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CGPP Report 2004/2

AT A GLANCE
The Cleaner Greener Production Programme
(CGPP) provided Atlanfish with a framework in
which to investigate the potential for reusing/recycling the significant quantities of
wastewater generated during the processing of
crab at its Donegal-based plant, which is one of
the largest crab processing facilities in Europe.
Typically, wastewater generated during the crab
cooking process contains a high level of
pollutants. Atlanfish believed that this
wastewater could have the potential for re-use,
either as a food ingredient or as a flavouring
product. As part of its involvement in the
Cleaner Greener Production Programme,
Atlanfish decided to carry out extensive on-site
trials on a membrane-filtration process, which
preliminary investigations had shown would
produce a distinctively crab-flavoured
concentrated liquid containing high levels of
proteins and salt. The membrane-filtration
process was also shown to produce sterile salt
water, which could be recycled for re-use in the
overall cooking process. Specific environmental
benefits that potentially could accrue as a result
of the companys participation in this CGPP
project include a 15% annual reduction in onsite water consumption and a 65% annual
reduction in wastewater emissions from the
plant.

ATLANFISH LTD
Atlanfish Ltd was founded in 1976. The
company, which is based in Carndonagh,
Co Donegal, employs up to 40 people at the
height of the annual crab season.
Atlanfish specialises in processing cooked
shellfish and producing value-added seafood
products. Its Co Donegal facility is one of the
largest crab processing plants in Europe,
accounting for approximately 30% of all
processed crab production output in the EU.

Printed on recycled paper using water based inks

The companys main products include chilled

and frozen cooked vacuum-packed crab; frozen
cooked vacuum-packed mussels, and wholeround frozen mackerel. It is also involved in the
cultivation of mussels and oysters.
All production output from the plant is
exported to the European market
predominantly.

COMPANY IDENTIFIES NEW FOOD INGREDIENTS

PRODUCT WITH THE POTENTIAL TO REDUCE
ON-SITE WATER CONSUMPTION BY 15% AND
WASTEWATER EMISSIONS BY 65%
AIMS OF THIS PROJECT
The Atlanfish Cleaner Greener Production

Prevention/reduction
Recycling/re-use

Programme (GPPP) team identified that

water generated during the crab cooking

Treatment

process was responsible for between 50%

and 70% of all waste emissions to water.

Disposal

As the waste management hierarchy

graphic shows (Figure 1), the preferred

Fig 1. The waste management hierarchy

methods for handling on-site waste are

reduction and recycling. For this reason,

The main aims of this CGPP project were

the CGPP team set out to investigate ways

to investigate the feasibility of using the

in which it might reduce the amount of

membrane-filtration process to produce

cook water produced, and/or recycle all

either a crab flavouring or a food

cook water used during the crab cooking

ingredients product; to develop

process.

production of the concentrate on a largescale commercial basis, and to research

One of the possible solutions identified for

potential market outlets for the product

closer investigation was membrane

in Ireland as well as further afield.

filtration as it was believed that the use of

this method would lead to the production
of a concentrated crab liquid, which could

PROJECT DESCRIPTION

be used either as a food ingredient or as a

flavouring product. Moreover, the use of

Preliminary research was carried out by

this membrane-filtration process would

the CGPP team on membrane- filtration

enable the re-use of cook water in the

equipment supplied by the Questor

overall crab processing cycle.

Centre at Queens University Belfast.

BETTER BUSINESS IN A BETTER IRELAND

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One of the distinguishing features of membranes is that

they enable salt and water to pass through them, while
simultaneously filtering out extraneous matter such as
protein particles.
The filtration process creates a clean permeate which can
be re-used during cooking thus reducing the volumes of
salt and water required.
An added advantage of using this process is that very little
of the original protein content is lost. Moreover, almost all
of the original flavour is retained.
The concentrate has the potential to be used as a crab
flavouring or as a food ingredients product.

Fig 2. Pilot-scale membrane treatment plant

The CGPP project team tested several different types of
membrane and a variety of different operating conditions.
The tests were carried out in optimum production
conditions. This enabled the team to evaluate the overall
process both in economic terms and in terms of operating
it on a plant-wide scale.

This involved compiling and analysing historical records of

on-site water, electricity and fuel consumption; packaging
usage, and waste production.
A new system of monitoring water consumption and
wastewater was introduced, and new equipment for
sampling and analysing on-site effluent was installed. Water
consumption for each individual production process was
recorded and analysed to see where savings or efficiencies
might be achieved.

OBSERVATIONS
A concentration factor of 5 was consistently achieved
during the trials: this was lower than anticipated. As such, it
reduces the concentrates value as a flavouring product and
it also increases storage and transport costs.

Fig 3. Photograph shows from left untreated cook water;

concentrated cook water, and treated permeate.
While the concentrate produced during this CGPP project
was found to be of food grade quality, tests carried out by
potential end-users confirmed that the levels of salt and
water in the product were unacceptably high.

Samples of the cook water concentrate were taken and

distributed to potential end-users for trial.

As a result, the Atlanfish management team is considering

carrying out further development work in order to tackle
the quality control issues raised by potential end-users.

SECONDARY AIMS

ACHIEVEMENTS

As well as evaluating the long-term implications of

implementing a large-scale membrane treatment process at
the plant, the CGPP team set out to identify ways in which
the generation of on-site waste might be reduced significantly.

