Environmental, Health, and Safety Guidelines

FOOD AND BEVERAGE PROCESSING

WORLD BANK GROUP

Environmental, Health, and Safety Guidelines for

Food and Beverage Processing

Introduction environment, and other project factors, are taken into account.
The applicability of specific technical recommendations should
The Environmental, Health, and Safety (EHS) Guidelines are be based on the professional opinion of qualified and
technical reference documents with general and industry- experienced persons.When host country regulations differ from
specific examples of Good International Industry Practice the levels and measures presented in the EHS Guidelines,
(GIIP) 1. When one or more members of the World Bank Group projects are expected to achieve whichever is more stringent. If
are involved in a project, these EHS Guidelines are applied as less stringent levels or measures than those provided in these
required by their respective policies and standards. These EHS Guidelines are appropriate, in view of specific project
industry sector EHS guidelines are designed to be used circumstances, a full and detailed justification for any proposed
together with the General EHS Guidelines document, which alternatives is needed as part of the site-specific environmental
provides guidance to users on common EHS issues potentially assessment. This justification should demonstrate that the
applicable to all industry sectors. For complex projects, use of choice for any alternate performance levels is protective of
multiple industry-sector guidelines may be necessary. A human health and the environment.
complete list of industry-sector guidelines can be found at:
www.ifc.org/ifcext/enviro.nsf/Content/EnvironmentalGuidelines Applicability
The EHS Guidelines contain the performance levels and These guidelines cover the processing of meat2, vegetable, and
measures that are generally considered to be achievable in new fruit raw materials into value-added food and beverage3
facilities by existing technology at reasonable costs. Application products for human consumption. Meat and poultry
of the EHS Guidelines to existing facilities may involve the slaughtering and processing activities, from reception of the
establishment of site-specific targets, with an appropriate animals until the carcasses are ready for sale or further
timetable for achieving them. The applicability of the EHS processing, are covered in the EHS Guidelines for Meat
Guidelines should be tailored to the hazards and risks Processing and the EHS Guidelines for Poultry Processing. This
established for each project on the basis of the results of an document is organized according to the following sections:
environmental assessment in which site-specific variables, such
Section 1.0 — Industry-Specific Impacts and Management
as host country context, assimilative capacity of the
Section 2.0 — Performance Indicators and Monitoring
Section 3.0 — References
1 Defined as the exercise of professional skill, diligence, prudence and foresight Annex A — General Description of Industry Activities
that would be reasonably expected from skilled and experienced professionals
engaged in the same type of undertaking under the same or similar
circumstances globally. The circumstances that skilled and experienced
professionals may find when evaluating the range of pollution prevention and
2 Meat includes beef, pig, and poultry.
control techniques available to a project may include, but are not limited to,
varying levels of environmental degradation and environmental assimilative 3 Includes only the manufacturing of non-fermented beverages. Beer
capacity as well as varying levels of financial and technical feasibility. manufacturing is addressed in the EHS Guidelines for Breweries.

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1.0 Industry Specific Impacts putrescible solid waste in the form of inedible materials and
rejected products from sorting, grading and other production
and Management
processes.5 Where meat products are the raw material, solid
The following section provides a summary of EHS issues
waste generated during processing may include organic
associated with food and beverage processing, which occur
materials that have the potential to significantly impact food
during the operational phase, along with recommendations for
safety due to the proliferation of pathogenic microorganisms.6
their management. Recommendations for the management of
EHS issues common to most large industrial facilities during the
Recommended measures to prevent and control solid waste
construction and decommissioning phases are provided in the
generation include the following:
General EHS Guidelines.
• Minimize inventory storage time for raw materials to reduce
1.1 Environment losses from putrefaction;

Essential tools for managing impacts while optimizing water, • Monitor and regulate refrigeration and cooling systems

energy, and resource use and improving working practices during storage and processing activities to minimize

involve the adoption of industry-specific good-manufacturing product loss, optimize energy consumption, and prevent

practice, quality management systems (including ISO 9000 odors;

series, ISO 22000), risk management systems (e.g., Hazard • Consider use of enclosure techniques to minimize damage

Analysis Critical Control Points, HACCP), and environmental to raw materials stored outdoors;
management standards (e.g., ISO 14000).4 • Monitor and optimize process yields, e.g. during manual
grading or cutting activities, and encourage the most
Environmental issues in food and beverage processing facilities productive employees to train others in efficient processing.
primarily include the following: • Clean, sort, and grade raw foodstuffs at an early stage

• Solid waste (e.g. at the farm site), in order to reduce organic waste and

• Wastewater substandard products at the processing facility;

• Energy consumption • Contain solid waste in dry form and consider disposal

• Emissions to air through composting and / or use for soil amendment;

