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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