C254 - Leiner Davis Gelatin N.Z. Ltd, Christchurch
- Canterbury region
Summary
The Target Zero cleaner production programme complemented Leiner Davis’s commitment
to continuous quality improvement and provided a key input to the accreditation
process for the site’s ISO14001 environmental management system. Two of the
cleaner production options that were identified required no capital investment,
providing Leiner Davis with immediate savings of $28,000 per year.
Business Profile
Leiner Davis Gelatin is a part of the Goodman Fielder group of companies and
manufactures gelatin and speciality gelatin products. Leiner Davis has been
producing gelatin at the Christchurch plant for 91 years. It is the smallest
and oldest plant in Leiner Davis Gelatin International, the largest edible
gelatin-manufacturing group in the world.
Gelatin is pure protein extracted in New Zealand from beef skin.
The Christchurch product is used mainly for confectionery and
dairy desserts. The plant exports two thirds of its production.
Type of Projects
Product waste reduction.
Reasons for Projects
Leiner Davis management recognised that improving the utilisation of inputs
and minimising the production of unwanted or low value outputs was fundamental
to improving profitability. Adopting a cleaner production approach has helped
staff become more aware of the consequences of environmental practices that
are unfriendly and that are detrimental to the company’s bottom-line. Leiner
Davis saw cleaner production playing an important role as it extended its
existing continuous quality improvement programme to incorporate environmental
performance, which resulted in 1999 with the integration of ISO14001 into
the existing ISO9001 quality standard.
Target Zero
The Leiner Davis Gelatin plant has been a participant in
Target Zero, a two-year sponsored cleaner production programme
involving 12 companies in Christchurch and 10 in Hawkes Bay during
the period 1997-1999. The programme was sponsored by the Sustainable
Management Fund of the Ministry for the Environment, Meridian
Energy Ltd (formerly ECNZ), and the local authority and electricity
company in each area.
The Projects
Dry Powder Recovery
|
Description
|
The project addressed activities and locations where gelatin
powder was set aside or taken from the process chain prior
to final packaging for sale. These sources included samples
for laboratory testing, torn (but not split) bags, blender
feedstock at the end of blend runs etc.
The existing procedure was for gelatin from these sources
(and some others) to be sent back to the extractor to be
re-processed. This was an additional direct cost and represented
an opportunity cost as well.
For selected and controlled sources of gelatin powder
an alternative procedure was adopted of heat conditioning
as additional positive food safety assurance, followed
directly by blending or packaging.
|
|
Environmental Benefit
|
Reduced resource use by eliminating additional processing.
|
|
Economic Benefit |
Capital cost $0
Savings $25,000/annum
Payback Immediate |
Specialty Line Flushing
| Description |
The Specialty Department
uses heat and other treatments to produce gelatin with a
range of different physical properties. Process runs are
small and the plant operates only a few hours a week, at
intervals. At the end of each run pipework is flushed out
and cleaned.The existing procedure was to wash the flushed
material with a high gelatin content to the drains. The flush
liquor is now collected and sent back for re-processing,
with the result that product yield is improved and the trade
waste discharge is reduced. |
| Environmental Benefit |
Reduced trade waste
discharge volume and loading. |
| Economic Benefit |
Capital
cost $0Savings $3,000/annumPayback Immediate |
|
For additional information contact:
Roger Seach
Leiner Davis Gelatin N.Z. Ltd
PO Box 19 542
Christchurch
Phone 03 384 3093
Fax 03 384 5899 roger.seach@gfingredients.com |
For further information about the Target Zero programme
see following publication:
- You too can profit from cleaner production
and waste minimisation
- Coordinating cleaner production programmes.
Lessons from Target Zero
|
|