• Organic and non-organic debris / soil, solid organic matter,
Solid Waste and liquid effluents, including sludge from wastewater
Depending on the raw materials, food and beverage processing
activities may generate significant volumes of organic, 5 For example, mushrooms have a low wastage factor (around 3 – 5 percent)

whereas the wastage factor for sweet corn kernel processing is much higher
(around 50-60 percent). United Nations Environment Programme (UNEP). 2004.
Working Group for Cleaner Production in the Food Industry. Fact Sheet 3: Food
4 HACCP is for the systematic identification and management of risks associated Manufacturing Series. Food and Beverage Processing.
with the production and distribution of foodstuffs. ISO 22000:2005 covers 6 The proportion of animal by-products in food processing activities in relation to

requirements for a food safety management system in which an organization in their carcass weight ranges from approximately 8 to 16.5 percent for pig, 7 to 8
the food chain demonstrates its ability to control food safety impacts to ensure percent for poultry, and 12 percent for beef. European Union (EU) Commission.
that food is safe at the time of human consumption. ISO 9000 series is an 2006. Directorate General Joint Research Council (JRC) Institute for
international standard for the certification of manufacturing and quality Prospective Technological Studies. Integrated Pollution Prevention and Control
management systems; ISO 14001 is an international standard for the Reference Document on Best Available Techniques in the Food, Drink and Milk
certification of environmental management systems. Industries.

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treatment, which remain after the implementation of waste separation of floatable solids; flow and load equalization;
prevention strategies should be recycled as a soil sedimentation for suspended solids reduction using clarifiers;
amendment (based on an assessment of potential impacts biological treatment, typically anaerobic followed by aerobic
to soil and water resources) or other beneficial uses such treatment, for reduction of soluble organic matter (BOD);
as energy production; biological nutrient removal for reduction in nitrogen and
• Collect and reuse rejected raw materials for manufacturing phosphorus; chlorination of effluent when disinfection is
other products;7 required; dewatering and disposal of residuals; in some
• Provide leak-proof containers for collected solid and liquid instances composting or land application of wastewater
waste; treatment residuals of acceptable quality may be possible.
• Segregating individual by-products from each other and Additional engineering controls may be required to contain and
from waste to maximize their use and minimize waste. neutralize nuisance odors.

Wastewater Management of industrial wastewater and examples of

treatment approaches are discussed in the General EHS
Industrial Process Wastewater
Guidelines. Through use of these technologies and good
Effluent streams from food and beverage processing may have practice techniques for wastewater management, facilities
a high biochemical and chemical oxygen demand (BOD and should meet the Guideline Values for wastewater discharge as
COD) resulting from organic wastes entering into the indicated in the relevant table of Section 2 of this industry sector
wastewater stream, and from the use of chemicals and document.
detergents in various processes including cleaning (discussed
below). In addition, effluent may contain pathogenic bacteria, Other Wastewater Streams & Water Consumption
pesticide residues, suspended and dissolved solids such as
Guidance on the management of non-contaminated wastewater
fibers and soil particles, nutrients and microbes, and variable
from utility operations, non-contaminated stormwater, and
pH. The effluent load should be reduced by preventing raw
sanitary sewage is provided in the General EHS Guidelines.
materials, intermediates, product, by-product and wastes from
Contaminated streams should be routed to the treatment system
unnecessarily entering the wastewater system, as discussed in
for industrial process wastewater. Food and beverage
the solid waste section above.
processing activities (e.g. washing, internal transport of raw
materials using water, cooling of blanched foods, and general
Process Wastewater Treatment
equipment cleansing) may consume large quantities of water.8
Techniques for treating industrial process wastewater in this In addition to the recommendations on water conservation
sector include grease traps, skimmers or oil water separators for included in the General EHS Guidelines, industry specific
measures include the following:
7 Secondary products may include jams and cut products, such as coleslaws;
sauerkraut; orange peels for use in dietary fiber supplements; potato pulp for
production of biofuel; onion material for onion oil production,
fructooligosaccarides, pectic polysaccharides, and low-lignin dietary fiber; 8 Water demands in meat processing are diverse and may, depending upon the
animal waste for production of animal feeds with strict recognition of biosafety specific operation, include thawing of frozen materials, continuous equipment,
considerations; and use of bones, fat, and other by-products from meat as raw boot, apron and clothing washing and disinfection as well as generation of
material for glue, detergents, gelatin, and other materials. steam and process heat, and cooling processes.

