Impressive Savings And Higher Effluent Quality
Compliant
Discharge
Reduced
Costs
Saved
Cost of
Chemicals
Water Tecnik worked closely with our team to enable us to integrate our existing plant with a new modern DAF system, through mutual planning this was completed with relevant ease and most importantly limited downtime.
Rich Sauces
Too Close to Discharge Limits for Comfort
Rich Sauces, a supplier of premium quality products to the catering and food manufacturing industries, has had an on-site effluent treatment system for around 15 years. Expansion and increases in production levels had inevitably led to an increase in effluent volume and contamination levels.
The higher contamination levels were resulting in higher charges being imposed by NI Water through its Mogden formula trade effluent billing calculations. Although rarely breaching discharge consent limits, the effluent was closer to the limits than Rich Sauces’ management team were comfortable with.
Too Close to Discharge Limits for Comfort
Rich Sauces, a supplier of premium quality products to the catering and food manufacturing industries, has had an on-site effluent treatment system for around 15 years. Expansion and increases in production levels had inevitably led to an increase in effluent volume and contamination levels.
The higher contamination levels were resulting in higher charges being imposed by NI Water through its Mogden formula trade effluent billing calculations. Although rarely breaching discharge consent limits, the effluent was closer to the limits than Rich Sauces’ management team were comfortable with.
The existing DAF system was undersized and unable to effectively cope with the increase in contamination levels and volume. It was also installed inside a very compact building, with limited access for machinery movement.
We were asked to take proactive measures to ensure that the company remained compliant with its discharge consent limits by upgrading and modernising the effluent system.
Hassle-Free Modernisation
We undertook a site survey and several site visits to present Rich Sauces with options for improving its water treatment system, before agreeing a plan of action.
The biggest change we actioned was the removal of the existing dissolved air floatation (DAF) system. We installed and commissioned a new DAF system in just two days, ensuring there was no loss of production time. The system includes a tank mix system for chemical dosing, which offers far more consistency and reliability than the previous pipe flocculator system.
We also installed an underground grease trap to remove surface oils from the effluent before it is pumped from the factory to a balance tank. By reducing the amount of oil that reaches the DAF system, we were able to reduce the amount of chemical needed for effective treatment of the effluent. We also introduced a new pH correction system to increase the treatability of the effluent.
We upgraded the transfer pumping station to increase the flow rates of effluent between the factory and the treatment plant.
Substantial Savings on Discharge Costs
Following installation of the new DAF system and the other changes we implemented, Rich Sauces’ effluent is now consistently well below NI Water’s discharge consent limits. As a result, the company has seen a substantial decrease in its cost per m3 to discharge effluent.
The changes to the way chemical dosing is managed within the treatment system has not only improved its efficiency and effectiveness but also dramatically reduced the amount Rich Sauces spends on chemicals.
With an increase in plant reliability across the board, Rich Sauces’ engineering team no longer needs to intervene as regularly to fix breakdowns and blockages. Resources are freed for other engineering works around the site
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