Wastewater management is a critical aspect of operations for food and beverage manufacturers, including ice cream factories. The treatment of wastewater is complex, expensive, and subject to strict regulations due to the diverse mix of contaminants present. Traditional metal-based chemical treatments have been commonly used, but they often lead to issues such as unstable water pH and heavy sludge formation, which can clog downstream systems. As environmental regulations become stricter and sustainability goals more prominent, companies are seeking better alternatives for wastewater treatment.
One Spanish ice cream manufacturer faced challenges with its wastewater treatment process, which involved the use of aluminum-based coagulants and caustic soda during the dissolved air flotation (DAF) stage. This method was effective but unstable, requiring constant adjustments to maintain pH levels. The excessive use of caustic soda led to increased conductivity levels, generating high volumes of oily sludge and causing performance issues in downstream biological treatment. The financial impact was significant, with treatment costs amounting to €1.48 per cubic meter and annual expenses totaling €275,000.
In search of a more stable, cost-effective, and sustainable solution, the manufacturer turned to Veolia Water Technologies. Veolia recommended switching from poly aluminium chloride (PAC) to a Hydrex plant-based coagulant, made from renewable raw materials and suitable for treating oily effluent commonly found in food and beverage facilities. The plant-based coagulant required lower doses, minimizing pH impact and reducing the need for caustic soda, while also decreasing sludge volume by up to 50%.
Extensive testing and trials confirmed the effectiveness of the plant-based coagulant, leading to a reduction in chemical costs by 40% and significant savings in PAC and caustic soda usage. The switch improved discharge quality, with conductivity levels falling within legal limits and a decrease in oily sludge production. Treatment performance remained strong, with reductions in chemical oxygen demand (COD) and total suspended solids (TSS), and improved stability against pH fluctuations.
The transition to the Hydrex plant-based coagulant not only improved operational efficiency but also resulted in environmental benefits. The reduced use of chemicals and lower waste production align with broader Environmental, Social, and Governance (ESG) goals, reflecting a commitment to sustainability in the industry. Consumers, regulators, and stakeholders are increasingly focused on sustainable practices, making responsible decision-making essential for long-term success.
The success of this case study highlights the potential benefits of exploring alternative wastewater treatment solutions in the food and beverage industry. By prioritizing operational needs, cost-effectiveness, and sustainability, manufacturers can improve their processes, reduce environmental impact, and align with evolving industry standards. As companies continue to face wastewater challenges and regulatory pressures, innovative solutions like plant-based coagulants offer a path towards more efficient and sustainable operations.
