Managing seasonal peaks in the food and beverage industry: innovative solutions for wastewater treatment

The wastewater challenge in the food and beverage industry

The food and beverage industry faces a significant challenge in wastewater management, especially due to the seasonal nature of production in some sectors. This industry is one of the largest water consumers and, therefore, one of the main generators of wastewater. Seasonality, driven by factors such as harvests, holidays, and changes in consumer demand, causes production peaks that can overload the treatment capacities of Industrial Wastewater Treatment Plants (IWWTP).

The treatment capacity of IWWTPs can be overwhelmed during these peaks, which can lead to inadequate treatment of wastewater. If not properly managed, this can result in the release of low-quality effluents into the environment, which could have negative consequences for both the ecosystem and the company's reputation. Additionally, non-compliance with environmental regulations can result in significant fines and legal sanctions.

Wastewater generated by the food and beverage industry often contains high levels of organic matter, suspended solids, and nutrients such as nitrogen and phosphorus. These components require effective treatment to avoid negative environmental impacts, such as eutrophication of water bodies, which can harm aquatic life and affect drinking water quality.

To mitigate these risks, it is crucial for companies to implement wastewater treatment solutions that are flexible and capable of adapting to seasonal variations in pollutant load. This may include investing in advanced treatment technologies that can efficiently handle production peaks, thus ensuring that the effluent complies with environmental regulations.

Strategies to mitigate challenges

To address these challenges, companies in the sector are exploring various strategies. Advance planning and efficient resource management are crucial to mitigate the effects of seasonality and comply with current regulations. Some companies are investing in wastewater storage systems, such as retention tanks, which allow for the accumulation of excess wastewater during production peaks. These systems act as buffers, allowing IWWTPs to process wastewater in a more controlled and efficient manner, avoiding overloads that could compromise treatment quality. However, storage tanks also present some disadvantages. They require a significant initial investment and additional physical space, which can be a challenge for facilities with space limitations. Additionally, prolonged storage of wastewater can generate odour problems and increase the risk of proliferation of unwanted microorganisms, which could complicate subsequent treatment. Therefore, it is crucial that companies consider these factors when deciding to implement storage systems.

Another alternative considered is the expansion of the IWWTP, although this option presents several significant challenges. First, space limitations can make this solution unfeasible for many facilities. Additionally, expansion requires extensive prior engineering studies and a construction phase, which implies not only a substantial investment but also a long implementation period. This delay in commissioning makes expansion ineffective in addressing immediate needs related to seasonality.

Moreover, there is an inherent risk in this strategy: the additional capacity created through expansion could be underutilised or even unused during off-season periods when wastewater volumes return to normal levels. This fluctuation in infrastructure utilisation raises questions about the long-term efficiency and profitability of such an investment.

Consequently, while expanding the IWWTP may seem like a logical solution at first glance, the complexities associated with its implementation and uncertainties about its effective utilisation throughout the year make it an option that must be carefully evaluated in the context of each specific situation.

MBBR Pack Technology: an innovative solution

MBBR Pack technology, based on Veolia Water Technologies' AnoxKaldnes technology, is presented as an innovative and effective solution to address the challenges associated with wastewater treatment in the food and beverage industry. This system uses an advanced biological process in which the biofilm, composed of microorganisms, grows on plastic carriers suspended in the water to be treated. These carriers provide a large surface area for microorganism growth, ensuring optimal contact between them and the wastewater.

This design maximises treatment efficiency by facilitating the removal of organic matter and nutrients.

One of the main advantages of the MBBR Pack is its compact design. Being transported in a 40" container, it allows for quick plug & play commissioning. This means that companies can implement the system quickly, significantly reducing infrastructure and civil engineering costs associated with installing more traditional treatment plants. This technology is suitable for both new installations and optimisation of existing biological processes, allowing companies to improve the efficiency of their treatment systems without the need for major structural modifications.

MBBR Pack technology is highly flexible and can be easily integrated with other wastewater treatment technologies. This allows companies to address a variety of challenges and meet different effluent quality objectives, adapting to the specific needs of each industrial client.

In summary, MBBR Pack technology represents a comprehensive solution for companies seeking to improve their wastewater management efficiently and sustainably. Its innovative design and ability to integrate with other technologies make this system an attractive option for the food and beverage industry, allowing companies to comply with environmental regulations and move towards more responsible production.

Success cases in the food and beverage industry

SICA and CALISPA, two major players in the food and beverage industry in Italy, faced the challenge of managing large variations in effluent load, especially during seasonal peaks associated with increased tomato production. The existing treatment lines could not effectively handle these fluctuations, increasing the risk of non-compliance with discharge regulations and, therefore, of receiving significant fines that could lead to temporary plant closure.

To address this problem, both companies chose to implement the MBBR Pack solution. This technology offered several key advantages that aligned perfectly with the clients' needs. First, its compact design, capable of treating between 500 and 600 kg of COD/day per unit, allowed for easy on-site installation. This not only reduced operating costs but also minimised downtime during the transition to the new system.

The MBBR Pack solution proved to be highly adaptable and robust in the face of load variations, while ensuring compliance with strict discharge requirements. The response time from contracting to commissioning of the equipment was only four months, which was crucial for the clients given the challenge they faced.

The solution has included a disc filter as an additional polishing stage to ensure that the effluent reached the required quality standards. This additional integration allowed SICA and CALISPA not only to comply with regulations but also to improve effluent quality, further reducing the risk of sanctions and contributing to a more sustainable and efficient operation.

Another notable example of the successful application of MBBR Pack technology can be found at Cervezas Victoria in Spain. This case illustrates how the solution perfectly adapts to the needs of growing companies with expansion prospects.

Cervezas Victoria, a company in full expansion phase, opted for MBBR Pack technology due to its remarkable versatility, especially regarding future expansions. The decision was based on several key factors:

• High efficiency in BOD and COD removal.
• Ease of adaptation to new treatment flows.
• Flexibility to combine with other pre- and post-treatment solutions.
• Veolia's ability to respond quickly to changes in water quality or load increases.

This case demonstrates how MBBR Pack technology not only solves current wastewater treatment problems but also positions itself as a long-term solution, capable of adapting to the changing needs of a growing company. The combination of efficiency, flexibility, and scalability makes this technology particularly attractive for dynamic industries like brewing, where changes in production and, therefore, in wastewater generation are frequent.

Conclusion: towards sustainable wastewater management in the industry

Efficient wastewater management in the food and beverage industry is a crucial challenge that requires innovative and adaptable solutions. The sector faces increasing pressures due to production seasonality and increasingly strict environmental regulations. In this context, the need for advanced technologies like MBBR Pack becomes evident.

MBBR Pack has proven to be a versatile and effective solution, capable of addressing the specific challenges of this industry. Its compact design, rapid implementation, and high efficiency make it an attractive option for companies of all sizes. Success cases in Italy and Spain illustrate its adaptability to different scenarios, from handling seasonal peaks to facilitating production expansion.

The adoption of these technologies not only helps comply with environmental regulations but also contributes to more sustainable production. By improving effluent quality and reducing environmental impact, companies can strengthen their reputation and leadership in sustainability.

Looking to the future, continuous innovation in wastewater management will be key. Investment in technologies like MBBR Pack is a smart strategy to face current and future challenges. Flexible and scalable solutions will be essential to maintain efficient and environmentally responsible operations.

Ultimately, sustainable wastewater management is fundamental for corporate responsibility and long-term competitiveness. Companies that proactively adopt these innovative solutions will be better positioned to thrive in an environment increasingly aware of the importance of environmental sustainability.

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