Hovis Achieve a 91% Reduction in Fats, Oils and Grease
Cod
Oils & Grease
PH
Now PH Neutral
TE
Installation
HSE Manager, Hovis
Overview
Hovis, a prominent food manufacturing company, have been baking bread for more than 130 years. They approached Water Tecnik as they were close to breaching compliance with FOGs (Fats, Oils, and Greases) and CODs (Chemical Oxygen Demand) in their wastewater. Seeking an effective and sustainable solution, they reached out to Water Tecnik, a specialist in water treatment solutions.
Hovis had been experiencing these issues for several years, and had previously installed a large underground 20,000L grease settlement tank. Unfortunately, as water Tecnik see on many sites, these grease traps are ineffective and reducing FOG levels, due to the emulsified nature of the contaminates, gravity separation method removes little or no emulsified oil.
Hovis had been experiencing these issues for several years, and had previously installed a large underground 20,000L grease settlement tank. Unfortunately, as water Tecnik see on many sites, these grease traps are ineffective and reducing FOG levels, due to the emulsified nature of the contaminates, gravity separation method removes little or no emulsified oil.
The Challenge
Hovis was close to breaching compliance with FOGs and CODs in their wastewater at one of their bakery sites in Belfast, requiring immediate attention. The wastewater from the production equipment rinse down, cleaning and hygiene procedures contained high levels of suspended solids and emulsified fats, oils and grease.
All companies have a legal responsbility to ensure that trade effluent discharged from their premises is of sufficient quality to be discharged to a sewer, river or other waterway. To address these challenges, the company wanted to implement a comprehensive wastewater treatment solution at their Belfast site. This would not only bring them into compliance but also ensure long-term sustainability.
The Solution
Water Tecnik began the process by conducting extensive jar testing and laboratory analysis to understand the site specific characteristics of Hovis’ wastewater. This data was crucial for designing a tailored solution that would effectively address the FOGs and CODs in the wastewater.
Water Tecnik proposed a phased approach to address the compliance issues. Instead of immediately implementing a full-scale water treatment plant, the decision was made to install a trial plant to assess its effectiveness. This approach allowed Hovis to evaluate performance before committing to a larger investment.
To make the most of available resources, we repurposed and modified two existing tanks; the existing grease trap as a balance tank and an existing 5m3 tank that Hovis had on site to be used as a sludge tank. This sustainable approach not only saved costs but also contributed to minimising waste. By repurposing and utilising these existing assets, we have demonstrated our commitment to optimising resources and environmental responsibility.
Implementation
1. DAF System Installation
2. Liquid PolyMakeup System
To enhance the effectiveness of the treatment process, a WT-LPS150 Liquid PolyMakeup system was integrated into the plant. This addition helped in the flocculation and separation of contaminants, further improving the water quality.
3. Chemical Dosing System
The Chemical Dosing and PH correction system was incorporated to work in tandem with the DAF. This system allowed for the controlled introduction of specific chemicals at certain stages of the treatment process to allow chemical precipitation of contaminants. This contributed to a thorough and efficient treatment process.
3. Chemical Dosing System
The Chemical Dosing and PH correction system was incorporated to work in tandem with the DAF. This system allowed for the controlled introduction of specific chemicals at certain stages of the treatment process to allow chemical precipitation of contaminants. This contributed to a thorough and efficient treatment process.
4. Self-Contained Electrical Control System
At Water Tecnik, we design and manufacture electrical control panels specific to each of our customers exacting requirements. PLC control systems completed with remote dial in access allow us to monitor and manage the plant’s operations seamlessly. This control system allowed for real-time adjustments, ensuring optimal performance and efficiency.
Our site installation and maintenance team seamlessly delivered the new system, ensuring a smooth transition and hand over to site operations.
The Results
The installation of the chemical DAF effluent treatment system yielded significant and positive outcomes for Hovis:
The Results
The installation of the chemical DAF effluent treatment system yielded significant and positive outcomes for Hovis:
1. Reduction in FOGs and CODs
The DAF system, along with the polymer system, led to substantial reductions in FOGs and CODs in the wastewater. The FOGs were substantially reduced by 91% and the COD was reduced by 79%. They also are now pH neutral. This brought Hovis into compliance with regulatory standards.
2. Operational Efficiency
The self-contained control system contributed to operational efficiency by allowing for precise control and adjustments, ensuring the optimal functioning of the trial plant.
3. Scalable Solution
Based on the success of the trial plant, Hovis now has the option to implement this system on other sites, providing a flexible and adaptive approach for the overall operation.
4. Environmental Compliance
Hovis is now in full compliance with environmental regulations, mitigating potential risks to production and demonstrating a commitment to sustainable and responsible wastewater management.
Conclusion
The collaboration between Hovis and Water Tecnik demonstrates the successful implementation of a trial water treatment plant to address compliance issues effectively. By opting for a trial system first and seeing immediate improvements, Hovis were able to progress the project relatively risk free.
This also gave the management team time to consider how this could work on other sites and analyse the results. This project highlights the importance of tailored solutions in the water treatment industry and the positive impact of strategic partnerships in achieving environmental sustainability.
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