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• Minimize water consumed during production processes: o Return condensate for use as boiler feed water.
o Optimize product conveying systems to reduce Alternative uses for condensate include as a sprinkling
contact of raw material and product with water, for agent for dust suppression or in general factory wash
example by using dry instead of wet conveying down (e.g. cleaning the floor)
systems. Optimize process line operations to avoid o Where feasible, recycle low grade wash water and
spills of raw materials and water, reducing the need to reusing it for the primary wash of raw materials or for
wastewater treatment and associated energy wet transport
consumption; o Explore opportunities collection and use of storm
o Use dry methods, such as air classifiers, magnetic water consistent with food safety requirements
separators and vibration over sieving and screening • Review process lines and operations to identify
devices, for the primary cleaning of robust raw opportunities to reduce the effluent load by minimizing
materials with low moisture content; contact with water at every stage of the process, to avoid
o Where feasible, use a continuous / batch steam or a contamination of the water and the need for consequent
dry caustic process for peeling activities, or treatment, including:
alternatively, consider dry caustic peeling;
o Use dry methods (e.g. vibration or air jet) to clean raw
o Minimize rate of make-up supply to continuously
materials
overflowing tanks, flumes etc.
o Install grids to reduce or avoid the introduction of solid
o Use taps with automatic shut-off valves and use high
materials into the wastewater drainage system. Install
water pressure and optimized nozzles,
trays to catch waste from trimming operations and
o Use counter-current wash techniques for primary
juice / product on conveyors
wash of raw materials;
o Ensure regular integrity testing of bulk storage tanks
o Implement dry clean of equipment with scraper or
for product and waste
broom before cleaning with water
o Provide secondary containment for storage and
o Minimize wet transport (pumping) of waste
process vessels to contain spills
• Reuse water streams in the production processes to the
o Adopt best-practice methods for plant cleaning, which
maximum extent possible while avoiding water
can be manual or automated Clean In Place (CIP) 9
contamination or compromising food safety:
systems, using approved chemicals and (or)
o Separate and recirculate cooling water from process
detergents with minimal environmental impact and
and waste water streams. Recirculate and reuse
compatibility with subsequent wastewater treatment
thawing water in a closed circuit provided this practice
processes.
does not compromise food safety
o Recirculate fluming water used in vegetable transfer
provided this practice does not compromise food
safety
9 Automated CIP systems reduce chemical, water, and energy consumption and
facilitate rinse recovery but may not be appropriate for all applications.

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Energy Consumption • Recover energy from thermal processes where possible.

Food and beverage processing activities may require high levels Heat recovery opportunities may include, for example11:
of thermal energy consumption in process heating, cooling, and o Recovering heat from ovens, dryers, evaporators,
refrigeration. In addition to the recommendations on energy pasteurizers and sterilizers.
conservation included in the General EHS Guidelines, industry o Maximizing regeneration efficiency in plate heat
specific measures include the following10: exchanger pasteurizers (regeneration efficiency up to
94 percent is possible)
• Implement operational, maintenance and housekeeping o Recovering heat from condensed steam for blanching
measures: and steam peeling operations before it is discharged
o Insulate refrigeration room/areas and use of o Using multi-effect evaporators in large scale
automatically closing doors and airlocks evaporator applications.
o Insulate refrigeration rooms / areas
• Optimize plant processes for energy efficiency: Emissions to Air
o Use Combined Heat and Power (CHP) particularly in The main air pollutants from food and beverage processing
plants which have high heat and power demand for operations consist of particulate matter (PM) and odor. PM may
more than 5000 hours/year arise from solids handling, solid reduction and drying. Odor may
o Reduce the size of refrigeration rooms where feasible, be released by thermal processing steps such as steam peeling,
but still taking food safety into consideration blanching and dehydrating and by microbial action in stored
o Design plant layout to reduce pumping and conveyor solid waste. In meat processing, odor may also be emitted from
belt transportation distances cooking and smoking activities. 12
o Ensure that fouling on heat transfer surfaces, for
Management of emissions to air from combustion sources for
example in the sterilization process, is regularly
electricity generation is addressed in the General EHS
cleaned to ensure optimum efficiency
Guidelines.
o Avoid refrigeration of fruits, vegetables and by-
products intended for animal feed by storing outside in
Particulate Matter
clean covered areas or in containers, when climate
conditions and plant design allow Recommended techniques to prevent and control particulate
o Use high temperature pre-cooling before refrigerated matter emissions include13:
cooling and freezing, for example, after blanching pre-
• Cover skips and vessels, and stockpiles, especially
chill products by passing them cold water before
outdoors;
freezing. This is particularly cost –effective when liquid
nitrogen freezing is used. • Enclose silos and containers used for bulk storage of
powders and fine materials;

11 EC (2006)
12 EC (2006)
13 Based on Environment Agency. 2003. Environment and Heritage Service.
10 EC (2006) Guidance for the Food and Drink Sector. Sector Guidance Note IPPC S6.20.

