CHP in the Food & Beverage Manufacturing Industry


		Beverages

		Bakeries & Tortillas

		Sugar & Confectioneries

		Seafood Preparation & Packaging

		Meat

		Dairy

		Grain & Oilseed Milling

		Fruit & Vegetable Preserving

		Snack Foods & Peanut Butter

Grain & Oilseed Milling
NAICS 3112
Wet Corn Milling - 311221 Soybean Processing - 311222 Breakfast Cereal Manufacturing - 311230
Wet Corn Milling
CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies Industry Facts • Nearly $8.5 billion in revenue generated from the sale of corn oil, starch, and sugars such as glucose, dextrose, and fructose. (U.S. Census Bureau) • Corn refiners use 15% of the nation's $25 billion domestic corn crop (Corn Refiners Assc.) CHP Market Saturation Data not available Geographic Location

Return to top > Industry Drivers • Energy intensive industry – wet corn milling establishments consume 15% of all electricity used by the food processing industry (ACEEE) • Large electric and thermal loads • Huge increase in process efficiency Thermal Opportunities Reciprocating engines, with a power size range of 30kW–8MW, generate engine jacket heat from 180-200°F, and exhaust heat at around 1200 °F. Industrial turbines, with a power range from 1-20+ MW, generates heat from 900-1100°F. This heat can be recovered and used to heat or cool products in a variety of food processing steps such as: • A constant supply of heat must be provided to warm steeping water at a temperature of approximately 122º F. (Corn Refiners Assc.) • Steepwater must be heated and evaporated to recover the aqueous starch • Starch is washed 8-14 times with water to remove protein. (Corn Refiners Assc.) • Starch needs to be dried before being packaged and sold • Fiber, gluten, and corn germs must also be dried before being processed for animal feeds Process Description Shipments of corn kernels are first inspected for quality control and food safety, and then cleaned to remove dust, dirt, plant material, and cob. The kernels are steeped in a large tank in 122º F (50º C) water, with a small amount of sulfur dioxide to prevent microbial growth. The corn kernels soak for 30-40 hours, and increase their moisture content from 15% to 45%. The starch is released into the water. The steepwater is separated from the corn kernels. The steepwater is condensed to capture the starch, and the corn is coarsely ground to separate the germ from other kernel components. The slurry of ground corn is sent to the germ separators which spins the lower-density germ away from the slurry. The germs are removed, washed to capture any remaining starch, and then corn oil is extracted from them. The leftover germ is used in animal feeds. The corn slurry leaves the centrifugal separator and is ground a second time, and then is sent through an attrition-impact mill, which separates the starch and gluten from the fiber. The starch-gluten mixture is centrifuged so that only the starch remains. Fiber and gluten are used in animal feeds. Starch is diluted and washed multiple times to ensure all protein has been removed. Starch may be dried at this point and sold, or may be processed further into a variety of sugar solutions. Excess water is evaporated, and syrup is created. The syrup is sold directly, or is processed further to create crystallized dextrose or high fructose corn syrup. (Corn Refiners Assc.) Associations Corn Refiners Association, Inc. Events Wet Milling Short Course - October 11-14, 2004 Industry Leaders/Case Studies ADM Corn Products International, Inc. Return to top >
Soybean Processing
CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies Industry Facts • Over $14 billion in revenue is generated from the production and sale of soybean oil, soybean cakes and meal, and concentrated soy protein. (U.S. Census Bureau) • The United States leads the world in soybean production and crushing (Agribusiness Center) CHP Market Saturation Data not available Geographic Location

Return to top > Industry Drivers • High thermal and electric loads • Energy Intensive Industry – the soybean processing sub-sector alone consumes 5% of all energy used by the food processing industry (ACEEE) • Process waste can be used as a fuel Thermal Opportunities • Warm, dry air is necessary for use in dryers • If soybeans are steeped, a heat source to warm steeping water is necessary • Discarded hulls can be used as a fuel in CHP systems Process Description Soybeans are first threshed after harvesting. The hulls and beans must not be broken during this process. The soybeans must be dried to lower the moisture content by swirling warm, dry air around the beans. The soybeans are then cleaned and separated from any foreign material, such as dirt and leaves. This separation is done using a hopper and a set of vibrating sieves. Soybeans are cracked, and the hull is removed, allowing the bean to be rolled in a flat flake. The oil is removed from the soybean with the aid of a solvent. The de-fatted flakes are dried, and ground to produce soy flour, grits, or protein. The oil saved for further processing. Another method of soybean processing involves steeping the soybeans in warm water, and then grinding them to extract soy milk, which can undergo further processing to manufacture a variety of products. (Nat'l Soybean Research Lab) Associations National Oilseed Processors Association United Soybean Board Events SANA/USB Symposium - October 14, 2004 Industry Leaders/Case Studies Archer Daniels Midland Riceland's Stuttgart Soybean Processing Plant - http://www.primenergy.com/Projects_detail_id11.htm Return to top >
Breakfast Cereal Manufacturing
CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies Industry Facts • $9 billion generated each year from the sale of breakfast cereals (U.S. Census Bureau) CHP Market Saturation Data not available Geographic Location

Return to top > Industry Drivers • High thermal loads • Increases process efficiency • Escalating Energy Costs • Alternative fuel opportunity in discarded oat hulls Thermal Opportunities • Large amounts of steam used for cooking • Heated air needed for dryers • Heat source also need for toasting ovens • Cool air used to prevent overcooking Process Description There are many different types of cereal, each of which has it’s own manufacturing process. Three general examples of industrial processes are as follows: Corn-based Flakes: When corn kernels arrive at the factory, they are cleaned and sorted by size. Only those kernels which fall into a certain size bracket will be used to manufacture cereal. The kernels are coarsely ground and combined with sugar, salt, and malt flavoring. The grits are poured into a steam-cooker. Vitamins and iron are added during the cooking process. The grits are rolled to form flakes, and then dried. The drying temperature must not exceed 250º F (121º C) or the flakes will be scorched (EPA). Flakes are tumble-toasted in an oven, and then immediately cooled and packaged (Cape Argus). Oat Cereals: Oats arrive at the factory and are separated from foreign material and clean using aspirators and gravity tables, as well as sieves. The groat is separated from the hull during a process known as impact hulling. The oats are fed through a rotating disc and made to tangentially strike a wall, which separates the groat from the hull. The groat is collected through aspiration, and the hulls are discarded. The groats are either cut or left whole, and then pass through a steam cooker to increase the moisture content. The oats are then processed further or packaged and sold directly. (EPA) Whole-grain shredded cereals: The grain is cleaned, and cooked in steam injection heated water at a temperature just below boiling. The water is drained, and the grain is immediately cooled to halt the cooking process. The grain is placed in large bins and allowed to temper for a period of time. The grain is shredded and shaped into individual biscuits, which are baked and dried before being packaged and sold. (EPA) Associations American Association of Cereal Chemists (AACC) Events AACC/Tortilla Industry Association Annual Meeting - September 19-22, 2004 Prepared Foods New Products Conference - October 10-13, 2004 Wet Milling Short Course - October 11-14, 2004 Industry Leaders/Case Studies General Mills Return to top >