96% Reduction In Fats, Oils And Grease
Oxygen Demand
Suspended Solids
Chemical Costs
Our latest trade effluent sample analysis report from NI Water has shown a huge improvement in our effluent discharge. We have achieved a remarkable 96% reduction on Fats, oil and grease following the installation of Water Tecnik’s turnkey effluent treatment system.
David Wilson Director,
Mauds Ice Cream
Reducing Effluent Discharge and Associated Costs
Award-winning ice cream manufacturer Mauds has been in business since 1979. An environmentally aware company, it has converted its state-of-the-art factory in Carrickfergus, Northern Ireland, to LED lighting indoors and outdoors and cut its plastic use by 80%.
Next on its environmental awareness plan was limiting Mauds’ impact on the water cycle. The company asked to provide guidance on improving the quality of its trade effluent, which is created during washing procedures in the ice cream production area. When milk and cream residue was rinsed from storage tanks, this was treated using a regular grease trap filter before being discharged into NI Water’s sewer network.
With Mauds having grown substantially since its factory was built in 2000, the grease trap filter was no longer controlling fats, oils and greases (FOG) effectively. While grease traps remove surface oil from wastewater, many fats were emulsified by detergents used in Mauds’ cleaning processes and its grease trap system was ineffective at removing emulsified FOG from the effluent.
As a result, Mauds was struggling to achieve NI Water’s discharge consent limit of 100mg/L for FOG.
Instant Benefits, No Disruption
Having collected effluent samples from the production site and performed chemical jar tests, we confirmed that undertaking a chemical treatment followed by dissolved air floatation (DAF) would deliver the best results for Mauds’ site-specific effluent.
We completed an outline process design and detailed quote to show Mauds our proposals for the most effective treatment system for its requirements.
After getting the go-ahead from Mauds, we supplied and installed a complete turnkey effluent treatment system, which included electrical and mechanical installation, commissioning and operator training for Mauds. With all work completed in-house by our team, we ensured continuity and consistency throughout the project.
The plug-and-play design of our containerised DAF system meant Mauds was able to enjoy instant operational and financial benefits with no disruption to production schedules.
Impressive Savings and Effluent Quality Improvements
The new water treatment system delivered an impressive 96% reduction in the amount of fats, oils and grease in Mauds’ effluent, which means the company is now fully compliant with all discharge consent limits.
In addition to achieving that key target, we have also reduced suspended solids in Mauds’ effluent by 80% and reduced chemical oxygen demand (COD) by 40%.
The remaining COD is due to dissolved sugars in the effluent. We have proposed to Mauds a secondary treatment, which would further reduce COD level and effluent disposal costs calculated via the Mogden formula. The relatively low volumes of effluent currently produced on site mean the secondary treatment is not currently required, but it offers a considerable efficiency saving further down the line as Mauds’ business continues to grow.
Our jar testing and wastewater lab analysis identified a more cost effective chemical treatment regime for Mauds’ effluent. Implementing this has cut the company’s chemical costs by 49%.
We continue to work with Mauds for service, maintenance and chemical supply, and look forward to our ongoing partnership.
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