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• Where enclosure is not feasible, use sprays, windbreaks, • Minimize storage duration for solid waste to avoid
sweeping, sprinkling, and other stockpile management putrefaction;
techniques to suppress dust ; • Operate facilities under partial vacuum to prevent fugitive
• Use closed conveyors equipped with filters to clean odor emission;
transport air prior to release; • Regular inspection of chilling and freezing equipment to
• Use cyclones and, if necessary, and fabric filters to remove monitor loss of refrigerants.
dust from exhaust air;
• Remove particulate matter from the gas stream using dry 1.2 Occupational Health and Safety
cyclones, venturi scrubbers, electrostatic precipitators Occupational health and safety issues associated with the
(ESPs) or dry filter systems, as necessary. operation of food and beverage processing during the
construction and decommissioning phases are discussed in the
Odor
General EHS Guidelines. Hazards during the operational
Recommended techniques to prevent and control point source phase include the following:
odor emissions include:
• Physical hazards
• Use exhaust stack heights that are consistent with Good
• Exposure to noise
Engineering Practice (GEP) as described in the General
• Biological hazards
EHS Guidelines;
• Chemical hazards
• If the plant is in close proximity to residential areas
• Exposure to heat and cold
consider the use of wet scrubbers to remove odor
emissions. Wet scrubbers are used to remove odors with a
Physical Hazards
high affinity to water, such as ammonia emitted during the
Physical hazards include exposure to same-level fall hazards
rendering process; and
due to slippery conditions, the use of machines and tools, and
• During the procurement of air emission systems for
collisions with internal transport equipment, such as forklift
smoking units, it is best practice to install integrated
trucks and containers. Guidance on general workplace
systems that combine air cleaning, incineration, and heat
conditions, including design and maintenance of working and
recovery. Such systems are highly effective with regard to
walking surfaces to prevent slips and falls, is presented in the
the reduction of odor emissions, production / energy
General EHS Guidelines. Additional, industry-specific
efficiency;
recommendations are presented below.
• Recirculate exhaust gas from frying and other cooking
operations to the burner. • Maintain walking and working surfaces clean and dry by
preventing spillages through equipment design and
Recommended techniques to prevent and control fugitive
operation, providing workers with anti slip footwear where
emissions of odor include:
still necessary;

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• Control of occupational risks at their source through Recommended measures to prevent and control worker
implementation of engineering controls. Address residual exposure to noise are discussed in the General EHS
risks based on hygiene and safety surveys and by Guidelines.
providing workers with training in the proper use and
maintenance of safety devises (including the proper use of Biological Hazards
machine safety devises) and personal protective Exposure to biological and microbiological agents may be

equipment (PPE), such as hearing protection, and gloves, associated with inhalation and ingestion of dust and aerosols.

aprons etc. to avoid cuts, amputations, and other sharp Dust from the ingredients used in food and beverage processing

instrument traumas; and high levels of humidity may cause skin irritation or other

• Ensure that the process layout reduces opportunities for allergic reactions.

process activities to cross paths, thus avoiding collisions

Recommendations for the prevention and control of exposures
and falls;
to biological hazards specific to food and beverage processing
• Demarcate transport corridors and working areas and
include the following:
ensure the proper placement of handrails on platforms,
ladders, and stairs; • Avoid dust- and aerosol-generating activities (such as use
• Prevent ingress of water; of compressed air or high-pressure water for cleaning) and,
• Ground all electrical equipment and installations; where they cannot be avoided, provide proper ventilation of
• Prepare emergency plans and train staff for emergency enclosed or semi-enclosed areas to reduce or eliminate
situations. exposure to dust and aerosols;
• Install exhaust ventilation equipped with filters, cyclones,
Lifting, Repetitive Work, and Work Posture Injuries etc., at sources of dust;
Food and beverage processing activities may include a variety • Provide workers with PPE that is appropriate for the
of situations in which workers can be exposed to lifting, carrying, process activity, e.g. masks and gloves;
repetitive work, and work-posture injuries. Such injuries may • Ensure physical segregation of work and welfare facilities
result from heavy manual lifting and repetitive work, including to maintain worker personal hygiene.
the operation of slicing and vacuum-packing machines and poor
working postures caused by inadequate workstation and Chemical Hazards
process activity design. Recommended management Exposure to chemicals (including gases and vapors) typically

approaches to reduce these injuries are discussed in the involves chemical-handling activities related to cleaning

General EHS Guidelines. operations, disinfection of process areas and use of

preservatives in long-term food storage, in addition to the
Exposure to Noise maintenance of heating (thermal oils) and cooling systems
A variety of operations in food and beverage processing units (ammonia). Recommended measures to prevent and control
generate substantial noise levels, for example the canning plant, exposure to chemicals are discussed in the General EHS
bottling machines, conveyors and blanching applications. Guidelines.

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Food and beverage processing sites usually have large be opposite to the flow direction of products (i.e. from “clean”
refrigeration systems, which often use ammonia as a primary towards “dirty” zones). Cleaning activities during processing will
refrigerant, and may have secondary refrigerants such as depend on the particular production and processing systems.
glycols or brines. Ammonia is a toxic substance and can form Daily cleaning and disinfection should comprise:
explosive mixtures with air. Guidance on the safe use of
ammonia and other refrigerants is readily available from • Ensuring proper equipment clearance for cleaning

professional refrigeration institution14 and should be considered. • Removal of solid waste

