EPA-660/2-74-075
DECEMBER 1974
Environmental Protection Technology Seri
Wastewater Characterization for the
Specialty Food Industry
National Environmental Research Center
Office of Research and Development
U.S. Environmental Protection Agency
Corvallis. Oregon 97330
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development,
U.S. Environmental Protection Agency, have been grouped into
five series. These five broad categories were established to
facilitate further development and application of environmental
technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in
related fields. The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY STUDIES series. This series describes research
performed to develop and demonstrate instrumentation, equipment
and methodology to repair or prevent environmental degradation from
point and non-point sources of pollution. This work provides the
new or improved technology required for the control and treatment
of pollution sources to meet environmental quality standards.
This report has been reviewed by the Office of Research and
Development, EPA, and approved for publication. Approval does
not signify that the contents necessarily reflect the views and
policies of the Environmental Protection Agency, nor does mention
of trade names or commercial products constitute endorsement or
recommendation for use.
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EPA-660/2-74-075
December 1974
WASTEWATER CHARACTERIZATION FOR
THE SPECIALTY FOOD INDUSTRY
Curtis J. Schmidt
John Farquhar
Ernest V. Clements, III
Grant No. R-801684
Program Element 1BB037
ROAP/TASK No. 21 BAB/028
Project Officer
i
Harold W. Thompson
Pacific Northwest Environmental Research Laboratory
National Environmental Research Center
Corvallis, Oregon 97330
NATIONAL ENVIRONMENTAL RESEARCH CENTER
OFFICE OF RESEARCH & DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CORVALLIS, OREGON 97330
For sale by the Superintendent of Documents, U.S Government Printing Office
Washington. B.C. 20402 - Stock No. S90U00990
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ABSTRACT
The specialty food industry generally falls within SIC
Codes 2032, 2035 and 2037 and includes approximately 2,300
plants in the United States which produce a wide variety of
food products. For waste categorization purposes the
specialty food industry was divided into ten categories on
the basis of ingredients used, type of product, and liquid
waste generation. Twenty-six nationally distributed spe-
cialty food plants were investigated and 24 of these field
sampled for ten days each to determine raw wastewater char-
acteristics and volume.
Related production and processing information was used to
calculate the wastewater generation per 1,000 kilograms of
production in terms of: 5 day Biochemical Oxygen Demand,
Chemical Oxygen Demand, Suspended Solids, Volatile Sus-
pended Solids, Total Phosphorus, Total Kjeldahl Nitrogen,
and Grease and Oil.
From one to six plants were covered in each specialty food
category. The categories showed wide variations in waste
generation between each other, and in some cases between
plants within a category. The results will be helpful to
all specialty food plants in gauging their waste generation
against other plants in their category. In addition, the
data will assist prediction of waste loads from new plants
and will aid regulatory agencies in establishing wastewater
discharge standards.
This report was submitted in fulfillment of Grant No.
R-801684, by SCS Engineers, under sponsorship of the Envi-
ronmental Protection Agency and the American Frozen Food
Institute. Work was completed as of September 1973.
ii
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CONTENTS
Section page
I Conclusions 1
II Recommendations 3
III Introduction 5
IV Sampling and Analytical Program 9
V Categorization and Wastewater
Characteristics 15
Prepared Dinners 16
Frozen Bakery Products 19
Dressings, Sauces and Spreads 20
Meat Specialties 21
Canned Soups and Baby Foods 23
Tomato-Cheese-Starch Combinations 24
Sauced Vegetables 26
Sweet Syrups, Jams and Jellies 28
Chinese and Mexican Foods 29
Breaded Frozen Products 30
VI Raw Waste Loads, Current.Treatment Technology,
and Plant Distribution 32
Standard Raw Waste Loads 32
Current Treatment Technology 39
Plant Distribution 41
VII Appendices
Appendix A 47
Appendix B 132
iii
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TABLES
No. Page
1 Average Pollutant Concentrations, Weights
Per Unit Production, and Wastewater
Generation by Category 8
2 Category 1, Average Pollutants Contained in
Wastewater Per Unit Production 18
3 Category 1, Average Wastewater Characteristics 18
4 Category 2, Average Pollutants Contained in
Wastewater Per Unit Production 19
5 Category 2, Average Wastewater Characteristics 20
6 Category 3, Average Pollutants Contained in
Wastewater Per Unit Production 20
7 Category 3, Average Wastewater Characteristics 21
8 Category 4, Average Pollutants Contained in
Wastewater Per Unit Production 22
9 Category 4, Average Wastewater Characteristics 23
10 Category 5, Average Pollutants Contained in
Wastewater Per Unit Production 23
11 Category 5, Average Wastewater Characteristics 24
12 Category 6, Average Pollutants Contained in
Wastewater Per Unit Production 25
13 Category 6, Average Wastewater Characteristics 26
14 Category 7, Average Pollutants Contained in
Wastewater Per Unit Production 27
15 Category 7, Average Wastewater Characteristics 28
16 Category 8, Average Pollutants Contained in
Wastewater Per Unit Production 2'9
17 Category 8, Average Wastewater Characteristics 29
18 Category 9, Average Pollutants Contained in
Wastewater Per Unit Production 30
IV
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TABLES (Continued)
No. Page
19 Category 9, Average Wastewater Characteristics 30
20 Category 10, Average Pollutants Contained in
Wastewater Per Unit Production 31
21 Category 10, Average Wastewater
Characteristics 31
22 Average Pollutants Contained in Wastewater 33
Per Unit of Production, By Category
23 Average Wastewater Characteristics By
Category 37
24 Specialty Food Plant Wastewater Treatment
Operations 40
25 Distribution of Specialty Food Plants By
Category and State 42
v
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ACKNOWLEDGEMENTS
Project Officer: Harold Thompson, Environmental Protection
Agency, Pacific Northwest Water Laboratory, Corvallis,
Oregon.
Project Director: John Farquhar, American Frozen Food In-
stitute, Washington, D. C.
Project Manager: Curtis Schmidt, SCS Engineers, Long Beach,
California and Reston, Virginia.
Laboratory Director: Walter Rose, National Canners Asso-
ciation, Berkeley, California.
Field Engineers: Ernest V. Clements III and Gary Mitchell,
SCS Engineers.
We are especially grateful to the 26 specialty food plants
which participated in this project. Each volunteered sub-
stantial personnel time during the field studies without
any compensation. We sincerely hope this report about waste
generation from the specialty food industry justifies their
unselfish contributions.
VI
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SECTION I
CONCLUSIONS
The canned and frozen specialty food industry includes
approximately 2,300 individual plants in the United
States. The greatest numbers are concentrated near the
large population centers, however, many of larger indi-
vidual plants are located in rural areas.
Categorization of the specialty food industry is extreme-
ly difficult because of the wide spectrum of different
products produced and the many other differences between
individual plants such as size, percent of maximum pro-
duction capacity utilized, etc. A preliminary division
into ten categories is suggested by this study, largely
on the basis of type of product.
Raw liquid waste loads generated by individual plants
within the specialty food industry vary greatly but in
general were found to be higher than was anticipated by
the investigating team. Average five day Biochemical
Oxygen Demand (BOD) generation ranged from 5 to 25 kilo-
grams per 1,000 kilograms (kg/kkg) (10 to 50 Ibs/ton) of
production, Suspended Solids (SS) generation from 1 to 26
kg/kkg (2 to 52 Ibs/ton) of production, and there were
similarly wide ranges for other waste constituents.
Average wastewater strengths in terms of BOD ranged from
300 to 3,200 milagrams per liter (mg/1), and in terms of
SS from 200 to 3,700 mg/1. Generally Chemical Oxygen
Demand (COD) values averaged about 200 percent of the
BOD values. Grease and oil concentrations ranged from
zero upward to a high of 2,000 mg/1.
The wide differences (more than 10:1) in raw waste
strength between categories of the specialty food indus-
try are due to the following major factors:
Richness of product ingredients.
Number and type of unit processes utilized during
production.
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Number of different products and frequency of changes
in product.
Extent of ingredient preprocessing which has occurred
elsewhere.
Moisture content of ingredients and final product.
Management desire to reduce waste generation.
Other factors, including plant size, number of shifts,
percentage of maximum production capacity in use,
cost of water supply and waste disposal, and economic
ability of the plant to modernize equipment.
Of the 26 specialty food plants investigated, 21 discharge
into municipal systems. The characteristics of the raw
wastes and the reported performance of existing treatment
facilities indicate that specialty food industry wastes
are satisfactory for combined treatment in municipal
treatment plants. Pretreatment prior to municipal dis-
charge ranged from no treatment up to activated sludge.
Complete treatment prior to direct discharge was prac-
ticed at five plants and was reported to achieve high
levels of pollution reduction. Treatment costs, where
reported, were also high due to the high raw waste
strengths.
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SECTION II
RE COMMEN DATION S
1. The results of this study should be given wide dissemi-
nation in the specialty food industry with the objec-
tives of:
(a) Obtaining opinions from knowledgeable individuals
as to the validity of the industry characterization
suggested by this study.
(b) Obtaining additional effluent characterization data
applicable to the various industry categories. The
American Frozen Food Institute (AFFI) could serve
as clearing house for (a) and (b).
(c) Causing individual plants to compare their waste
generation with similar plants described in this
study. Those plants which feel their waste gener-
ation is excessive should look to in-plant programs
to reduce waste discharged to the sewer.
2. In order to achieve wide dissemination, it is suggested
that the following be considered:
(a) Printing of the report by the government printing
office as soon as possible, with concurrent notifi-
cation by AFFI and National Canners Association
(NCA) to their membership that the report is avail-
able through the National Technical Information
Service or Government Printing Office.
(b) Printing of the report by AFFI and/or NCA for dis-
tribution.
(c) The scheduling of well-publicized technology trans-
fer seminars in several locations. The seminars
would use this report and other manuals as a basis
for assisting industry personnel in assessing and
reducing wastewater discharges. It is apparent
that plants which undertake a comprehensive program
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of in-plant education and process modification are
able to achieve remarkable reductions in liquid
waste generation.
In preparation for industry-wide effluent guidelines
which will probably be promulgated by the United States
Environmental Protection Agency (EPA) in late 1974, the
industry should immediately begin expanding upon the
data base developed in this "broad brush" report. In
order to develop realistic and equitable guidelines more
reliable data is required to describe the industry,
characterize its wastes, evaluate various treatment
methods, and provide confirmable economic data showing
the economic'impact of increasing degrees of pollution
control upon various plants in the industry. A series
of case studies is suggested as the best method to ac-
complish this recommendation. Initial case studies
should be made at specialty food plants which are
presently achieving exemplary results in reducing in-
plant pollution generation and/or end-of-the-pipe waste-
water treatment. The methods used and costs incurred by
these exemplary plants (three plants investigated for
this study report Biochemical Oxygen Demand (BOD) re-
duction in the 90 percent range) should be accurately
determined. Following-these initial case studies, a
second series of case studies should be made with the
objective of determining the technical feasibility and
economic impact of applying similar pollution reduction
requirements upon other typical plants in the industry.
Emphasis should be upon plants of various size produc-
tion capacity, the availability of land for treatment
and disposal, and the economic resources of the plant.
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SECTION III
INTRODUCTION
Specialty foods, as used in this project, includes frozen
and canned items containing several major ingredients. In-
cluded are such varied products as frozen dinners, frozen
and canned pre-cooked fish, beef, and poultry dishes, frozen
and canned stews and soups, frozen or canned ethnic/nation-
ality foods, frozen vegetables in sauce, frozen bakery
products and other prepared and/or pre-cooked foods.
Specialty food firms generally fall within SIC Codes 2032,
2035 and 2037.
The magnitude of this segment of the food industry is made
obvious by a stroll through any supermarket: more shelf
and freezer space is taken by specialty foods than by ordi-
nary canned and frozen fruit and vegetable items. Exact
production data on a national scale is lacking. However,
combined statistical sources estimate that specialty foods
production exceeds other types of food production.
Section VI of this report contains a tabulation of specialty
food plant distribution by type and state. A total of 2,321
specialty food plants are shown, with the largest number in
the states of California, New York, Illinois and Pennsyl-
vania. Meat specialties has the largest number of individ-
ual plants among the categories.
During the second half of 1973 AFFI conducted a study to
characterize wastewater generation by the specialty food
industry. AFFI was aided by NCA, which performed all labor-
atory analyses, and SCS Engineers, which performed all field
work and prepared the final report. Financial assistance
was provided by EPA under Grant No. R-801684.
The major objectives of the project were to:
Inventory and categorize the specialty foods
industry.
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Investigate typical raw waste loads generated by
major categories of the specialty foods industry.
This information is needed by AFFI, NCA and EPA to increase
their background knowledge in answering questions concerning
waste generated by the specialty food industry and to regu-
late industry waste generation in an equitable manner.
Categorization proved difficult because of product diversity,
but the industry was eventually divided into ten categories
on the basis of ingredients used, type of product, and
liquid waste generation.
The final ten categories are:
1. prepared dinners
2. frozen bakery products
3. dressings, sauces and spreads
4. meat specialties
5. canned soups and baby foods
6. tomato-cheese-starch combinations (Italian
specialties)
7. sauced vegetables
8. sweet syrups, jams and jellies
9. Chinese and Mexican foods
10. breaded frozen products
Section V describes in detail the categories and the ration-
ale for their selection.
To achieve the second project objective, i.e., preliminary
characterization of raw wastewater loads generated by plants
within each category, an effluent sampling program was
initiated. Data was obtained from field investigations of
24 specialty food plants and historical study of 2 others,
located throughout the United States. Field investigation
generally consisted of daily time-interval composite sam-
pling of raw wastewater for 10 consecutive operating days
supplemented by the gathering of related wastewater volume,
plant production, and basic processing information. Indi-
vidual case studies of these plants are found in Appendix A
and provide wastewater concentrations, volumes generated,
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productivity factors, products, ingredients and wastewater
generating operations. Simplified process flow diagrams
accompany the studies where obtained.
Field determination was made of pH, temperature, volume
(existing records and metering devices) and any unusual
visual characteristics of the waste. Laboratory analysis
included chemical oxygen demand (COD),5-day biochemical oxy-
gen demand (BOD), suspended solids (SS), volatile suspended
solids (VSS), total kjeldahl nitrogen (TKN) as mg/1 N, total
phosphorus (TP), and oil and grease.
Results of the wastewater characterization effort are pre-
sented and analyzed in Section V. Table 1 on the following
page, provides a summary of BOD and SS concentrations and
weight per'unit of production, as well as average wastewater
generation figures for all the categories.
Final treatment or pre-treatment of the wastes from the
specialty food industry was not within the scope of this pro-
ject, per se. The field team did, however, note treatment
practices at the individual plants investigated. Their ob-
servations are described in Section VI. The majority of
plants utilized gravity settling and flotation prior to dis-
charge to a municipal sewer. Several of the large plants,
however, maintain extensive biological or physical-chemical
facilities including one or more combinations of the fol-
lowing processes: aerobic and anaerobic lagoons, activated
sludge, trickling filters, coagulation/floculation, aera-
tion, and land disposal.
