Water Specialists for the Food & Beverage Sector · 2015-09-10 · Water Specialists for the Food &...

Water Specialists for the Food & Beverage Sectorcreating value in water through innovation, creativity and expertise

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Ovivo - creating value in water through innovation, creativity and expertise in clean water, process water, wastewater treatment, waste-to-energy and water reuse markets across 5 continents.

Ovivo - Industrial Markets


As society and the global economy demand more and more from water, there is a growing requirement for ever more specialist applications to manage clean water, to create specialist process waters, to treat wastewater, to extract energy from wastewater and to champion the reuse of water.

The 2010 merger of Eimco Water Technologies, Enviroquip. Aqua Engineering and Christ Water Technology plus many smaller specialist firms allows Ovivo to offer a unique combination of advanced solutions, probably the most significant application knowledge base in the world and some of the best brains in the business.

Ovivo aims to become the water partner of choice for clients in the public and private sectors and the leading source of water expertise for engineers and consultants across the globe.

For further information, visit

ovivowater.com

A New Global Force in Water

Ovivo - bringing water to life


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Water Specialists for the Food & Beverage Sector

We all need water. In the food industry, businesses’ consumption of water ensures that the food we eat is kept clean and made safe for consumption itself. It is an ingredient. It condenses, dissolves and extracts. Water washes raw materials. It heats in boilers, chills in refrigerators and cools equipment. In fact, water is such an integral component in food production, without effective management, production and food safety can be affected.

This is a challenge, and the bigger your company, the bigger the challenge. Now, more than ever before, businesses are required to demonstrate a commitment to water sustainability. Whatever foodstuffs you produce, whatever type of operation you are responsible for, whether it involves industrial or kitchen wastewaters, prepared meals or in-flight catering, the chances are that Ovivo already has experience in your sector.

Managing water from source to safe disposalOvivo can recommend solutions that will manage the water resources at your disposal safely and effectively, from pre-treating meats, fruits and vegetables on factory processing lines, to treating wastewater for reuse or disposal.

Every business has its own particular water needs dependent on location. Ovivo understands how water sources impact on processes. Food businesses handle the very substance of human wellbeing and are regulated accordingly. We appreciate that the means of disposal will determine the processes best suited to your own business.

A suitable solution for every client siteYour plant may process meats and require technology to deal with fats, feathers and offal. It may process potatoes, corn or soya and have specific requirements for dealing with starch. The broad range of dairy products creates varying forms of wastewater which each need their own forms of treatment. It may make drinks and require water to clean fruit at the outset of a process and clean bottles for packaging at its close. As a global water specialist, Ovivo has the capability to recommend and implement end-to-end solutions that extract the full value from water resources at your disposal so that you can maximize the output of your plant.

Food production can be highly seasonal. Inputs and outputs can vary accordingly. Ovivo’s knowledge of the food and beverage industry is rooted in our successful experience of helping factory operations achieve the results they require throughout the year. Ovivo specializes in designing, constructing and providing highly technical solutions for the treatment and recycling of wastewater across industries all over the world. However you help your customers fulfil their fundamental food needs, the chances are we can help you.

Our Role in your Industry

Ovivo’s advanced water treatment plant allows us to recycle more than 75% of our wastewater, or around 3ML/day. The savings in mains water and discharge costs easily outweigh the operational costs of the plant, which should pay for itself in a matter of years.

Creating Value


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Poultry The processesOvivo’s preliminary treatment by primary screening removes bulk solids (i.e. feathers, offal and foreign material). Finer solids are removed after chemical balancing in a Dissolved Air Flotation system (DAF). Ovivo’s DAFs can remove more than 90% of fats and solids and 70% of the Biochemical Oxygen Demand (BOD) load and produce water of suitable quality for discharge to most municipal treatment plants.

Sequential Batch Reactors (SBR), Moving Bed Bioreactors (MBBR), Membrane Bioreactors (MBR) or conventional activated sludge plants are secondary treatment processes which prepare poultry wastewater for discharge to waterways. Low and high rate anaerobic processes can be incorporated into the design, but such systems are often limited in nutrient removal and are usually not appropriate as a single stage of treatment.

Meat Processing The processes Wastewater from meat processing usually contains high levels of fat, solids, nitrogen and phosphorous. Unacceptable Biological Oxygen Demand (BOD) and Chemical Oxygen Demand (COD) levels require treatment too. Typically a preliminary water treatment stage involves screening to remove bulk solids, such as offal and other foreign material.

After flow equalization, Ovivo removes finer solids by DAF. With an appropriate chemical regime, a DAF system can remove more than 90% of fats and solids and 70% of the BOD load. This treatment will often provide water of suitable quality for discharge to most municipal treatment plants.

Dairies The processes Ovivo’s broad experience of dairy food processing helps us to anticipate the wastewater characteristics and fluctuations of dairy wash water, be it mild from fluid milk plants, or concentrated from cheese manufacturers.

