This is an illustrative scenario showing how Reynolds & Bauhm equipment can be configured for this application. Every site has unique requirements — contact us for a solution tailored to your specific wastewater characteristics.
Premium food and beverage manufacturing campus with on-site craft brewery and artisan dairy. Wastewater 250 m3/day with combined COD 6,500 mg/L, fat 550 mg/L, protein 350 mg/L, and significant microplastic contamination from packaging (800 particles/L). Site sustainability mandate requires 95% water recovery with treated effluent reused for process washing, cooling tower makeup, and boiler feed. Discharge standard COD <10 mg/L, TSS <1 mg/L, conductivity <80 µS/cm, microplastics zero, total coliforms <1 CFU/100mL. No advanced biological treatment permitted due to campus biosecurity policy. Challenges: microplastics pass through conventional filtration, protein foam interferes with UV reactors, brewery tannins reduce UV transmittance, mixed waste creates complex organic matrix resistant to single-stage oxidation.
Step-by-step process configuration from raw wastewater to compliant discharge.
Heated DAF at 37°C with specialised coagulation protocol. Ferric chloride (200 mg/L) coagulates fats and proteins while entrapping microplastic fibres (PET, PP) from packaging waste. Microplastics >20 µm captured in float sludge with 95% efficiency. Anionic polymer (1 mg/L) strengthens floc structure for reliable microplastic capture. COD reduced from 6,500 to 4,500 mg/L. Float sludge at 10% solids incinerated to destroy microplastics — no landfill disposal. Automatic skimmer with micro-screen prevents plastic re-entrainment.
Dairy proteins create stable foam that reduces UV transmittance. Dedicated foam separation chamber with mechanical foam breaker and antifoam (silicone emulsion 2 mg/L) dosing. pH optimised to 5.5 with CO2 sparging — at this pH, protein foam collapses and UV transmittance increases from 45% to 72%. Simultaneously, acid pH shifts carbonate equilibrium to dissolved CO2, preventing calcium carbonate scale on UV quartz sleeves. Online turbidity <2 NTU required before UV reactor — achieved via 50-micron bag filter.
Multi-wavelength UV system combining medium-pressure (254 nm for disinfection + 185 nm for TOC reduction) with H2O2 at 1,000 mg/L. 254 nm photolyses H2O2 to hydroxyl radicals oxidising brewery tannins and dairy whey proteins. 185 nm directly photolyses water to OH* and photoreduces TOC. Total UV fluence 1,200 mJ/cm2. COD reduced from 4,500 to 600 mg/L (87% removal). Complete coliform inactivation >6-log. Automatic quartz sleeve wiping every 4 hours prevents protein film buildup. UVT monitor adjusts H2O2 dose in real-time.
Three-layer GAC system: 1) 1 mm anthracite cap captures any microplastics <50 µm that passed DAF, 2) 2-4 mm GAC removes residual UV byproducts and trace organics (EBCT 35 min), 3) 0.5 mm GAC fine polishing for colour and taste compounds. COD reduced from 600 to 80 mg/L. Multi-layer design extends carbon life to 24 months. Backwash stratification maintains layer separation. Headloss differential across anthracite layer indicates microplastic loading and triggers cap replacement.
Tight NF/RO hybrid with 200 Dalton NF pre-stage and 100 Dalton BWRO final stage. NF removes residual colour and large organics (COD 80 to 25 mg/L). RO achieves final polishing (COD 25 to <10 mg/L). Combined 95% recovery. Microplastic rejection >99.99% (verified by FTIR analysis). Conductivity <80 µS/cm. Boron rejection for dairy boron compounds >85%. Permeate UV disinfected as final barrier. Concentrate (5%) minimal — disposed as controlled liquid waste.
Treated water stored in 100 m3 reuse tank with online quality monitoring: TOC <5 mg/L, conductivity <80 µS/cm, free chlorine 0.5 mg/L residual. Distributed to three reuse streams: 1) process washing (40%), 2) cooling tower makeup (35%), 3) boiler feed pretreatment (25%). Monthly third-party testing verifies microplastic zero, endocrine disruptors <0.01 µg/L, and pharmaceutical residues <0.005 µg/L. Full water balance tracking via SCADA with annual sustainability report.
The specific equipment selected for this application, sized for the flow rate and contaminant load.
DAF 12 m3/h, 37°C, microplastic capture protocol, ferric/polymer dosing, incineration-ready sludge.
View EquipmentMechanical foam breaker with antifoam dosing, CO2 pH control, bag filter, UVT conditioning.
View Equipment254+185 nm UV, 1,200 mJ/cm2, auto sleeve wiping, real-time H2O2 dose control.
View EquipmentThree-layer: anthracite cap + GAC + fine GAC, 35 min EBCT, microplastic guard, 24-month life.
View Equipment200 Da NF + 100 Da BWRO, 95% recovery, >99.99% microplastic rejection, conductivity <80 µS/cm.
View Equipment100 m3 reuse tank, online TOC/conductivity/chlorine, three-stream distribution.
View EquipmentRepresentative performance data based on typical operating conditions for this equipment configuration.
Explore the full range of equipment used in this and similar applications.
H2O2, antifoam, CO2, ferric, polymer, chlorine preparation with precision metering.
View EquipmentUV-persulfate TOC analyser for real-time organic carbon monitoring.
View EquipmentDiscover how these treatment processes connect to form complete wastewater treatment solutions.
Multi-wavelength UV photochemical oxidation for complex organic matrix.
Heated DAF with microplastic capture for packaging-contaminated waste.
Multi-layer GAC with anthracite microplastic guard and fine polishing.
NF/RO hybrid for pharma-grade water with microplastic rejection.
95% water recovery with three-stream distribution and QA monitoring.
Multi-barrier microplastic capture from food packaging wastewater.
Our engineers will adapt this equipment configuration to your specific wastewater analysis, flow rate, and discharge requirements.
Our expertise spans multiple industries with sector-specific water treatment solutions.