This study is the initial attempt to characterize the wastes
generated by a major segment of the nations food processing
industry. The results will be helpful to all specialty food
plants in gauging their waste generation against other
plants in their category. In addition, the data presented
will assist prediction of waste loads from future new plants
and will aid regulating agencies in establishing wastewater
discharge standards. Finally, this initial venture points
the way for future work in several areas of importance as
described in the recommendation's section of the report.
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00
Table 1. AVERAGE POLLUTANT CONCENTRATIONS,
WEIGHTS PER UNIT PRODUCTION,(D AND
WASTEWATER GENERATION BY CATEGORY
Category
BOD
Ave. cone.
(mg/1)
Wt. per unit
production
(kg/kkg)
SS
Ave. cone.
(mg/1)
Wt. per unit
production
(kg/kkg)
Wastewater
volume per unit
production
(1/kkg)
1
2
3
4
5
6
7
8
9
10
1,900
3,200
2,600
820
560
370
310
2,400
570
2,400
17
23
7.5
9.5
12
7.2
25
5.1
6.9
26
1,500
2,200
1,200
460
320
220
250
400
200
3,700
14
14
3.
6.
7.
6.
21
1.
2.
26
5
1
6
0
0
8
12,000
11,000
2,800
10,000
22,000
29,000
85,000
2,400
14,000
48,000
(1) See next page for explanation of production weights.
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(1) In this study the investigators were faced with some
category situations where production data was available
only in terms of finished product and in other cases
where production data was available in terms of raw
product. Waste loads for the following categories are
stated in terms of finished production tons: 1, 2, 3,
4, 71 8, and 9; and waste loads for categories 5 and
10 are stated in terms of raw product tons. In the
case of category 6, plant R is stated in terms of raw
product tons and plants 0, P, and Q in terms of finished
product tons.
Since the majority of specialty food plants are largely
reprocessors of food pre-processed elsewhere there often
is little difference between raw product tonnage and
finished product tonnage. Below, an estimate is pro-
vided of the percentage of finished product weight to
raw product weight by category:
Finished Product wt
Category raw product wt x 100 Comment
1
2
3
4
5
6 (frozen)
6 (canned)
7
8
9
95
100
100
90-100
70-110
100
130
40-90
100-150
80-100
wtr added
wtr added
wtr added
fat trim
variable
product
much wtr
added
variable
product
wtr added
dependent
on vege-
tables
processed
10 100
8a
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SECTION IV
SAMPLING AND ANALYTICAL PROGRAM
This section of the report describes the approach used in
selecting specialty food plants to be investigated, per-
forming the field investigation programs, and categorizing
the industry according to the results received.
PLANT SELECTION
A preliminary assessment of the types, number and locations
of specialty food plants was prepared, and a tentative
determination made of representative plants in the west,
midwest, and east which appeared to be desirable candidates
for field investigation. Each candidate plant was contacted
by phone and letter, given a description of the project, and
requested to indicate a preliminary assurance of cooperation.
A series of meetings were arranged by AFFI in San Francisco,
Chicago, and Washington, D.C. at which the project technical
team met with company representatives to work out details of
individual plant investigations. Every attempt was made to
insure that the participating industry plants were cognizant
of their responsibilities to the project. The final selec-
tion of participating plants was made to provide diversity
in type of product and geographical area. The plants were
located as follows:
East - 6 plants
Midwest - 9 plants
West - 11 plants
FIELD INVESTIGATION
During the field investigations, the procedure followed at
each plant was generally similar. Once plants in the same
geographic region had agreed to participate, the project
technical director visited each plant to review the plant
layout; determine a proper location for installation of a
composite sampler; initially educate plant personnel in
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their responsibilities to extract and store samples; advise
the necessity for obtaining concurrent information on pro-
duction and waste volume; observe waste treatment facilities,
and agree upon a date to begin waste sampling.
On the agreed date, the field engineer arrived at the plant.
He carried -with him all the equipment necessary for the
sampling program. Equipment used throughout the study is
listed below:
Three N-Con "Surveyor" samplers, each with intake
and exhaust hoses,0.64 cm opening intake basket
screen, 9.5 liter sample collection container,
and a 30 m. extension cord.
One Brailsford "EV-1" sampler with accessories.
One Brailsford "DU-2" sampler with accessories.
Six Coleman insulated coolers - made of heavy
plastic with locking lid.
120 0.95 liter plastic sample bottles with twist-on
lids.
180 1.9 liter sample bottles with twist-on lids.
300 printed information tags with wire for fastening
to sample bottles.
One portable Beckman automatic pH meter.
Two thermometers for water temperature measurements.
»
70 heavy cardboard boxes with styrofoam lining for
sample shipping.
91 kg. of dry ice purchased from ice houses or
donated by food plants for sample preservation
during shipping.
At each plant, the field engineer installed the automatic
sampling unit at a site pre-selected by the project director
and plant staff. The sampling sites were located to obtain
representative samples of screened raw waste prior to pre-
treatment units. Areas of turbulence were chosen to insure
mixing and suspension of solids. Once the engineer had in-
stalled the sampler, he instructed the plant personnel in
proper sampler operation and sample handling. In most cases
tliis involved merely turning the unit on and off at the
beginning and end of shifts, filling a sample bottle from
10
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the large 9.5 liter sample collection container, after
swirling the latter to achieve a homogeneous wastewater
solution, and placing the sample in the Coleman cooler in
the plant freezer. The engineer also advised plant managers
as to what supplemental data would be needed on production
tonnages and wastewater volumes and urged them to compile
this information during the sampling period.
During the sampling period, the investigator returned to the
plant every 3 or 4 days to insure proper operation and to
pick up frozen samples. These samples were packed in dry
ice in the styrofoam lined boxes and transported by the
quickest means to the NCA Laboratory in Berkeley, California.
Most of the samples were shipped air freight to San Francis-
co for pickup by the laboratory. Samples collected from
plants in northern California were delivered by car to the
laboratory the same day.
At the end of the sampling period, the engineer picked up
the last of the frozen samples, shipped them to the lab, and
acquired whatever volume and production data was available
at that time.
Sampling frequency, type, and procedures were somewhat
dependent upon circumstances found at each plant. Approxi-
mately ten "end of pipe" time interval composite samples for
ten consecutive operating days were collected at each plant.
These samples were generally 24 hour composites, but excep-
tions were made due to plant operation or collection time
requirements. If distinct "processing" and "clean-up"
shifts existed, samples of each shift were taken along with
related wastewater volume data. At two of the plants (S
and T), additional grab samples were taken of major waste
streams (i.e., sauce room clean-up). Some food plants in-
vestigated had their own permanent automatic sampler. In
these situations, the field engineer supplied the sample
bottles, and storage cooler. Plant personnel took their
routine composite samples and divided the sample for use by
this study, and for their own analysis work.
ANALYSIS
When shipments of samples arrived at the NCA lab, they were
kept frozen until lab analysis was to begin. Samples were
analyzed for the following constituents using the standard
procedures listed below:
Test Procedure
COD Standard methods (13th edition)
11
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Test Procedure
BOD Standard methods: 5-day, 20°C, cylinder
dilution procedure.
SS Standard methods using glass fiber
filter paper.
VSS Standard methods.
Total P From Methods for Chemical Analysis of
Waste and Water, EPA, 1971, 16020
07/J1.
TKN Standard methods.
Grease and oil From Methods for Chemical Analysis of
Waste and Water, EPA, 1971, 16020
07/71.
Two of the 26 plants studied (E, P) were not sampled, but
provided comprehensive historical information on wastewater
concentrations, volumes, and production weights. Productiv-
ity factors were calculated from this data just as it was
for the other plants. Appendix B provides a detailed ex-
planation of the methods of productivity factor calculation
used for each of the 26 plants.
The field work was accomplished successfully, considering
the number and distribution of the plants involved, but not
without problems. The most difficult task was the sched-
uling of sampling periods at a group of plants in the same
geographical area while all those plants were in representa-
tive production. The project team had optimistically antic-
ipated being able to sample five plants in an area (200 mile
radius) concurrently and then moving on to the next area.
Practically this proved impossible to coordinate, and gen-
erally only two or three plants were being sampled concur-
rently. This caused an overrun of project schedule and
substantially more travel expense than anticipated.
Another problem encountered was the inherent inability of
the Brailsford samplers to take representative samples with
respect to suspended solids. These units utilize a small
suction pump which slowly draws a small volume of sample up
a.64 cm.intake tube into the container. It seems probable
that the suspended solids content of the sample is lower
than actual because solids tend to settle by gravity down
the intake tube during the off periods in the pumping cycle.
The Brailsford samplers should be used only on wastewaters
with low solids concentrations, which is usually not the
12
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case at food plants. No problems were experienced with the
N-Con sampler. This unit provides representative samples
because it uses a more powerful pump to draw large sample
volumes through the 1.3 cm. intake hose and pump impeller
before diverting a small part of the flow into the sample
container.
Another hindrance to efficient data analysis was the long
delay in getting production and/or wastewater volume data
from some of the plants. Proper authorization must often
come from company headquarters and once sampling has ended,
it is often difficult to obtain the information needed
through follow-up phone calls and letters. These delays can
be minimized by early explanation to plant personnel as to
what data is needed, and by constant reminders when the
field engineer makes his stops to pick up samples.
APPROACH TO CATEGORIZATION
Categorization of the specialty foods industry is made com-
plex by the great number of plants and wide diversity of
products. In addition, many plants make several products
and it is virtually impossible to relate wastewater charac-
teristics back to a certain product because a variety of
products are processed simultaneously, and the mix is often
continually changing. Another hindrance to categorization
is the fact that although two plants may produce virtually
the same final products, one may employ more intensive raw
material processing than the other, and thus their waste-
water properties could vary significantly. Moisture content
of products can vary between product styles, affecting
productivity factors based on final product weight.
Other factors which may have a significant effect upon
wastewater generation from a particular plant include, plant
size, number of shifts, percentage of production capacity in
use, cost of water supply and wastewater disposal, degree to
which ingredients have been pre-processed eIsewhere/manage-
ments desire to reduce waste generation, and economic abil-
ity of the plant to modernize equipment.
Each of the factors described above may have an important
effect upon waste generation from a particular plant. This
study obtained data from an average of less than three
plants per category. Considering the many uncontrollable
variables involved and the limited number of plants investi-
gated, the category selections and wastewater characteris-
tics presented in this report should be considered as
preliminary.
13
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In order to obtain the most equitable categorization, within
the bounds of the scope of work, we have based our decisions
for plant groupings on three basic factors:
Primarily: Type of product.
Secondarily: a) Type and degree of raw material
processing, b) wastewater productivity factors (kg
pollutant/kkg product)-
The advantages of this approach to industrial categorization
are as follows:
Simplicity and ease of initial categorization -
rough grouping by "type of final product" is a com-
paratively simple task and provides a point of
departure for more detailed analysis. After "prod-
uct" grouping, processing differences or wastewater
characteristics can be reviewed to further substan-
tiate categorial selections or to reclassify the
plants that appear misplaced.
Provides easy comparison to other plants - grouping
by product allows members of the specialty food
industry to compare their overall plant wastewater
characteristics to similar plants preparing the same
products.
Good probability of similarity in other parameters -
plants initially grouped by product type frequently
show good correlation in overall wastewater proper-
ties (concentrations, volume per unit product, etc.)
if similar raw ingredient processing operations are
performed.
Final category selections are described in the following
section.
14
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SECTION V
CATEGORIZATION AND WASTEWATER CHARACTERISTICS
As previously described in Section IV, field investigations
of liquid waste characteristics were performed at 24
specialty food plants, and historical data acquired at an
additional two plants. Individual case studies of these
plants are found in Appendix A and provide details of waste-
water volumes, pollutant concentrations, products, and in-
gredients. Simplified process flow diagrams, when obtained,
accompany the case studies. The plants are designated
by letter (A, B, etc.) and located only by very broad geo-
graphical area (West, Mid-West, East). This was done to
protect the confidentiality of the information provided.
In this chapter, wastewater characteristics are detailed and
discussed specifically for each category. Comparisons are
drawn where significant and discussions of individual plants
provide explanation of typical results.
In full recognition of the difficulties involved in cate-
gorizing a complex industry of over 2,000 plants, the fol-
lowing ten categories were established for the purpose of
this investigation.
Category 1
Category 2
Category 3
Category 4
Category 5
Category 6
Category 7
Category 8
- Prepared Dinners
- Frozen Bakery Products
- Dressings, Sauces and Spreads
- Meat Specialties
- Canned Soups and Baby Foods
- Tomato-Cheese-Starch Combinations
- Sauced Vegetables
- Sweet Syrups, jams and Jellies
15
-------
Category 9 - Chinese and Mexican Foods
Category 10 - Breaded Frozen Products
PREPARED DINNERS (Category 1)
Plant letter codes included in this category are A, B, C, D,
E, and F. The major products of this category are frozen
prepared dinners and pot pies including meat, poultry or
fish, vegetable, and starch (potato, rice, noodles). Plant
A produces significant frozen bakery products and Plant E
significant vegetable dishes in addition to prepared din-
ners.
The plants in this category do very little processing of
raw materials. The meat portions have been slaughtered and
dressed elsewhere, and the vegetables have also generally
been pre-processed elsewhere and shipped frozen in bulk.
The ingredients are usually cut into meal size portions,
cooked, assembled and frozen. Figure 1 on the following
page illustrates in a simplified flow diagram the "assembly
plant" nature of plants in this category.
The primary wastewater generating activity is plant clean-
up, which is generally concentrated during a late night or
early morning "clean-up" shift. However, cleaning of equip-
ment is carried out continuously as the product mix changes
or spills occur. Other wastewater sources may include,
vegetable rinsing and blanching operations, frying, cooking,
and cooling water.
This category was the most thoroughly covered of the ten
categories with six plants investigated. The plants are
usually very large, and are often located in small towns or
in rural areas where their wastes may constitute a signifi-
cant potential treatment problem.
Tables 2 and 3 show the waste generation and waste strength
of the effluents from plants in this category. BOD genera-
tion ranges from 9 to 34 kilograms per 1,000 kilograms
(kg/kkg) or 18 to 68 Ibs/ton of production. Waste strength
varies from 600 to 4,000 milligrams per liter (mg/1) of
BOD. We believe that the highest levels represent plants
which (1) produce a higher proportion of rich foods and/or
(2) have not instituted a rigid in-plant program to avoid
excessive disposal of food materials into the sewer. Plant
E, for example, claims to have greatly reduced its waste
generation through, a comprehensive program of personnel edu-
cation and in-plant modifications.
