The food production industry is large and ever-growing, encompassing all activities related to the processing, preparation, preservation, packaging, and distribution of food. Valued at over $8 trillion globally, the food and beverage market is set to grow steadily, driven by population growth, urbanization, and changing consumer spending habits. In the UK, production plants are widespread, ranging from manufacturing and packing plants to large breweries. These facilities are typically located in industrial areas where raw agricultural products are transformed into finished food products, including packaged meats, ready-to-eat sandwiches, and beverages found on supermarket shelves.
Image Source: https://www.vecteezy.com/free-photos/barley
Challenges Faced by the Food Plant Industry
A common challenge for food production plants is managing the high volume of waste they produce, which includes large quantities of organic waste, packaging waste, and byproducts. These facilities must adhere to local, national, and international regulations on waste disposal, emissions, and resource usage, particularly those operating globally. Waste management practices must also comply with food safety standards set by agencies such as the FSA, ensuring they do not compromise product quality or safety. Additionally, these facilities typically have high water consumption in processing, cleaning, and cooling operations, necessitating efficient water management and wastewater treatment systems. Addressing these challenges requires a comprehensive approach that combines regulatory compliance, innovative technologies, efficient resource management, and a commitment to sustainability.
Solution
To maintain high standards and ensure efficiency, production plants plan shutdowns. These halts in production operations are typically for maintenance, safety, compliance, or emergencies. Shutdowns allow production facilities to perform essential work that minimises unexpected breakdowns and ensures operations remain safe and efficient. The most common services undertaken during shutdowns include maintenance and waste disposal. Most food production plants will undergo shutdowns 1-4 times a year. In general, food production facilities aim to resume operations as quickly as possible to minimise disruptions to supply chains and meet consumer demand.
Food Production Facility Services Conducted During Shutdowns:
Waste management and environmental service companies, such as Hydro-Cleansing Ltd, are tasked with handling the numerous maintenance jobs needed at food production facilities.
CCTV Surveying
Drain conditions can be surveyed using a CCTV camera to identify any problems, such as blockages, root damage, and pipe collapse. HCL can generate a comprehensive report on the site’s drainage systems, assessing their integrity, cleanliness, and operational effectiveness. This is useful for food production plants, as it aids in verifying compliance and planning maintenance shutdowns more efficiently. HCL uses an advanced CCTV inspection survey camera system which is supplied with 500m of Kevlar-reinforced cable, an auto self-levelling HD colour camera, and a 4-wheel drive for smoothness. With a catalogue of surveying cameras, HCL can inspect pipes as small as 1 ¼ inches (31mm) up to 2 metres sewers (350mm), and anything in between. CCTV surveying is a non-invasive method for accurately diagnosing issues and performing preventative maintenance, which is crucial for cost-effectiveness during shutdowns.
Unblocking Drains
Drain blockages are common in food plants due to the high volume of waste such as food scraps, grease, and fats, along with extensive water use during cleaning and food processing operations. Accumulation of grease and fats can lead to the formation of solid masses which can block pipes, necessitating the need for regular maintenance in food plants. HCL’s vast range of specialist equipment allow drainage solutions for every situation. Hydro-cleansings jetting vans are equipped with 100m jetting hoses, able to double to 200 metres to reach deep into drainage systems and thorough cleaning of pipes that are otherwise difficult to access. With a jetting pressure of 4,000 psi, equating to 12 gallons per minute, HCL can remove even the toughest of clogs. Wet and dry vacuum cleaners allow HCL to handle both liquid and solid debris in an efficient and thorough manner.
Pump station Maintenance
Pump stations are crucial in food plants for efficiently managing water, wastewater, and other liquids used in the production process. Regular pump station cleaning and maintenance are essential to optimise operational efficiency, uphold hygiene standards, prolong lifespan, and minimise energy usage. Hydro-Cleansing Ltd offers multiple services such as pump station maintenance, cleaning, repair, emptying, and degreasing. HCLs has a powerful fleet of vacuum and jetting plants to efficiently solve any issues, as well as trained and certified pump engineers under Thames Water CP2 in confined space.
Interceptors Maintenance
Interceptors are used to capture and separate grease, oil, and solids from wastewater before it enters the drainage systems to prevent pollution and overflow which can cause serious environmental issues. This helps prevent blockages, lower maintenance expenses, and ensure adherence to environmental regulations. Interceptors must be cleaned and maintained to ensure they remain functional and up to standard. Hydro-Cleansing has an experienced team of experts capable of cleansing, installing, and servicing all sizes and types of interceptors, ensuring they are clean, functional, and compliant with current PPG3 environmental regulatory standards. Using power jet vacuum tankers and high-pressure water jetting equipment, even the largest and most difficult-to-reach oil interceptors can be fully serviced to the highest standard.
Waste Disposal
Waste from food plants must be disposed of sustainably to meet regulatory and hygiene standards. European Waste Catalogue (EWC) codes offer a standardised classification system for waste. This system ensures consistent identification, proper handling, treatment, and disposal. Hydro-Cleansing Ltd manages a range of EWC codes at their Waste Recycling Facility, ensuring safe and compliant waste disposal. Additionally, they operate many licensed waste facilities across the country to minimise unnecessary transportation, prioritising environmental impact. HCL’s specialised tankers, such as the Terminator and the Hydra, incorporate some of the most efficient processes in the industry. As a result, material recovery is maximised, and waste volumes are minimised through environmentally responsible recycling. Hydro-Cleansing’s efficient water management not only reduces the overall water used during processing but also ensures there is no contamination in the water transfer process. Hydro-Cleansing provides weighbridge tickets, duty of care certificates, EA notes, and all required documentation to ensure clients have proof of compliance with regulatory standards.
Why Hydro-Cleansing?
Hydro-Cleansing is the UK’s leading experts in environmental and waste management services, 24/7 availability, 365 days a year for emergencies. Food production facilities encounter numerous challenges, and HCL provides optimal solutions tailored to these needs. Recognising the criticality of environmental standards in the food industry, partnering with HCL offers several advantages:
- HCL holds sustainability permits and operates a wet waste recycling facility, ensuring optimal disposal methods.
- By guaranteeing comprehensive inspections and maintenance, HCL helps businesses achieve cost savings through enhanced efficiency.
- Leveraging some of Europe’s top-tier fleet, HCL executes operations swiftly and efficiently, minimising downtime, and enhancing operational efficiency at your facility.
If you are interested in any of these services, Hydro-Cleansing covers it all. Contact us today at 0800 740 8888.