• Pre-rinsing with water
Heat and Cold • Application of detergent(s)
Food and beverage processing may create changing • Rinsing
temperature conditions due to activities such as heat treatment, • Disinfection
chilling and freezing. Workers may be exposed to heat from • Post rinsing
steam peeling, pasteurization, and canning processes and • Post treatment
exposed to low temperatures in refrigerated areas / rooms.
Irradiation dosing to extend the shelf-life of fruits and vegetables Staff should be trained in food safety issues and should follow
should be monitored for occupational exposure to radiation. established procedures for hand washing, working attire
Recommended measures to prevent and control exposure to (clothes, shoes, gloves and hair coverage), and how to handle
heat, cold, and radiation are discussed in the General EHS injuries and diseases.
Guidelines.
Food Safety Impacts and Management
1.3 Community Health and Safety A food product recall caused by contaminated or adulterated
food products can devastate a viable business. If a company
Community health and safety impacts during the construction
can trace its products to specific lot numbers, then recall is a
and decommissioning of food and beverage processing facilities
matter of removing all foods associated with those numbers.
are common to those of most industrial facilities and are
With a robust food safety program in place, a company can
discussed in the General EHS Guidelines. Industry-specific
protect itself from product adulteration, contamination, and the
issues with the potential to impact the community are those
impacts of food recalls.
associated with hygiene and food safety.
Food and beverage processing should therefore be performed
Process, Equipment, and Staff Hygiene according to internationally recognized food safety standards
The design of the processing plant should be organized to consistent with the principles and practices of Hazard Analysis
ensure that products move from “dirty” to “clean” areas to avoid
Critical Control Points (HACCP)15; and Codex Alimentarius16.
recontamination. Employee movement within the facility should

14See the Institute of Refrigeration (IOR) for guidelines on the safe design of
ammonia and other refrigeration systems, as well as safe handling of ammonia. International Organization for Standardization (ISO) (2005)
15

Also, the American Society of Heating, Refrigerating and Air-Conditioning 16Food and Agriculture Organization of the United Nations (FAO) and World
Engineers (ASHRAE). Health Organization (WHO) (1962-2005)

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The Codex Alimentarius provides Current Official Standards for frameworks. These guidelines are achievable under normal
a range of specific products from the food and beverage operating conditions in appropriately designed and operated
processing sector including canned, quick frozen, and whole facilities through the application of pollution prevention and
fresh food products. In addition the Codex Alimentarius provides control techniques discussed in the preceding sections of this
Current Official Standards for general and specific document. These levels should be achieved, without dilution, at
manufacturing steps in the production process, for example least 95 percent of the time that the plant or unit is operating, to
General Principles of Food Hygiene, Recommended be calculated as a proportion of annual operating hours.
International Code of Hygienic Practice for Canned Food and Deviation from these levels in consideration of specific, local
Beverage Products and the Recommended International Code project conditions should be justified in the environmental
of Practice for the Packaging and Transport of Tropical Fresh assessment.
Food and beverages. In general, recommended food safety
principles include: Effluent guidelines are applicable for direct discharges of treated
effluents to surface waters for general use. Site-specific
• Strictly maintain cold chains and other preservation discharge levels may be established based on the availability
processes; and requirements of publicly operated sewage collection and
• Full institutionalization of HACCP prerequisites as well as treatment systems or, if discharged directly to surface waters,
Standard Operational Procedures, including: on the receiving water use classification as described in the
o Sanitation General EHS Guidelines.
o Good Manufacturing Practice (GMP)
Emissions from food processing activities are principally
o Pest control
associated with particulate matter (PM) and odor. PM and odor
o Chemical control
emissions from point sources such as ventilation exhaust
o Allergen control
systems and smoking units should be released through GEP-
o Staff hygiene and education
designed stacks. Smoking unit emissions of PM should typically
o Customer complaints mechanism
not exceed 50 mg/Nm3. Combustion source emissions
o Traceability and reuse
guidelines associated with steam- and power-generation
activities from sources with a capacity equal to or lower than 50
2.0 Performance Indicators and
MWth are addressed in the General EHS Guidelines with
Monitoring
larger power source emissions addressed in the Thermal Power
2.1 Environment EHS Guidelines. Guidance on ambient considerations based on
the total load of emissions is provided in the General EHS
Emissions and Effluent Guidelines
Guidelines.
Table 1 presents effluent guidelines for this sector. Guideline
values for process emissions and effluents in this sector are
indicative of good international industry practice as reflected in
relevant standards of countries with recognized regulatory

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Table 1. Effluent levels for food and beverage

processing Resource Use and Waste Generation
Pollutants Units Guideline Value Tables 2 and 3 provide examples of resource consumption
pH pH 6 –9 indicators for energy, water, materials, and waste in this sector.

BOD5 mg/l 50 Industry benchmark values are provided for comparative

purposes only and individual projects should target continual
COD mg/l 250
improvement in these areas.
Total nitrogen mg/l 10

Total phosphorus mg/l 2

Environmental Monitoring
Oil and grease mg/l 10 Environmental monitoring programs for this sector should be
Total suspended solids mg/l 50 implemented to address all activities that have been identified to
Temperature increase °C <3b have potentially significant impacts on the environment, during
Total coliform bacteria MPN / 100 ml
a 400 normal operations and upset conditions. Environmental
Active Ingredients / To be determined on a case specific monitoring activities should be based on direct or indirect
Antibiotics basis
indicators of emissions, effluents, and resource use applicable
Notes:
a MPN = Most Probable Number to the particular project.
b At the edge of a scientifically established mixing zone which takes into
account ambient water quality, receiving water use, potential receptors and
assimilative capacity Monitoring frequency should be sufficient to provide
representative data for the parameter being monitored.
Monitoring should be conducted by trained individuals following
Table 2: Waste Generation in the Food and
monitoring and record-keeping procedures and using properly
Beverage Processing Sector
Solid waste produced per Industry calibrated and maintained equipment. Monitoring data should be
Unit
tonne of product Benchmark analyzed and reviewed at regular intervals and compared with
Maize Kg 40
the operating standards so that any necessary corrective
Peas Kg 40
actions can be taken. Additional guidance on applicable
Potatoes Kg 40 sampling and analytical methods for emissions and effluents is
Broccoli Kg 200 provided in the General EHS Guidelines.
Carrots Kg 200

