Frito Lay Topeka KS Curtis Leiker Kansas State

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 • Corn => RRST, Fritos, UTC 2, WOW • Sunchips

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

Overall Projected 2007 lbs Standard (gal/lbs) 26. 998 0. 82 22. 138 21. 97 Gold 9. 306 0. 20 1. 861 1. 85 Baked 5. 689 0. 20 1. 138 1. 13 12. 914 0. 15 1. 937 1. 92 3. 779 0. 15 0. 567 0. 56 4 Corn 44. 800 1. 29 57. 680 57. 25 Sunchips 22. 682 0. 68 15. 424 15. 31 Line PC Fried Funyuns Total 126. 168 MM Gallons (STD) 100. 745 % Usage

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

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

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

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

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

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

Low Water Users • Gold – 0. 2 gal/lbs • Baked – 0. 2 gal/lbs • Fried – 0. 15 gal/lbs • Funyuns – 0. 15 gal/lbs

4 Corn lines • Restaurant, Fritos, UTC 2, WOW • All similar in nature • Cook, quench, transfer, sieve, halo, wash tumbler, drain belt, mill water

Corn Cooking • ~315 gal cook water • • per batch ~365 gal quench (varies seasonally) Can use recycled water on RRST, UTC 2, WOW for cook water

Transferring Corn • Cook to Soak • Soak to Washer • Recycled – RRST, UTC 2, WOW • Fresh – Fritos, just started using recycled

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

Sunchips • Standard is 0. 68 gal/lbs, probably lower • Cook water – 160 gal per batch • Quench – 140 gal • Transfer • Rinse, sieve

Sanitation • PC – 27, 000 gal/cycle • Gold – 18, 000 gal • Extruded, Baked, • • • Fried, Funyuns – 25, 000 gal RRST – 15, 000 Fritos – 15, 000 UTC 2 - 19, 000 WOW – 14, 500 Sunchips – 16, 500

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 • UTC 2 Cook-to-Soak (29 -15 gpm) 1. 67 • WOW Cook-to-Soak (19. 5 -15 gpm) 0. 45

Cost Analysis • Use primary and secondary treatment onsite • $5. 03 for every 1000 gallons (WWWT) • 11. 41 million gallons saved • $57, 400 annually

Questions?