Optimizing Wastewater and Recycling for Sustainable Operations for a Leading F&B Manufacturer in Southern India

Project Overview

Food & Beverage (F&B) conglomerate with a manufacturing presence in southern India initiated a project to address its need for environmental sustainability. This project aimed to identify a skilled supplier partner capable of treating and recovering high-quality water from a daily volume of 2000m³ of treated wastewater. The comprehensive project scope included the design, engineering, manufacturing, supply, delivery, construction, erection, and commissioning of an advanced wastewater recycle package. This system was designed with precision to meet the effluent recycling needs while ensuring the output of water was of a high quality, suitable for use within the conglomerate’s operations.

Challenges

The project encountered various challenges that necessitated creative and effective solutions

Conceptualization of Treatment Scheme: The hazardous nature of the treated wastewater, filled with contaminants, necessitated a careful and thoughtful approach in conceptualizing a treatment scheme that was both effective and safe

Space Constraints: The limited availability of space posed a significant challenge, demanding a compact yet efficient design solution.

Integration with Existing Infrastructure: The requirement to utilize existing civil structures added a layer of complexity to the design and implementation phases.

Aggressive Timelines: The project was under stringent time constraints, necessitating an aggressive timeline for completion without compromising on quality or safety standards.

Solutions

To overcome these challenges, the project team employed a series of strategic and technical solutions:

High-Rate Solid Contact Clarifier (HRSCC) Implementation: At the outset, an HRSCC was utilized to effectively deal with most of the potential contaminants present in the treated wastewater. This preemptive measure was crucial in safeguarding the downstream units from contamination.

Dual-Layer Filtration: To further refine the quality of the treated wastewater, a two-layer filtration system was introduced. This system played a pivotal role in polishing the suspended solids content, thereby preventing fouling in the membrane processes.

Optimized Pretreatment: The robust pretreatment process facilitated a commendable recovery rate of approximately 85%, significantly contributing to the health and efficiency of the treatment system.

Optimal Chemical Usage: The project emphasized the optimal use of chemicals to achieve the target water quality parameters, balancing efficiency with environmental responsibility.

Results

The project resulted in several significant achievements that highlighted its success

High-Quality Product Water: The treated water met and exceeded quality standards, qualifying it for direct use in the manufacturing process. This not only represented a significant environmental milestone but also offered considerable cost savings.

Compliance with Safety Norms: All project activities were conducted in strict compliance with stringent safety norms, underscoring the commitment to workforce safety and environmental protection.

Efficient Space Utilization: Despite the initial space constraints, the project team’s innovative design solutions ensured effective utilization of available space.

Integration with Existing Infrastructure: The successful incorporation of existing civil structures into the project underscored the team’s ability to blend new technologies with existing assets, optimizing resources and minimizing the need for additional construction.

Robust Treatment Scheme: The comprehensive and carefully designed treatment scheme ensured the long-term health and efficiency of the wastewater recycling system.