The companys participation in this project confirmed the

feasibility of, as well as the potential benefits of using a
membrane treatment plant to produce a high-grade
concentrate for commercial food production purposes.

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The project also confirmed the potential for achieving a

reduction in both water usage and salt usage as a direct
result of using recycled permeate.
The use of a membrane filtration process also has the
potential to reduce waste emissions to water from an
average of 12.5 kg chemical oxygen demand (COD) per
tonne of product to around 4.4 kg COD per tonne of
product. This represents a reduction of around 65% on
average annual emissions from the plant.
In addition, by making optimum use of permeate, it is
possible to recycle up to 80% of the water from each batch
as well as about 75% of the salt from each batch.

In addition to reducing waste emissions, the use of

membrane filtration technology has two other major
benefits: the potential to produce a concentrated byproduct, and the potential to recycle permeate in other
areas of the production process.
Potential users of this technology might include food
companies looking for a market outlet for concentrates
produced from one of their wastewater streams. In addition,
companies that have a high water requirement may find it
advantageous to use membrane treatment to recover water
for re-use. This type of recovered water is very clean and
therefore could be used in a wide range of manufacturing
processes.
The use of membrane filtration technology may also appeal
to companies that are obliged to operate in a constrained
environment/ production space. This is because, typically, a
membrane processing plant creates a much smaller footprint
than a conventional processing plant.

MORE INFORMATION
For more information on this project contact:
Fig 4. Graph illustrating the potential reduction in
environmental emissions to water.
The good housekeeping and waste minimisation measures
that were identified during the environmental audit have
enabled the company to reduce its water consumption by
approximately 4% per kg unit of production output.
Additional energy conservation and waste management
measures identified as a result of the companys
participation in this CGPP programme have the potential to
reduce water consumption by an additional 10-20% per
year. These measures are currently being implemented.
Other benefits that have derived from the companys
participation in this CGPP project include an enhanced
image for Atlanfish among the companys neighbours and
among local authority representatives in the area.

LESSONS
The use of membrane technology as a recycling option has
the potential to be replicated not only by other crab
processors but also by a variety of other industries.

Suzanne McDermott
Environmental Manager
Atlanfish Ltd
Station House
Carndonagh
Co Donegal
Tel: 07493 74285
Fax: 07493 74685
E-Mail: suzanne@atlanfish.com
Website: www.atlanfish.com

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CLEANER GREENER
PRODUCTION IS
the application of integrated preventive environmental
strategies to processes, products, and services to increase
overall efficiency and reduce risks to humans and the
environment.
Production processes: conserving raw materials and
energy, eliminating toxic raw materials, and reducing the
quantity and toxicity of all emissions and wastes
Products: reducing negative impacts along the life cycle
of a product, from raw materials extraction to its
ultimate disposal.
Services: incorporating environmental concerns into
designing and delivering services.

CLEANER GREENER
PRODUCTION REQUIRES
new attitudes, better environmental management, and
evaluating available technology options. We need to take
good environmental practice to the stage where it is an
inherent part of any business operation.

HOW IS CLEANER GREENER

PRODUCTION DIFFERENT?
Much of the current thinking on environmental protection
focuses on what to do with wastes and emissions after they
have been created. The goal of cleaner, greener production
is to avoid generating pollution in the first place.
This means:

Better efficiency
Better business
Better environmental protection
Lower costs
Less waste
Less emissions
Less resource consumption

WHY IS THE CLEANER

GREENER PRODUCTION
PROGRAMME BEING RUN?

The long-term goal is to ensure that cleaner, greener production

becomes the established norm in Ireland. The programme seeks to
promote environmentally friendly business through increased
resource productivity, waste reduction, recovery of materials,
improved efficiency in a product value chain, energy management,
and a change of culture within organisations.
The programme aims are focussed on avoiding and preventing
adverse environmental impact rather than treating or cleaning up
afterwards. This approach brings better economic and
environmental efficiency.

PROGRAMME MANAGERS:
The Clean Technology Centre (CTC) at Cork Institute of
Technology was appointed to manage the programme in
association with OSullivan Public Relations Ltd, and Energy
Transport Actions Ltd, (ENTRAC).
The CTC was established in 1991 and is now nationally and
internationally regarded as a centre of excellence in cleaner
production, environmental management and eco-innovation across
a range of industrial sectors.

WHERE CAN I GET

FURTHER INFORMATION?
This case study report is one of 29 reports
available from the organisations that
participated in the first phase of the Cleaner
Greener Production Programme. A summary
of all the projects and CD containing all the reports
are also available. More information on the Programme
is available from the Environmental Protection Agency
Ms. Helen Walsh,
CGPP,
Environmental Protection Agency,
Richview, Clonskeagh Road, Dublin 14, Ireland.
Tel. 01 2680100
Website

Fax. 01 2680199

www.epa.ie

select link to cleaner production.

Email. ertdi@epa.ie
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The Irish Government, through the National Development

Plan 2000 - 2006, has allocated funds to a programme for
Environmental Research, Technological Development and
Innovation (ERTDI).

The Department of the Environment and Local Government asked

the Environmental Protection Agency (EPA) to run the CGPP as
part of the ERTDI programme. With the programme continuing to
2006 about 60 businesses will be supported to implement cleaner
greener production and to demonstrate their achievements to the
rest of Ireland.