The food processing industry, in general, generates excessive amount of waste. Food waste, in many cases, ends up in landfill sites or gets dumped in vacant grounds. This bio-degradable is also being used effectively to produce bio-fuels and the Pepsico Fritolay unit at Pune is today generating biogas to run its Kurkure chips line! A Report
Big and small potatoes bathing below water jet sprays, tumbled and lurched ahead on the conveyor belt, inching closer and closer to be processed into potato chips and be branded Lays! But not all potatoes make it to the brand, as the not so good ones and the badly shaped ones get picked out of the belt and tossed down into the gutter, which carries rejects to the waste processing plant.
The rest get sliced, washed and rinsed thoroughly, and the starch rich wastewater is carried to the small starch plant where tonnes of processed starch makes its way to hotels on a daily basis.
The sliced potatoes again get sorted and the not-so-neatly shaped ones are automatically dropped into a bin below the belt. A pile of shapely slices again make their way to the waste processing plant.
The Pepsico plant in Pune on an average generates about 18MT of waste per day. The waste consists of potato rejects, peels, slices, process waste and wastewater sludge.
The successful biogas plant gave the confidence to invest in Bio Methane Plant at Pune
– Shivshankar Tekale with Indra Nooyi
CEO of PepsiCo
“The most common way of food waste disposal is vermi-composting and to handle waste to the volume of 18MT per day, we would need approximately three acres of land,” said Shivshankar……
On the other hand, aerobic processing of sludge water gives rise to foul smell, causing inconvenience to nearby villages.
“We took up the challenge at the Pune plant to overcome the issue of waste disposal by converting food waste into a sustainable solution for the organization, society and environment,” said Shivshankar, the man who has been instrumental in the successful production of biogas at the Pepsico, Pune.
In the initial stage, a Pilot plant was installed to understand the process, its controls and variations and also to identify the potential of biogas production. After six months, after rigorous trials, the process and design of the full scale plant was finalized.
“To utilize best, the biogas should have direct firing.” The potential of bio-degradable waste coming from the process is enough to generate 2500M3 of biogas per day.
“This way we could reduce waste by 80% the rest 20% could be biologically digested. Generated Biogas could be used in Kurkure fryer by having a purification process and modifying the burners; thereby replacing fossil fuel LPG.
“Earlier, Slicer fines were filled in trolleys and were disposed off outside the factory in tractor trolleys. This required manpower and there was a continuous movement of trolleys in the shopfloor.
“Hence, an automatic on line feeding system was developed. This is first-of-its-kind initiative in PepsiCo where slicer fines are conveyed through screw conveyor crushed and then transferred through pump to the biogas digester. This not only saved manpower but also improved hygiene conditions inside plant.
“This system also insures constant feeding to Digester hence constant generation of biogas. The Bio Methane plant currently generates 2000M3 biogas/day.
“The biogas after purification is used directly on one Kurkure Fryer, thus saving 140MT of LPG and approximately cost of $140 million per annum.
“Currently, we have achieved 65% reduction in waste and 390 tons/year reduction in greenhouse gas.”
The food processing industry, in general, generates excessive amount of waste. Food waste, in many cases, ends up in landfill sites or gets dumped in vacant grounds. This bio-degradable is also being used effectively to produce bio-fuels and the Pepsico Fritolay unit at Pune is today generating biogas to run its Kurkure chips line! A ReportBig and small potatoes bathing below water jet sprays, tumbled and lurched ahead on the conveyor belt, inching closer and closer to be processed into potato chips and be branded Lays! But not all potatoes make it to the brand, as the not so good…
Clean India Journal - Editor
Biogas Case Studies
Biogas case studies are very useful documents as they allow others to review an operating system, study the lessons learned which provides valuable insight to improve and develop better systems. For instance in the anaerobic digester at Farber Farm it was found, “A 5-day retention time in a fixed film digester will provide odor control as well as 30 cubic foot of biogas per cow per day. The gas production is sufficient to maintain operating temperatures in the digester with a biogas boiler even during the winter.” Often the biogas case studies can provide insight at the design stage to avoid pitfalls, verify design parameters, or give greater confidence in the overall approach.
Biodigester Global Case Studies [from around the world], December 2011, Hojnacki, A. et al., D-Lab Waste.
Productive Biogas: Current and Future Development Five case studies across Vietnam, Uganda, Honduras, Mali and Peru, 2014, SNV Netherlands Development Organisation and the Fact Foundation
Biogas in Ghana: Sub-Sector Analysis of Potential and Framework Conditions, 2014, GIZ, German Federal Minisitry of Economic Affairs and Energy.
Development of Anaerobic Digester for the Production of Biogas using Poultry and Cattle Dung: A Case Study of Federal University of Technology Minna Cattle & Poultry Pen, 2013, Aduba, J. et al., International Journal of Life Sciences Vol.2. No.3. 2013. Pp. 139-149.
Design of Biogas Plant for Rural Households in Uganda: Case Study Apac District, 2012, Second International Conference on Advances in Engineering and Technology
Kenya National Domestic Biogas Programme, Ashington Ngigi, Updated 2013, An initiative under the Africa Biogas Partnership Programme.
Life Cycle Approach for Evaluating Sanitation Projects Case Study: Biogas latrine, 34th WEDC International Conference, Addis Ababa, Ethiopia, 2009.
