Kelloggs
Kalic dishes up a winner for Kellogg's.
THE factory that makes breakfast cereals for millions has hired a new helper: Kalic, the liquid lime dosing system from Buxton Lime.
The Kellogg's factory in Trafford Park, Manchester is the biggest cereal manufacturing plant in the world. For the UK alone, it makes enough Corn Flakes to fill a billion bowls a year. Also on its menu are Rice Krispies, Frosties, Coco Pops and Crunchy Nut.
Tasty brands. But in common with other food processing industries, cereal manufacturing has its by-products. In this case, the effluent waste water from the processing includes a cocktail of sugars, starches, syrups and flavours. In technical terms, the mixture has a high Chemical Oxygen Demand (COD) - a measure of water quality, defined by the amount of oxygen that's needed to oxidize materials in the water.
What it means is that the waste water can't just be discharged into Manchester's sewers without the appropriate treatment - and Kalic is helping.
"Kellogg's wants to build on its reputation as a good neighbour at Trafford Park," says John Darwin, Facilities Manager at the Trafford Park plant. "Kalic gives us pinpoint pH control, resulting in a good consistent material that also reduces odour levels. And it saves us money, because it reduces COD and it's more efficient."
Kellogg's was so pleased with Kalic's contribution to its environmental performance at Trafford Park that it has also installed Kalic system at its plant in Wrexham, which produces bran-based cereals.
Made from a natural material, Kalic is a non-toxic, non-corrosive and cost-effective calcium hydroxide suspension. It has proved itself across several industries, from the treatment of drinking water to food processing. Another food producer that uses Kalic is Birds Eye Walls, for its ice cream factory in Gloucester.
Located just down the road from Manchester United's home at Old Trafford, the Kellogg's plant is one of Manchester's best known landmarks. With 1000 staff, it's also one of the city's biggest employers.
The factory was built in 1938 and treats its own effluent waste water. But as the factory's output grew, the system was starting to struggle. Currently it is handling 2½ times its original capacity and acidic content has grown to a level that requires lime dosing to ensure the pH is correct.
Kellogg's conducted tests and then extended trials with Kalic two years ago using a temporary bulk rig. Kalic came through with flying colours, proving itself highly effective and quick and simple to use, so Kellogg's decided to install a permanent full bulk system. "Kalic is extremely fast reacting," says Wilf Oates, Kellogg's utilities engineer. "It's easier and quicker to get results."
So where does Kalic fit in at Trafford Park? The plant has two giant bio treatment tanks, one holding 2000m³, the other 1000m³. From there the effluent waste is passed into a ballast tank that regulates loads through the system, and beyond that a Dissolved Air Flotation tank. Next stop is sludge storage, before it gets to the Kalic liquid lime dosing system. Through that it's out to the sewer. United Utilities monitors the output for COD, acidity and alkalinity and volume.
According to Peter Whitney of Elyo, which operates all utilities at the Kellogg's site, the waste water treatment plant uses about 1000 tonnes of Kalic a year with deliveries every ten days.
Editors' notes
Kalic Liquid Lime represents a major advance in lime-based treatment for acidic effluent, drinking water and waste water. It is used in industries such as water and sewage treatment, food processing, pharmaceuticals, steel production, oil and agri-chemicals.
Kalic's key selling points are technical superiority and cost-effectiveness. It's fine particles provide a stable suspension and large surface area that make it highly reactive and extremely efficient. It is safer than caustic soda. Also, its costs are lower, for handling, protection, plant maintenance and environmental protection. Kalic complies with safety and anti-pollution legislation.
Kalic can help protect tanks, vessels, valves and pipework from corrosion. Its low freezing point (0ºC) reduces the need for lagging and trace heating of pipework, pumps and tanks. It is also easy to pump, handle and transport.
Kalic is made by Buxton Lime, the largest producer of lime and lime products in the UK. It is part of the Tarmac group of companies, owned by Anglo American plc.
