Dairy Producer Achieves Extra Income through Effluent Optimisation by Veolia Water Technologies
Key points
Veolia Water Technologies has optimised the performance of an effluent treatment plant (ETP) for leading butter and cream producer Kerry Foods. The Yorkshire processing facility is now benefiting from a switch to a plant-based coagulant that has yielded a massive 50% reduction in sludge volume. This latest development has ensured that annual sludge collection and disposal costs are eliminated for this manufacturer, hence reducing its overall carbon footprint in the process.
Sustainable Optimisation at Kerry Foods, Ossett
The Kerry Foods site in Ossett, West Yorkshire, processes butter and cream products. The site's ETP is based on a dissolved air flotation (DAF) unit, which was using conventional metal-based coagulants. In an effort to optimise the process, Engineering Maintenance Manager Owen Millar and his team were pleased to receive Veolia Water Technologies' offer to implement a more sustainable, plant-based coagulant.
With an established relationship with other Kerry Foods sites already in place, Veolia Water Technologies was well-placed to deliver an effective solution. Brian Jones, Business Development Manager, identified a substantial cost-saving opportunity following an initial consultation with the Yorkshire-based team.
Reducing Costs and Improving Environmental Impact
Sludge production was another area ripe for optimisation. The existing configuration dictated the facility had to rely on weekly sludge collections at a cost of approximately £50,000 per year. After jar tests, Veolia Water Technologies proposed dosing with HYDREX® 62925, a plant-based coagulant, which would reduce sludge volume by 50% while continuing to meet the requirements of the Trade Effluent Consent Agreement.
HYDREX® 62925 is part of the HYDREX® 6000 series, offering customers a more environmentally friendly alternative to classical metal-based additives for wastewater treatment. The range offers tailored chemical solutions to meet the needs of various industrial and chemical sectors.
Unlocking New Revenue Streams
The new treatment process increased the concentration of sludge, hence its calorific value, by up to 50%, rendering it a viable feedstock for AD facilities. Independent testing confirmed the sludge's suitability, opening the opportunity for Kerry Foods to generate revenue from AD feed sales, rather than incurring ongoing removal costs.
Moreover, the site has drastically reduced its transport movements for sludge collection by about 75%, thus further reducing its carbon footprint. Changing to a plant-based coagulant has also minimised chemical dosing and handling risks – an important factor in ecological and operator-friendly benefits.
A Collaborative and Efficient Transition
Owen Millar, Engineering Maintenance Manager at Kerry Foods, was complimentary of the level of expertise and support from Veolia Water Technologies throughout the transition:
“The Veolia Water Technologies team was very supportive through this process, guiding us through with a good deal of useful advice, while still allowing ample time to perform trials and make our own decisions.”
Therefore, Veolia Water Technologies included comprehensive training for operators. The dosing and pH control could be efficiently managed when the transition began and therefore caused minimal disruption to the operations.
Operators have gained equally from greater reliability and stability in the new chemical process applied, enabling their involvement in various other important jobs rather than busy monitoring of ETP.
“Veolia Water Technologies provided expert knowledge, helping us achieve significant operational savings while reducing our environmental impact. As such, I would have no hesitation in recommending them to any food and beverage facility looking to optimise its processes and identify opportunities to save costs,” concluded Owen Millar.
Find Out More
To learn more about Veolia Water Technologies' chemical solutions, visit: www.veoliawatertechnologies.co.uk.
