Industrial Wastewater Pretreatment: Why It’s Important for Industrial Food & Beverage Plants

What Is Industrial Wastewater Pretreatment?

Industrial wastewater pretreatment refers to the processes and technologies used to remove contaminants from wastewater before it is discharged into municipal sewer systems. The goal is to reduce the levels of pollutants like Biological Oxygen Demand (BOD), Chemical Oxygen Demand (COD) and Total Suspended Solids (TSS) to comply with regulatory standards.

Wastewater pretreatment is necessary in industries like food and beverage where large volumes of organic matter and chemicals can significantly impact the efficiency of municipal wastewater treatment facilities. Without pretreatment, these facilities would face excessive loads, leading to higher treatment costs and potential environmental harm

Why Do Industrial Plants Have Pretreatment?

Industrial plants have pretreatment for several reasons:

1. Compliance with Regulations 

One of the primary drivers for industrial pretreatment is compliance with environmental regulations. The Environmental Protection Agency (EPA) regulates municipalities, which in turn regulate industrial users. All industrial users are required to obtain an Industrial User (IU) permit to ensure their wastewater discharge meets specific standards. Failure to comply with these regulations can result in significant penalties, including:

• Monthly Fines: Fines for non-compliance can range from $20K to $100K per month.
• Notice of Violations (NOVs): Persistent non-compliance can lead to NOVs, which, if not addressed, may result in state and EPA intervention, and in extreme cases, plant shutdowns.
• Un-normalized Flow and Heavy Loads: Discharges with un-normalized flow or high Biological Oxygen Demand (BOD5), Chemical Oxygen Demand (COD) and Fats, Oils and Grease (FOG) can disrupt municipal wastewater treatment plants, leading to additional fines and operational challenges

2. Cost Management 

Pretreatment systems play a crucial role in reducing the operational costs associated with wastewater management. By implementing effective pretreatment systems, industrial users can significantly reduce these costs by lowering the pollutant load in their wastewater before it reaches municipal systems. Key cost-related factors include:

• Biological Oxygen Demand (BOD) Monthly Charges: Municipalities take monthly grab samples to calculate the BOD5 in the wastewater. Charges for BOD5 can range from $10K to $150K or more per month depending on the load.
• Total Suspended Solids (TSS) Charges: Like BOD, TSS levels are monitored monthly with charges ranging from $1K to $10K or more per month.
• Daily Average Flow Charges: Industrial users are billed based on the daily flow of wastewater, either influent or effluent, measured by meters. The average monthly charges for flow, BOD5 and TSS combined can range from $20K to $100K or more.

3. Operational Efficiency and Sustainability

Pretreatment is also essential for maintaining operational efficiency and supporting corporate sustainability goals:

• Odor and Sewer Surcharge Mitigation: Pretreatment helps control odors and reduces sewer surcharge fees by treating the wastewater at the source.
• Reduced Operating and Maintenance Costs: By lowering the volume of sludge and the need for chemicals and energy in municipal treatment processes, pretreatment systems reduce overall operating and maintenance expenses for industrial users.
• Sustainability Initiatives: Effective pretreatment supports Environmental, Social and Governance (ESG) goals, demonstrating a commitment to reducing environmental impact.
• Inflation Reduction Act: Industrial users can also benefit from financial incentives under the Inflation Reduction Act, which offers tax incentives of up to 50% of the project cost for implementing sustainable practices, including pretreatment systems.

What Types of Food and Beverage Plants Need Industrial Wastewater Pretreatment?

Dairy 

• Manufacturing and distributing dairy-based products

Beverage

• Concentrate plants
• Beverage distribution
• The production and distribution of carbonated and noncarbonated soft drinks
• Bottled water, ice and alcoholic beverages

Meat/Poultry/Seafood 

• Distribution from farms

Fruits and Vegetables

• Distributing fresh fruits, vegetables, spices and herbs to food retailers and foodservice providers

Sugar/Confectionary

• Refining sugar for industrial and consumer use

Grain 

• Companies that mill flour and rice, malt grains and mix prepared flour mixes and dough.

Pulp & Paper

• Companies that produce corrugated boxes and paper

Ethanol Plants 

• Production of ethanol and related by-products

How Does Industrial Wastewater Pretreatment Work? 

Industrial wastewater pretreatment involves several stages designed to remove contaminants and ensure the wastewater is safe for discharge or further treatment. Each stage plays a role in reducing the environmental impact and operational costs associated with wastewater management in the food and beverage industry. Here’s an overview of the key components involved in the pretreatment process:

1. Lift Station/Pump Station 

The lift station or pump station transfers the wastewater from the point of generation to the treatment house. It ensures that the wastewater is moved efficiently through the system, particularly in cases where gravity flow is not sufficient.

2. Screening

Screening involves removing large solids from the wastewater that could damage equipment or hinder treatment processes.

3. Equalization Tank 

The equalization tank neutralizes the pH of the wastewater and equalizes the flow to help avoid overloading the system during peak production periods.

4. Dissolved Air Flow Treatment (DAF)

DAF treatment introduces air bubbles into the wastewater that attach to suspended solids and fats, oils and grease and cause them to float to the surface. These materials are then skimmed off and removed.

5. Clarifier Treatment

Clarifiers are used to remove additional solids from the wastewater. They work by allowing heavier particles to settle to the bottom, while lighter materials float to the top, both of which are then removed.

6. Aerobic Treatment

In aerobic treatment, oxygen is introduced into the wastewater to breakdown organic matter by aerobic bacteria. This process takes place in open-top tanks.

7. Anaerobic Treatment

Anaerobic treatment occurs in closed tanks, where anaerobic bacteria break down organic matter in the absence of oxygen. This process not only treats the wastewater but also produces biogas, which can be captured and used as an energy source.

8. Sludge Holding Tanks

Sludge holding tanks store the sludge produced during the treatment process before it is further treated or disposed of.

9. Chemical Feed Tanks and Containment

Chemical feed tanks are used to store and dose chemicals into the wastewater for pH adjustment, nutrient removal or other treatment needs.

10. Biogas Storage and Equipment

In facilities using anaerobic treatment, biogas produced during the process is stored in dedicated tanks and can be used to generate energy or heat for the facility.

The Role of Coatings in Industrial Wastewater Pretreatment 

Sherwin-Williams provides specialized coatings that protect the infrastructure used in industrial wastewater pretreatment to ensure longevity and reliability. Our coatings are designed to withstand the harsh conditions of wastewater pretreatment systems. By applying our advanced coatings, food and beverage plants can extend the life of their equipment, reduce maintenance costs and enhance overall system performance.

Sherwin-Williams wastewater coatings and linings are resistant to high levels of hydrogen sulfide (H2S) and other corrosive substances commonly found in industrial wastewater. This protection is crucial for components that are integral to the industrial wastewater pretreatment process.

Extend the Life of Your Industrial Wastewater Pretreatment System with Sherwin-Williams

Industrial wastewater pretreatment is critical to efficient and sustainable operations in the food and beverage industry. With the cost rising and regulations for treatment changing and becoming stricter, we are going to see a shift for many food and beverage plants installing pretreatment plants to significantly reduce their monthly charges and stay compliant.

By investing in advanced pretreatment technologies and protective coatings from Sherwin-Williams, businesses can ensure regulatory compliance, reduce costs, and protect the environment while extending the life of their pretreatment systems. For more information on how our solutions can benefit your facility, contact Sherwin-Williams today.