MANUFACTURE OF FOOD PRODUCTS AND BEVERAGES # 31

Background:

O. Kavli A/S Bergen in Nesttun, Norway is a dairy products industrial unit. The unit comprises the cheese department and the delicacy department. The raw materials used are circular cheese and block cheese (which arrives on pallets), fish-spawner (which arrives in brine in wood barrels), soya oil (which arrives in tanks), and spices and taste substances which arrive in bags or cardboard boxes. The products made by this unit are: melted cheese in boxes or tubes, mayonnaise and caviar in tubes and dressing in small barrels or buckets.

The company has 160 employees in Bergen, and a turnover of 170 million NOK. The total financial turnover for the plants in Bergen, Vestfold, Sweden, Denmark and United Kingdom is 900 million NOK.

The plant produced 2700 tons of consumer products in 1992. The production of waste during the same year was 10 tons of detergent, 220 tons of solid waste and an unknown amount of waste discharged with the effluent. To make the manufacturing process less resource intensive and more economical the unit implemented a series of CP measures.

Cleaner Production Principle:

Housekeeping; Process modification

Cleaner Production Application:

A set of CP options were identified, some of which that required no investment were immediately implemented while others which involved some investments were proposed to be implemented in the future.

The following housekeeping options were implemented immediately:

The following actions were proposed to be implemented in the near future with low costs :

Change in packing of raw materials was implemented by replacing 2,100 paperbags with 52 big bags while 24 barrels were replaced with 6 containers. The containers and big bags will be returned to the supplier.

Actions requiring investments which could be implemented in the future include:

The technology needed to carry out all the above identified options are commercially available, except for an efficient fat separator.

Samples for quality control checks were proposed to be taken from the laboratory and the test kitchen.

Environmental and Economic Benefits:

The water consumption will be reduced by 3 m³ per day and the pollutant load will be reduced, if the CIP are installed. The production of cheese will increase by 13 tons, which is equivalent to recovering cheese and the sale of cheese waste for animal food reduced to 7 tons. There will be no change in the energy consumption.

The costs for CP options requiring investments are as follows:

The CP options will not increase operational or maintenance costs.

Reuse of cheese and delicacy waste will give savings of 750,000 NOK per year, in addition there are several small savings which will give a total saving of about 1,000,000 NOK per year.

O. Kavli A/S, Bergen will thus reduce operational costs and reduce the impact on the environment.

Constraints:

None reported.

Contacts:

O. Kavli A/S Bergen

Att: Gunnar Snibsoeer Sandbrekkvn. 91

5050 NESTTUN NORWAY

Tel : +47 55 10 00 00; Fax : +47 55 10 15 00

State Pollution Authority Postbox 8100 Dep.,

0032 OSLO, Norway

Tel : +47 22 57 34 00

Review Status:

This case study was submitted by : The Oestfold Research Foundation Institute for Pollution Prevention Box 276 1601 Fredrikstad Norway, Tel : + 47 693 41 900, Fax : + 47 693 42 497 e-mail : auduna@telepost.no (Contact: Audun Amundsen) Advisor: Dr Ing Sven Milch Tel : +47 55 23 29 00. The project was carried through from April to December 1993. Additional information is available in the Organization Report. "Teknisk miljanalyse O. Kavli A/S, Bergen".

The case study was edited by UNEP IE in May 1996, and subsequently it underwent a formal technical review in September 1998 by Dr. Prasad Modak, Environmental Management Centre, Mumbai, India.