16
-------
PREPARATION
ASSEMBLY
FOWL
CUTTING
TURKEY
(processed elsewhereLjCOOKING
and frozen)
COOKING
CHICKEN
(processed elsewhere 4 CUT
and frozen)
BONING
BONING
COOKING'
BONING
FLOURED
J *} SLICING ["
| - |
SLICING
FRYING
NOTE
HEAVY ARROW
DESIGNATES MAJOR
LIQUID WASTE
GENERATION
MEAT
MEATLOAF
VEAL
(patties prepared
elsewhere)
BEEF
(prepared elsewhere
and rolled)
-{ BROILINGJ-
-| SLICED |-
(meat juice from f ]
cooking )
VEGETABLES
MIXhU J " ^COME
(processea eisewnere j DPFAKUrl
nnri frnzanl j CLUuTCn BREAKUP |
POTATOES
MEXICAN 4r
i ITOME
(FREE
DRIED BEANS -[WASHING]- |COOKING | j MASHING j
CORN
(aenusKea cecoroea i COQK NQ _^_GR|NOir
elsewhere) ^UUMNVJ «- oniivuir
prep
RITF . . - I onon'iMc !
j PLANT
._, CUTTIWR . , ,.
INED)
JINEIP)
ZINGJ PACKAGED)
JR . iNTn > ^rniuiRiMiMrA Jprmi/iMp. ^
orod rhf P-5P I SAUCING 1 - -
CLEAN- UP J |
FIGURE 1
,
^yZlXCOMBINED)
t
(^ FROZEN^)
1-
PREPARED DINNER PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
17
-------
Table 2. CATEGORY 1, AVERAGE POLLUTANTS
CONTAINED IN WASTEWATER PER UNIT
PRODUCTION
Plant
code
Constituent (kg/kkg finished
COD
A 69
B 42
C 28
D 27
E 20
F 17
Average 34
Range 17-
69
BOD
35
18
13
15
11
8.8
17
9-
34
SS
34
11
11
14
6.6
6.2
14
6-
34
VSS
33
11
11
14
6.0
6.2
14
6-
33
Total
P
0.25
0.18
0.24
0.16
-
0.12
0.19
.12-
.25
TKN
0.44
0.25
0.61
0.55
-
0.37
0.44
.25-
.61
product)
Grease
and oil
44
21
-
2.9
3.8
4.8
15
2.9-
44
Volume
(1/kkg)
8,700
6,200
22,000
21,000
9,400
4,400
12,000
4,400-
22,000
Table 3. CATEGORY 1, AVERAGE
WAS TEWATE R CHARACTE RISTICS
Plant
code
Concentration
COD
A 7,900
B 6,800
C 1,300
D 1,300
E 2,100
F 3,800
Average 3,900
Range 1,300-
7,900
BOD
4,000
2,900
620
720
1,240
2,000
1,900
620-
4,000
SS
3,900
1,800
530
680
700
1,400
1,500
530-
3,900
VSS
3,800
1,700
510
650
640
1,400
1,500
510-
3,800
(mg/1)
Total
P
29
30
11
7.6
-
28
21
7.6-
30
TKN
51
34
28
26
-
85
45
26-
85
Grease
and oil
5,100
3,400
-
140
400
1,100
2,000
140-
5,100
18
-------
FROZEN BAKERY PRODUCTS (Category 2)
Plant letter codes included in this category are G and H.
The major products of this category are frozen bakery des-
sert products such as cakes, pies, brownies, cookies, rolls,
and other desserts.
The plants are very large scale kitchens which purchase the
ingredients such as butter, flcur, shortening, eggs, sugar,
flavoring, fruit filling, etc., in much the same way as the
housewife would were she making the baked goods from
scratch. Plants G and H are both major producers of these
products with national distribution.
Tables 4 and 5 summarize the waste generation and waste
strength of the effluents from the two bakery products
plants. Waste strength is very high with BOD in the range
of 2,100 to 4,300 mg/1. Unfortunately, Plant H would not
provide production information, making it impossible to de-
termine the average pollutants per unit of production for
this plant.
Table 4. CATEGORY 2, AVERAGE POLLUTANTS
CONTAINED IN WASTEWATER PER UNIT
PRODUCTION
Plant
code
Constituent (kg/kkg finished product)
COD
BOD
SS
VSS
Total
P
TK\
Grease
and oil
Volume
(1/kkg)
G 52 23 14 14 0.082 0.30 11 11,000
H No Production Information Provided
Waste is generated from clean-up of spills and equipment
and from the disposal of substandard ingredients and prod-
ucts. The major ingredients are very rich and high in BOD,
suspended solids, and grease. Variations in frequency of
product mix changes and house cleaning practices help to
account for differences in effluent concentrations.
19
-------
Table 5. CATEGORY 2, AVERAGE
WASTEWATER CHARACTERISTICS
Plant
code
Concentration (mg/1)
COD
BOD
SS
VSS
Total
P
TKN
Grease
and oil
G 4,600 2,100 1,300 1,200 7.8 27 940
H 9,300 4,300 3,100 3,000 5.7 45 690
Average 7,000 3,200 2,200 2,100 6.8 36 820
DRESSING, SAUCES AND SPREADS (Category 3)
Plant codes I and J are included in this category. Major
products are salad dressings, mayonnaise, mustard and barbe-
cue sauces. Typical ingredients include tomato paste, vege-
table oil, spices, eggs, vinegar, mustard, and small quanti-
ties of dairy products. Generally, the ingredients are
blended, bottled, cooked, and cooled. Clean-up of the
blending and cooking vats contributes most of the waste load.
The two plants sampled were a very small batch type plant
(J) and one of the nation's largest plants (I). As seen
from Tables 6 and 7 correlation was surprisingly good be-
tween the plants. Both exhibited very strong wastes with
average BOD of 2,600 mg/1, however, waste generation in
terms of production averaged a low 7.5 kg/kkg (15 Ib/ton) of
product. Wastewater volume averaged only 2,800 1/kkg (670
gal/ton) of product.
Table 6. CATEGORY 3, AVERAGE POLLUTANTS
CONTAINED IN WASTEWATER PER UNIT
PRODUCTION
Plant
code
Constituent (kg/kkg finished product)
COD BOD
I 12 5.6
J 14 9.4
SS
2.6
4.4
VSS
2.4
4.4
Total
P
0.039
0.018
TKN
0.036
0.038
Grease
and oil
3.1
8.3
Volume
dAkg)
2,600
3,100
Average
13
7.5 3.5 3.4 0.028 0.037
5.7
2,800
20
-------
Table 7. CATEGORY 3, AVERAGE
WASTEWATER CHARACTERISTICS
Plant
code
Concentration (mg/1)
COD
BOD
SS
VSS
Total
P
TKN
Grease
and oil
I 4,900 2,300 1,000 960 16 15 1,300
J 4,500 3,000 1,400 1,400 5.8 12 2,700
Average 4,700 2,600 1,200 1,200 11 14 2,000
The overall low productivity factors for this category are
due to the fact that equipment clean-up is the primary
wastewater producing activity, and relatively small volumes
of water are used. One misleading factor in the low prod-
uctivity and wastewater generation factors is that water is
a major weight component in the final product and most of
the initial ingredients. This tends to make the production
tonnages artificially high compared to other categories pre-
paring low water content products. Final productivity fac-
tors would be substantially higher for this category if
only product dry weight was considered.
Plant I has installed an automatic flow-proportional com-
posite sampler with refrigerated storage. Samples are taken
daily and analyzed for BOD and SS in the plant quality con-
trol laboratory. Plant management uses raw waste strength
as a gauge of their in-plant efficiency in minimizing waste
of valuable ingredients into the sewer. They informed our
investigator that if the weight of BOD in the raw waste ex-
ceeds one percent of the production weight they investigate
to determine the reason. As shown in Table 6, the BOD
during our sampling period averaged only 0.56 percent of the
production weight. Incidentally, the BOD and SS results of
the plant laboratory analyses for the sampling days corre-
lated very closely with the BOD and SS results of the NCA
Laboratory analyses run on the frozen samples.
MEAT SPECIALTIES (Category 4)
Plant codes K and L are included in this category. Major
products are ham, sausages, stews, pickled meats, hash, and
chile, plus frozen items such as pre-fried meat patties.
The meats have been slaughtered, dressed and packed else-
where. Added ingredients are largely spices and preserva-
21
-------
tives. Substantial quantities of grease and oil are present
in the waste flow from the cleaning of cooking vats, frying
ovens, and other equipment which comes in contact with the
meat.
The two plants sampled represented opposite ends of the meat
specialties category in terms of amount of processing per-
formed. Plant K is a very small operation preparing a
limited number of products. Processes include grinding,
mixing with additives, then canning and cooking or patty
forming and freezing. Minimal amounts of water are used for
clean-up activities. Plant L on the other hand is a large
meat canning operation preparing a wide assortment of meat
specialties. Processing is more extensive, product changes
more frequent, and waste generation significantly higher
than Plant K.
Tables 8 and 9 show the waste generation and strengths
recorded for the two plants. We believe that Plant L is
more typical of plants producing meat specialties, with BOD
values of 16 kg/kkg (32 Ibs/ton) of production and 1,100
mg/1 concentration. Also, we believe the sampler used at
Plant K may not have taken representative samples due to low
flow volume in the sampler suction tube.
Table 8. CATEGORY 4, AVERAGE POLLUTANTS
CONTAINED IN WASTEWATER PER UNIT
PRODUCTION
Plant
code
Constituent (kg/kkg finished product)
COD
BOD
SS
VSS
Total
P
TKN
Grease
and oil
Volume
(1/kkg)
K 5.1 3.0 1.2 0.97 0.086 0.16 0.68 5,700
L 33 16 11 10 0.11 0.98 7.3 15,000
Average 19 9.5 6.1 5.5 0.098 0.57 4.0 10,000
22
-------
Table 9. CATEGORY 4, AVERAGE
WASTEWATER CHARACTERISTICS
Plant
code
Concentration (mg/1)
COD BOD SS
K 900 530 210
L 2,300 1,100 720
VSS
170
670
Total
P TF
Grease
.N and oil
15 28 120
6.7 67 490
Average 1,600
820 460 420
11
48
300
CANNED SOUPS AND BABY FOODS (Category 5)
Plant codes M and N are included in this category. Canned
soups and baby foods, are put in one category because the
plants typically are large, and produce many product varie-
ties which contain different vegetable, meat, starch, and
fruit ingredients. Both plants perform significant raw
product processing of vegetables, as reflected by the rela-
tively high wastewater generation figures shown in Tables 10
and 11. In this respect they are more closely allied with
straight commodity processors than with many other cate-
gories of the specialty foods industry. Major wastewater
sources are plant clean-up; washing, trimming, blanching of
raw vegetables; washing, peeling and coring of raw fruit;
and cooking of meat. Generally, waste discharges will vary
greatly in volume and strength, depending upon which varie-
ties are being manufactured, and the relative quantities of
raw commodities and pre-processed ingredients.
Table 10. CATEGORY 5, AVERAGE
POLLUTANTS CONTAINED IN WASTEWATER
PER UNIT PRODUCTION
Plant
code
Constituent (kg/kkg raw product)
COD
BOD
SS
VSS
Total
P
TKN
Grease
and oil
Volume
(1/kkg)
M 14 8.5 4l3 3.1 0.068 0.19 - 15,000
N 27 15 10 8.4 0.29 0.75 2.4 29,000
Average 20 12 7.2 5.8 0.18
0.47
22,000
23
-------
Table 11. CATEGORY 5, AVERAGE
WASTEWATER CHARACTERISTICS
Plant
code
Concentration (mg/1)
COD
BOD
SS
VSS
Total
P
TKN
Grease
and oil
M 1,000 590 280 210 4.1 12
N 940 520 360 290 10 26 82
Ave rage
970 560 320 250
7.0
19
TOMATO-CHEESE-STARCH COMBINATIONS (ITALIAN SPECIALTIES) - Category 6
Plant codes 0, P, Q and R are included in this category.
Major products are canned and frozen spaghetti, lasagne,
ravioli, frozen pizza, and other Italian specialties made
with tomato, starch, and cheese base. These plants were
placed in one category because they typically have the three
principal ingredients listed, all of which are pre-processed
elsewhere. The wastes are generated primarily from spills
and clean-up of blending vats and cooking kettles.
As seen from Tables 12 and 13 this category showed poor
correlation in waste generation. We believe this wide di-
versity is due to selectionv-of three plants which are vastly
different in their operations due to size, product style,
and percent of total plant capacity being used at the time
of sampling.
Plant R is the smallest operation covered in this study.
Processing is done largely by hand. Virtually no water is
used except for end of the day clean-up of equipment. As
shown in the tables, wastewater generation was extremely low
(1,800 1/kkg or 430 gal/ton product). This minimal clean-up
flow provided little dilutio'n, thus the high concentrations.
However, the wastewater volume was so low that even the
higher strength of the waste could not significantly effect
the productivity factor. The 2.6 kg COD/kkg product factor
was the lowest of all 26 plants investigated.
Plant O is a new plant operating at only a fraction of its
design capacity. With increased production to optimum
levels, the use of water for clean-up purposes is expected
to become more efficient in terms of volume per unit produc-
tion and cause the present high productivity factors and
24
-------
to
Table 12. CATEGORY 6, AVERAGE POLLUTANTS
CONTAINED IN WASTEWATER PER UNIT
PRODUCTION
Plant
code
Constituent (kg/kkg
COD BOD SS
0 39 19 14
P - 3.3
Q 8.8 5.2 3.4
R 2.6 1.1 0.65
Total
VSS P
13 0.79
- -
3.1 0.052
0.59 0.011
product)
Gre
TKN and
0.59
0.12
0.15 4
0.061
ase Volume
oil (1/kkg)
80,000
9,800
.7 26,000
1,800
Average 17
7.2
6.0
5.6
0.28
0.23
29,000
-------
Table 13. CATEGORY 6, AVERAGE
WASTEWATER CHARACTERISTICS
Plant
code
Concentration (mg/1)
o
p
Q
R
Average
COD
500
-
340
1,500
780
BOD
240
340
200
690
370
SS
180
-
130
360
220
vss
150
-
120
330
200
Total
P T*
10 7.
11.
2.0 5
6.0 34
6.0 15
Grease
CN and oil
6
8
.6 180
wastewater generation to drop significantly. This plant
also prepares institutional salads. Significant amounts of
wastewater are generated by the washing of lettuce and
blanching of other salad ingredients.
Plant P is a very large plant which produces canned tomato-
cheese-starch products. These canned products contain lar-
ger volumes of water than do similar frozen items. High
product water content generates artificially high production
weights and thus lowers substantially the effluent produc-
tivity factors.
To summarize Category 6 we believe that none of the plants
sampled could be called a "typical" situation. It is en-
tirely possible, however, that the pollutant generation
levels shown in Table 12 result in reasonable average values
for this category in spite of the wide ranges.
SAUCED VEGETABLES (Category 7)
Only Plant S whose major product is frozen vegetables with
and without cheese or butter sauce was sampled in Category
7. This category represents plants whose wastes are largely
generated by the washing, peeling, cutting, blanching, and
cooking or freezing of raw vegetables. The addition of
butter sauce, tomato sauce, spices, etc. may technically
26
-------
place this plant under the specialty food category, however,
we believe the waste load is similar to that of a straight
vegetable processor, with added waste load from spillage and
clean-up of sauce equipment.
