WATER TREATMENT AND USE IN FOOD PROCESSES

• Sponsoring Institution: National Institute of Food and Agriculture
• Project Status: COMPLETE
• Funding Source: HATCH
• Reporting Frequency: Annual
• Accession No.: 1004521
• Project Start Date: Dec 5, 2014
• Project End Date: Sep 30, 2019
• Program Code: [(N/A)]- (N/A)

Recipient Organization
OKLAHOMA STATE UNIVERSITY
(N/A)
STILLWATER,OK 74078

Performing Department
Biosystems & Ag Engineering

Non Technical Summary
Water is the primary ingredient in many foods and is universally used for cleanup of equipment and plant environments. Water availability and quality are important issues for food processors, but water is often an undervalued and misused resource. Processors need to understand the importance of water and have access to sound ideas and plans for water treatment and use. This project is aimed at improving the water use practices of food processors by helping them to understand the issues, describing existing solutions and how they may be effectively applied, and developing new solutions.

Animal Health Component

100%

Research Effort Categories

Basic

0%

Applied

100%

Developmental

0%

Classification

Knowledge Area (KA)	Subject of Investigation (SOI)	Field of Science (FOS)	Percent
501	5010	2020	100%

Knowledge Area
501 - New and Improved Food Processing Technologies;

Subject Of Investigation
5010 - Food;

Field Of Science
2020 - Engineering;

Keywords

water

treatment

use

waste

conservation

filtration

food

process

Goals / Objectives
Objectives:The overall objective of this project is to improve water use practices by food processors. Specific objectives include the following:Identify water treatment and use techniques and equipment that show potential application for the food processing industry of Oklahoma.Develop or implement at least two unique systems of water treatment and use for food processes that can be used by the industry of Oklahoma.Prepare a technical publication and presentation for the techniques identified in objective number two that is intended to result in widespread use of the techniques.Develop or improve on at least one new method or means of water treatment or use that includes innovative equipment and/or techniques.

Project Methods
Procedures:Specific procedures corresponding to the stated objectives follow:1. Identify water treatment and use techniques that show the most promise for the food processing industry. This step will begin with a comprehensive review of the state-of-the-art of water use in Oklahoma and neighboring states, and a review of the pertinent literature. A survey of Oklahoma's food processors is vital to determine their needs, commonalties and potential for impact on the state's economy. The survey will be coordinated with other members of the FAPC and the "value-added" faculty of OSU. Much of the information to be learned will be uncovered by site visits and discussion with others that are familiar with the issues. Because of the diversity and breadth of products in the food processing industry, it may be expedient to initially concentrate on selected process types, such as meat processing or baking because of their importance to Oklahoma. Information for the literature review will be obtained from applied food science literature and recent issues of food processing trade publications. This information will indicate trends in the industry and illuminate possible, future directions for research. Literature will be obtained from studies conducted in other industries, such as oil and gas processors and the heavy machinery industry, which commonly utilize water in their processes. Many techniques and some of the technology developed for these industries can be adapted for food processing. An economic analysis of the water processing system will be conducted to identify return on investment (ROI). Only systems with an attractive ROI will be considered.2. Develop water treatment and use techniques for the food industry through experimentation and discussion with FAPC clients. Using the literature review as a basis, it may be possible to develop a water use program for selected food processors that provides immediate and verifiable results. Experimentation will be necessary when water processing techniques have not been applied to food processes. Experimentation will be accomplished through industrial partners and activities at the FAPC. The industrial partners will be encouraged to participate in experimental programs through their own desire to improve, support provided by the FAPC, and grant monies. A study that is already under development through an SBIR grant provides an example. The goal of the study is to purify water using UV light produced by LED bulbs. A full-scale model will be built and tested in the FAPC for effects on bacteria. Concepts used in the project have direct application to industries where water treatment is required.3. Develop an implementation plan for the new water treatment and use scheme. Since any processing technique is only useful if implemented, a simple, foolproof plan of execution must be formulated, reviewed and refined through repeated application. The final results will include refereed publications detailing water treatment and use techniques and equipment. The publication and case studies will lead to widespread understanding and use of the information in the food industry.4. New applications for water treatment or use will be developed. New ideas are expected to be identified after surveying the food processors of Oklahoma and reviewing the literature. The national effort to reduce water consumption and carbon emissions provides a fertile environment for development of this proposal. Communication of successes in this area will be vital to the expansion of the program into new and existing processes and commercial water treatment and use systems.

