DMP Saves Food Manufacturer $432K in Six Months By Improving Wastewater Processes

Indianapolis, IN

Background

Dairy producer seeks cost-saving changes to wastewater treatment program

Wastewater treatment is essential in most industries, and food and beverage is no exception.  Some companies resist paying for high-end wastewater treatment solutions, however, believing they won’t see a return on that investment.  But when an Indianapolis-based dairy company needed to make huge budget cuts or face possible closure, it teamed with an innovative wastewater treatment provider to reduce overhead while also improving water treatment and recovery.

This dairy producer of popular canned whipped cream already had a wastewater treatment provider for advice on technologies and chemicals, but the Indianapolis plant saw an opportunity to improve their dairy wastewater treatment by partnering with DMP.

Challenges

Assessment of dairy wastewater finds key areas to optimize wastewater treatment for better efficiency

The facility was in need of lower overhead, so they were skeptical when DMP proposed a treatment strategy that built upon their existing equipment.  However, DMP’s unique, modular approach provided better water recovery for a lower capital investment.

Because this company dealt with fats, oils, grease, and detergent during their CIP sanitation process on a daily basis, a coagulant was needed with a broad enough range to treat a variety of contaminants in their dairy wastewater.  DMP’s initial treatability survey found that its versatile coagulant 9070 was the ideal product, but DMP developed a method to provide even more value.

Solutions

Smart storage and automation for wastewater treatment deliver incredible results

Based on the various contaminants of their dairy wastewater, DMP determined that their coagulant DMP 9070 was the best choice. To ensure the manufacturer received the best price, they and DMP negotiated a bulk storage arrangement for the 9070. By storing in bulk, the facility cut costs associated with shipping, storing, and refilling smaller containers.

A new bulk tank was installed, capable of holding 5,000 gallons, significantly greater than the 275-gallon container they were using. When they need to refill the containers, only the liquid ships.

In addition to re-envisioning the storage and input of the coagulant, DMP installed equipment to help feed it properly. This included an equalizer, helping to process the facility’s wastewater flows, evening out the contaminant levels. Further, DMP implemented a dissolved air flotation (DAF), which worked more effectively with the new 9070.

Next, they initiated automation of the delivery of chemical based on strength. With the more consistent influent system, they achieved improved equalization.

Third, DMP trained the dairy producer’s wastewater treatment operators to optimize the equipment and ensure an efficient process.  Without training on the correct wastewater chemical dosages and other variables, operating costs could easily escalate.  DMP also provided in-house technical staff for in-depth training and oversight when necessary.

Results

DMP reduces dairy producer's wastewater operational costs by $432k in 6 months

The new process for storing and refilling the coagulant saved the company a significant amount in packaging, shipping, and storage.

The cost savings after six months of the new processes were as follows:
• $237,000 in solid waste disposal
• $148,000 in chemicals
• $47,000 in compliance

They were also able to reduce waste stream solids by 57%.

The client did not expect immediate results and cost savings but after six months, it was clear that DMP had provided an effective solution.  In that time, the food manufacturer saved $237,000 in solid waste disposal, $148,000 in chemicals and $47,000 in compliance for a total cost reduction of $432,000.  Waste stream solids were also reduced by 57 percent.

By partnering with DMP Corporation and committing to the solutions provided, the dairy producer was able to exceed all of its cost-reduction goals without compromising dairy wastewater treatment efficiency – in fact, DMP improved upon it.

If your organization would like to revise their wastewater treatment solutions and find cost savings, visit DMP’s wastewater upgrades page to learn more. We provide upgrades to competitor’s systems, just like we did with this dairy producer’s wastewater system.