Strawberries Kg 60

Apples Kg 90

Peaches Kg 180

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2.2 Occupational Health and Safety Table 3: Resource and Energy

Consumption in Food and Beverage Processing
Occupational Health and Safety Guidelines
Industry
Occupational health and safety performance should be Outputs per unit of product Unit
Benchmark
evaluated against internationally published exposure guidelines, Electricity Consumption a
of which examples include the Threshold Limit Value (TLV®)
Sorting of vegetables (carrots) 8
occupational exposure guidelines and Biological Exposure
Caustic peeling of vegetables 2
Indices (BEIs®) published by American Conference of
Steam peeling of vegetables 3.5
Governmental Industrial Hygienists (ACGIH),17 the Pocket
Washing of vegetables (carrots) 2.5
Guide to Chemical Hazards published by the United States kWhe/t frozen
Mechanical processing prior to vegetables 2.5
National Institute for Occupational Health and Safety (NIOSH),18 freezing (diced carrots)
Permissible Exposure Limits (PELs) published by the Drum blanching in deep freezing 0.5 – 1.3
of vegetables
Occupational Safety and Health Administration of the United Countercurrent water cooling of 0.5 – 1.3
vegetable
States (OSHA),19 Indicative Occupational Exposure Limit Values
Belt blancher with water cooler 2-9
published by European Union member states,20 or other similar
Belt blancher with air cooling 7 - 30
sources.
Water Consumption

Accident and Fatality Rates Canned fruit 2.5-4.0

Projects should try to reduce the number of accidents among Canned vegetables 3.5-6.0
project workers (whether directly employed or subcontracted) to Frozen vegetables 5.0 – 8.5
a rate of zero, especially accidents that could result in lost work
Fruit juices 6.5
time, different levels of disability, or even fatalities. Facility rates m /ton
3
Jams 6.0
may be benchmarked against the performance of facilities in this
Potato processing: b
4.5 – 9.0
sector in developed countries through consultation with Range
Well managed 5.1
published sources (e.g. US Bureau of Labor Statistics and UK
Cooked Ham b 4 - 18
Health and Safety Executive)21.
Cured Ham b 2 - 20

Occupational Health and Safety Monitoring Sausages, ham, bacon, etc. b 10 - 20

The working environment should be monitored for occupational NOTES

a Tables 3.31 – 3.39. European Commission. IPPC. Reference Document on
hazards relevant to the specific project. Monitoring should be
BAT in the Food Drink and Milk Industries. P. 169 - 177.
b Table 3.20: Water consumption for some processes in the food and beverage
sector. European Commission. IPPC. Reference Document on BAT in the Food
Drink and Milk Industries. P. 162.
17 Available at: http://www.acgih.org/TLV/ and http://www.acgih.org/store/
18 Available at: http://www.cdc.gov/niosh/npg/
designed and implemented by accredited professionals22 as part
19 Available at:
of an occupational health and safety monitoring program.
http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDAR
DS&p_id=9992
20 Available at: http://europe.osha.eu.int/good_practice/risks/ds/oel/ 22Accredited professionals may include Certified Industrial Hygienists,
21 Available at: http://www.bls.gov/iif/ and Registered Occupational Hygienists, or Certified Safety Professionals or their
http://www.hse.gov.uk/statistics/index.htm equivalent.

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Facilities should also maintain a record of occupational

accidents and diseases and dangerous occurrences and
accidents. Additional guidance on occupational health and
safety monitoring programs is provided in the General EHS
Guidelines.

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3.0 References and Additional Sources

