Cereal production is a water intensive operation. It generates a large quantity of wastewater containing high levels of total suspended solids and organics. Wastewater treatment presents a total cost impact on chemicals, trade waste charges and labor requirements.
Food processors are looking for innovative ways to improve their wastewater treatment performance and lower their overall operating costs while increasing their personnel efficiency
An Australian food manufacturing facility producing various cereal products generates on average 700kL of wastewater per week. Wastewater is processed through a Dissolved Air Flotation (DAF) unit using a manual chemical feed program to adjust pH and allow TSS removal.
With a need to reduce overall water consumption and the loss of experienced DAF operators, the plant processors searched for ways to automate and optimise the wastewater operations. They consulted Waterwerx on the use of its STREAMWISE for DAF automation technology to:
In the graph above (Table 1), we see how STREAMWISE’s proprietary control vs manual control significantly lowers the plants total cost of operation. STREAMWISE control reduced trade waste charges by 19% and chemical costs by 75%. Ultimately, the STREAMWISE system will save this food processor over $290,000 per year. In addition to considerable TCO savings given the more consistent low TSS effluent the plant is in the planning stages of running an MBR trial to recycle part of the waste stream.
STREAMWISE for DAF technology is helping this food processor produce cleaner and more consistent wastewater that is suitable for further inhouse processing to allow water reuse and recycle.
In addition, this consistent and better-quality water is produced using significantly less treatment chemistry and operator involvement resulting in an overall TCO savings of 62%.