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Frito Lay – Topeka, KS

Frito Lay – Topeka, KS. Curtis Leiker Kansas State University Biological and Agricultural Engineering & Natural Resources and Environmental Sciences. Overview of Plant. 10 production lines needing water Potato Chips (PC) Gold Extruded => Baked, Fried, Funyuns

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Frito Lay – Topeka, KS

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  1. Frito Lay – Topeka, KS Curtis Leiker Kansas State University Biological and Agricultural Engineering & Natural Resources and Environmental Sciences

  2. Overview of Plant • 10 production lines needing water • Potato Chips (PC) • Gold • Extruded => Baked, Fried, Funyuns • Corn => RRST, Fritos, UTC2, WOW • Sunchips

  3. Current Usage • Current standard for plant 0.81 gallons per pound of finished product • 2002 – 1.71 gal/lbs • 2006 – 1.17 gal/lbs • Produced 127.7 million pounds • Corresponds to ~150 million gallons • Olympic sized swimming pool is 660,000 gal

  4. Overall

  5. Potato Chips • Biggest user of freshwater • Approximately 115 gallons per min (gpm) freshwater and 33 gpm recycled water when in production • Company standard of 0.82 gal/lbs • When running 5500 lbs/hr, ~1.3 gal/lbs

  6. Destoner/Vertical Lift • Uses 10 gpm freshwater plus recycled • Cleans off large particles • Vertical lift to transport potatoes

  7. Peelers • Use 2 of 3 peelers • Each has a fresh and recycled water spray bar • 9 nozzles on each 6 spray bars

  8. Slicers • 4 slicers • Water over the heads • Water for flumes to push potato slices onto conveyor belt

  9. Spray Bars • 5 total bars • Defoamer • Beach bar • 3 spray bars to remove starch and spread out slices

  10. Starch Recovery • Uses 20 gpm freshwater • Removes starch from used water on PC line • Water treated with Tsunami • Water put back in line

  11. Low Water Users • Gold – 0.2 gal/lbs • Baked – 0.2 gal/lbs • Fried – 0.15 gal/lbs • Funyuns – 0.15 gal/lbs

  12. 4 Corn lines • Restaurant, Fritos, UTC2, WOW • All similar in nature • Cook, quench, transfer, sieve, halo, wash tumbler, drain belt, mill water

  13. Corn Cooking • ~315 gal cook water per batch • ~365 gal quench (varies seasonally) • Can use recycled water on RRST, UTC2, WOW for cook water

  14. Transferring Corn • Cook to Soak • Soak to Washer • Recycled • RRST, UTC2, WOW • Fresh • Fritos, just started using recycled

  15. Corn Washing • Goes through sieve • Collects in hopper • Halo of water used as lubrication • Washed in tumbler • Placed on conveyor belt • Spray bar to clean belt

  16. Sunchips • Standard is 0.68 gal/lbs, probably lower • Cook water – 160 gal per batch • Quench – 140 gal • Transfer • Rinse, sieve

  17. Sanitation • PC – 27,000 gal/cycle • Gold – 18,000 gal • Extruded, Baked, Fried, Funyuns – 25,000 gal • RRST – 15,000 • Fritos – 15,000 • UTC2- 19,000 • WOW – 14,500 • Sunchips – 16,500

  18. Annual Savings Operation (MM gallons) • Vertical lift (10 to 5 gpm) 2.15 • Peeler #3 (19 to 10 gpm) 2.07 • Flumes (recycled) 2.87 • RRST halo (15 to 10 gpm) 1.12 • Fritos drain belt timer (50-25%) 1.08 • UTC2 Cook-to-Soak (29-15 gpm) 1.67 • WOW Cook-to-Soak (19.5-15 gpm) 0.45

  19. Cost Analysis • Use primary and secondary treatment onsite • $5.03 for every 1000 gallons (WWWT) • 11.41 million gallons saved • $57,400 annually

  20. Questions?

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