Ammonia and nitrogen levels can be high. Primary balancing tanks equalize flow variations and concentrations. A facility to bypass or just store product spills is good practise, as surges of highly concentrated wastewater upset both primary and secondary treatment processes.

The pH of dairy wastewater is reduced to de-emulsify milk fats prior to DAF allowing excellent fat, oil, grease, BOD and suspended solid reductions.

Most commonly secondary treatment processes are based on MBBR or MBR technology. Both processes are more tolerant to sludge bulking, a phenomenon commonly found in biological treatment of dairy wastewater.

Breweries The processes Brewing produces a wastewater stream that is high in organic loading. Most of the organic component is soluble and requires biological treatment. Brewery wastewater is highly biodegradable and reacts rapidly, so biological treatment is efficient and simple. Ovivo can recommend the most effective treatment of wastewater depending upon the outlet for disposal, be it the local sewage treatment or recycling plant, river or ocean.

Preliminary screening removes bulk solids. Then a high-rate anaerobic process is ideal because brewery wastewater usually contains high levels of soluble BOD. Ovivo can achieve more than 90% reductions in COD /BOD loads this way. Any gas produced can be flared off or, for larger applications, used to fire a boiler or combined heat and power unit. If required, secondary treatment by SBR, MBBR or MBR leaves wastewater of a quality suitable for discharge into the environment.

Industries in which we work

Creating Value

Wastewater production from fruit and vegetable operations can be highly seasonal and variable. Ovivo’s knowledge of factory operations and the sources of wastewater is vital for the effective design of wastewater treatment plants.


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General Food The processes Screening as a primary treatment removes gross solids and foreign material. DAF removes over 90% of finer fat and solids present. For sewer discharge, some coagulation, pH correction and flocculation processes are normally used.

Secondary treatment processes – SBR, MBR, MBBR, conventional activated sludge plants - enable discharge to waterways. Low and high rate anaerobic processes are also quite common when nutrients are not present in significant quantities.

Potato & ChipsThe processesHigh soil and grit volumes in raw potato processing require solids-handling when conveying and dewatering plant. Ovivo’s effective, two-stage process for treating starch reduces chemical use and the quantity of sludge for disposal. DAF removes starch from sludge so it can be reused. Ovivo also supplies specialist process equipment to pre-treat and handle hot caustic boil-outs and other highly concentrated streams.

Ovivo recommends SBR, MBBR, MBR, or conventional activated sludge plants where stringent regulations require them. We can also incorporate low and high rate anaerobic processes into the design when appropriate. Ovivo has constructed several recycling plants in the potato chip industry, which incorporate tertiary treatment processes such as Ultra Filtration (UF), Reverse Osmosis (RO), disinfection and water conditioning, allowing you to reuse more than 70% of your wastewater in the processing factory.

Vegetable & Fruit The processes Wastewater characteristics will vary greatly depending upon the types and condition of fruit or vegetable used and the processing techniques deployed (e.g. washing, blanching, peeling etc). Using brine or chemicals in processing involves specialist clean-up methods.

In the beverage industry, decomposable organic compounds (leading to BOD) and suspended solids of various types are contaminants of particular concern. Elevated loadings of nutrients (nitrogen and phosphorus) also need to be addressed.

Screening and pH correction are essential as primary treatments. Anaerobic processes remove 90% of the soluble BOD load. Subsequent aerobic processes reduce BOD to acceptable discharge levels whilst simultaneously removing nutrients. Sludge dewatering plants, screens and solids handling equipment require careful design, which Ovivo applies to every client’s circumstance.

Primary Clarification

Fine Screening

Dissolved Air Flotation

Equalisation Tank

FlooBed® MBBR

MBR

Factory

Anaerobic Treatment


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Our Food & Beverage processesDiscover the ways we can help you with your wastewater challenges and help save you money

Activated Sludge

Sludge Dewatering

Media Filtration

SBR

Micro Filtration

ReverseOsmosis

Disinfection

Treated Water Storage

Sludge Stabilisation/Thickener

Sludge Storage


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Case Study Food & Beverages

Wastewater Treatment, Brisbane, Australia

BriefThe prestigious Australian Prime Minister’s Water Wise Award recognizes water efficiency excellence among commercial and industrial water-users and was won by Ovivo’s client, Inghams Enterprises, in 2010.

SolutionPoultry processing uses large volumes of water to ensure clean, safe food production. Ovivo installed an Advanced Water Treatment Facility for Inghams Enterprises which fulfilled its corporate commitment to long-term water reuse.

A comprehensive audit protocol emerged from a six-stage approval process that included guidelines to regulate purified water-use at Inghams Enterprises’ site.

The plant uses commercially available technology to produce water of drinking quality from treated wastewater, combining physical, biological nutrient removal and aerobic membrane separation techniques, as well as ultraviolet radiation and chlorination.