The Potential of Small-Scale Biogas Digesters to Improve Livelihoods and Long Term Sustainabiloity of Ecosystems Services in Sub-Saharan Africa, 2nd Quarterly Report, 19 August 2012, funded by UK Department for International Development.
The Potential of Flexible Balloon Digesters to Improve Livelihoods in Uganda: A case study of Tiribogo, April 2013, Tumwesige, V., thesis submitted for the Degree of Master of Science in Environmental Science, University of Aberdeen.
Biomethane from Dairy Waste A sourcebook for Production and Use of Renewable Natural Gas in California, Prepared for Western United Dairymen, July 2005.
Dairy, Reinfold Farm (Pennsylvania) digester designed for 1,000 cows, Department of Agricultural & Biological Engineering, 2009.
Farm to Fuel: Devoloper’s Guide to Biomethane as a Vehicle Fuel, Agriculture and Agri Foods Canada, July 2013.
Fixed Film Anaerobic Digester at Farber Farm: Case Study, New York, Peter Wright and Jianguo Ma Dept. of Biological and Environmental Engineering, Cornell University
Haubenschild Farms Digester Fnal Report, Minnesota Project, Carl Nelson & John Lamb, 2002.
Wisconsin Biogas Casebook Prepared for Focus on Energy by Joe Kramer Energy Center of Wisconsin, 2008.
The Generation of Biogas On-Farm using Animal and Dairy Waste, Paul Wilson, AgriFood Skills International Fellowship, 2013.
Biogas Energy for an Innovative Pork Industry, Dr. Stephen Tait, University of Queensland, 2013.
Estimates of Manure Production From Animals for Methane Generation, Australian Government, Rural Industries Research and Devlopment Corporation, 2010.
Canadian Biogas Study, Benefits to the Economy, Environment and Energy, Biogas Assocation, December 2013.
Central – South America
Case Study: The technical and econonmic feasibility of electricity generation with biogas in Costa Rica, Agriculture Engineer Joaqyuin Viquez Arais, 2009.
Biogas Production in China: Current status and future development, Dr. Xiujin Li, Department of Environmental Engineering, Beijing University of Chemical Technology, 2013.
Chinese Biogas Digester A potential model for small scale rural applications (a manual for construction and operation) prepared by Charles H Nakagawa US Peace Corps Volunteers Dec 1981.
Domestic biogas in a changing China: Can biogas still meet the energy needs of China’s rural households?, 2013, Zuzhang, Z., International Institute for Environment and Development, United Kingdom.
Beelan Pig Farm in North West Germany with a 250kW biogas plant running on slurry from 4500 fattening pigs, plus a combination of maize, grass and rye silage grown on the 290ha of mainly sandy soils.
Biogas Buses: A Cost Estimate [Sweden], Mattias G, 2013, Study commissioned by DANNINCO, Denmark.
Biogas Case Studies in Slovenia, Big>East Biogas for Eastern Europe, by Matjaž Grmek, Ivo Blaznik, Feb 2010.
Biogas and Biomethane in Europe, Fagonyte E, European Biomass Association, 2010.
Household Biogas Digesters – A Review, Karthik Rajendran, Solmaz Aslanzadeh and Mohammad J. Taherzadeh, School of Engineering, University of Boras, Sweden 2012.
Greimel Biogas Plants, Grüntegernbach, Bavaria, Germany, University of Glamorgan 2009.
Economic Evaluation of Strategic Biogas Investment Options – Case Study in the Region of Larisa (Greece), May 2012.
Socio-Economic Evaluation of Selected Biogas Technologies, Scientific Report from Danish Centre of Environment and Energy, 2013.
Biogas Digesters in India by Robert Jon Lichtman, 1982.
The Appropriate Rural Technology Institute (ARTI), 2006, Ashden Awards Case Study, India.
Evaluation of small-scale Biogas System for the Treatment of Faeces and Kitchen Waste, Case Study Kochi, South India, Estoppey, N. 2010, Swiss Federal Institute of Aquatic Science and Technology (Eawag),
Making Nightsoil-biogas plants viable in Maharashtra’s district, Dr SV Mapuskar, United Nation’s Children Fund, 2007.
Pour-flush Toilets with Biogas Plant at DSK Training Institute, Gujarat, India by the Sustainable Sanitation Alliance, Dec 2009.
Biogas: Bottling in India, Renewable Energy Akshay Urja, by ML Bamboriya, 2012.
Biogas For Climate Justice: A Story of Change in Nepal, Ugan Manandhar, Hunger -Nutrition – Climate Justice 2013.
Transforming the use of biogas in Pakistan:From household application towards powering small holder irrigation, April 2014, SNV Netherlands Development Organisation and
Rural Support Programmes Network .
Biogas Power Opportunities Romania 2014, SLOW Energy Europe.
Biogas from manure and waste products – Swedish case studies, 2008, Held. J., Swedish, Gas Centre, Swedish Biogas Association.
Biogas in Sweden, Swedish Gas Association, 2011.
Technical & Biological Performance of the ARTI Compact Biogas Plant: Kitchen Waste Case Study from Tanzania, October 2009, Voegeli, Y. et al., Proceedings Sardinia 2009, Twelfth International Waste Management and Landfill Symposium, CISA Publisher, Italy.