MICROFILTRATION of CHICKEN PROCESS WATERS FOR REUSE: PLANT STUDIES and PROJECTED OPERATING COSTS¹

Abstract

Commercial scale ceramic microfilters were used in plant tests to determine flux rate and operating parameters for waters from a poultry scalder, a poultry chiller, and brine from a delicatessen products chiller, under commercial conditions. Filtration produced clear permeate from all waters. Microorganism counts were essentially reduced to zero in scalder and chiller water permeates, with BOD reduced by about 70% in scalder water permeate and about 60% in chiller water permeate. Flux rates were in the range of 224‐204 L/m2h for scalder water at 54°C and 114‐81 L/m2h for chiller water at ambient temperature. Test results were used to project nonlabor operating savings and/or costs resulting from the use of microfiltration to recondition and reuse bath overflow. For a processing rate of 140 birds/min and bath size of 37,850 L (10,000 gal), an annual savings of $21,000‐$26,000 were estimated for scalder water filtration, while annual costs of $65,000‐$84,000 were estimated for chiller water filtration. For a deli brine bath size of 1,170 L (300 gal), annual costs of about $700 were estimated. Retentate heating and electrical usage associated with centrifugal filter pumps were projected as predominant cost factors. Besides costs, other factors such as nonchemical control of microbial growth, water savings, and reduced discharge levels may also be important reasons for considering microfiltration.

Reconditioning of Poultry Chiller Overflow by Ultrafiltration

“…This assessment indicates a 2.4‐year simple payback period. This compares favorably to microfiltration (Hart et al. 1990), where net savings were negative.…”

“…This assessment indicates a 2.4-year simple payback period. This compares favorably to microfiltration (Hart et al 1990), where net savings were negative. The estimated $300,000 capital cost of a 380-L/min (100 gal/min) ultrafiltration system also compares favorably with $1,920,000 cost of a 236-L/min (62 gal/min) ceramic microfiltration system.…”

“…Chang et al (1989) found diatomaceous earth filtration to be effective for reconditioning poultry process water, but large quantities of filter aid requirement was seen as a disadvantage. Microfiltration of chiller water using 0.2-m m ceramic microfiltration membranes reduced microorganism levels in poultry chiller water to almost zero and turbidity by 90% (Hart et al 1990 andHart et al 1988). However, the use of ceramic microfiltration systems for this application on a commercial scale was not considered cost-effective because of high capital and operating costs.…”

“…(1989) found diatomaceous earth filtration to be effective for reconditioning poultry process water, but large quantities of filter aid requirement was seen as a disadvantage. Microfiltration of chiller water using 0.2‐µm ceramic microfiltration membranes reduced microorganism levels in poultry chiller water to almost zero and turbidity by 90% (Hart et al. 1990 and Hart et al.…”

Recycling of poultry process wastewater by ultrafiltration

“…These trials produced over 73% rejection of COD, over 99.2% reduction in turbidity and over 5.4 log cycle reduction in microbial counts (Mannapperuma,& Santos, 2004). Microfiltration of chiller water using 0.2 μm ceramic membranes reduced microorganism levels to almost zero and turbidity by 90% (Hart et al, 1990) and because of larger pore size, produced higher fluxes than ultrafiltration. However, they tend to get fouled, more rapidly by micron-range particles compared to ultrafiltration membranes.…”