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

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

Overall Line Projected 2007 lbs Standard (gal/lbs) MM Gallons (STD)% Usage PC Gold Baked Fried Funyuns Corn Sunchips Total

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Questions?