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Bottled Water Solution

Bottled Water Companies Use Hollow Fiber Technology to Reduce Operating Costs

Product: Pall Aria

 

Challenges

Two prominent bottling plants were searching for new ways to lower their operating costs. Both produce spring water, but each one faced a unique challenge.

 

The first company is a well-known spring water company, with over 100 years of industry experience. The company encountered elevated levels of iron and manganese on one line. Initially, this was addressed by incorporating a conventional treatment process utilizing diatomaceous earth (DE).

 

DE is a consumable requiring constant expenditure, manpower and maintenance. More importantly, it may present possible disposal and occupational health and safety issues. While addressing these concerns, the impact of accruing operational costs surfaced. These types of operating costs for water companies are of critical importance to profitability.

 

Another example of high operational costs was witnessed by a different bottled water plant faced with suspended matter variations in the spring water. To keep the source water clean and free of suspended solids, frequent change-outs of disposable filters were necessary. The plant had been using pre-filters and 0.2-micron final filters. Operating multiple bottling lines, variations in suspended matter resulted in unexpected filter costs due to rapid blockage. This was a significant cost to the large operation.

 

In both cases, producing bottled spring water from various sources and by conventional methods resulted in costly, unexpected downtime and product loss. The spring water companies had different complications, but they were driven to find the same solution. They needed a company with the knowledge and technology to help them dry up their leaky profits.

 

Solution

The growing competition in the bottled water industry mandates that every bottled water company must keep a close eye on the cost to produce its brand. Large chain retailers continue to grow in strength, pressuring suppliers to improve quality, reduce costs and increase output. Gaining even marginal savings on operating costs can dictate success or failure for a bottler.

 

Pall Corporation is revolutionizing the production of higher quality bottled water, while reducing operating costs. The Pall Aria™ system utilizes 0.1-micron hollow fiber membrane technology in conjunction with a highly efficient air scrub regeneration, potentially eliminating the use of all disposable filters.

 

If a bottler encounters short filter life or operating costly conventional treatment systems, the Pall Aria system could be the solution for reducing operating costs. After accessing the inefficiencies in each bottled water factory, the technicians felt the implementation of the Pall Aria system would be the right fit for the job. The Pall Aria system was the best economical solution as it reduced their operating costs and could change how it produced bottled water.

 

Bottled water producers can realize the benefits of the Pall Aria system on all water sources – from spring to purified. Once installed the system use uniquely designed filtration modules in a hollow fiber configuration to remove viruses, bacteria, arsenic and suspended solids. And then the benefits begin to flow in. No matter the water source, or its variability because of frequent turbidity spikes, the hollow fiber technology is up to the task. The elimination of feed water variability, minimized cost and maximized uptime translate into cost-saving benefits for the producers that can’t be beat.

 

Results

The first bottler had to consider the expense of displacing its current treatment for a new system. It meant disrupting current production and coming to terms with the expense to replace and upgrade. But one of the many benefits of the Pall Aria system is that it is easy to adapt it to match the bottled water producer’s requirements. Since the system was very flexible, implementation for preliminary testing was very smooth. After a short demonstration period, the results came in and blew the first bottled water factory away.

 

Pall Aria water treatment systems are specifically designed to produce drinking water that meets today’s stringent standards. The quality assurance (QA) requirements were naturally extensive. Blind taste test challenges were mandatory, as were water quality profiles. The results showed no change in taste and complete removal of the desired constituents. A true success.

 

In addition to replacing a costly DE process, the bottler could produce higher quality water and perform an automatic integrity test. Now, the QA manager can confirm the integrity of the filter system each day. The result: current cost of operations decreased by 90%.

 

The second bottler with variations in spring water also purchased the Pall Aria system. The Pall Aria system eliminated incoming water variability. By doing so, the bottler was no longer caught by surprised by the need to change filters. Compared to their standard disposable cartridges, the system yielded a 10-fold increase in downstream filter life.

 

The quick turnaround provided a sense of relief for both bottled water plants. Minimizing operational costs enabled the companies to focus on financial gains – while still meeting, or exceeding, EPA standards. For more information about Pall Aria systems, contact our knowledgeable Food and Beverage team today.

