AEM performed various engineering and design services for a major food-processing manufacturer in Georgia that had been receiving fines and surcharges for its sewer discharge to the local Publicly Owned Treatment Works. The wastewater from the food facility activities regularly exceeded discharge standards for 5-Day Biochemical Oxygen Demand (BOD₅), Total Suspended Solids (TSS), Oil & Grease, and pH range (both low and high).

AEM conducted a first facility audit to reduce pollutant loadings in facility wastewater. In particular, best management practices were recommended to reduce wet washing activities of food materials causing high TSS and BOD₅ and to control acid preservative and caustic cleaners causing large pH fluctuations. The facility audit showed that industrial wastewater pretreatment would be necessary in order to meet the standards of 250 mg/L for BOD₅, 250 mg/L for TSS, and 100 mg/L for Oil & Grease.

AEM developed a design for an aerobic wastewater treatment system. During the design process, variable flow rates were measured during weekday and weekend operations and sampling was performed to determine wastewater characteristics for treatment. AEM determined that aerobic biological treatment was the best alternative and conducted a successful treatability study on the wastewater prior to full-scale implementation. As the design was developed, AEM also prepared the industrial pretreatment permit application for submittal to the Georgia Environmental Protection Division – Water Protection Branch.

AEM solicited vendor equipment pricing quotes and procured system equipment. AEM also developed construction specifications for the general and specialty contractors for the project.

The system design included a lift station to reroute wastewater flow and a 32,000-gallon activated sludge aeration tank to accommodate the highest pollutant loadings for the plant’s variable flow conditions. The design also included a clarifier, sludge holding tank, and automated controls to operate system pumps and equipment.

AEM assisted the general contractor in obtaining a building permit and provided oversight during all construction phases, especially assembly, plumbing, and wiring of the treatment equipment. AEM then commenced startup activities to reroute wastewater flow and seed the aeration tank with activated sludge. System parameters were monitored and adjusted as required to optimize system operation. In addition, AEM provided training and support for facility personnel for the necessary operation and maintenance requirements for the system.

After startup activities, monitoring data showed that the system effluent was meeting the required pretreatment standards for BOD₅, TSS, Oils & Grease, and pH.