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Modular wastewater treatment for the Food and Beverage sector

Water, wastewater and the food and beverage sector

The food and beverage industry is a major contributor to wastewater production in Europe, with significant environmental implications. In the European Union, the food and beverage sector is responsible for approximately 60% of all water consumption, highlighting the substantial water footprint associated with this sector.

This industry not only uses significant amounts of water in production processes but also generates considerable volumes of wastewater. Among different industrial sectors, the food and beverage industry emits the highest amounts of organic wastewater pollution, ranging from 10-30% of the total amount of industrial wastewater generated in Europe. This underscores the critical need for effective water management and treatment solutions within the sector.

The food and beverage industry in Europe continues to experience growth, driven by various factors including population increase and changing consumer preferences. As of 2021, the EU food and drink industry generated a turnover of €1,196 billion and employed 4.7 million people, solidifying its position as a leading manufacturing sector. This growth trajectory is expected to continue, with the European food market projected to expand at a compound annual growth rate (CAGR) of 5.27% between 2025 and 2029

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FBBR

The wastewater problem

As the industry expands to meet rising demand, the challenge of managing and treating wastewater is becoming a pressing concern, necessitating innovative solutions and stringent environmental practices.

There are a number of different drivers behind the need to treat this wastewater, including the following.

Regulatory compliance: Both direct dischargers (to sewers) and indirect dischargers (to the environment) face increasingly stringent regulations and enforcement. Failure to comply can result in significant fines, legal action, and reputational damage.

Environmental protection: Proper wastewater treatment helps prevent pollution of water bodies, protect ecosystems, and safeguard public health.

Resource conservation: Many companies are adopting wastewater reuse strategies to reduce freshwater consumption, particularly in water-stressed areas.

Cost savings: Implementing effective wastewater treatment and reuse can lead to reduced water procurement costs and lower disposal fees.

Corporate sustainability: Treating and reusing wastewater aligns with environmental objectives and demonstrates corporate social responsibility.

Operational continuity: Ensuring compliance and adopting sustainable water management practices can help companies secure their water supply and maintain operations in the face of increasing water scarcity.

 

By treating wastewater effectively, companies can meet regulatory requirements, minimize environmental impact, and potentially create value from what was once considered a waste stream.

The challenges with cleaning wastewater from the food and beverage sector

Cleaning wastewater from the food and beverage industry presents significant challenges due to its highly variable nature and complex composition. The wastewater streams in this sector are characterized by fluctuating flows and loads, which can vary dramatically based on production schedules, seasonal changes, and even daily operational shifts. This variability makes it difficult to design and operate treatment systems that can consistently perform effectively across all conditions.

Sludge disposal of the ClearFox® DAF

The composition of food and beverage wastewater adds another layer of complexity to the treatment process. These effluents often contain high levels of organic matter, resulting in elevated Biochemical Oxygen Demand (BOD) and Chemical Oxygen Demand (COD), as well as significant amounts of fats, oils, and grease (FOG). Additionally, the presence of dissolved salts, nutrients like nitrogen and phosphorus, and other inorganic contaminants further complicates treatment efforts.

Containerized wastewater treatment plant for an antipasti manufacturer

Case study

Innovative Wastewater Treatment Solution for a German Antipasti Manufacturer

A German food manufacturer specializing in antipasti production for major European retail chains faced a significant challenge in managing its wastewater. The company was incurring substantial costs by transporting approximately 100 m³ of untreated wastewater offsite daily. To improve sustainability and reduce expenses, the company sought a treatment solution that would allow direct discharge into the local sewer system.

The Challenge

The local municipality approved sewer discharge under the condition that the wastewater met a stringent Chemical Oxygen Demand (COD) limit of <800 mg/L. However, the untreated wastewater had considerably higher values:

  • COD: >30,000 mg/L
  • High concentrations of salts, fats, and greases

To comply with discharge regulations, the COD needed to be reduced by 97%.

Evaluating Treatment Options

The company collaborated with consultants and wastewater treatment specialists for a year, exploring membrane and chemical treatment processes. Despite multiple pilot studies, no viable solution was identified, leading to a temporary pause in the search for a treatment system.

Identifying a Suitable Solution

A turning point came when the company was referred to PPU Umwelttechnik GmbH, a provider of modular wastewater treatment technologies. With experience across various industries, including food and beverage, pharmaceutical, and waste management, PPU was able to propose a tailored solution with process guarantees.

PPU’s approach involved:

  1. Conducting in-house laboratory analysis of the wastewater.
  2. Developing a customized treatment concept.
  3. Obtaining approval from the company’s external wastewater consultant.

The Modular Treatment System

PPU designed and manufactured a modular treatment system within 12 weeks, minimizing site installation requirements. The system included:

  1. Mechanical pretreatment for solids separation and removal of fats, oils, and greases (FOG).
  2. Aerated flow equalization tanks.
  3. Dissolved Air Flotation (DAF) system with pH adjustment and flocculation.
  4. Fixed Bed Biofilm Reactor (FBBR) for biological treatment, suited to high Total Dissolved Solids (TDS).
  5. Lamella clarifier.
  6. Final filtration step.
  7. Sludge thickening and dewatering components.
Sludge dewatering

Implementation and Outcomes

The fully automated system was installed with operator training provided to ensure smooth operation. Key benefits achieved included:

  • Compliance with wastewater discharge requirements.
  • Elimination of 2-3 daily tanker transports for offsite wastewater removal.
  • Significant cost savings, with an estimated two-year payback period.
  • Flexibility for future system expansion, including potential wastewater reuse.

This case study highlights the role of modular treatment technologies in addressing industrial wastewater challenges. The implementation of a tailored wastewater treatment system not only enabled regulatory compliance but also improved operational efficiency and cost-effectiveness for the manufacturer.

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