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 CLB - Demonstration of a closed loop
blanching system for the potato processing
industry
LIFE05 ENV/NL/000035
Project description Environmental issues Beneficiaries Administrative data R e a d m o r e Contact details:
Project Manager: Derk SOMSEN
Project description:
Background
The hot-water blanching of potatoes is a standard procedure in the production
of chips (french-fries), and other potato-based products. The process is
necessary to inactivate enzymes, gelatinise starch and reduce sugar content. The
beneficiary currently processes 1.4 million tonnes of potatoes, using 0.35 million
m3 of water for potato blanching, as well as 88 200 GJ (gigajoule) of energy to
heat the water. Current blanching techniques neither recycle water nor recover heat from the
water, emitting both water and heat to wastewater treatment plants instead.
Furthermore, around 10-30% of potato solids are leached out during the process,
resulting in an unwanted loss of 50 400 tonnes of raw material a year, in the
form of potato waste water.
Objectives
The project aimed to demonstrate a closed-loop blanching technology that
avoids the negative environmental impacts, and loss of raw materials, that are a
characteristic of existing techniques. A pilot blanching system would be
constructed and operated that would use selective de-sugaring to prevent
browning, while avoiding the loss of valuable potato mass. In addition,
wastewater would be processed and reused for blanching, thereby minimising
water consumption. Results
The CLB project developed an innovative system for the blanching of potatoes,
which prevents the leaching out of nutrients that occurs in currently used
blanching techniques. The concept of closed loop blanching (CLB) is based on selective leaching out of
sugars during the blanching, by keeping the concentration levels of all
components in the blanching water (ions enzymes, amino acids, anti oxidants,
vitamins and organic acids) at a constant level, and selectively removing sugars
from the water. As a consequence, leaching out of valuable raw materials is
prevented and the objective of the blanching sequence (reducing sugars) is still
achieved. The sugars are removed from the blanching water using a batch
fermentor and the water is subsequently pumped back into the blancher. The
sugar concentration difference between the potato strips and the surrounding
water creates a driving force for the leaching process.
The results of the project show that the CLB system can yield considerable
savings in energy, water and raw materials. The environmental and economic
results of the project can be summarised as follows: Significant savings of 3.6% raw material were realised.
Reduction of groundwater retraction of about 240 l/tonne potatoes.
Reduction of wastewater treatment requirements of 240 l/tonne potatoes.
Energy reduction of 94 MJ/ tonne potatoes, which is equal to 3 m3/tonne of
natural gas savings, resulting in 5.3 kg CO2 and 3.1 g NOx emission
reduction per tonne processed potatoes.
Savings in raw material results also in 3.6% reduced truck movements to
transport the raw material to the factory (30 tonnes per truck, average
travel distance of 125 km), which results in 0.121 kg CO2 and 1.5 g NOx
emission reduction per tonne processed potatoes.
Overall emission reduction (transport to factory plus at the factory) per
tonne processed potatoes of 5.4 kg CO2 and 4.6 g NOx.
Maintenance of nutritional value in the product.
The technology will first be implemented at the Aviko plant in Steenderen
(production volume 500 000 tonnes potatoes), and subsequently in other plants
of the beneficiary (total production volume 1.2 million tonnes potatoes). Total
production volume in Europe (suitable for application of the CLB technology): 10
million tonnes. An investment decision for the first production line in Steenderen
is currently under preparation and is expected to be taken in August 2009. The
first implementation of the CLB system on a full scale is expected to take place in
2010.
This project has been selected as one of the 17 "Best" LIFE Environment projects in
2 0 0 8 - 2 0 0 9 . Top
Environmental issues addressed:
Themes
Environmental management - Cleaner technologies
Industry-Production - Food and Beverages
Keywords
clean technology‚ food production Target EU Legislation
Water
Directive 2000/60 - Framework for Community action in the field of water
policy (23.10.2000)
Industry and Product Policy
COM(2001)68 - "Final Green Paper on Integrated Product Policy (IPP)”
(07.02.2001) Natura 2000 sites
Not applicable
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Beneficiaries:
Coordinator
Type of organisation
Description
Partners
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AVIKO BV
Large enterprise
Owned by Royal Cosun BV since 2001, Aviko is
one of Europe’s two largest potato processing
companies, with a production volume of 1.2
billion tonnes per year. It produces more than
50 deepfreeze and fresh potato products in
eight production facilities, employing around 1
400 people. None Administrative data:
Project reference
Duration
Total budget
EU contribution
Project location
LIFE05 ENV/NL/000035
15-JAN-2005 to 31-DEC -2007
1,007,627.00 €
302,288.00 €
Gelderland(Nederland)
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Read more:
Project web site
Publication: Layman report
Project's website (NL/EN)
Title: Layman report (EN) Year: 2007 No of
pages: 5 Top
Project description Environmental issues Beneficiaries Administrative data R e a d m o r e