Integrierte Vermeidung und Verminderung der Umweltverschmutzung

Integrierte Vermeidung und Verminderung der Umweltverschmutzung Integrierte Vermeidung und Verminderung der Umweltverschmutzung

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Chapter 2 2.2.8.4 Sweeteners Starch slurry is the starting raw material for the manufacture of sweeteners or sugar syrups. These are produced by the action of acids, enzymes or a combination of both, however enzymes are more commonly used. In a typical process, the starch slurry is heated to gelatinise the starch and then mixed with acids and/or enzymes and reacted in different liquefaction, saccharification and isomerisation reactors. The temperature is then raised to around 140 °C. Conversion of the starch only takes a few minutes. The mass is neutralised and after several stages of purification, i.e. separation of insolubles, demineralisation and decolourisation, the product obtained is evaporated. The liquor is usually filtered and treated with active charcoal or ion exchange resins to remove colour, ash and other minor impurities, e.g minerals. The liquid sweetener resulting can be sold as such, or dried, or crystallised to produce dry sweeteners. 2.2.8.5 Modified (physical/chemical) starch The properties of native starch can be changed to produce modified starch. Modification can be carried out with chemicals, enzymes or physically. The chemicals added can either be dry or wet, so final drying may be necessary. In the dry chemical modification process, dewatered and dried native starch is used. The product is chemically modified starch. In the wet process, the starch slurry, or the re-slurried native starch, is fed directly into the reactor with chemicals and the reaction takes place in liquid form. The resulting slurry can be washed and/or dewatered prior to drying. The product is a physico-chemically treated or modified starch. 2.2.9 Animal feed The compound feed industry consists of two distinct sectors, i.e. animal feed and petfood. Animal feeds are predominantly dry, while petfoods often have a significant moisture content. In both sectors, the manufacturing process involves the blending of a range of ingredients such as cereals, protein sources, vitamins, minerals, fats and oils, to produce nutritionally balanced foods. By far the most important moist petfood ranges are those for dogs and cats. These foods are classified according to moisture, packaging and processing systems, and include moist foods and semi-moist foods. In the UK, although moist foods currently comprise a major portion of the market, semi-moist foods are becoming increasingly popular. Moist foods have a moisture content of 60 to 85 % and are usually preserved by heating. Heat treatment may be applied before or after packaging. Moist foods can be subdivided into canned foods, premium moist foods, brawns and frozen meats. 2.2.9.1 Animal feed and dry petfood The main animal feed types are compound feeds. These consist of a variety of blended ingredients. The composition is varied depending on the type and age of the animal to be fed, but typically includes ingredients such as cereals, animal and vegetable proteins, fibre sources, minerals and supplements such as vitamins, antibiotics and other additives. Some of the ingredients are co-products and by-products of the FDM sector. The raw materials are received at the feed mill and may be pneumatically conveyed or mechanically transferred to bulk storage silos. Some small ingredients which may be mixed in during the process, such as supplements, may be sent pre-bagged in appropriate quantities. Ingredients are weighed automatically in modern installations and transferred to holding bins prior to grinding, typically using hammer mills. After grinding, the ingredients are thoroughly mixed and any supplements are added. The blend may then be drawn off as meal or mash feed, or pressed to produce pelleted feed. More commonly, the blend goes on to be manufactured into feed pellets. Steam is injected into the feed in a process known as conditioning before being forced through holes in the pelletising die. The resulting pellets vary in size depending on the intended use. After this stage of manufacture, the pellets are dried and then cooled, typically in 96 January 2006 RHC/EIPPCB/FDM_BREF_FINAL