These processes provide a multi-barrier approach that removes micro-organisms and

complies with tough Australian drinking water guidelines. This is the first time an Advanced Water Treatment Facility has been used to produce potable water from treated wastewater at a poultry processing plant.

OutcomeInghams Enterprises reduced its reliance on mains water by 70% and saves 545 megalitres of water annually using Ovivo technology. This exceptional reduction in water use represents global best practice in water management.

How we created value

• Inghams Enterprises reduced mains water reliance by 70%.

• OvivosavedInghamsEnterprises 545 megalitres of water annually.

• TheexceptionalefficiencyofOvivo’sdesign and engineering is a benchmark for food and beverage plants worldwide.


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Jaspers is the West Country’s foremost independent beef and lamb producer.

BriefJaspers utilized approximately 17,000 m3 of water each year, and their annual charges for wastewater disposal are £100,000; additionally, the Treburley and Botathan sites consumed large amounts of costly potable water in low-grade wash-down applications.

SolutionJaspers selected Ovivo’s Membrane Bioreactor (MBR) to treat the low-flow, high-strength wastewater stream at both sites. Almost immediately, this simple, low-cost and low-maintenance system provided a cost-effective solution to treating the process effluent.

First screened by a 3mm perforated plate automatic screen, influent wastewater then enters the MBR’s treatment tank where the mixed-liquor activated sludge degrades the Chemical Oxygen Demand (COD). This treatment tank contains flat-sheet membrane panels to separate treated effluent from the mixed-liquor activated sludge and to remove bacteria and viruses. Due to the high influent COD load, the treatment tank incorporates a fine bubble diffuser air zone to ensure efficient oxygen transferred to the mixed-liquor activated sludge. Treated effluent is stored prior to reuse, and the unused high quality permeate is discharged into a local watercourse.

In just four months, 60% of the treated wastewater at the Treburley beef plant had already been reused in low-grade

applications, while the lamb abattoir in Botathan was reusing 90% of its water.

OutcomeThe quality of the final effluent has far exceeded original expectations, with Biological Oxygen Demand (BOD), Total Suspended Solids (TSS) and Nitrogen As Ammonia (NH

4N)

concentrations all less than 10 mg/l - and often less than the limits of laboratory detection.

Ovivo’s efficient membrane filtration system, and the reuse water it generates, enabled Jaspers to be the first abattoir in the UK to receive a Certificate of Environmental Benefit, and so instead of disposing wastewater to land, Jaspers are now making a net saving of around £90,000 per annum.

Case Study Jaspers, Treburley & Botathan Cornwall, UK

How we created value

• SignificantOPEXsavings.

• Paybackperiodreducedtoless than 5 years.

• 60-90%waterreuse.

• “Savingusmoney”.

Creating Value

From the supply of spare parts and chemicals to overhauls and the full operation and maintenance of water and wastewater facilities on a food and beverage site, Ovivo ensures that water and wastewater treatment need never be a reason to stop production.


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Ovivo takes a business-orientated view of total operating costs in water and wastewater. Each office can draw upon global best practice and in-depth application knowledge to ensure the efficient and effective running of water solutions within clients’ businesses. Ovivo’s commitment to clients is total, with experts dedicated to the provision of high quality operational support, maintenance, refurbishment and specialty chemical supply. Ovivo teams worldwide can test and confirm the operating capabilities of systems via regular inspections, either onsite or remotely. They will calibrate water treatment equipment periodically, as specific client service contracts require it.

Your local Ovivo team operates a quality system that conforms to ISO 9001 ensuring that: • Communicatingisaseasyaspossible.• Localresourcesareusedwhereverpossible.• Costsarekepttoaminimum.

Backed by a comprehensive telephone support service and spare-part supply agreements, Ovivo’s commitment is to develop productive, long-term customer service relationships with every client. Its teams ensure that plant is kept in optimum condition, minimizing downtime for your business and enabling you to operate at optimal efficiency.

Prolonging the efficient life of your assets


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Industry Solution Application

Food & Beverage Process Water Treatment Biological Aerobic Treatment

Pre-Treatment

Sludge Treatment Anaerobic Digestion

Chemical Physical Wastewater Treatment

Sludge Treatment

Waste to Energy (WTE) Biological Anaerobic Treatment

Organic Residual Management

Wastewater Treatment Biological Aerobic Treatment

Biological Anaerobic Treatment

Chemical Physical Wastewater Treatment

Headworks

Organic Residual Management

Sludge Treatment

Water Reuse Biological Aerobic Treatment

Applications and Solutions

Water Specialists for the Food & Beverage Sector · 2015-09-10 · Water Specialists for the Food &...

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Transcript of Water Specialists for the Food & Beverage Sector · 2015-09-10 · Water Specialists for the Food &...