American Society of Heating, Refrigerating and Air-Conditioning Engineers United Kingdom (UK) Environment Agency. 2003. Environment and Heritage
(ASHRAE). http://www.ashrae.org/ Service. Sector Guidance Note IPPC S6.10 Guidance for the Food and Drink
Sector. Bristol: Environment Agency. Available at
Arbejdstilsynet (Danish Working Environment Authority). 2006. Konserves og http://publications.environment-agency.gov.uk/pdf/GEHO1205BJZJ-e-e.pdf
drikkevarer mv. (Preserved foods and drinks). Arbejdsmiljøvejviser 39 – 2.
udgave. Copenhagen: AT. Available at http://www.at.dk/sw5801.asp United States Department of Labor, Bureau of Labor Statistics (US BLS).
2004a. Industry Injury and Illness Data – 2004. Supplemental News Release
Australian Government Department of Environment and Heritage (Environment Tables. Table SNR05: Incident rate and number of nonfatal occupational injuries
Australia). 1999. National Pollutant Inventory (NPI). Emission Estimation by industry, 2004. Available at http://www.bls.gov/iif/oshwc/osh/os/ostb1479.pdf
Technique Manual for Food and Beverage Processing Industry. Canberra:
Environment Australia. US BLS. 2004b. Census of Fatal Occupational Injuries Charts, 1992-2004.
Number and rate of fatal occupational injuries by private industry sector, 2004.
Australian Government Department of Primary Industries and Water (DPIW). Available at: http://www.bls.gov/iif/oshwc/cfoi/cfch0003.pdf
Tasmania. 2002. Emisión Limit Guidelines for Fruit & Vegetable Processing
Activities that Discharge Pollutants into Fresh and Marine Waters. Hobart: United States Environment Protection Agency (US EPA) . 1995. Compilation of
DPIW. Available at: http://www.dpiw.tas.gov.au/inter.nsf/attachments/cdat- Air Pollutant Emission Factors. Volume 1: Stationary Point and Area Sources,
5ba9fv/$file/guidelines%20for%20fruit%20and%20veg%20processing%20activiti AP 42, Fifth Edition, Volume I. Chapter 9: Food and Agricultural Industries.
es.pdf Sections 9.8.1 Canned Food and Vegetables and 9.8.2 Dehydrated Food and
Vegetables. North Carolina, USA: US EPA. Available at
European Commission (EC). 2006. Directorate General Joint Research Council http://www.epa.gov/ttn/chief/ap42/ch09/index.html
(JRC) Institute for Prospective Technological Studies (IPTS). Integrated
Pollution Prevention and Control Reference Document on Best Available
Techniques in the Food, Drink and Milk Industries. Seville: IPTS. Available at
http://www.jrc.es/home/index.htm

Food and Agriculture Organization of the United Nations (FAO) and World
Health Organization (WHO).1962-2005. Codex Alimentarius. Geneva: FAO and
WHO. Available at http://www.codexalimentarius.net/web/index_en.jsp

Food Processing Technology – Principles and Practice. 2000. Second edition.

Fellows, P.J. Cambridge: Woodhead Publishing.

Institute of Refrigeration (IOR). http://www.ior.org.uk

International Organization for Standardization (ISO). 2005. ISO 22000: 2005:

Food safety management systems - Requirements for any organization in the
food chain. Geneva: ISO. Available at
http://www.iso.org/iso/en/CatalogueDetailPage.CatalogueDetail?CSNUMBER=3
5466&ICS1=67&ICS2=20&ICS3

ISO. 2004. ISO 14001: 2004: Environmental Management Systems -

Requirements with guidance for use. Geneva: ISO. Available at
http://www.iso.org/iso/en/CatalogueDetailPage.CatalogueDetail?CSNUMBER=3
1807&ICS1=13&ICS2=20&ICS3=10

ISO. 2004. ISO 9001: 2000: Quality Management System. Geneva: ISO.
Available at http://www.iso.org/iso/en/iso9000-14000/index.html

Konserveringsteknik (Preservation technology) 1. 2004. Second edition. Bøgh-

Sørensen, L. and Zeuthen, P. Copenhagen: DSR.

Konserveringsteknik (Preservation technology) 2. 2002. Second edition. Bøgh-

Sørensen, L. and Zeuthen, P. Copenhagen: DSR.

United Nations Environment Programme (UNEP). 2004. Working Group for

Cleaner Production in the Food Industry. Fact Sheet 3: Food Manufacturing
Series. See http://www.gpa.uq.edu.au/CleanProd/

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Annex A: General Description of Industry Activities

The food and beverage processing sector covers a wide range packed beetroot. Typical examples of soft drinks are food and
of products. Many process steps are common to the beverage juices and concentrated fruit extracts for dilution with
manufacture activities of different products. Food and beverage water.
processing plants vary in size and location, and are ideally
located in close proximity to fresh water resources. Plant Receipt of Raw Materials
operation is often seasonal reflecting the harvesting of the raw Raw materials are typically delivered in bulk on trucks and are
materials, however product lines are unaffected by seasonal off-loaded directly for processing or for storage (e. g. in silos).
variations and take place throughout the year. Other solid material ingredients may be delivered in bags on
pallets. Liquid raw materials and ingredients may be transported
Figure 1.0 summarizes the major processes for most food and
in bulk tankers and pumped to storage tanks or delivered in
beverage products from fruit and vegetable sources, though the
containers on pallets. Solid raw materials are conveyed by belts
actual process flow will vary depending on the product and the
and elevators.
plant set-up. Figure 2.0 summarizes the major steps for
processing of meat products, specifically applicable to cooked
Primary Grading / Screening
ham manufacturing.
This process stage often covers grading and sorting but its main
Fruit and Vegetable Processing 23 objective is the assessment of the overall quality of the food
Fruit and vegetable production begins with the preparation of using a number of criteria. Solid raw materials should preferably
the raw food and beverages thorough a variety of methods be sorted and graded on the farm in order to minimize the
including cleaning, trimming and peeling to reduce the product quantity of waste material, organic and non-organic debris, and
to a uniform size before cooking, canning, drying or freezing, as off-specification product that is transported to the processing
well as pulping and filtration to make soft drinks. The process plant.
culminates with the packaging and transport of the final product.
Intermediary Storage
There are two major sub-sectors including fresh packed
Storage of food and beverages can be required at various
products and processed products. Processed products involve
stages of the manufacturing process and the storage conditions
other unit operations such as cooking, evaporating and drying to
will be dependent on the product. In general the parameters to
provide product diversity and increase shelf-life. Common
be controlled for storage include humidity, temperature,
examples of processed fruit products are canned peaches and
atmospheric conditions, and hygiene.
pears, dried fruits, jams and jellies, and fruit purees for use in
the food industry. Examples of processed vegetable products Primary Cleaning
include canned beans and frozen peas, as well as vacuum
Primary cleaning removes and separates off-specification
23This section briefly describes the major manufacturing steps in the food and material, organic and non-organic debris, metals, and pesticide
beverage processing sector and has been adapted from text in the British
Environment Agency’s Guidance for the Food and Drink Sector, Environmental residues, among other contaminants, from the raw material prior
Agency (2003).

