Liquid Assets for Your Poultry Plant

Prepared by:
Roy E. Carawan
Extension Food Science Specialist
North Carolina State University

Bill Merka
Extension Poultry Scientist
University of Georgia

Published by: North Carolina Cooperative Extension Service

Publication Number: CD-20

Last Electronic Revision: March 1996 (JWM)

Did you realize that your broiler processing plant may use more than 400 million gallons of water every year - enough to supply a town of 7,500 people?

Water Use and Conservation

Water is used for many purposes in poultry processing - scalding, washing, waste fluming, chilling, and cleanup. Until recently, conserving water was not a concern for most poultry processors because water and sewer costs were usually low. Now, uncontrolled water use combined with rapidly rising water and sewer charges has begun to cut into profits. Some municipalities providing water and sewer service to poultry processors have increased their charges ninefold over the past 25 years. By comparison, broiler prices have about doubled during that period.

Less than 10 years ago, poultry processors were using as much as 12 gallons of water to process one broiler. Since that time, many plant managers have come to realize that water costs real money. As a result, their plants are now using less than 4 gallons per broiler.

Multiple Benefits

Cutting costs is not the only reason to take water conservation seriously. Processing plants are often located in rural communities where the water system is designed to serve a small population. Because it takes large amounts of water to process poultry, a plant can have a major ef fect on the local water supply even under the best of circumstances. During a drought the impact can be disastrous.

In 1986, the southeastern states were stricken by the worst drought in nearly a century. Had the situation worsened, poultry processors would have faced water limitations, production cutbacks, and even temporary plant closings. By reducing water consumption now, processors can increase their chances of getting through the next drought without having to curtail operations.

In almost all food processing plants. reducing water use is also accompanied by a reduction in the wastewater treatment load. Using less water results in less leaching of solubles, better screen recovery rates, and more efficient operation of dissolved air flotation cells. In designing new plants, planning for water conservation can help cut construction costs because the size and cost of the wastewater treatment system can be reduced substantially.

Saving by Conserving: An Example

To see how much money can be saved by reducing water use, consider the case of two plants that each processes 250,000 broilers a day and pays Sl.90 per thousand gallons for water and sewer services. The table shows the savings that can be realized by using only 4 gallons of water rather than 7 gallons per broiler.

Plant A uses 3 gallons less water per bird than plant B - and its managers can put $l,425 more in the bank each day, a savings of over S350,000 per year. In effect, processor B is pouring that amount of money down the drain.

Water and Sewer Costs and Savings for Two Poultry Plants Processing 250,000 Broilers Per Day
	Plant A	Plant B	Savings
Water use per bird (gallons)	4	7	3
Daily water and sewer costs	$1,900	$3,325	$1,425
Annual water and sewer costs	$475,000	$831,250	$356,250
Cost per thousand broilers	$7.60	$13.30	$5.70

Processor A saves $5.70 per l,000 broilers processed. To estimate the potential savings for your plant, determine your current water usage, cost, and the amount you think water usage could be reduced. Then enter the current and target valucs in the following worksheet.

Water and Sewer Charges for Your Poultry Plant
	Current	Target
Enter current and target water usage per bird (gallons)	_________	_________
Enter Number of birds processed per day	_________
Multiply current and target water values by daily production to determine daily water use	_________	_________
Divide daily water use by 1,000 to determine daily water use in thousands of gallons	_________	_________
Enter your combined water and sewer cost per thousand gallons	_________
Multiply your daily water use (in thousands of gallons) by your water and sewer cost to determine your daily cost	$________	$________
Enter the number of days your plant operates each year	_________
Multiply the daily water and sewer cost by the number of days your plant operates each year to determine your annual water and sewer cost	$________	$________
Subtract the annual cost for your target use from the annual cost for your current use to determine your potential annual savings	$________

Where Do You Start?

Begin your water conservation program with a positive attitude. In talking with your staff, emphasize the importance of conserving water as a way of reducing water and sewer costs. The effects of your positive attitude and actions will soon spread to workers at all levels. Some proven ways to conserve water are listed in the box.

Saving Dollars Makes "Cents"

A study at a poultry processing plant in the early 1970s demonstrated that making process changes to conserve water would cost about 8.6 cents per thousand gallons of water saved. These same changes today would probably cost about 20 cents per thousand gallons saved. When compared with water and sewer service costs of $1.90 per thousand gallons, spending 20 cents to save Sl.9o really does make sense.

Managers set the pace for water conservation and waste reduction. Your interest and involvement will let everyone in the plant know that reducing water use is important. There's no better time than now to take a close look at your plant and encourage your employees to work with you in conserving water and cutting waste.

Be considerate. . . and be prepared. Start conserving water now.

Water Conservation Hints

Always consider water as a raw material with a real costs
Set water conservation goals for your plant
Install water meters and monitor water use
Train employees how to use water efficiently
Use a high-pressure, low-volume cleaning system
Don't let people use water hoses as brooms.
Don't let water run continuously unless necessary - for example, cycle the side-pan wash.
Resuse water where permitted.
If large amount of water are being used to flush feathers, parts, or debris away, consider redesigning the work area to prevent these material from collecting.

Distributed in furtherance of the Acts of Congress of May 8 and June 30, 1914. Employment and program opportunities are offered to all people regardless of race, color, national origin, sex, age, or disability. North Carolina State University, North Carolina A&T State University, U.S. Department of Agriculture, and local governments cooperating.

CD 20

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