Plant S generates exceptionally high wastewater volume due
to inefficient water use in the washing, cutting, cooling
and transporting of the produce. The plant is about twenty-
five years old and was designed at the time that water con-
servation and wastewater volume reduction were not con-
sidered important. Little modernization of equipment has
been implemented, and the plant owners will soon be faced
with the choice of large expenditures to reduce volumes dis-
charged to the city sewer, or shut-down. The large volume
provides dilution of pollutant concentrations and the plant
effluent has a low BOD concentration of 310 mg/1.
As can be seen from Tables 14 and 15. the sauce room clean-
up wastewater is high in strength, being comprised of
cheese, margarine and shortening; but it is insignificant in
volume (less than 1 percent of the total wastewater flow).
The sauce room waste accounts for about 15 percent of the
total plant COD and BOD loads, 7 percent of the SS load, 27
percent of the total phosphorus load (phosphorus containing
detergents used for sauce room clean-up), and 4 percent of
TKN.
Table 14. CATEGORY 7, AVERAGE POLLUTANTS
CONTAINED IN WASTEWATER PER UNIT
PRODUCTION
Plant
code
S
Constituent (kg/kkg finished product)
COD
BOD
SS
VSS
Total
P
TKN
Volume
(1/kkg)
24-hour 45 25 21 16 0.33 1.1
plant raw
wastewater
85,000
Sauce room 6.4 3.5 1.4 1.3 0.090 0.047 490
clean-up
wastewater
On the basis of this one plant, it appears that the rapid
growth in the sale of sauced vegetables will increase the
pollution load generated by the vegetable processing indus-
try.
27
-------
Table 15. CATEGORY 7, AVERAGE
WASTEWATER CHARACTERISTICS
Plant
code
Concentration (mg/1)
COD
BOD
SS
VSS
Total
P
TKN
24-hour
raw
wastewater
560
310
250
200
Sauce room 14,000 8,000 3,300 3,100
clean-up
wastewater
4.4
230
13
100
SWEET SYRUPS, JAMS ANF) JELLIES (Category 8)
Plant codes T and U fall into this category. Major products
are syrups, fruit toppings, jams, jellies, and preserves.
Typically, the ingredients include fruit, sugar, chocolate,
nuts, cocoanut, and flavorings. Most ingredients are pre-
processed elsewhere. The plants blend various proportions
of ingredients, cook and package the products.
Plant U processed only jams, jellies, and spreads. Plant T
processed a variety of sweetened products plus jello, choco-
late, cocoanut and instant rice. In spite of its variety of
products, Plant T was placed in this category because the
instant rice processing water is separately disposed and not
included in Tables 16 and 17, and the chocolate, cocoanut
and jello are very dry processes which contribute less
wastewater than does the syrup operation.
As seen from the tables the wastes are strong in dissolved
organic strength, but relatively low in pollutant load per
unit weight of production. Major wastewater generation is
from clean-up of mixing vats and cookers during changes in
product runs and at the endiof each day. Apparently, clean-
up operations were efficient as indicated by low wastewater
volumes for both plants.
28
-------
Table 16. CATEGORY 8, AVERAGE POLLUTANTS
CONTAINED IN WASTEWATER PER UNIT
PRODUCTION
Plant
code
Constituent (kg/kkg finished product)
COD
BOD
SS
VSS
Total
P
TKN
Grease
and Oil
Volume
(1/kkg)
T 5.4 3.0 1.3 1.1 0.076 0.057
U 12 7.2 0.68 0.60 0.019 0.030
Average 8.7 5.1 1.0 0.85 0.048 0.044
0.62
2,700
2,000
2,400
Table 17. CATEGORY 8,.AVERAGE
WASTEWATER CHARACTERISTICS
Plant
code
Concentration (mg/1)
COD
BOD
SS
VSS
Total
P
TKN
Grease
and Oil
T 2,000 1,100 470 410 28 21 230
U 6,100 3,600 340 300 9.6 15
Average 4,000 2,400 400 360 19 18
CHINESE AND MEXICAN FOODS (Category 9)
Included in this category are plant codes V, W and X. Major
products are Chinese specialties such as chop suey, chow
mein, and fried rice; and Mexican specialties such as thick
vegetable sauces, hot peppers and dip mix.
These plants correlated well because the product of all
three plants is canned and high in vegetable content.
A substantial portion of the raw vegetables are processed
at the plants while all other ingredients are pre-prepared
elsewhere. Major waste flows originate from washing and
blanching of vegetables, and frora clean-up of mixing and
cooking vats. Tables 18 and 19 show waste generation and
strength. BOD generation averages 6.9kg/kkg 13.8 Ibs/ton) of
production and 570 mg/1.
29
-------
Table 18. CATEGORY 9, AVERAGE POLLUTANTS
CONTAINED IN WASTEWATER PER UNIT
PRODUCTION
Plant
code
Constituent (kg/kkg
COD
V 12
W 12
X 12
BOD
6.3
6.7
7. 8
SS
2.4
4.0
1.9
VSS
2.2
3. 8
1.2
Total
P
0.084
0.041
0.29
finished product)
TKN
0.36
0.27
0.21
Grease
and Oil
1.2
4.7
-
Volume
dAkg)
14,000
18,000
8,900
Average 12 6.9 2.8 2.4 0.14
0.28
3.0
14,000
Table 19. CATEGORY 9, AVERAGE
WASTEWATER CHARACTERISTICS
Plant
code
Concentration (mg/1)
COD
V 830
W 670
X 1,300
BOD
450
370
900
SS
170
220
210
VSS
160
210
140
Total
P TK
6.0 26
2.3 15
34 22
Grease
N and Oil
85
260
-
Average
930 570 200 170
14
21
170
BREADED FROZEN PRODUCTS (Category 10)
\
Included in this category are plant codes Y and Z. Plant Y
breads mushrooms, onions, and pre-processed perch after
minimal washing. Plant Z prepares fish and shellfish that
have been cleaned and dressed at a seafood processing plant.
Generally, the seafood is thawed, washed, dried, dipped in
batter, breaded and frozen. The breaded seafood is not
fried. The major wastewater sources are plant clean-up,
washing and rinsing of raw product, and thawing of frozen
raw seafood in the case of Plant Z.
30
-------
Tables 20 and 21 show the wastewater generation and
strengths of the effluent from the two plants. Plant Z
utilizes huge volumes of water to thaw and frequently wash
the product. As a result, waste strength is a relatively
low 400 mg/1 BOD. Plant Y is primarily a producer of
breaded onion rings. The batter is very rich and clean-up
of equipment and spills results in a wastewater with an
average 300 of 4,500 mg/1. In direct contrast to Plant Z,
Plant Y operation generates very little wastewater but pro-
duces the strongest waste of all plants investigated.
Table 20. CATEGORY 10, AVERAGE POLLUTANTS
CONTAINED IN WASTEWATER PER UNIT
PRODUCTION
Plant
code
Constituent
COD
Y 40
Z 66
Average 5 3
BOD
15
37
26
SS
23
30
26
VSS
23
29
26
(kg/kkg raw
Total
P
0.12
0.58
0.35
TKN
0.33
4.8
2.6
product)
Grease
and Oil
1.2
-
-
Volume
d/kkg)
3,300
92,000
48,000
Table 21. CATEGORY 10, AVERAGE
WASTEWATER CHARACTERISTICS
Plant
code
Concentration (mg/1)
COD
Y 12,000
Z 720
Average 6,400
BOD
4,500
400
2,400
SS
7,100
330
3,700
VSS
7,100
320
3,700
Total
P TK
Grease
N and Oil
37 100 360
6.3 52
22 76
These plants illustrate the differences between two plants
with similar major process techniques (i.e., raw product
cleaning, cutting, battering, breading, freezing) but with
different water usage patterns; one being a very wet opera-
tion and the other very dry.
31
-------
SECTION VI
RAW WASTE LOADS, CURRENT TREATMENT
TECHNOLOGY, AND PLANT DISTRIBUTION
STANDARD RAW WASTE LOADS
Great product diversity in this industry is reflected by
large differences in waste generation between the different
categories identified in Section V. Table 22 on the fol-
lowing page summarizes average wastewater productivity fac-
tors for all categories in terms of kilograms of pollutant
per thousand kilograms of finished product. Figures 2 and
3 provide a graphical representation of similar data. Using
COD as a measure of organic strength, Table 22 shows that
category 10 (breaded frozen products) produces approximately
50 kg of COD per 1,000 kg of production (100 Ibs/ton). The
lowest category in terms of COD production is number 8
(sweet syrups, jams and jellies) in which the two plants
sampled produced an average of only 9 kg of COD per 1,000
kg of production (18 Ibs/ton). Values of BOD's generally
ran about 50 percent of COD values in the samples analyzed.
Average values for other waste constituents shown in Table
22 generally indicate that the industry produces suspended
solids (SS) which are highly organic (VSS), the wastes are
often deficient in nutrients (Total P and N) which must be
added for satisfactory biological treatment, that grease and
oil are significant ingredients where substantial frying is
done, and finally, that wastewater volumes vary greatly.
Table 23 summarizes average raw wastewater constituent con-
centrations for all categories. Figure 4 provides a graphi-
cal representation of similar data. With few exceptions the
average results reflect typical food processing wastes which
are very high in COD and BOD concentrations, and organic
suspended solids. In general, the wastes are amenable to
discharge into municipal systems for joint treatment. In
certain instances, pre-treatment may be required for removal
32
-------
TABLE 22. AVERAGE POLLUTANTS CONTAINED
IN WASTEWATER PER UNIT OF PRODUCTION,
BY CATEGORY
Category Aver<
COD I
age productivity factors (kg/kkg product)
BOD SS VSS
1 34 17 14 14
2 52 23 14 14
3 13 7.5 3.5 3.4
4 19 9.9 6.1 5.5
5 20 12 7.6 5.8
6 17 7.2 6.0 5.6
*
7 45 25 21 16
8 8.7 5.1 1.0 0.85
9 12 6.9 2.8 2.4
10 53 26 26 26
Total
P
0.19
0.082
0.028
0.098
0.18
0.28
0.33
0.048
0.14-
0.35
TKN
0.44
0.30
0.037
0.57
0.47
0.23
1.1
0.044
0.28
2.6
G&O
15
11
5.7
4.0
2.4
4.7
-
0.62
3.0
-
Volume
(1/kkg)
12rOOO
11,000
2,800
10,000
22,000
29,000
85,000
2,400
14,000
48,000
33
-------
70
60
a:
O
h-
o
a
o
o
CO
I-
O
Z>
O
O
a:
a.
y
o
o
a:
a.
o
UJ
x
CO
LL
en
50
40
30
20
10
Average
Lowest Plant
Highest Plant
ill
LOWEST AND HIGHEST REFER TO THE
LOWEST AND HIGHEST AVERAGE
PLANT EFFLUENTS OVER THE SAMPL-
ING PERIOD, NOT ONE DAY VALUES
23 456785
CATEGORY
Figure 2.COD productivity factors for all categories
10
-------
CO
Ul
UJ
*
O
o
H-
o:
UJ
UJ
0
(T
UJ
;D
o
0
o:
Q.
0
UJ
CO
u.
0>
90,000
80,000
70,000
60,000
50,000
40,000
30,000
20,000
10,000
LOWEST AND HIGHEST REFER TO
Average
Lowest Plant
Highest Plant
456
CATEGORY
8
10
THE LOWEST AND HIGHEST AVER- _. _ ... . . .. , ,
AGE PLANT EFFLUENTS OVER THE Figure 3. Wastewater generation for each category
SAMPLING PERIOD, NOT ONE DAY
VALUES.
-------
CO
I
I-
o
z
UJ
o:
i-
co
a:
UJ
UJ
o
o
o
o
12,000
11,000
10,000
9,000
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
LOWEST AND HIGHEST REFER TO
THE LOWEST AND HIGHEST AVER-
AGE PLANT EFFLUENTS OVER THE
SAMPLING PERIOD, NOT ONE DAY
VALUES.
Average
Lowest Plant
Highest Plant
I 2 3 4 5 67.8
CATEGORY
Figure 4. COD concentration for all categories
10
-------
Table 23. AVERAGE WASTEWATER
CHARACTERISTICS BY CATEGORY
Category
Concentration (mg/1)
COD
BOD
SS
VSS
Total
P
TKN
G&O
1
2
3
4
5
6
7
8
9
10
3,900
7,000
4,700
1,600
970
780
560
4,000
900
6,400
1,900
3,200
2,600
820
560
370
310
2,400
570
2,400
1,500
2,200
1,200
460
320
220
250
400
200
3,700
1,500
2,100
1,200
420
250
200
200
360
170
3,700
21
6.8
11
11
7.0
6.0
4.4
19
14
22
45
36
14
48
19
15
13
18
21
76
2,000
820
2,000
300
82
180
-
230
170
360
of grease and oil to prevent deposition in the municipal col-
lection system. Where the specialty food processing plant
provides final treatment and disposal, the wastes can be suc-
cessfully treated with properly designed biological treatment
processes.
It is important to note the wide differences (more than 10:1)
in waste strength between categories of the specialty food
industry as shown in Table 23. This wide difference in waste
strength is due to a variety of reasons, the most significant
of which are summarized in the following paragraphs.
Richness of product ingredients. All food processing
plants undergo extensive clean-up of equipment,
floors, spillages, etc. The principal waste com-
ponents of the wash water are the ingredients used
in product manufacture. Where these ingredients
are high in fats, carbohydrates, sugar, etc. the
resultant waste is correspondingly strong. As an
example, the categories showing the high gener-
ation of organic wastes were frozen breaded prod-
ucts, which use a rich egg batter, and frozen
37
-------
bakery desserts which use large quantities of but-
ter, eggs, and sugar.
Number and type of processes performed. The plant
process line may consist of many steps (cooking,
blending, etc.) or very few. The individual process
steps may contribute heavily to wastewater genera-
tion (blanching, washing, etc.) or very little. It
was beyond the scope of this project to investigate
wastes generated by individual process steps, how-
ever, even casual observation revealed the signifi-
cance of this aspect.
Number of different products and frequency of
changes in product. As a rule when the type of
product is changed all equipment in the process
line is thoroughly cleaned. Therefore, plants
which have relatively short runs of many different
products generate more clean-up waste than do plants
which run the same product for many days.
Moisture content of ingredients and the final prod-
uct. In this report pollution generation factors
are calculated per unit weight of product. A major
shortcoming of this approach is that the moisture
of ingredients and products varies widely. For
example, a canned spaghetti plant will produce less
pollution per unit weight of production than a fro-
zen pizza plant even though both are primarily a
starch and tomato product. The canned spaghetti
product has a much higher moisture content - there-
fore weighs more - and shows lower pollution prod-
uctivity per unit weight of production.
Management desire to reduce waste generation. With-
out question, a major factor in waste generation
from any plant is the presence or absence of in-
plant waste management programs designed to minimize
waste disposal to the sewer.
Other factors. A multitude of other factors may
have a significant effect upon wastewater generation
from a particular plant. These include, plant size,
number of shifts, percentage of production capacity
in use, cost of water supply and wastewater dispos-
al, degree to which ingredients have been pretreated
elsewhere, and economic ability of the plant to mod-
ernize equipment.
38
-------
CURRENT TREATMENT TECHNOLOGY
The specialty food plants investigated exhibited a wide
spectrum of wastewater treatment facilities from no treat-
ment to extensive biological and physical-chemical systems.