Progress 12/05/14 to 09/30/19

Outputs
Target Audience:Professionals in the food and agricultural products manufacturing industry, including food processors and food equipment manufacturers. Food science and engineering students. Consumers and users of water. The scope of audience is national and international. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?Graduate students that worked on the project received training, worked in hands-on applications and developed an understanding of water use and conservation in food processing. Undergraduate students that attended lectures received knowledge and exposure to issues. Professionals involved in one-on-one projects received training and development that benefitted the companies they worked for and some personally. How have the results been disseminated to communities of interest?Workshops, publications (fact sheets and book chapters), class lectures at OSU, one-on-one projects with clients from industry. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? Water use and treatment techniques and equipment were identified for application in the food processing industry of Oklahoma. The PI identified treatment options suitable for boiler makeup water for direct injection and contact with foods. A low-cost and convenient additive was found that may be used by a wide range of food processors with similar water conditions. The PI consulted with an international engineering firm to identify water conservation techniques for a large goat/dairy farm in India. Techniques included rainwater collection, greywater reuse and an efficient cleaning system for equipment and surfaces. The same techniques have a widespread application in the food and agricultural industry. The PI and a graduate student, Ms. Sagarika Bhargava, developed a unique, innovative, and low-cost water treatment system for point of use water systems. A carbon-based prefilter was designed, fabricated and tested for removal of heavy metals (lead and cadmium) from water. The carbon was made from coconut shells. The water treatment system can be used, or adapted for use almost anywhere, and is especially applicable in developing areas. The PI worked with other faculty members and students to develop an improved method to construct biosand water filters. The new method simplified the procedure of forming and finishing concrete filter housings. Implementation has a widespread application in developing areas that make use of biosand water filters. The PI and local food processors worked together to identify and test methods to control moisture condensation in food processing facilities that included water management and conservation. Uncontrolled condensation in food processing facilities can result in contamination and unsanitary conditions. Unique water treatment systems were developed or implementedfor use in food processing. The PI, working with a local meat processor, identified and implemented a new boiler feedwater treatment system for well water. Water and steam quality, boiler performance and condition were monitored. The treatment system was a success and could be an effective solution for other rural food processors in similar circumstances. The PI and a graduate student, Ms. Sagarika Bhargava, developed a unique, innovative, and low-cost water treatment system for point of use water systems. A carbon-based prefilter was designed, fabricated and tested for removal of heavy metals (lead and cadmium) from water. The carbon was made from coconut shells. The system can be adopted for widespread use, especially in developing areas Technical publications and presentations on water treatment and use in the food industry were made to disseminate results The PI and Dr. Rodney Holcomb published an applied extension article for financial analysis of commercial kitchens located on and off farms. The financial model included water use and costs. Users of the model will have a better understanding of water needs, expenses and conservation measures. Six new publications are available for download and distribution to the target audience at no cost. The publications directly address water treatment and use in food processing and include: reducing water use in food processing, biosand water filter construction, water treatment for removal of lead and cadmium, strategies to manage moisture condensation in food processing facilities, low-cost pecan sanitizer (with recycled sanitizer to reduce water use), and a financial model of commercial kitchen (including water use). Two workshops were repeated each year during the project to disseminate information: Sanitation in the food industry, and preventive measures for food safety. Both workshops included water use and conservation techniques. Innovate equipment and/or techniques were developed for water treatment and use. Working with a rural meat processor, the PI improved on a method to pretreat boiler feedwater. The method included a proprietary chemical additive and successfully reduced scaling in the boiler. The PI was a coauthor of a fact sheet detailing a process for sanitizing pecans. The fact sheet targeted small-scale processors that are now required to include a sanitizing step for shelled pecans. The fact sheet included a complete set of construction drawings for the system and operating instructions. The system was designed to reduce water use by recycling sanitizing solution and reducing aerosolization.