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to further processing. The method used depends on the type of Product Processing
materials to be removed and may include the use of water
Food and beverages can be processed as a single operation or
although dry methods are favored for water conservations and
in a combination of several operations. The most common
wastewater prevention reasons.
processing methods are through heat application and heat

When water is used, the raw materials may be sprayed, and removal. The heat application methods include blanching,

then immersed for organic and non-organic debris removal pasteurization, heat sterilization, evaporation, and dehydration

using brushes, shaking, and stirring. The spray water may be including heat processing by baking or cooking in oils. Heat

chlorinated and detergents may be added to the wash water, removal processing includes chilling, controlled or modified

which may also be heated to increase cleaning efficiency. storage and packaging (to reduce the rate of respiration),
freezing, and freeze-drying. Other preservation and processing
Sorting, Grading and Inspection methods include the use of sodium chloride and sugar, food
additives, and irradiation.
The washed material may be sorted, graded and inspected prior
to further processing to ensure uniformity. Sorting is the
Packaging
separation of materials into categories and the main factors are
size, shape, weight, and color. Size sorting is typically done Products are packed to provide containment, protection,

using screens and sieves. Shape sorting may be done manually communication, and convenience. Packaging materials typically

or mechanically and weight sorting is typically used for valuable used in the food and beverage processing sector include flexible

material such as tropical fruits. Color sorting is performed polymer materials (e.g. single films and laminates), paper,

manually or by use of computer technology whereby the cardboard and corrugated cardboard, glass, cans, and wooden

material passes the control point on conveyor belts at high rates or polymer boxes.

and rejected items are blasted away using compressed air.

Meat Processing
Product Preparation If beef, poultry and pork are received frozen, processing
involves thawing after arrival to the processing plant using air,
Most raw materials have parts that are inedible and need to be
water showers, or water immersion techniques. The first two
removed in order to make the raw materials uniform and
techniques generally require less water consumption than
suitable for further processing. In the product preparation phase,
immersion thawing methods. Thawed meat is then cut into retail
the sorted and graded materials are subjected to a variety of
portions using electric cutting systems. Excess fat and bones
processes including trimming (manual or by rotating knives),
can be reprocessed into commercial products such as gelatin,
peeling, and size reduction, as well as mixing, forming,
glues, etc. Fresh cuts are refrigerated prior to further processing
separation and concentration of the food components. Various
into preserved meat products, such as sausage, ham, and
peeling methods are available including flash steam, flame,
bacon. Cuts may be ground down and reconstituted into
knife, abrasion, and caustic.
different product shapes using various processing machinery.
Preservation techniques include heat, such as cooking (e.g. in
water bath, shower, steam, and hot air ovens) and smoking,

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dehydration, fermentation, brining, curing, pickling, and canning.

These activities are performed to increase the shelf life of the
product. Brining, curing and pickling typically involve injection of
a saline solution, followed by a massaging process to ensure
mixing of ingredients and product additives. Meats are then
inserted into casings to define their shape and size.

Figure A.1: General Process for

Food and Beverage Processing Operations

Receipt of raw materials

Primary grading / screening

Intermediary storage

Primary cleaning and washing

Sorting, grading, and inspection

Product preparation

Product processing

Further processing

Packaging

Storage and dispatch

Source: Adapted from UNEP (2004)

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Figure A.2: Canned Meat Production (Including Cured and Cooked Meat)

CANNED

Receipt of raw
materials

Thawing

Cutting/trimming
CURED COOKED

Cans Meat dosing Salting Pickling

Weight control Refrigeration Moulding

Cooking (de-aeration) Resting Cooking (de-aeration)

Sealing Trimming Cooking and smoking

Can washing Washing Re-moulding/cooling

Thermal treatment Dehydration Trimming and stuffing Mould washing

Cooling Curing Surface pasteurization

Storage Packing under vacuum Cooling

Refrigeration

Packaging

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