While evaluation of waste treatment systems was outside the
scope of the project, a brief description of study team ob-
servations is provided.
Of the 26 plants investigated, 6 provided the equivalent of
secondary treatment using biological systems in conjunction
with other unit processes. The most extensive treatment
facility observed is described in the case study for plant
A (See appendix) and is reported to achieve in excess of 99
percent BOD reduction on raw waste with average BOD levels
of 4,000 mg/1. The treatment facility has a design capacity
of 350,000 gpd and is estimated by the owner to have a re-
placement value of approximately 3 million dollars. Other
excellent secondary and tertiary treatment facilities were
observed at Plants F, T and N. Plant D utilizes a land
disposal system which has successfully operated for over 20
years.
Twenty-one of the 26 plants investigated discharged into
municipal systems. Plants 0 and H provide activated sludge
pre-treatment in order to reduce BOD levels 90 percent or
more prior to discharge into the municipal sewer. Each is
a large plant located in a small community. Plant V pro-
vides only screening on its' waste, but is reported to have
a long term arrangement with the small community where it
is located whereby the company pays approximately 85 percent
of all capital and operating costs for municipal sewage
treatment facilities.
Of the other 18 plants investigated, 4 provided no pre-
treatment, 2 provided grease traps only, and the remainder
provided various degrees of screening, settling, or flota-
tion prior to discharge to sewers. Several clarification
operations utilized chemical treatment for pH adjustment and
to promote coagulation .
Table 24 summarizes the treatment at each plant investiga-
ted. There is no correlation between category and degree
or type of treatment.
39
-------
Table 24. SPECIALTY FOOD PLANT
WASTEWATER TREATMENT OPERATIONS
Treatment Plants utilizing
None J, R, u, Y
Collection baskets in E
drains (only)
Grease trap (only) F, K
Screening A, C, M, N, P, Q,
S, T, V, W, Z
Settling A, B, C, D, F, G,
H, I, L, N, T,
X
Coagulation B, N, W
Trickling filtration A, N
Activated sludge
Conventional A, H
Extended aeration O, T
Lagooning
Anaerobic A
Aerobic P
. Aerated F, N, P
Dissolved air flotation A, B, F, N, W
Chlorination A, F, N, P
Sand filtration F
Land disposal D, N, P
(partial or total)
40
-------
PLANT DISTRIBUTION
Table 25 on the following pages lists the number of special-
ty food plants in each state by category. The table was
compiled by the AFFI staff, using the best industry direc-
tory information available. (I/2, 3) A total of 2,321
specialty food plants are shown, with the largest number
in the states of California, New York, Illinois and Pennsyl-
vania. Meat specialties and breaded frozen products
have the largest number of individual plants among the
categories.
(1)American Frozen Food Institute Membership Directory -
1974 Edition.
(2)The Directory of the Canning, Freezing, Preserving
Industries, 1970-1971, Published by Edward E. Judge &
Sons.
(3)Quick Frozen Foods, 1972 Directory of Frozen Food
Processors, Published by Conover-Mast Publications,
Division of Cohners Publishing Co., Inc.
41
-------
Table 25. DISTRIBUTION OF SPECIALTY
FOOD PLANTS BY CATEGORY AND STATE
10
Categories
1. Prepared
dinners
2. Frozen bakery
products
State
AL AZ AI< AR CA CO CT DE
11 3 25 2 4 1
4 3 29 2 51
3. Dressings, sauces 12 2 21 2 1 1
& spreads
4. Meat
specialties
5. Soups and
baby foods
6. Tomato- cheese-
starch comb.
7. Sauced
vegetables
8. Sweet syrups,
12 3 10 42 5 8 1
1 15 2
1 3 15 1 1 1
1 2 43 2 3
14
FL
4
5
4
13
6
1
5
GA
2
3
1
15
1
2
2
3
jams & jellies
9 . Chinese & Mexi-
can foods
10. Breaded frozen
products
TOTAL
1 3 20 1 3 2
7 1 18 4 48 1 24
22 9 22 31 272 16 26 14
4
40
82
4
6
39
-------
Table 25 (continued). DISTRIBUTION OF SPECIALTY
FOOD PLANTS BY CATEGORY AND STATE
u>
Categories
1.
2.
3.
4.
5.
6.
7.
8.
Prepared
dinners
Frozen bakery
products
State
MA MI MN MS MO MT NE
638 7 4
5 14 6 1 10 5
Dressings, sauces 44415 3
& spreads
Meat
specialties
Soups and
baby foods
Tomato- chees e-
starch comb.
Sauced
vegetables
Sweet syrups ,
9 14 12 7 5 1 10
1231 4
1141 3
3 11 1 1 2
6 1
NV NH NJ
1 14
13
1 10
1 1 19
1 8
6
4
1 2
jams & jellies
9.
10.
Chinese & Mexi-
can foods
Breaded frozen
products
TOTAL
11 5 6 2 4
38 8 7 6 5 7
84 62 51 17 36 1 42
18
13
2 4 107
-------
Table 25 (continued). DISTRIBUTION OF SPECIALTY
FOOD PLANTS BY CATEGORY AND STATE
*».
Categories
1.
2.
3.
4.
5.
6.
7.
8.
Prepared
dinners
Frozen bakery
products
State
NM NY
26
25
Dressings, sauces 19
& spreads
Meat
specialties
Soups and
baby foods
Tomato - cheese-
starch comb.
Sauced
vegetables
Sweet syrups,
40
14
11
12
7
NC
2
4
1
4
1
1
1
1
ND OH OK
8
1 13 4
9 5
2 27 9
10
1
5 1
2 4
OR
3
8
1
4
2
30
2
PA
8
12
13
33
11
2
14
9
RI SC
1 1
1
2 1
3 2
1 2
1
1
jams & jellies
9.
10.
Chinese & Mexi-
can foods
Breaded frozen
products
TOTAL
1 22
43
1 219
2
7
24
9 4
1 1
4 85 27
4
11
65
11
20
133
1 1
6 2
15 11
-------
Table 25 (continued). DISTRIBUTION OF SPECIALTY
FOOD PLANTS BY CATEGORY AND STATE
Ul
Categories
1.
2.
3.
4.
5.
6.
7.
8.
Prepared
dinners
Frozen bakery
products
State
HI ID IL
1 1 28
1 3 25
Dressings, sauces 13
& spreads
Meat
specialties
Soups and
baby foods
Tomato - cheese-
starch comb.
Sauced
vegetables
Sweet syrups,
3 33
1 9
1 5
197
214
IN IA KS
442
5 3
521
10 11 2
3
2
4
1 1
KY LA
1 2
2
2 6
2 4
3 3
1
1 2
2 3
ME MD
2 6
3 7
10
3 9
2 8
5
1 5
4
jams & jellies
9.
10.
Chinese & Mexi-
can foods
Bre.aded frozen
products
TOTAL
1 1 29
11 24
7 30 177
4
3 1
41 21 6
3
2 26
13 52
6
6 28
17 88
-------
Table 25 (continued). DISTRIBUTION OF SPECIALTY
FOOD PLANTS BY CATEGORY AND STATE
Categories
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Prepared
dinners
Frozen bakery
products
State
SD TN
5
6
Dressings, sauces 2
& spreads
Meat
specialties
Soups and
baby foods ""
Tomato - cheese-
starch comb.
Sauced
vegetables
1 6
2
12
5 -
Sweet syrups , 2
jams & jellies
Chinese & Mexi-
can foods
Breaded frozen
products
TOTAL
4
5
1 49
TX UT VT VA WA WV WI WY Total
6 145
7 2146
12 2 14
15 3 76
3 1 3
1 21
5 1 1 1 36
2 4
6 1124
20 1 20 35
77 10 5 45 100
4 211
4 253
6 184
14 441
2 124
89
7 230
4 82
1 202
17 505
59 2,321
-------
SECTION VII
APPENDICES
APPENDIX A
FIELD INVESTIGATION REPORTS
Page
Plant A - Prepared Dinners and Bakery Desserts, Cate-
gory 1 49
Plant B - Prepared Dinners, Category 1 54
Plant C - Prepared Dinners, Category 1 59
Plant D - Prepared Dinners, Category 1 62
Plant E - Prepared Dinners, Vegetables, Category 1 65
Plant F - Prepared Dinners, Category 1 68
Plant G - Frozen Bakery Products, Category 2 71
Plant H - Frozen Bakery Products, Category 2 74
Plant I - Salad Dressings and Oil, Category 3 76
Plant J - Dressings, Sauces and Pie Fillings, Cate-
gory 3 79
Plant K - Meat Specialties, Category 4 83
Plant L - Canned Meat Specialties, Category 4 86
Plant M - Baby Foods, Category 5 89
Plant N - Canned Soups, Category 5 92
Plant 0 - Tomato-Cheese-Starch Combinations, Cate-
gory 6 95
Plant P - Tomato-Cheese-Starch Combinations, Cate-
gory 6 98
Plant Q - Tomato-Cheese-Starch Combinations, Cate-
gory 6 100
Plant R - Tomato-Cheese-Starch Combinations, Cate-
gory 6 102
47
-------
Page
Plant S - Sauced Vegetables, Category 7 105
Plant T - Sweet Syrups, Category 8 109
Plant U - James and Jellies, Category 8 113
Plant V - Chinese Foods, Category 9 116
Plant W - Chinese Foods, Category 9 119
Plant X - Mexican Foods, Category 9 122
Plant Y - Breaded Frozen Products, Category 10 126
Plant Z - Breaded Fish and Shellfish, Category 10 129
48
-------
PREPARED DINNERS
Plant Code: A
Location: East
Category: 1
Products: Prepared dinners, meat entrees,bakery desserts
Dinners: beef, meat loaf, Salisbury steak, ham, spa-
ghetti and meatballs, franks and beans, macaroni and
beef, macaroni and cheese, beef enchaladas, chicken,
turkey, fish, shrimp, tuna.
Pot Pies: beef, chicken, turkey, .tuna.
Bakery Products: pies, cakes, toppings, pastries.
Significant Ingredients (used during sampling period)
Processed at Plant
Gravies
Poultry (cutting,
deboning, frying,
or boiling)
Sampling Procedure
Pre-Processed Elsewhere
All vegetables
Poultry (initial cleaning and
slaughtering)
Beef Shortening Eggs
Flour Flavorings Fruits
Milk Chocolate Sugar
An automatic sampler was used to collect ten 24-hour time
interval composite samples of the raw plant wastewater.
The samples were taken just downstream from the 20 mesh
screening operation.
Wastewater Characteristics
Combined Process and Clean-Up Wastewater
(24 Hour Composites)*
COD
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
7,900
3,900-
17,000
BOD
4,000
2,000-
6,500
SS
3,900
1,700-
8,300
VSS
3,800
Total
P
29
1,700- 20-
8,300
41
TKN
51
14-
82
Grease
& Oil
5,100
2,200
9,900
*Ten samples
pH range - 4.7-10.0
49
-------
Productivity Factors
Based upon average daily wastewater volumes, production
data supplied by the plant, and wastewater quality
characteristics from lab analysis, the following produc-
tivity factors were calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg
Constituent Finished Product
COD
BOD
SS
VSS
Total P
TKN
Grease & Oil
69
35
34
33
0.25
0.44
44
Wastewater
Generation 8,700
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Treatment facilities
Treatment facilities at this specialty food plant are ex-
tensive as shown on Figure A-l and include the following
operations:
Rotary screening
Gravity sedimentation
Dissolved air flotation
Anaerobic lagooning
- Biological trickling filtration
Aeration
Final clarification
Chlorination
This unit processes chain is reported to consistently pro-
duce an effluent of less than 20 mg/1 BOD starting with
a raw waste of 3,000 to 4,000 mg/1 BOD. Grease and oil
is reduced to about 2 mg/1 and suspended solids to less
than 40 mg/1. According to the operators, the key treat-
ment units are the anaerobic lagoons which stabilize the
waste and equalize the flow into the trickling filters.
50
-------
A tabulation of reported unit reductions of screened
wastes in BOD, G&O, and SS follows:
Percent Reduction
Sedimentation
Flotation
Anaerobic lagoon
Trickling filter
Activated sludge
Total
BOD
40
15
4
15
26
100
G&O
80
14
6
-
100
SS
73
16
7
(3)
6
99
This treatment facility evolved over a ten year period
and is not suggested as an optimum design for a new
facility. The final effluent is discharged to a small
creek and is the only water source into the creek most
of the year.
Design data for the waste treatment plant shown in Figure
A-l is as follows:
Design Flow: Approximately 0.5 MGD.
Screens: Two 20 mesh Sweco screens remove approximately
1,000 Ibs/day of screened solids which are disposed to
landfills.
Sedimentation Tanks: Two rectangular clarifiers, 10 ft x
125 ft x 10 ft, 187,000 gal. capacity.
Dissolved Air Flotation Tanks; Two rectangular tanks,
200 sq ft surface area each.
Anaerobic Lagoons; Three lagoons, 1.93 million gal. capa-
city each, with approximately 100 percent recirculation
from final lagoon to first lagoon.
Trickling Filters: 5,500 cu ft plastic media and 11,000
cu ft rock media in series.
Activated Sludge Aeration Tanks; Four rectangular tanks,
each 141,000 gal capacity, with mechanical aerators.
Final clarifiers; Two circular clarifiers with 962 sq ft
and 1,590 sq ft surface area respectively. Activated
sludge recirculation rate is approximately 50 percent.
51
-------
Primary Sludge and Waste Activated Sludge is centrifuged,
thickened and disposed to landfill. Approximately
4,500 Ibs per day of grease is recovered and sold for
2-1/2
Chlorine Contact Tank: Provides 0.5 hours contact time.
52
-------
RAW
PLANT
EFFLUENT
SCREENING
SEDIMENTATION
oo
TRICKLING FILTERS
ANAEROBIC LAGOONS
DISSOLVED
, AIR FLOTATION
CENTRIFUGE
SLUDGE THICKENER
FINAL
EFFLUENT
ACTIVATED SLUDGE
FIGURE A-l
PLANT A
WASTEWATER TREATMENT FACILITY
CLARIFIERS
-------
PREPARED DINNERS
Plant Code: B
Location: West
Category: 1
Products: Prepared dinners and pot pies
Entrees: sliced turkey, fried chicken, meat loaf, roast
beef, beef enchiladas, cheese enchiladas.
Other Ingredients: potatoes, rice, corn, peas, beans.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Gravies All vegetables
Beans Poultry (initial slaughtering
Turkey (deboned, and cleaning)
cooked, sliced) Beef Olives
Chicken (cut, Rice Flour
fried or deboned, Cheese Milk
boiled)
A simplified schematic diagram of plant operations is
shown in Figure A-2.
Sampling Procedure
An automatic sampler was used to collect two time inter-
val composite samples per day of the raw waste at the
inlet to the pre-treatment flotation tank. Five samples
of the basic production operation (6:30 a.m.-4:30 p.m.),
and five samples of the general cleanup and ingredient
preparation activities (4:30 p.m.-6:30 a.m.) were taken.