Publications

• Type: Book Chapters Status: Published Year Published: 2019 Citation: Bowser, T.J. 2019. Food Processing Facility Design, Ch 24 in Handbook of Agricultural and Farm Machinery, 3rd edition. M. Kutz, editor. Elsevier, Inc.
• Type: Book Chapters Status: Published Year Published: 2019 Citation: Bowser, T.J. 2019. Sanitary Pump Selection and Use, Ch 25 in Handbook of Agricultural and Farm Machinery, 3rd edition. M. Kutz, editor. Elsevier, Inc.

Progress 10/01/17 to 09/30/18

Outputs
Target Audience:Food Processors, food processing equipment suppliers and manufacturers, farmers, water utility providers Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?1. Two workshops. One on sanitation in the food industry and the second on preventive measures for food safety. Both workshops included or involved water treatment and conservation. The workshops each offered certificates of completion that are recognized by the industry. Total attendees were about 45 industry professionals. 2. One-on-one projects with fifteen clients in the food industry involving water use for cleaning, as an ingredient, and for production of steam. Clients were mentored in techniques of water treatment, use, and conservation. 3. One-on-one training of three graduate students. Graduate student training included the use of water as a food ingredient and the importance and methods of water treatment. 4. Lectured about 25 undergraduate and graduate students (as a guest lecturer for FDSC 3373, Food Chemistry) on the properties and uses of water in food processing. Described conservation techniques. How have the results been disseminated to communities of interest? Two workshops. One on sanitation in the food industry and the second on preventive measures for food safety. Both workshops included or involved water treatment and conservation. Two published journal articles. Word of mouth between clients and their personnel and peers. Lecture notes distributed to undergraduate and graduate students in class (FDSC 3373, Food Chemistry). What do you plan to do during the next reporting period to accomplish the goals? Publish additional fact sheet(s) to disseminate information. Participate/lead in additional workshop(s) to disseminate information. Meet with clients (one-on-one) in the food industry to help with their needs regarding water treatment and use.

Impacts
What was accomplished under these goals? (a) Worked with a local meat packing company to identify an inexpensive water treatment system to meet their needs. Their water source was an on-site well with variable quality. Treated water needed to be suitable for steam boiler makeup. The treatment system included an ion exchange unit and a proprietary chemical additive. The additive was manufactured by a local company that specialized in boiler feed water treatment. (b) Consulted for eMi (Engineering Ministries International) to identify techniques to reduce water use on a large goat farm/dairy in India. Three systems were designed to improve water conservation: rainwater collection and use; greywater reuse system; and, an efficient cleaning system for equipment and surfaces. Implemented a new boiler feedwater treatment system at a small meat packing plant in rural Oklahoma that sourced their water from a well. Monitored water quality, boiler condition and performance. The treatment system was a success and could be effective for rural food processors in similar circumstances. Published an applied extension article for financial analysis of commercial kitchens located on and off farms. The financial model included water use and costs. Readers will have a better understanding of water needs and expenses and will be more likely to adopt conservation measures. Improved on a method to pretreat boiler feedwater for a rural food processor in Oklahoma that obtained water from a well. The method included a proprietary chemical additive and successfully reduced scaling in the boiler.

Publications

• Type: Journal Articles Status: Published Year Published: 2017 Citation: Bowser, T.J., F. Ojwang, R. Sahs, and L. Brandenberger. 2017. Promotion of orange flesh sweet potato by demonstration of acceptance and food product development. African Journal of Food Science 11(12): 383-388. DOI: 10.5897/AJFS2017.1647; ISSN: 1996-0794
• Type: Journal Articles Status: Published Year Published: 2018 Citation: Bowser, T.J. and R.B. Holcomb. 2018. Financial analysis tools for on-farm and off-farm commercial kitchens. Article #2TOT3. Journal of Extension 56(2).