 

TFF Technology Increases Yield and Reduces Waste Streams

Up to 80% of the extract contained in the surplus yeast that collects at the bottom of tanks after fermentation and maturation can now be recovered rather than disposed of. Beer can be recovered and blended back into the brewing process at a ratio of up to 5% without negatively influencing the beer quality, increasing the yield and reducing the total beer volume needing to be produced. This represents a lower CO2 footprint, reduced water usage, and a lowering of production costs, plus the minimized waste stream reduces disposal costs and ensures a lower level of BOD’s and COD’s are returned back into the environment.
Up to 80% of the extract contained in the surplus yeast that collects at the bottom of tanks after fermentation and maturation can now be recovered rather than disposed of. Beer can be recovered and blended back into the brewing process at a ratio of up to 5% without negatively influencing the beer quality, increasing the yield and reducing the total beer volume needing to be produced. This represents a lower CO2 footprint, reduced water usage, and a lowering of production costs, plus the minimized waste stream reduces disposal costs and ensures a lower level of BOD’s and COD’s are returned back into the environment.
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Craft Brewery Preserves Image and Limits Losses

Although beer is restrictive to bacterial growth due to its low pH, ethanol concentration, and low oxygen content, the presence of certain beer spoilage bacteria including Lactobacillus, Pediococcus, Pectinatus, and Megasphaera can generate off-flavors, turbidity and acidity. Such quality deficiencies render the product unacceptable and often result in high economic losses and negative brand image. Throughout the production process, undesirable microbial contamination must be prevented to achieve the required final beer quality. Such contamination may originate from ingredients (including yeast), air and water utilities coming into contact with the product, and the environment.
Although beer is restrictive to bacterial growth due to its low pH, ethanol concentration, and low oxygen content, the presence of certain beer spoilage bacteria including Lactobacillus, Pediococcus, Pectinatus, and Megasphaera can generate off-flavors, turbidity and acidity. Such quality deficiencies render the product unacceptable and often result in high economic losses and negative brand image. Throughout the production process, undesirable microbial contamination must be prevented to achieve the required final beer quality. Such contamination may originate from ingredients (including yeast), air and water utilities coming into contact with the product, and the environment.
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Pall Aria™ System Rescues Bottled Spring Water Producer from Plant Closure

Spring water is a valuable natural resource, which requires good purification treatment before appearing on grocery store shelves as high purity, visually pleasing bottled product. Filtration is a key process step required to achieve consistently high product quality. The costs associated with filtration may be substantial, depending on source water quality. Disposable filters are a technically sound solution but their use may become economically unsustainable in the face of difficult or variable quality source water.
Spring water is a valuable natural resource, which requires good purification treatment before appearing on grocery store shelves as high purity, visually pleasing bottled product. Filtration is a key process step required to achieve consistently high product quality. The costs associated with filtration may be substantial, depending on source water quality. Disposable filters are a technically sound solution but their use may become economically unsustainable in the face of difficult or variable quality source water.
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Microflow System Offers 10 Months Payback in Cheese Brine Purification

Salting by immersion in brine is used for many varieties of cheese worldwide. During repeated immersions fat, curd particles and microorganisms from the cheese plus the accumulation of proteins and other components builds up a nutrient-rich environment for the salt resistant microorganisms. Reused brine may then become a reservoir of unwanted microorganisms, such as gas- or pigmentproducing bacteria, yeast and mold, or salt resistant pathogens, cross-contaminating the cheese and impacting their quality. Good control of the brine and the brining operation is essential to ensure consistent daily production. Additionally, brine disposal is coming under increasing focus. High disposal costs or volume limitations in specific areas are driving the demand for greater brine reuse, to generate operating cost savings and minimize the plant environmental footprint.
Salting by immersion in brine is used for many varieties of cheese worldwide. During repeated immersions fat, curd particles and microorganisms from the cheese plus the accumulation of proteins and other components builds up a nutrient-rich environment for the salt resistant microorganisms. Reused brine may then become a reservoir of unwanted microorganisms, such as gas- or pigmentproducing bacteria, yeast and mold, or salt resistant pathogens, cross-contaminating the cheese and impacting their quality. Good control of the brine and the brining operation is essential to ensure consistent daily production. Additionally, brine disposal is coming under increasing focus. High disposal costs or volume limitations in specific areas are driving the demand for greater brine reuse, to generate operating cost savings and minimize the plant environmental footprint.
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Distillers Improve Quality While Reducing Operating Costs with SUPRApak™ Technology

Filtration of spirits can be a challenging task. It is essential to remove contaminants that may cause turbidity while retaining the quality enhancing components in the product. Filter sheets are the traditional method for achieving this delicate balance. Sheets are comprised of a unique matrix of materials that provide an excellent combination of adsorption and depth filtration, making them an ideal solution for turbidity reduction and haze removal in spirits. Filter sheets are available in multiple grades to cover a wide range of applications from filtration of cordials to chill haze reduction in brown spirits to particle removal in white spirits. Additionally many plate and frame filter units have the flexibility to add or remove sheets to suit the batch size, flow rate or the specific product to be filtered.
Filtration of spirits can be a challenging task. It is essential to remove contaminants that may cause turbidity while retaining the quality enhancing components in the product. Filter sheets are the traditional method for achieving this delicate balance. Sheets are comprised of a unique matrix of materials that provide an excellent combination of adsorption and depth filtration, making them an ideal solution for turbidity reduction and haze removal in spirits. Filter sheets are available in multiple grades to cover a wide range of applications from filtration of cordials to chill haze reduction in brown spirits to particle removal in white spirits. Additionally many plate and frame filter units have the flexibility to add or remove sheets to suit the batch size, flow rate or the specific product to be filtered.
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Fermentation Broth Clarification Systems for Food and Feed Ingredients Manufacturing