Wastewater Characteristics
54
-------
PREPARATION
ASSEMBLY
FOWL
CUTTING
TURKEY
(processed elsewhereL|cOOKING
and frozen)
COOKING
CHICKEN
(processed elsewhere 4 CUT
and frozen)
BONING
BONING
BONING
FLJOURED
COOKING
J.[SLICING]-
SLICING
FRYING
NOTE
HEAVY ARROW
DESIGNATES MAJOR
LIQUID WASTE
GENERATION
MEAT
MEATLDAF
VEAL
(patties prepared
elsewhere)
BEEF
(prepared elsewhere
and rolled)
i
BROILING
-\ SLICED |-
tjKAVIbS
(meat juice from
cooking )
VEGETABLES
(processed elsewhere
and frozen)
POTATOES
MEXICAN
DRIED BEANS *-
CORN
(dehusked decobbed ___
elsewhere) ~"~
RIPF
flour milk
1 1 - Pui^
^ | MIXcu | - lyjivic
*. I PI i i^Trr? RDF&I^I IP|-
4
I POfiflF
(FREE
{WASHING! (COOKING |j MASHING J
[COOKING]-~-[GRINDING|
prepared che(
^^^^^^^^^^^^^j
PLANT CLEAN-
01 ITTING
INED)
JINED)
ZING") ("PACKAGED)
INTO (COMBINING)HCOOKING |-^-
>-v J^AUnMRI
IDl
t
l
clSw>S9e"mi^OMBINED3
*
(FROZEN")
FIGURE A-2
PLANT B
PREPARED DINNER PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
-------
Production Shift Wastewater*
(6:30 a.m. - 4:30 p.m.)
Total Grease
COD BOD SS VSS P TKN & Oil
Avg. Cone.
(mg/1) 12,000 4,800 2,700 2,700 16 44 7,800
Range of
Cone. 6,400- 3,200- 1,800- 1,800- 10- 1.9- 5,600-
(mg/1) 20,000 8,600 3,400 3,400 30 62 10,000
*Five samples
pH ra'nge - 5.2-6*1
Clean-Up and Gravy Preparation
Shift Wastewater*
(4:30 p.m. - 6:30 a.m.)
Total
COD BOD pH SS VSS P TKN
Avg. Cone.
(mg/1) 3,100 1,500 1,100 1,100 39 27
Range of
Cone. 1,800- 570- 6.3- 630- 620- 28- 21-
(mg/1) 6,800 3,000 6.8 2,200 2,200 60 45
*Five samples
Productivity Factors
Based upon wastewater volumes and production figures pro-
vided during the 10 sampling periods, productivity fac-
tors were calculated for (1) the total 24 hours, (2) the
production shift, and (3) the clean-up and gravy prepara-
tion shift. The results are shown on the following three
tables.
56
-------
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg Range kg/kkg
Constituent finished product finished product
COD
BOD
SS
VSS
Total P
TKN
Grease & Oil*
42
18
11
11
0. 18
0.25
21
25-82
10-39
7.0-17
6.9-17
0.16-0.24
0.08-0.30
14-29
Wastewater
Generation 6,200 6,100-6,400
(1/kkg finished
product)
*Data available for production shift only.
PRODUCTIVITY FACTORS
Production Shift Wastewater
(6:30 a.m. - 4:30 p.m.)
Average kg/kkg Range kg/kkg
Constituent finished product* finished product*
COD
BOD
SS
VSS
Total P
TKN
Grease & Oil
45
27
10
10
0.060
0.16
31
22-83
11-51
6.6-14
6.6-14
0.042-0.12
0-0.21
20-42
Wastewater
Generation 3,600 3,500-4,200
(1/kkg finished
product)
*Average during designated time period.
57
-------
PRODUCTIVITY FACTORS
Clean-Up and Gravy Preparation Wastewater
(4:30 p.m. - 6:30 a.m.)
Average kg/kkg Range kg/kkg
Constituent finished product* finished product*
COD 37 26-78
BOD 18 7.1-34
SS 13 7.9-25
VSS 12 7.7-25
Total P 0.46 0.35-0.69
TKN 0.32 0.26-0.51
Wastewater
Generation 12,000 11,000-13,000
(1/kkg finished
product)
*Average during designated time period.
1 Ib/ton =0.5 k/kkg
1 gallon/ton = 4.173 1/kkg
Approximately 70 percent of the plant production occurs
during what is called the "Production Shift," while 30
percent occurs during the "Clean-Up Shift." The tables
show that the general clean-up period at this plant
generates approximately 60 percent of the total daily
flow volume.
Pre-Treatment Facilities
Pre-treatment prior to discharge to the city sewers con-
sists of pressurized dissolved air flotation, coagulation
and settling for removal of grease, flotables, and sus-
pended solids.
58
-------
PREPARED DINNERS
Plant Code: C
Location: West
Category: 1
Products: Prepared dinners and pot pies
Entrees: macaroni and cheese, macaroni and beef, sliced
turkey, fried chicken, beans and franks, swiss steak,
meat loaf, chopped beef sirloin, pork loin, veal par-
migiana, chow mein, beef enchiladas, tamales, sweet'n
sour chicken and pork.
Other Ingredients: carrots, corn, peas, green beans,
refried beans, rice, potatoes, apples, desserts.
Pot Pies: beef, turkey, chicken.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Beans All vegetables Rice
Gravies All fruit Flour
Macaroni Milk
Beef Cheese
Turkey Sauces
Chicken Chocolate
Pork Eggs
Potatoes
A simplified schematic diagram of plant operations is
shown in Figure A-3.
Sampling Procedure
An automatic sampler was used to collect eight 24-hour
time interval composite samples of the raw plant waste-
water at the inlet to the settling tank.
Wastewater Characteristics
59
-------
PREPARATION
VEGETABLES
(FROZEN)
DUMP AND INSPECT
POTATOES
FROZEN AND FRESH
WHIPPED OR FRIED
MEAT
TURKEY, PORK, BEEF,
AND CHICKEN
COOKED 8 FROZEN,
SLICED ft DICED
MEAT PATTIES
PREPARE MIX,
FORM PATTY AND
COOK
CORN
COOK, GRIND, FORM
TORTILLA OR PRE-
PARE MASA MIX.
TAMALES, ENCHILADAS
BEANS
WASH, SORT, AND
COOK
FISH
(FROZEN)
BATTER AND FRY
DOUGH
MIX DOUGH
MACARONI.
SPAGETTI, NOODLES
COOK a BLEND
WITH SAUCE
SOUPS. PUDDINGS.
AND SAUCES
BLEND AND COOK
ASSEMBLE
DINNER
GRAVIES
BLEND AND COOK
MUFFINS a CAKES
MIX
FRUITS
DRAIN, SORT, AND
COOK
PLANT
CLEAN-UP
FIGURE A-3
PLANT C
PREPARED DINNER PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(HEAVY ARROWS DESIGNATE MAJOR WASTEWATER GENERATING OPERATIONS)
60
-------
Combined Process and Clean-Up Wastewater
(24 Hour Composites)*
Total
COD BOD pH SS VSS P TKN
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
1,300
850-
2,400
620
490-
920
6.3-
7.2
530
330-
650
510
320-
640
11
9.3-
14
28
7.3-
43
*Eight samples
Productivity Factors
Based upon daily wastewater volumes, production data
supplied by the plant, and wastewater quality character-
istics from the lab, the following productivity factors
were calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg Range kg/kkg
Constituent finished product finished product
COD 28 19-55
BOD 13 9.2-18
SS 11 8.8-14
VSS 11 8.5-14
Total P 0.24 0.17-0.33
TKN 0.61 0.16-0.93
Wastewater
Generation 22,000 18,000-27,000
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173
Pre-Treatment Facilities
Pre-treatment consists of settling followed by 20 mesh
rotary screening for removal of solids and BOD. The
effluent is then discharged to the sewer.
61
-------
PREPARED DINNERS
Plant Code: D
Location: East
Category: 1
Products: Prepared institutional dinners
Entrees: meat loaf, choppen sirloin, swiss steak,
chicken fricassee, stuffed peppers, fish.
Other Ingredients: creamed spinach, peas, beans, corn,
other vegetables, potatoes.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Spinach Beef (initial butchering)
Bell peppers Chicken (initial cleaning)
Beef (cooking only) Fish Butter
Chicken (cutting, Rice Potatoes
deboning, cooking) Milk Seasonings
A simplified schematic diagram of plant operations is
shown in Figure A-4.
Sampling Procedure
An automatic sampler was used to take eight 24-hour,
time interval composite samples of the raw wastewater at
the inlet to the settling tank.
Wastewater Characteristics
Combined Process and Clean-Up Wastewater
(24 Hour Composite)*
Total Grease
COD BOD SS VSS P TKN & Oil
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
1,300
790-
2,600
720
200-
1,500
680
420-
1,400
650
380-
1,400
7.6
3.5-
12
26
12-
59
140-
120-
200
*Eight samples
pH range - 4.4-7.1
62
-------
MEAT PREPARATION
THAWING OF
FROZEN POULTRY
BEEF, PORK OR
FISH PRE-PROCESSED
ELSEWHERE
r
GRAVY PREPARATION
WITH ADDITION OF
FLOUR, CONDIMENTS
ETC.
SLICING, CUBING
SHAPING
FRYING
SIMMERING
OR
BAK ING
THAWING OF
FROZEN VEGETABLES
PRE-PROCESSED ELSEWHERE
VEGETABLE
COOKING
( PARTIAL )
ASSEMBLY
LINE
PLANT CLEAN -UP
FIGURE A-4
PLANT D
PREPARED DINNER PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(heavy arrows designate major
wastewater generating operations)
-------
Productivity Factors
Based upon average, daily wastewater volumes, production
data supplied by the plant, and wastewater quality char-
acteristics from laboratory analyses, the following pro-
ductivity factors were generated.
PRODUCTIVITY FACTORS
Combined Process and
Clean-Up Wastewaters
Average kg/kkg
Constituent finished products
COD 27
BOD 15
SS 14
VSS 14
Total P 0.16
TKN 0.55
Grease & Oil 2.9
Wastewater
Generation 21,000
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Treatment Facilities
Wastewater treatment includes settling for solids removal
and land disposal by spraying into a wooded area.
64
-------
PREPARED DINNERS, VEGETABLES
Plant Code: E (Historical Data Only)
Location: Midwest
Category: 1
Products: Prepared dinners, vegetables
Entrees: tuna noodle casserole, potatoes au gratin,
lasagna, creamed chipped beef, spinach souffle,
macaroni and cheese, macaroni and beef.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Beef (cutting, Beef (initial butchering)
cooking) Tuna Cheese
Potatoes Milk
Noodles Flour
Vegetables Butter
Sampling Procedure
Three composite samples were obtained for the tests, each
representing four hours of operation on a different day.
Each sample consisted of a composite of grab samples
taken at five minute intervals over a period of four
hours. A composite total of five gallons was obtained
during each sampling period.
All samples were taken from the combined waste manhole,
on the plant property. The samples were taken in such a
manner as to insure collection of representative portions
of solids and floating material. The samples were
refrigerated during the collection period and while in-
transit to the laboratory.
Wastewater Characteristics
65
-------
Combined Process and Clean-Up Wastewater
(24 Hour Composites)*
Avg. Cone.
COD
2,100
BOD
1,200
PH
SS
700
VSS
640
Grease
& Oil
400
(mg/1)
Range of
Cone.
(mg/1)
1,700-
2,400
1,000-
1,500
8.3-
9.1
380-
1,100
360-
1,000
200-
800
*Three samples
Productivity Factors
Based upon daily wastewater volumes, production data
supplied by the plant, and wastewater quality character-
istics from lab'analysis, the following productivity
factors were calculated.
PRODUCTIVITY FACTORS
Combined Process and
Clean-Up Wastewaters
kg/kkg finished
Constituent product
COD 20
BOD 11
SS 6.6
VSS 6.0
Grease & Oil 3.8
Wastewater
Generation 9,400 1/kkg
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
Collection baskets are used in the trench drains to col-
lect solids such as macaroni and potatoes, before the
66
-------
wastewater enters the sewer. No other pre-treatment is
provided.
67
-------
PREPARED DINNERS
Plant Code: F
Location: East
Category: 1
Products: Prepared dinners, pot pies, stews and other
meat entree dishes
Dinners: beef, chicken, pork, turkey.
Pies: beef, chicken, turkey.
Stews: beef, brunswick, lamb, chicken, mixed.
Miscellaneous: stuffed peppers, stuffed cabbage, beef
gravy, chicken and gravy, chicken and noodles,chicken
(boned), chili con carne, hamburgers, meat balls,
Salisbury steak, turkey with gravy, veal parmigiana,
shrimp creole, lasagne, macaroni, spaghetti.
Significant Ingredients
Processed at Plant Pre-Processed Elsewhere
Gravies All vegetables
Noodles Beef Shrimp
Turkey Flour
Chicken Milk
Pork Seasonings
Lamb Tomatoes
Sampling Procedure
An automatic sampler was used to collect seven 24-hour,
time interval composite samples of the raw plant waste-
water. The samples were taken just downstream from a
preliminary screening operation at the inlet to the
wastewater treatment facility.
Wastewater Characteristics
68
-------
Combined Process and Clean-Up Wastewaters
(24 Hour Composites)*
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
Total
COD BOD SS VSS P
3,800 2,000 1,400 1,400 28
1,700- 1,200- 460- 440- 22-
8,200 4,700 3,000 2,900 41
Grease
TKN & Oil
85 1,100
55- 230-
100 2,900
*Seven samples
pH range: 5.7-9.8
Productivity Factors
Based upon average daily wastewater volumes, production
data supplied by the plant, and wastewater quality
characteristics, the following productivity factors were
calculated.
PRODUCTIVITY FACTORS
Combined Process and
Clean-Up Wastewaters
Constituent
Average kg/kkg
finished product
COD
BOD
SS
VSS
Total P
TKN
Grease & Oil
Wastewater
Generation
(1/kkg finished
product)
17
8.8
6.2
6.2
0.12
0.37
4.8
4,400
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Treatment Facilities
The wastewater treatment facility at the plant is quite
extensive and includes the following operations:
69
-------
primary settling
grease removal
air flotation
aerated lagooning (8 day retention time)
- final clarification
sand filtration
chlorination
The treated effluent is discharged to a nearby creek,
70
-------
FROZEN BAKERY PRODUCTS
Plant Code: G
Location: Midwest
Category: 2
Products: Complete assortment of frozen bakery products
Bakery Items: cakes, pies, rolls, pastries, cookies.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
None Flour Chocolate
Butter Milk
Shortening Eggs
Sugar Flavorings
Fruits - Salt
A simplified schematic diagram of plant operations is
shown in Figure A-5.
Sampling Procedure
An automatic sampler was used to collect ten 24-hour,
time interval composite samples of the raw wastewater at
the surge tank immediately preceding the pre-treatment
unit.
Wastewater Characteristics
Combined Process and Clean-Up Wastewater
(24 Hour Composites)*
Total Grease
COD BOD SS VSS P TKN & Oil
Avg. Cone.
