 146: 182-191. doi: 10.1016/j.jfoodeng.2014.08.019
[34]	Niedziółka I, Zuchniarz A (2006) An energetic analysis of selected plant biomass samples (in Polish: Analiza energetyczna wybranych rodzajów biomasy pochodzenia roślinnego). MOTROL, Motoryzacja i Energetyka Rolnictwa. Lublin, tom 8A, 232-237.
[35]	Keijzers G (2002) The transition to the sustainable enterprise. J Cleaner Prod 10: 349-359. doi: 10.1016/S0959-6526(01)00051-8
[36]	Kolomaznik K, Janacova D, Solc J, et al. (2011) Mathematical modeling of gelatine production processes. In Proceedings of the 13th WSEAS international conference on Mathematical and computational methods in science and engineering. World Scientific and Engineering Academy and Society (WSEAS), 317-321.
[37]	Makarichi L, Jutidamrongphan W, Techato KA (2018) The evolution of waste-to-energy incineration: A review. Renewable Sustainable Energy Rev 91: 812-821. doi: 10.1016/j.rser.2018.04.088
[38]	Mariod AA, Adam HF (2013) Review: gelatin, source, extraction and industrial applications. Acta Sci Pol Technol Aliment 12: 135-147.
[39]	Meyer M, Trommer K (2015) Soft collagen-gelatine sponges by convection drying. Braz Arch Biol Technol 58: 109-117. doi: 10.1590/S1516-8913201400139
[40]	Mokrejs P, Langmaier F, Mladek M, et al. (2009) Extraction of collagen and gelatine from meat industry by-products for food and non food uses. Waste Manage Res 27: 31-37. doi: 10.1177/0734242X07081483
[41]	Ableeva AM, Salimova GA, Rafikova NT, et al. (2019) Economic evaluation of the efficiency of supply chain management in agricultural production based on multidimensional research methods. Int J Sup Chain Mgt 8: 328-338.
[42]	Wittich WJ (2005) New automated industrial technologies for improving chemical penetration of bovine pieces in the raw material processing and conditioning areas of gelatine manufacture. University of Canterbury, Christchurch, New Zealand.
[43]	Cascarosa E, Gea G, Arauzo J (2012) Thermochemical processing of meat and bone meal: A review. Renewable Sustainable Energy Rev 16: 942-957. doi: 10.1016/j.rser.2011.09.015
[44]	Kowalski Z, Krupa-Żuczek K (2007) A model of the meat waste management. Pol J Chem Technol 9: 91-97. doi: 10.2478/v10026-007-0098-4
[45]	Borowski PF (2020) Nexus between water, energy, food and climate change as challenges facing the modern global, European and Polish economy. AIMS Geosci 6: 397-421. doi: 10.3934/geosci.2020022
[46]	Tashtoush FM, Al-Zubari WK, Shah A (2019) A review of the water-energy-food nexus measurement and management approach. Int J Energy Water Res 3: 361-374. doi: 10.1007/s42108-019-00042-8

Reader Comments

Your name:*

Email:*
© 2020 the Author(s), licensee AIMS Press. This is an open access article distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0)