Chapter 2 coolers in which the pellets enter from the top and cool air is blown in from the bottom. To account for moisture loss during pelletising, drying and cooling, water may be added to some feeds, at the blending stage. The pellets are then either stored in bulk or packed. Some feeds may be coated in fat prior to packing. 2.2.9.2 Moist petfood The raw materials used in moist petfoods are typically co-products of the FDM sector. These co-products must be fit for human consumption, although they would not typically be used for this purpose. Ingredients used include meat processing co-products, whole grain, ground cereals, flavourings, and vitamin and mineral supplements. Petfoods are designed to be nutritionally balanced to meet the needs of a particular type of animal. 2.2.9.3 Semi-moist petfood The raw materials used in moist petfoods are typically co-products of the FDM sector. Ingredients commonly used include dry cereal sources, vitamin and mineral supplements and some meat slurries. The ingredients are blended, conditioned and extruded into small shaped pieces. The pieces are dried and fat or meat extracts may be sprayed onto the surface. This type of feed is often multi-component. After drying, various fractions manufactured in a similar way are blended to produce the finished feed. The feed is then packaged. 2.2.10 Bread One of the main bakery products is bread. Bread includes several bakery products and the types vary significantly from country to country. In France, about 80 % of bread is still produced in small bakeries. The most common traditionally eaten bread is the baguette. It is produced with four basic materials, i.e. flour, water, salt and yeast. It represents more than 50 % of French bread production. Other French speciality breads include fine wheat bread or “pain de gruau”, viennese bread, and biscottes [87, Ullmann, 2001]. In Germany, baked products are divided into two types. The production of bread allows a maximum of 10 parts sugar and/or fat to 90 parts flour. Products with more than 10 parts sugar and/or fat to 90 parts flour are called fine bakery wares or “Feine Backwaren”. Bread is divided into five main groups: • wheat breads, at least 90 % wheat • mixed wheat and rye breads, at least 50 % wheat • mixed rye and wheat breads, at least 50 % rye • rye breads, at least 90 % rye • bread specialities. Each of the first four groups were established based on the proportion of wheat and rye in the formula. These groups are further classified into subgroups according to the type of milled raw materials used, i.e. low extraction flour bread, meal bread, and wholemeal bread. Speciality breads can also be prepared. These contain, e.g. nonbread grains, such as oat, barley, rice and maize; raw materials of plant origin, such as oilseeds, germs and raisins, materials of animal origin, e.g. milk, butter, yogurt and whey. Otherwise they may be produced by using special baking techniques, e.g. a wood-heated oven; steam oven or stone oven. From the total German bread consumption, about 15 % is eaten as small rolls and its consumption is increasing. Recently, the so-called nonbread grain breads have become very popular. Also the production of dark breads such as wholemeal flour breads is on the increase [87, Ullmann, 2001]. RHC/EIPPCB/FDM_BREF_FINAL January 2006 97

Chapter 2<br />

coolers in which the pellets enter from the top and cool air is blown in from the bottom. To<br />

account for moisture loss during pelletising, drying and cooling, water may be added to some<br />

feeds, at the blending stage. The pellets are then either stored in bulk or packed. Some feeds<br />

may be coated in fat prior to packing.<br />

2.2.9.2 Moist petfood<br />

The raw materials used in moist petfoods are typically co-products of the FDM sector. These<br />

co-products must be fit for human consumption, although they would not typically be used for<br />

this purpose. Ingredients used include meat processing co-products, whole grain, gro<strong>und</strong><br />

cereals, flavourings, and vitamin and mineral supplements. Petfoods are designed to be<br />

nutritionally balanced to meet the needs of a particular type of animal.<br />

2.2.9.3 Semi-moist petfood<br />

The raw materials used in moist petfoods are typically co-products of the FDM sector.<br />

Ingredients commonly used include dry cereal sources, vitamin and mineral supplements and<br />

some meat slurries. The ingredients are blended, conditioned and extruded into small shaped<br />

pieces. The pieces are dried and fat or meat extracts may be sprayed onto the surface. This type<br />

of feed is often multi-component. After drying, various fractions manufactured in a similar way<br />

are blended to produce the finished feed. The feed is then packaged.<br />

2.2.10 Bread<br />

One of the main bakery products is bread. Bread includes several bakery products and the types<br />

vary significantly from country to country.<br />

In France, about 80 % of bread is still produced in small bakeries. The most common<br />

traditionally eaten bread is the baguette. It is produced with four basic materials, i.e. flour,<br />

water, salt and yeast. It represents more than 50 % of French bread production. Other French<br />

speciality breads include fine wheat bread or “pain de gruau”, viennese bread, and biscottes [87,<br />

Ullmann, 2001].<br />

In Germany, baked products are divided into two types. The production of bread allows a<br />

maximum of 10 parts sugar and/or fat to 90 parts flour. Products with more than 10 parts sugar<br />

and/or fat to 90 parts flour are called fine bakery wares or “Feine Backwaren”. Bread is divided<br />

into five main groups:<br />

• wheat breads, at least 90 % wheat<br />

• mixed wheat and rye breads, at least 50 % wheat<br />

• mixed rye and wheat breads, at least 50 % rye<br />

• rye breads, at least 90 % rye<br />

• bread specialities.<br />

Each of the first four groups were established based on the proportion of wheat and rye in the<br />

formula. These groups are further classified into subgroups according to the type of milled raw<br />

materials used, i.e. low extraction flour bread, meal bread, and wholemeal bread. Speciality<br />

breads can also be prepared. These contain, e.g. nonbread grains, such as oat, barley, rice and<br />

maize; raw materials of plant origin, such as oilseeds, germs and raisins, materials of animal<br />

origin, e.g. milk, butter, yogurt and whey. Otherwise they may be produced by using special<br />

baking techniques, e.g. a wood-heated oven; steam oven or stone oven. From the total German<br />

bread consumption, about 15 % is eaten as small rolls and its consumption is increasing.<br />

Recently, the so-called nonbread grain breads have become very popular. Also the production of<br />

dark breads such as wholemeal flour breads is on the increase [87, Ullmann, 2001].<br />

RHC/EIPPCB/FDM_BREF_FINAL January 2006 97

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