(mg/1) 4,600 2,100 1,300 1,200 7.8 27 940
Range of
Cone. 3,000- 1,700- 730- 710- 4,1- 14- 500-
(mg/1) 6,000 2,400 1,600 1,500 12 42 1,500
*Ten samples
pH ranges 4.5-6.2
71
-------
INGREDIENTS
STORAGE
SCALING
DEPOSITING
BAKING
PLANT
CLEAN-UP
COOLING
FINISHING
PACKAGING
FREEZING
SHIPPING
FIGURE A-5
PLANT G
FROZEN BAKERY PRODUCTS PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(heavy arrow designates major wastewater generating operations)
72
-------
Production Factors
Based upon daily wastewater volumes, production data
supplied by the plant, and quality characteristics of
the wastewater, the following production factors were
calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg Range kg/kkg
Constituent finished product finished product
COD 52 31-83
BOD 23 17-29
SS 14 7.5-21
VSS 14 7.3-20
Total P 0.082 0.045-0.11
- TKN 0.30 0.15-0.59
Grease & Oil 11 5.2-15
Wastewater
Generation 11,000
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
Pre-treatment at the bakery consists of settling for
removal of solids.
73
-------
FROZEN BAKERY PRODUCTS
Plant Code: H
Location: Midwest
Category: 2
Products: Complete assortment of frozen bakery products
Bakery items: pies, cakes, pastries, rolls, bread.
Significant Ingredients
Processed at Plant Pre-Processed Elsewhere
None Flour Fruits
Milk Chocolate
Eggs Flavorings
Butter Spices
Shortening Nuts
Oil Sugar
Sampling Procedure
An automatic sampler was used to collect eight daily,
time interval composite samples of the raw wastewater
at the inlet to the wastewater treatment facility.
Wastewater Characteristics
Combined Processing and C.lean-Up Wastewater
(7 a.m. - 11:30 p.m.)*
Total Grease
COD BOD SS VSS P TKN & Oil
Avg. Cone.
(mg/1) 9,300 4,300 3,071 2,991 5.7 44.7 688
Range of i
Cone. 4,600- 2,700- 800- 780- 2.1- 3.2- 350-
(mg/1) 23,000 8,000 12,000 12,000 12 83 1,400
*Eight samples
ph range: 4.3-5.7
Productivity Factors
This plant was the only one investigated that did not
cooperate in supplying production data. Thus no waste-
74
-------
water productivity factors could be calculated.
Pre-Treatment Facilities
Pre-treatment at this bakery consists of activated sludge
and clarification for removal of BOD and solids. The
effluent is discharged to the city sewer.
75
-------
SALAD DEESSINGS AND OILS
Plant Code: I
Location: West
Category: 3
Products: Sauces, dressings, and oils
Barbecue sauces, shortening, margarine and vegetable
oil, jellies and toppings, drink bases, processed
cheese, marshmellows, mustard.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Mustard seed
Marshmellows
Vegetable oil
Fruits
Chocolate
Cheese
Milk
Vinegar
Salt
Sugar
Seasonings
Spices
A simplified schematic diagram of plant operations is
shown in Figure A-6.
Sampling Procedure
Ten 24-hour time interval composite samples of the raw
plant wastewater were taken by plant personnel. The
samples were collected at the inlet to the plant waste-
water treatment facility.
Watewater Characteristics
Combined Process and Clean-Up Wastewaters
(24 Hour Composites)*
Avg. Cone.
Cmg/1)
Range of
Cone.
(mg/1)
Total
COD BOD SS VSS P TKN
4,900 2,300 1,000 960 16 15
3,200- 1,100- 420- 420- 2.3- 8.1-
8,400 4,000 1,400 1,300 24 33
Grease
& Oil
1,300
1,100-
1,300
*Ten samples
pH range: 6.1-9.0
76
-------
DRINK BASE
B^^H
SUGAR
FLAVORINGS
JELUNDTOPPING
PARED ELSEWHERE)
SUGAR, PEETIN, ACID H
MILK-
CHOCOLATE
FLAVORINGS
DRESSINGS^AND SAUCES
VINEGAR
FLAVORINGS
OILS
^ARSHMELUWS
SUGAR
WATER
/lUSTARD
MARGARINE^ND^SHORTEN ING
VEGETABLE OIL
SALT
FLAVORINGS
COLORING
Ji-L
OIL
(PRE-PROCESSED
ELSEWHERE)
:HEES
NATURAL CHEESE
(PREPARED ELSE-
WHERE)
FLAVORINGS
MUSTARD
SEED MIL
PLANT
CLEAN-UP
VINEGAR
1 SPICES
.LING """ MIXING
BOTTLING
STORAGE
FIGURE A-6
PLANT I
SALAD DRESSING a SAUCE PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(HEAVY ARROW DESIGNATES MAJOR WASTEWATER PRODUCING OPERATION)
-------
Productivity Factors
Based on daily metered wastewater flows, wastewater qual-
ity characteristics, and production data supplied by the
plant, the following productivity factors were calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg Range kg/kkg
Constituent finished product finished product
COD
BOD
SS
VSS
Total P
TKN
Grease & Oil
12
5.6
2.6
2.4
0.039
0.036
3.1
0
0
5.4-20
2.4-9.0
1.0-3.7
1.0-3.1
.010-0.067
.019-0.069
1.9-3.9
Wastewater
Generation 2,600 1,800-3,200
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
Wastewater pre-treatment at this food plant consists of
gravity settling for solids removal and skimming for
removal of grease and floatables.
The final effluent is discharged to the municipal sewer.
78
-------
DRESSINGS, SAUCES, AND PIE FILLINGS
Plant Code: J
Location: Northern California
Category: 3
Products: Dressings, sauces and pie fillings
Dressings: bleu cheese, French, green goddess, Italian,
thousand island, mayonnaise, cole slaw.
Sauces: taco, tarter, barbecue.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
None Worcestershire sauce
Seasonings Oil
Red pepper Salt
Tomatoes Cheeses
Vinegar
A simplified schematic diagram of plant operations is
shown in Figure A-7.
Sampling Procedure
An automatic sampler was used to collect ten time inter-
val composite samples of the raw wastewater from the
surge tank proceeding discharge to the sewer.
Five samples of the process shift (8:00 a.m.-4:00 p.m.)
and five samples of the clean-up shift (4:00 p.m.-12
midnight) were taken.
Wastewater Characteristics
79
-------
RAW
INGREDIENTS
(LIQUID)
PRE
MIX
FILL
_ FINAL
"PRODUCT
COOK
PLANT
CLEAN-UP
I
NOTE
HEAVY ARROW
DESIGNATES MAJOR
LIQUID WASTE
GENERATION
FIGURE A-7
PLANT J
SALAD DRESSING PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
80
-------
Process Shift Wastewater*
(8 a.m. - 4 p.m.)
Total Grease
COD BOD SS VSS P TKN & Oil
Avg. Cone.
(mg/1) 3,100 2,000 880 870 2.0 11 2,100
Range of
Cone. 1,200- 750- 430- 420- 0.25- 2.2- 930-
(mg/1) 4,500 3,000 1,300 1,200 5.4 19 3,900
*Five samples
pH range: 4.2-4.9
Clean-Up Shift Wastewater*
(4 p.m. - 12 midnite)
Total Grease
COD BOD SS VSS P TKN & Oil
Avg. Cone.
(mg/1) 5,700 4,000 1,900 1,900 9.2 14 3,200
Range of
Cone. 4,100- 2,800- 1,400- 1,400- 6.9- 2.9- 2,100-
(mg/1) 7,500 5,200 2,500 2,500 12 28 4,900
*Five samples
pH range; 6.1-9.3
Productivity Factors
Based upon average wastewater volumes generated during
the process and clean-up shifts, quality characteristics
of the wastewater, and production data supplied by the
plant, the following production factors were calculated
for the process shift, the clean-up shift, and the total
effluent.
81
-------
PRODUCTIVITY FACTORS
Average kg/kkg
Finished Product
Total
COD BOD SS VSS P TKN G&O W.W.
Process
Shift 4.6 3.0 1.3 1.3 0.0030 0.016 3.2 1,500
Clean-Up
Shift 9.1 6.4 3.0 3.0 0.015 0.022 5.1 1,600
Total Daily
Operation 14 9.4 4.4 4.4 0.018 0.038 8.3 3,100
^-Wastewater Generation in 1/kkg finished product.
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
There is no pre-treatment at the plant. All wastewater
discharges into a small surge tank and then to the sewer.
82
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MEAT SPECIALTIES
Plant Code: K
Location: West
Category: 4
Products: Fresh frozen and pre-cooked meats:
beef patties, canned turkey, Salisbury steak, breaded
veal patties, pork patties, canned chicken.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
None Beef Salt
Turkey Soy Protein
Flour Seasonings
A simplified schematic diagram of plant operations is
shown in Figure A-8.
Sampling Procedure
An automatic sampler was used to take nine time interval
samples of the combined raw processing and clean-up
wastewater out of a final grease trap.
Wastewater Characteristics
Combined Process and Clean-Up Wastewaters
(9 a.m. - 11 p.m.) *
Total Grease
COD BOD SS VSS P TKN & Oil
Avg. Cone.
(mg/1) 900 530 210 170 15 28 120
Range of
Cone. 510- 290- 56- 40- 1.0- 9.5- 12-
(mg/1) 1,700 860 430 370 38 56 400
*Nine samples
pH range: 6.2-7. 6
83
-------
Portion Control Line
additives
Meat
(prepared else
where, frozen)
soy protein
mixing
grinding
packaged
freeze^
package
00
yp>r] p.lsp
grinding
mixing
canning
cooking
casing
Turkey
(prepared
where, deboned)
PLANT CLEAN UP
FIGURE A-8
PLANT K
MEAT PATTY PREPARATION AND CANNING PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(heavy arrow designates major
wastewater producing operations)
-------
Productivity Factors
Based upon average daily wastewater volumes and quality
characteristics, and production figures provided by the
plant, the following productivity factors were calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg
Constituent finished product
COD
BOD
SS
VSS
Total P
TKN
Grease & Oil
5.1
3.0
1.2
0.97
0.086
0.16
0.68
Wastewater
Generation 5,700
(1/kkg finished
product)
1 gallon/ton = 4.173 1/kkg
1 Ib/ton =0.5 kg/kkg
Pre-Treatment Facilities
Wastewater pre-treatment equipment at this canned meat
plant consists merely of a grease trap.
85
-------
CANNED MEAT SPECIALTIES
Plant Code: L
Location: Midwest
Category: 4
Products: Canned meat products:
potted meat, Vienna sausage, beef stew, hash, chile,
pork brains, lobster bisque, crab.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Sausage (mixing, Meat (initial butchering)
filling, cooking) Lobster Vegetables
Meat (cutting, Crab Potatoes
deboning, Beans Sauces
cooking)
A simplified schematic diagram of plant operations is
shown in Figure A-9.
Sampling Procedure
An automatic sampler was installed at the inlet to the
wastewater settling tanks and collected nine, time
interval composite samples of the total plant effluent
and one composite sample of the late shift clean-up
operation.
Wastewater Characteristics
Combined Process and Clean-Up Wastewater*
(6;30 am - 11 pm)
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
COD
2,300
1,300-
3,300
BOD
1,100
600-
1,400
SS
720
140-
1,200
VSS
670
140-
1,100
Total
P
6.7
3.0-
20
TKN
67
51-
100
Grease
& Oil
490
100-
970
*Nine samples
pH range* 5.5-8.0
86
-------
FROZEN
RAW INGREDIENTS
FRESH
RAW INGREDIENTS
FREEZING
TEMPER /THAW
BLEND
MIX
REHYDRATE
FILLING
COOKING
STORAGE
COOLING
PLANT
CLEAN-UP
FIGURE A-9
PLANT L
CANNED MEAT PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(HEAVY ARROWS DESIGNATE MAJOR
WASTEWATER GENERATING OPERATIONS)
87
-------
Clean-Up Wastewater
(11 p.m. - 6:30 a.m.)*
Total Grease
COD BOD pH SS VSS P TKN & Oil
Concentration
(mg/1) 2,300 680 8.4 800 760 11 47 670
*0ne sample
Based on daily wastewater volumes, wastewater quality
characteristics from the lab, and production data
supplied by the plant, the following productivity factors
were calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg Range kg/kkg
Constituent finished product finished product
COD
BOD
SS
VSS
Total P
TKN
Grease & Oil
Wastewater
Generation
(1/kkg finished
product)
33
16
11
10
0.11
0.98
7.3
15,000
22-59
7.7-28
5.3-26
5.1-24
0.030-0.45
0.52-1.8
1.9-22
9,100-23,000
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 '1/kkg
Pre-Treatment Facilities
Pre-treatment at this canned meat plant consists of
aeration and settling for removal of BOD and solids.
The effluent is discharged to the city sewer.
88
-------
BABY FOODS
Plant Code: M
Location: West
Category: 5
Products: Strained and junior baby foods:
vegetables and meat products, cereal, vegetables, fruit
desserts, fruits, fruit juices, starch products, starch
and meat products.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Peaches, (pealed, Fruit Meat Starch
cored, sliced,
mashed, cooked) Bananas Chicken Spaghetti
Pineapple
Plums Dairy
Cottage Cheese
A simplified schematic diagram of plant operations is
shown in Figure A-10.
Sampling Procedure
An automatic sampler was used to collect 10 daily time
interval composite samples of the raw waste at the inlet
to the pre-treatment units.
Wastewater Characteristics
Combined Process and Clean-Up Wastewaters*
(8 a.m.,- 9 p.m.)
Total
COD BOD pH SS VSS P TKN
Avg. Cone.
(mg/1) 1,000 590 280 210 4.1- 12
Range of
Cone. 410- 200- 4.3- 110- 100- 1.9- 2.6-
(mg/1) 1,700 860 9.2 440 260 7.6 50
*Ten samples
89
-------
PLANT
CLEAN-UP
RAW
r 1 WA^HIMC 1 nn ivr 1 WAOI»"'» '
noiiiiMVj I * UK LTL * 1 WASHING 1 »
ETC. ) '
FRUIT LINE
NNAL I COOKING 1 PULPER/ r 1 PIT
PRODUCT 1 J FINISHER | REMOVAL
INSPECTION
DO T
BtLI
1
RAW
t
t
VFRFTARI Ffi ~
(POTATOES,
CARROTS,
ETC.)
FINAL
PRODUCT
FROZEN ^-1 G
\jL/AOI.IIMft 1 »
TURKE
STE
OR
PEE
AM
vc
LT t
LING
1 WAollllNO 1 *
INSPECTION
BELT
iY- VEGETABLE LINE
UUUKINo 1 *
F7iMniMf; 1 . IPRF
I
:OOK
FINISHER
BLANCH
ING
NOTE
HEAVY ARROW
DESIGNATES MAJOR
LIQUID WASTE
GENERATION
FIGURE A-IO
PLANT M
BABY FOOD PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM (2 LINES)
90
-------
Productivity Factors
Based upon average daily wastewater volumes, raw ingred-
ient consumption data supplied by the plant, and quality
characteristics of the wastewater, the following produc-
tion factors were calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg Range kg/kkg
Constituent raw product raw product
COD
BOD
SS
VSS
Total P
TKN
Wastewater
Generation
(1/kkg raw
product)
14
8.5
4.3
3.1
0.068
0.19
15,000
7.3-24
3.5-16
1.8-7.7
1.6-4.7
0.021-0.13
0.039-0.75
8,800-24,000
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
Pre-treatment at this baby food plant consists of vibra-
tory screening to remove larger solids such as leaves,
pits, etc.