Progress 10/01/16 to 09/30/17

Outputs
Target Audience:Food processors Food processing equipment suppliers and manufacturers Farmers Water utility providers Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?A sanitation workshop for food processors was held at Oklahoma State University in May. It was attended by food industry professionals from Oklahoma and surrounding areas. The workshop helped participants to understand, identify and apply water saving applications in cleaning and sanitizing food production facilities and equipment. How have the results been disseminated to communities of interest?Results have been disseminated by visiting with food processing clients in the State of Oklahoma and working with them to conserve water. Presented at Sanitation Workshopat Oklahoma State University. The workshop was attended by food processors located in and around Oklahoma. The workshop included information on water use and conservation during cleaning and sanitizing processes in food processing facilities. What do you plan to do during the next reporting period to accomplish the goals?Write a fact sheet on the topic of water conservation for the food processing industry. Identify and implement new or underutilized methods of water conservation for the food industry. Work with individual clients in the food industry to improve water use and conservation.

Impacts
What was accomplished under these goals? Worked with a local supplier (Don Helfers & Associates, Chesterfield, MO) of spray nozzle equipment to test a new device. Helfers represents BETE Fog Nozzle, Inc., of Greenfield MA. BETE has developed a new nozzle, the HydroClaw, for rapid and efficient cleaning of tanks. The HydroClaw is self-flushing and does not clog as easily as standard nozzles. We have been negotiating with Helfer's to receive a HydrClaw for testing and evaluation. Plans are to test the unit on food and agricultural tanks, stage demonstrations at workshops and other extension events and report results. A fact sheet detailing the design and construction of a small-scale pecan sanitizer was published. The target audience was small-scale pecan growers and shellers. The fact sheet describes an effective and economical method for water and sanitizer application to pecans. A unique and innovative system of water treatment was developed for food processors: A carbon-based prefilter was designed, fabricated and tested for removal of heavy metals (lead and cadmium). The carbon was made from coconut shell. Coconut shell is a food industry byproduct in many countries that is available worldwide as a bedding and mulch material. The carbon was treated with food-grade acids to improve uptake of heavy metals. Results and additional information are available in the thesis by S. Bhargava listed in the products section. Four new publications (one thesis, two fact sheets, and one financial model) are available for download and distribution to the target audience at no cost. These publications directly address water treatment and use in food processes. A new prefilter and method of manufacturing and using the prefilter are described in the thesis written by Ms. Bhargava and the poster on the topic that was presented at a research symposium. A fact sheet was written and published on pecan sanitization. The water and sanitizer are recycled.

Publications

• Type: Theses/Dissertations Status: Published Year Published: 2017 Citation: Bhargava, S. 2017. The construction and adsorption efficiency of a carbon pre-filter for the removal of heavy metals from drinking water in developing areas. M.S. Thesis, Oklahoma State University.
• Type: Other Status: Published Year Published: 2017 Citation: Holcomb, R. and T. Bowser. Financial analysis model for building/operating a commercial kitchen. . R.M. Kerr Food & Agricultural Products Center, Oklahoma State University (available at: http://fapc.biz/services/feasibility-analysis)
• Type: Other Status: Published Year Published: 2016 Citation: Bowser, T.J. 2016. Reducing water use in food processing. Fact Sheet FAPC-204. Available at: http://factsheets.okstate.edu/documents/fapc-204-reducing-water-use-in-food-processing/
• Type: Other Status: Published Year Published: 2017 Citation: Mackey, B., T. Bowser, and P. Weckler. 2017. Low-cost pecan sanitizer plans for small-scale producers. Fact Sheet FAPC - 208. Available at: http://factsheets.okstate.edu/documents/fapc-208-low-cost-pecan-sanitizer-plans-for-small-scale-producers/