Producers of bulk food and feed ingredients such as amino acids, organic acids, and vitamins use fermentation as the basis of their production. Today’s modern industrial biotechnology processes use carefully selected and purified microbial cell cultures to produce an ever-increasing variety of ingredients and increase productivity. During fermentation, the microorganisms multiply in industrial bioreactors, utilizing a carbohydrate source for energy. The course of microbial growth progresses under well-controlled conditions of aeration, agitation rate, temperature, pH and other parameters. Fermentation can last from a few hours to several days. The metabolic end products produced by the microorganisms are the basis for many ingredients used today.
Producers of bulk food and feed ingredients such as amino acids, organic acids, and vitamins use fermentation as the basis of their production. Today’s modern industrial biotechnology processes use carefully selected and purified microbial cell cultures to produce an ever-increasing variety of ingredients and increase productivity. During fermentation, the microorganisms multiply in industrial bioreactors, utilizing a carbohydrate source for energy. The course of microbial growth progresses under well-controlled conditions of aeration, agitation rate, temperature, pH and other parameters. Fermentation can last from a few hours to several days. The metabolic end products produced by the microorganisms are the basis for many ingredients used today.
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Cider Producer Maximizes Yield and Increases Capacity with the Oenoflow™ HS System

Filtration is a key operation in modern cider production to deliver visually bright and shelf stable product. Traditionally, cider clarification has been performed with diatomaceous earth or sheet based filtration technologies. However, with more favorable economics, easier operation and lower waste volumes, crossflow filtration systems like Pall’s Oenoflow XL system have become more widely adopted over the past decade.
Filtration is a key operation in modern cider production to deliver visually bright and shelf stable product. Traditionally, cider clarification has been performed with diatomaceous earth or sheet based filtration technologies. However, with more favorable economics, easier operation and lower waste volumes, crossflow filtration systems like Pall’s Oenoflow XL system have become more widely adopted over the past decade.
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TAB Filtration Significantly Improves Ready to Drink Tea Quality and Yield

Ready to drink tea, fruit juices and drinks, carbonated soft drinks, and other beverages are subject to spoilage due to the presence of heatresistant, acidophilic bacterial spores (TAB). The thermoacidophilic spores may originate either from exposure to agricultural raw materials such as in fruit juice production, or from contamination in the beverage ingredients, such as sweeteners, juice and tea concentrates, or flavors, essences, and colors from natural extracts.
Ready to drink tea, fruit juices and drinks, carbonated soft drinks, and other beverages are subject to spoilage due to the presence of heatresistant, acidophilic bacterial spores (TAB). The thermoacidophilic spores may originate either from exposure to agricultural raw materials such as in fruit juice production, or from contamination in the beverage ingredients, such as sweeteners, juice and tea concentrates, or flavors, essences, and colors from natural extracts.
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Cross-flow Lees Filter Experience Delivers Efficiency and Economy at Yalumba

Recovery of wine from lees represents one of the most challenging forms of filtration faced by wineries. The high concentration and variability of the suspended solids limit the suitable filtration technologies, while strict environmental regulations and sustainability programs are increasing pressure to reduce waste volumes. Traditionally, lees filtration is performed with filter aid based systems like rotary vacuum drum (RVD) or chamber press filters. While these systems typically have good volumetric recovery of the wine from the solids, there are some inherent drawbacks that can affect wine quality. The open design allows for oxygen pick-up and the recovered wine often needs further processing. The wine is typically downgraded in value and used in blends instead of added back to the original batch.
Recovery of wine from lees represents one of the most challenging forms of filtration faced by wineries. The high concentration and variability of the suspended solids limit the suitable filtration technologies, while strict environmental regulations and sustainability programs are increasing pressure to reduce waste volumes. Traditionally, lees filtration is performed with filter aid based systems like rotary vacuum drum (RVD) or chamber press filters. While these systems typically have good volumetric recovery of the wine from the solids, there are some inherent drawbacks that can affect wine quality. The open design allows for oxygen pick-up and the recovered wine often needs further processing. The wine is typically downgraded in value and used in blends instead of added back to the original batch.
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