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Gedney Food Company
Groundwater Management
Groundwater Management
Presentation to the Minnesota Groundwater Association
April 22, 2015
April 22, 2015
Gedney Foods Company
an introduction
MJH 150409
G d
Gedney
Today
T d
Manufacturer and marketer of branded premium pickled
vegetables.
Broad-based, experienced co-packer to quality-focused
clients.
Long-standing valued member of our community.
A responsible employer of people who care.
MJH 150409
O Market
Our
M k t Presence
P
MJH 150409
O Roots
Our
R t
Founded 1881 in Minneapolis by M. A. Gedney.
First Chaska operations in 1893.
Move to current Chaska site in 1958.
Cain’s acquisition in 2000.
Majority acquisition by PMC Global Inc. in 2010.
MJH 150409
O Brands:
Our
B
d Gedney®
G d
®
The Minnesota Pickle—with fans nationwide.
Leaders in small, fresh-pack pickles: BabiesTM
Highest velocity snack pickle in the USA.
MJH 150409
O Brands:
Our
B
d State
St t Fair®
F i®
Premium hand-crafted recipes inspired by State Fair
winners—personal, wholesome, fresh, local.
Emphasis on natural flavor combinations and eye appeal.
Exceptional quality at an attractive price point.
Registered brand of Gedney Foods.
MJH 150409
O Brands:
Our
B
d Cain’s®
C i ’ ®
Traditional New England recipes from the Cain’s Food
C
Company,
ffounded
d d 1924
1924.
Spicy flavor profiles and hearty product forms
popular in this market.
Strong
g regional
g
brand recognition—top
g
pickle relish in
New England.
MJH 150409
O
d D
t
Our B
Brands:
Dell M
Monte
National brand with west-coast roots.
Strong “field-to-store” association with Del Monte fruit and
vegetables.
t bl
Industry benchmark in sweet pickles and relish.
Premium quality recognition—top market positions on west
coast.
MJH 150409
M
Manufacturing
f t i
SQF-3/GFSI certified facility.
Union Orthodox Kosher certified
Filtered well water supply
supply.
Focus on fresh stock, with 100 salt tanks on site.
3 acidified food lines
1 relish line, 1 condiment line.
Pasteurization and hot fill capability.
Dedicated wastewater facility.
MJH 150409
Waste Wate
er
Aerators in pond A. This pond feeds pond B, which then discharges to the river. A third pond, C, is
used to isolated or quarantine water flows, and allows greater operation flexibility of the entire system.
Water usage reduction at Gedney Water
usage reduction at Gedney ‐
modern history
•
•
•
•
•
•
•
2006 77 MM gallons used as case sales increased
2007 59 MM gallons used as case sales increased
2007 59 MM gallons used as case sales increased
2010 54 MM gallons used as case sales increased
2011 69 MM ll
2011 69 MM gallons used as case sales increased
d
l i
d
2012 95 MM gallons used as case sales increased
2013 96 MM gallons used as case sales increased
2014 88 MM gallons used as case sales increased
General means to use less water at the Gedney Company
d
• Install automatic nozzles on all water hoses
• Install water saver nozzles on all water hoses
• Use exact amounts of water in desalt tanks to desalt to a set level. Do not over desalt (double‐edged sword)
• Improve and operate cooling compressors on pasteurizers year round
pasteurizers year round
• Improve counter‐current cooling in pasteurizer
• Install new cooling tower for spent pasteurizer water
Install new cooling tower for spent pasteurizer water
• Capture and reuse steam condensate from pasteurizers (double savings in water usage and energy savings)
General means to use less water at the Gedney Company (cont.)
d
(
)
• Clean‐up crews use shovels instead of hoses to remove p
debris from floor
• Replace water usage on cooling side of plate heat exchangers with close‐
h
ith l
l
loop Freon system
F
t
• Replace water usage on cooling side of scrape‐surface heat exchangers with closed‐loop
heat exchangers with closed
loop Freon system
Freon system
• Work with MNTAP (Paul Pagel), using partial grant in summer of 2013 to have Uof M engineering student (Ryan Venteicher) to be intern to study water conservation and its effects on Company operations
• THINK water conservation
THINK water conservation
Chloride usage reduction must accompany water conservation methods
i
h d
• In 2012 huge water conservation accomplished 0
uge ate co se at o acco p s ed
while holding chlorides static at 2,000 mg/l
g
• Eliminate food service customers using salt stock
• Reduce number of fermentation tanks
• Reduce salt stock winter hold from 18% to 12%
• Recycle spent brine
g
• Bring in salt stock fermented outside of Minnesota (net gain to environment is 0)
• Desalt to exact levels
Chloride usage reduction must accompany water conservation methods (cont.)
i
h d (
)
• Reduce salt level in finished products
• Require incoming fermented stock in barrels to not exceed 10% salt
• Fast track CaCl2 research
Fast track CaCl2 research
• Ferment in 1% CaCl2 instead of 7% NaCl
• Cannot be wintered in Minnesota
• Asked by three municipalities to sell spent fermentation A k d b th
i i liti t
ll
tf
t ti
brine for winter road application. Asked by MPCA to do test with DOT
• NOT a solution
NOT
l ti
• Corrosiveness (not just salt, but acid and salt)
• High BOD
g
Conclusions
Minnesota’s most precious resource is its water. Because of its abundance it is easy to forget that it is an asset with a finite amount. To make sure that we always have
amount. To make sure that we always have adequate supplies in the future we must all do what we can now to conserve and protect that precious resource.
t t th t
i