Progress 10/01/15 to 09/30/16

Outputs
Target Audience:Food processing industry in US and developing nations and those in need of purified water. Changes/Problems:One of the water treatment methods developed is more suitable for use in developing populations that have limited access to clean water. This is a change from the targeted audience of food processors in Oklahoma and the U.S., but the technology and process can be adapted to work in many locations and under many conditions. What opportunities for training and professional development has the project provided?Sanitation workshop developed and held on May 19th, 2016at Oklahoma State University for food industry professionals. The workshop featured information about water purity and use of water for cleaning and sanitation in food processing.About 20 industry professionals attended. How have the results been disseminated to communities of interest?Three new publications (one journal article and two fact sheets) are available for download by target audience at no cost. What do you plan to do during the next reporting period to accomplish the goals?Plans for the next reporting period: (a) additional workshop on sanitary design; (b) additional research and development of carbon-based prefilter for biosandwater filter; and (c) work with food processors in Oklahoma on improving water-use practices.

Impacts
What was accomplished under these goals? 1. The following water treatment and use techniques were developed for food processors: (a) Biosand water filter for purification; (b) Water use reduction through performance of a water balance and implementation of a proactive strategy to reduce water waste; and (c)Moisture condensation managementusing a strategy for moisture reduction and control. 2. The followingunique systems of water treatment and use were developed/applied for food processors: (a)Biosand water filter; and,(b)currently inthe process of developing a carbon-based prefilter to remove contaminants from water. 3. The following publications helped to meet objectives: Fact sheets FAPC-204 and FAPC-203 (see publications section for complete references). 4. Innovated new methods of water treatment: (a) Biosand water filter construction method (see IJSLE publication"Improved field methods..." in publications section).

Publications

• Type: Journal Articles Status: Published Year Published: 2016 Citation: Bowser, T.J., P.R. Weckler, M. Bugg, E. Lam, and J. Chamberlain. 2016. Improved field methods for construction of concrete biosand water filter housings. IJSLE, V 11(1): 32-50.
• Type: Other Status: Published Year Published: 2016 Citation: Bowser, T.J. 2016. Reducing water use in food processing. Fact Sheet FAPC-204. Available at: http://pods.dasnr.okstate.edu/docushare/dsweb/Get/Document-10433/FAPC-204web.pdf
• Type: Other Status: Published Year Published: 2016 Citation: Bowser, T.J. and R. Jadeja. 2016. Strategies to reduce moisture condensation in food facilities. Fact Sheet FAPC-203. Available at: http://pods.dasnr.okstate.edu/docushare/dsweb/Get/Document-10432/FAPC-203web.pdf

Progress 12/05/14 to 09/30/15

Outputs
Target Audience:Food processing industry and those in need of purified water. Changes/Problems:One of the water treatment methods developed is more suitable for use in developing populations that have limited access to clean water. This is a change from the targeted audience of food processors in Oklahoma and the US, but the technology and process can be adapted to work in many locations. What opportunities for training and professional development has the project provided?Travel to Mwanza, Tanzania and Norman, Oklahoma to lead workshops or workshop sessions on biosand water filter construction, use, and maintenance. How have the results been disseminated to communities of interest?An article on biosand water filter construction has been prepared and is in the process of being submitted to a journal. Fact sheets are under preparation for publication through standard University outlets and non-profit water-centered service websites. What do you plan to do during the next reporting period to accomplish the goals?Conduct research to identify a water treatment/use method or equipment that can help the food processing industry of Oklahoma. Test and develop the identified water treatment/use method or equipment. Publish results and make presentations at workshops.

Impacts
What was accomplished under these goals? Two full-scale model sand filters were constructed using new low-cost field techniques. A portable water purification system was designed to remove off-flavors from municipal water that is used as an ingredient in a beverage. A water-spray cooler was designed to reduce volumes of wastewater generated at a sausage processing facility.

Publications