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Ice Cream Manufacturer, UK

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Ice Cream Manufacturer, UK

This ice cream manufacturing plant based in the UK is one of Europe’s largest ice cream manufacturers. The company own and manufacture many household ice cream brand labels. As with all companies, it is essential for this manufacturing plant to minimise the impact they make on the environment. They are committed to continual environmental improvement and pollution prevention, which has enabled them to reduce their waste and to treat their waste water through a state-of-the-art treatment system.

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Problem

Effluent is treated with Reverse Osmosis (RO) and Ultra Filtration (UF) processes, but the plant was suffering from very high pre-treatment spikes in COD levels – up to 50,000mg/l, causing an issue with UF membranes in particular. Plant shut downs were necessary while the membranes were cleaned. This made the storage of huge quantities of pre-treatment effluent a necessity while factory production continued; risking production shut downs if the effluent plant was out of action too long.

Solution

Working closely with the client, NCH Waste Water installed a BioAmp™ 5000 CCU unit in March 2013 and was targeted to drop the average COD level by at least 10% and reduce the 35cm fat layer (7m in diameter) in the stored pre-treatment effluent tanks, again by 10% or more. The BioAmp™ 5000 CCU, which delivers a large amount of safe and active bacteria on a daily basis, has been designed to digest organic waste (COD and FOG) on the scale that is produced at major sites like this plant.

Result

After the first 13 weeks of treatment, the client reported COD and FOG levels were reduced to below targets. COD spikes had disappeared (none above c.18,000 mg/l) and the system also has faster recovery rates from fat leaks into the process. In September 2013, the client confirmed that the BioAmp™ 5000 CCU has had a significant impact over the hugely busy summer months – with all the extra ice cream manufactured.

By October all FOG issues affecting the UF membranes had disappeared or reduced significantly meaning that the flow rate through the membranes was maintained, avoiding the need for early cleaning shut downs. The tankering of FOG laden waste off-site has also been reduced by 5%.

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