Food Company Meets Regulations, Reduces Operating Costs by 14 Percent

Challenge

A global maker of sausage products is increasing production to meet rising market demand and product diversification. Anticipating this growth and its impact on wastewater treatment systems, the company wanted to optimize wastewater operations at its two adjacent treatment plants. The goal of the evaluations was to stay in compliance with regulations and provide the facilities with the production flexibility they needed, now and into the future. The evaluation included phosphorous limits, hydraulic limitations and operational costs.

Solution

SEH wastewater specialists developed a master plan for a facilities upgrade to address these issues and save money. All key stakeholders participated in workshops to make sure the proposed design met their needs. The completed facilities upgrade addressed each of the company’s key areas of concern:

  • Phosphorous limit compliance
  • Hydraulic limitations increased flexibility
  • Operational costs reduced by 14 percent

Features

  • Reduced residual management costs by eliminating the need for trucking from 300 trucks per month to 100 trucks per month.
  • Eliminated the micro-filtration system to reduce high chemical costs.
  • Reduced electrical costs by optimizing blower operation from two full-time to two-and-one-thirds time.
  • Eliminated muriatic acid, sodium hypochlorite and sodium bisulfate.
  • Avoided permit exceedance penalties by maintaining NPDES permit compliance for BOD, TSS and TP during construction and three months of extreme cold weather conditions.
  • Developed stability in the activated sludge process.

Project
Wastewater Facilities Master Plan

Location
Midwest

Client
Global Sausage Company

Services

  • Wastewater Engineering