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Case Study: Wastewater Treatment Optimization at a Large-Scale Prepared Food Facility

Background

A major prepared food facility in the Greater Montreal area specializes in producing a diverse range of perishable food items such as salads, deli products, pies, etc. Due to the rapid production schedule and high hygiene standards, the facility utilized substantial water volumes for cooking, cooling, and daily sanitation activities, generating over 450 m³ of wastewater daily. This wastewater contained significant food-derived contaminants requiring rigorous treatment to comply with municipal regulations.

Food production line

Challenges

The facility's existing wastewater treatment system faced multiple operational challenges:

  • Significant fluctuations in wastewater pH, hindering treatment efficiency.

  • Excessive simultaneous consumption of acidic and basic chemicals, reducing process effectiveness.

  • High water consumption, particularly in cooling and sanitation processes.

  • Elevated operational costs due to chemical use and waste management.

 

BIODE’s Solution

BIODE Engineering Consulting was contracted to optimize wastewater treatment and minimize environmental impacts through a structured four-objective approach:

  1. Diagnostic Evaluation: Conducted comprehensive data analysis using an integrated MATLAB software tool, allowing precise identification of system inefficiencies, notably the erratic fluctuations of wastewater pH and simultaneous acid-base consumption.

  2. Automated System Optimization:

    • Implemented advanced sensors, including turbidity meters and automated pH sensors, to monitor treatment processes continuously.

    • Stabilized pH levels through optimized equalization tank operations and precise chemical dosing.

    • Automated chemical dosing based on real-time contaminant measurements, reducing chemical usage by approximately 35%.

  3. Clean Technology Implementation:

    • Selected a simple yet robust cooling technology, reducing cooling water requirements by over 80%, saving approximately 80,000 liters daily (equivalent to more than 20 million liters annually).

  4. Continuous Improvement and Training:

    • Developed real-time monitoring systems enabling self-auditing capabilities.

    • Conducted comprehensive staff training and implemented a cultural shift towards sustainable resource management.

 

Results Achieved

  • Enhanced Treatment Efficiency: Achieved a highly efficient, fully automated wastewater treatment system that reduced pollutant levels consistently within regulatory limits.

  • Water Usage Reduction: Substantial decrease in water consumption by more than 80%, significantly lowering both environmental footprint and operational costs.

  • Operational Savings: Annual savings exceeded $180,000, attributed to reduced chemical consumption ($105,000/year) and water savings ($75,000/year).

  • Environmental and Compliance Success: Consistently passed independent audits by municipal authorities, demonstrating sustained compliance and commitment to environmental excellence.

 

Conclusion

BIODE’s targeted intervention transformed the facility’s wastewater management, delivering significant economic, operational, and environmental benefits. This project exemplifies how advanced analytics, smart engineering solutions, and a dedicated approach to sustainability can drive profitability and regulatory compliance in food processing industries.

BIODE Engineering Consulting remains committed to supporting sustainable, efficient, and compliant operations across diverse industries.

For customized solutions in wastewater management and environmental compliance, contact us today.

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