Beverage World - October 15, 2007 - (Page 50)

PRODUCTION OPERATIONS OBSERVATIONS Realistically ‘Green’ by john peter koss T he hot topic on the street these days is “green.” Most 21st century industries are being categorized and evaluated according to their commitment and action programs focused on and resulting in a “green” plant operation. What beverage plant operations contribute to an environment that should be protected or improved? This is straightforward and involves the infrastructure. First, consider source water, its use, conservation and discharge handling. Water is the prime raw material used in point: 1) faulty valves; 2) leaky/ improper connections; 3) insufficient cleaning methods; 4) operator/procedure negligence and 5) uncontrolled/ malfunctioning conveyor lubrication systems all contribute to ineffective water usage. Second, electricity has become increasingly critical in terms of availability, usage and cost. Machinery manufacturers are designing “energy efficient” modules to reduce power consumption and increase productivity while utility companies are attempting to use more efficient, less costly “alterna- From a conservation viewpoint, recycling can become a cost effective initiative for most beverage producers. producing every beverage category, whether treated for product formulation and process machinery cleaning, ozone processed for container rinsing or used from the tap for external machine cleaning—it is KING! Water not consumed for product manufacture becomes wastewater normally discharged into a sewer system. Wastewater not contained and recycled, may create a significant environmental “green” impact; nevertheless, from a conservation viewpoint, recycling can become a cost effective initiative for most beverage producers. Process piping systems, (water and ingredients flow) if not adequately maintained, can present a negative operating situation when trying to accomplish a “green” condition. Several potential improvement areas illustrate the 50_BEVERAGE WORLD_OCTOBER 2007 tive power sources.” These are external factors that may not be available or desirable for bottlers in all areas; however, beverage people, in their own way, will continue to focus on internal “green condition” initiatives that are realistically cost related and operationally efficient. External and internal lighting systems provide excellent “green” improvement initiatives by: 1) installing fewer fixtures with greater coverage; 2) using energy efficient bulbs with improved illumination, longer life and easier maintenance; 3) revising turn on/turn off policies and 4) updating periodic cleaning schedules. Energy efficient machines and alternative power sources for beverage process systems can and do provide potential improvement and contribu- tion for a “green” condition. Refrigeration and air systems are now designed for use on a demand basis resulting in power reduction and extended machinery life. The concept is not new; however advanced technologies have increased the potential for improvement in these service and support areas. Several technology advances involve computerized and automated shutdown/startup of production line machinery and systems resulting in realistic power savings and conservation. Third, material waste has always been an issue from environmental, space and cost viewpoints. Positive contribution toward making a plant “green” may focus on improved or new methods related to material waste creation, reduction, disposition and recycling. Improved storage areas, better inventory control and in-plant logistics can result in waste and loss reduction. Better-trained material handlers, hightech equipment and more efficient routing of materials can also contributed to minimizing the waste creation situation. The final stage for beverage plant materials is the usage area. Some packaging areas like fillers, cappers and packers affect usage yield; however, improper material handling at these areas can significantly impact material usage and the goal of being in a realistic “green” condition. BW John Peter Koss, a beverage operations advisor, has more than 45 years of beverage business experience associated with General Cinema Beverages, Carling Brewing and PepsiCola. He was an assistant professor of industrial engineering at Kent State University. Contact him at Tel: 305.829.3631 Fax: 305.829.2484 BEVERAGEWORLD.COM http://www.beverageworld.com/

Table of Contents Feed for the Digital Edition of Beverage World - October 15, 2007

Beverage World - October 15, 2007 Table of Contents Global Recycling Trends Editor’s Note CCE’s Recycling Initiative New Beverages: VeeV New Beverage Roundup Market Metrics: Green-Minded Consumers Cover Story: Earth’s Brewer Adina World Beat Beverages • Fetzer Vineyards Kim Jeffery, Nestlé Waters North America Sambazon Icelandic Water Holdings John Compton, PepsiCo North America Dennis Puffer, Coors Brewing Co. ITO EN Sierra Nevada Brewing Co. • Cuca Fresca Exports Jeff Seabright, The Coca-Cola Company Mendocino Wine Co. Doug Muhleman, Anheuser-Busch Seth Goldman, Honest Tea Supply Chain: Waste Management Production: Environmental Operations Operations Observations Packaging: Lightweight Bottles Trendspotting R&D: Eco Beverages • Ask the Expert Sales & Marketing: Green POS Materials Distribution: Green Fleets Distribution: Fleet of the Month: Manhattan Beer Distributors FleetBeat The Beverage World Top 100 Classifieds Ad Index

Beverage World - October 15, 2007

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