91
-------
CANNED SOUPS
Plant Code: N
Location: Midwest
Category: 5
Products: Soups, bean products, juices (tomato, cock-
tail vegetable), macaroni products,
spaghetti products, sauces, gravies, stews
(beef, chicken), chili, puddings.
Significant Ingredients
Processed at Plant Pre-Processed Elsewhere
Poultry (cutting,
deboning, cooking)
Meat, fish (cutting,
cooking)
Meat,fish, poultry (initial
butchering)
Vegetables Spices
Dairy products Salt
Eggs Sugar
Flour Fats
Starches Oils
Spaghetti Noodles
Sampling Procedure
Eight 24-hour composite samples were collected at the
inlet to the plant wastewater treatment facility.
In addition, two time interval composite samples were
taken during the clean-up shift only (12 midnight -
7:00 a.m.) .
Wastewater Characteristics
Combined Process and Clean-Up Wastewaters
(24 Hour Composites)*
COD
BOD
ss
Total Grease
VSS P TKN & Oil
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
940
760-
1,200
520
420-
610
360
210-
840
290
200-
660
10
4.3-
21
26
17-
46
82
64-
120
*Eight samples
pH range: 6.6-10.5
92
-------
Clean-Up Wastewater
(12 midnite to 7:00 a.m.)*
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
COD
770
510-
1,000
BOD
410
260-
570
SS
380
290-
470
VSS
290
200-
370
Total
P
17
16-
18
TKN
41
38-
44
Grease
& Oil
220
76-
360
*Two samples
pH range? 11.8-11.8
Productivity Factors
Based on metered daily wastewater flows, wastewater qual-
ity characteristics, and average daily raw ingredient
consumption data supplied by the plant, the following
productivity factors were calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average
kg/kkg raw
Constituent product
COD
BOD
SS
VSS
Total P
TKN
Grease & Oil
Wastewater
Generation
(1/kkg raw
product)
27
15
10
8.4
0.29
0.75
2.4
29,000
1 Ib/ton =0.5 kg/kkg
1 gal/ton = 4.173 1/kkg
93
-------
Treatment Facilities
The wastewater treatment facilities consist of the fol-
lowing operations:
bar screening
gravity grit removal
air flotation (with chemical coagulation)
primary trickling filter treatment
clarification
secondary trickling filter treatment
aerated lagooning
final clarification
chlorination
anaerobic sludge digestion
The treated effluent is discharged to a river.
94
-------
TOMATO-CHEESE-STARCH COMBINATIONS
Plant Code: 0
Location: Midwest
Category: 6
Products: Tomato-cheese-starch combinations
(Institutional):
chili with beans, veal parmagiana, beef
ravioli, grilled american cheese, macaroni
and cheese, salads.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Various salad Juices Dressings
components Spices Lettuce
(blanching) Meat Bread
Kidney beans Margarine
Tomatoes Macaroni
Cheese Milk
Flour
A simplified schematic diagram of plant operations is
shown in Figure A-11.
Sampling Procedure
Ten 24-hour composite samples of the screened raw waste
were collected by the plant staff prior to the wastewater
treatment facilities.
Wastewater Characteristics
Combined Process and Clean-Up Wastewaters
(24 Hour Composites)*
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
COD
500
79-
1,500
BOD
240
20-
760
pH
8.7-
11.0
SS
180
62-
400
VSS
150
42-
390
Total
P
10
4.9-
16
TKN
7.6
3.0-
14
*Ten samples
95
-------
SALADS
CANNED COMPONENTS
DRESSING
COLORING , JUICE, SPICES
LETTUCE
VEGETABLES
CHILE WITH BEANS
MEAT-
FILLING
FREEZE
SPICES, TOMATO PASTE, KIDNEY
WATER 7 BEANS
| COOKING_j-Lj
FILLING
FREEZE
VEAL PARMAGIANA
MEAT -j GRINDING - { MIXING f FORM -j BATTER
PATTIES
TOMATO PASTE SLURRY
SPICE,
BEEF RAVIOLI CHEESE
TOMATO SA
GRILLED CHEESE
ING j BREADING -^ FRYING
C
E
.
COOKING ' *" f,
t
DOUGH V
PODS
* COOKING
UCE
f
%
)
A
3
i
FREEZE
\
^/
PLANT
CLEAN - UP
CHEESE
MARGARINE
JdACARONI AND CHEESE
CHEESE SAUCE
MACARONI
COOKING
COOKING
~
RINSING
BLENDING
>-
FILLING
-*.
FREEZE
FIGURE A-ll
PLANT 0
TOMATO-CHEESE-STARCH PRODUCTS PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(HEAVY ARROW DESIGNATES MAJOR WASTEWATER GENERATING OPERATIONS)
96
-------
Productivity Factors
Based upon daily wastewater volumes, production data
supplied by the plant, and quality characteristics of the
wastewater, the following productivity factors were gen-
erated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg Range kg/kkg
Constituent finished product finished product
COD
BOD
SS
VSS
Total P
TKN
w.w. (i)
39
19
14
13
0.79
0.59
80,000
4.7-110
2.2-54
2.4-31
1.6-28
0.42-1.7
0.14-1.3
39,000-134,
000
1 Ib/ton =0.5 kg/kkg
1 gal/ton = 4.173
Wastewater generation (1/kkg finished product)
Pre-treatment Facilities
Wastewater pre-treatment at the plant consists of ex-
tended aeration. At present, production levels, are so
low that treatment facility performance is not represen-
tative of what it will be under design loadings. The
plant is considering shutdown of their treatment opera-
tion until such time as the production levels become
large enough to economically justify its operation.
97
-------
TOMATO-CHEESE-STARCH COMBINATIONS
Plant Code: P (Historical Data Only)
Location: West
Category: 6
Products: Tomato-cheese-starch combinations (canned):
chili con carne, meat balls with gravy,
spaghetti (with meat balls, with cheese),
ravioli (beef, cheese), stew (beef, meat
ball), tomato pastes, tomato sauce (with
meat, with mushrooms), lasagne, manicotti,
beefaroni.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
None Tomatoes (processed at plant
during tomato season)
Beef Vegetables
Cheese Seasonings
Flour Mushrooms
Cereals
Sampling Procedure
An automatic sampler was used to collect six 24-hour
flow proportional samples of the raw plant wastewater.
All the effluent was discharged from the kitchen opera-
tion as no tomatoes were being processed.
The samples were collected during the period of 7/6/72-
7/17/72.
Wastewater Characteristics
Combined Process and Clean-Up Wastewater
(24 Hour Composites)*
BOD pH TS1 TKN
Average Cone.
(mg/1) 340 920 12
Range of
(mg/1)
Cone.
210-
420
6.
7.
9-
8
1
750-
,100
6.
20
5-
*Six samples
iTotal Solids
98
-------
Productivity Factors
Based on daily wastewater flow measurements, wastewater
quality characteristics from the lab, and average daily
production data supplied by the plant, the following
productivity factors were calculated.
PRODUCTIVITY FACTORS
Kitchen Operation
(No Tomato Processing)
Combined Process and
Clean-Up Wastewaters
Average kg/kkg
Constituent finished product
BOD 3.3
Total Solids 9.0
TKN 0.12
Wastewater Generation 9,800
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
Wastewater treatment at the plant consists of screening
and aeration, followed by retention in stabilization
ponds. The final effluent is chlorinated and discharged
to a creek.
99
-------
TOMATO-CHEESE-STARCH COMBINATIONS
Plant Code: Q
Location: East
Category: 6
Products: Tomato-cheese-starch combinations:
lasagne, ravioli, spaghetti, pizza.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
None Beef Seasonings
Pork Cheese
Flour Tomato
Milk Green pepper
Oil Onion
Sampling Procedure
An automatic sampler was used to collect eight 24-hour,
time interval composite samples of the raw plant waste-
water. The samples were taken just upstream from the
plant's wastewater screening operation.
Wastewater Characteristics
Combined Process and Clean-Up Wastewater
(24 Hour Composites)*
Total Grease
COD BOD SS VSS P TKN & Oil
Avg. Cone.
(mg/1) 340 200 130 120 2.0 5.6 180
i
Range of
Cone. 150- 79- 50- 50- 0.50- 0.20- 13-
(mg/1) 560 300 240 240 4.2 11 380
*Five samples
pH range: 6.1-7.6
100
-------
Productivity Factors
Based upon average daily wastewater volumes, production
data supplied by the plant/ and wastewater quality char-
acteristics from the lab, the following productivity
factors were calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg
Constituent finished product
COD 8.8
BOD 5.2
SS 3.4
VSS 3.1
Total P 0.052
TKN 0.15
Grease & Oil 4.7
Wastewater Generation 26,000
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
Pre-treatment at this plant consists merely of screening
for solids removal prior to discharge to the city sewer.
101
-------
TOMATO-CHEESE-STARCH COMBINATIONS
Plant Code: R
Location: East
Category: 6
Products: Tomato-cheese-starch Combinations:
lasagne, pizza, eggplant parmigiana.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Eggplant (washed, Beef Cheese
peeled, sliced) Flour Tomato
Milk Onion
Oil Green pepper
Seasonings
A simplified schematic diagram of plant operations is
shown in Figure A-12.
Sampling Procedure
An automatic sampler was used to collect ten time inter-
val, composite samples of the raw plant wastewater just
prior to discharge into the municipal sewer system.
Wastewater Characteristics
Combined Process and Clean-Up Wastewaters
(8 a.m. - 5 p.m.) *
Total
COD BOD SS VSS P TKN
Avg. Cone.
(mg/1) 1,450 690 360 330 6.0 34
Range of
Cone. 400- 180- 85- 65- 1.6- 15-
(mg/1) 5,400 3,000 1,500 1,300 18 110
*Ten samples
pH range: 5.5-7.7
102
-------
Raw
Eggplant
Washing
Peeling
Washing
Flour
Beef
(pre-processed
elsewhere)
i
I
Shortening
Combining
Dough
Preparation
Slicing
sauces-
cheese-
spices
Combining
Packaging
Plant
Clean-up
Freezing
FIGURE A-12
PLANT R
TOMATO-CHEESE-STARCH PRODUCTS PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(heavy arrows designate major wastewater generating operations)
103
-------
Productivity Factors
Based upon average daily wastewater volumes, raw material
consumption data supplied by the plant, and wastewater
quality characteristics from the lab, the following pro-
ductivity factors were calculated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average kg/kkg
Constituent raw product
COD 2.6
BOD 1.2
SS 0.65
VSS 0.59
Total P 0.011
TKN 0.061
Wastewater Generation 1,800
(1/kkg raw product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
At present, there is no wastewater pre-treatment at this
food plant.
104
-------
SAUCED VEGETABLES
Plant Code: S
Location: West
Category: 7
Products: Vegetables
Processed: cauliflower (bulk; with cheese sauce),
brussel sprouts (bulk; with butter sauce) , spinach
(bulk; with butter sauce) , broccoli (bulk; with butter
sauce; with cheese sauce).
Repackaged: corn, peas, green beans, lima beans.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Broccoli Butter Cheese
Cauliflower Shortening Salt
Sugar
A simplified schematic diagram of plant operations is
shown in Figure A-13.
Sampling Procedure
An automatic sampler was used to obtain ten time inter-
val, 24 hour composite samples of the raw waste prior to
vibratory screening at the food plant.
In addition, three grab samples of the sauce room clean-
up wastewater were manually collected.
Wastewater Characteristics
Combined Process and Clean-Up Wastewaters
(24 Hour Composites)*
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
COD
560
380-
890
BOD
310
140-
550
pH
7.0-
7.7
SS
250
170-
410
VSS
200
130-
360
Total
P
4.4
1.9-
9.9
TKN
13
5.1-
27
*Ten samples
105
-------
PLANT
CLEAN-UP
t
RAW
PRODUCE
(BROCOLLI,
CAULIFLOWER,
BRUSSEL
SPROUTS,
SPINACH )
REMOVAL
OF
UNWANTED
LEAVES
CORES, ETC.
₯ Y
,-r-rii^n 1
UJMING 1 * WASHING BLANCHING |
RECIRCULATION
_J
WATER TRANSPORT
flNAL - fVr, ,-,--,. i.Tl ,
PRODI
NOTE
HEAVY ARROW
DESIGNATES
MAJOR LIQUID
WASTE GENERATION
Dl ITTCTD .
LJLJ 1 1 Ln
cHORTFNING
puppop
SALT
SUGAR
SAUCE
ADDITION
... rooi INC
*
COOKING
SAUCE
> ROOM
OPERATION
CLEAN-UP
I
FIGURE A-13
PLANT S
SAUCED VEGETABLE PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
106
-------
Sauce Room Clean-Up Wastewater
(Grab Samples)*
Total
COD BOD SS VSS P TKN
Avg. Cone.
(mg/1) 14,000 8,052 3,340 3,078 227 104
Range of
Cone. 3,400- 2,200- 1,000- 1,000- 130- 14-
(mg/1) 28,000 16,000 5,600 5,100 280 160
*Three samples
pH range: 10.9-11.9
Productivity Factors
Based upon daily and clean-up wastewater volumes, pro-
duction factors supplied by the plant, and wastewater
characteristics from the lab, the following productivity
factors were generated.
PRODUCTIVITY FACTORS
Combined Process and Clean-Up Wastewaters
Average,kg/kkg Range kg/kkg
Constituent finished product finished product
COD 45 16-76
BOD 25 7.1-47
SS 21 7.0-44
VSS 16 6.0-30
Total P 0.33 0.12-0.53
TKN 1.1 0.31-2.9
Wastewater
Generation 85,000 38,000-160,000
(1/kkg finished
product)
1 gallon/ton = 4.173 1/kkg
1 Ib/ton =0.5 k/kkg
The table on the following page shows the portion of
total kg/kkg production contributed by clean-up of the
sauce room where all the dairy operations are performed
(e.g., cheese sauce and butter sauce preparation).
107
-------
Sauce Room Clean-Up Wastewater
Average kg/kkg % of total
Constituent finished product pollutant load
COD 6.4 15
BOD 3.5 14
SS 1.4 7
VSS 1.3 8
Total P 0.090 27
TKN 0.047 4
Wastewater
generation 490 0.6
(1/kkg finished
product)
Pre-Treatment Facilities
Pre-treatment at the sauced vegetable plant consists of
20 mesh vibratory screening for removal of solids.
108
-------
SWEET SYRUP PRODUCTS
Plant Code: T
Location: East
Category: 8
Products: Sweet syrup^products:
chocolate and cocoa products, ready mixed desserts,
syrups, whipped toppings, coconut based products,
tapioca.
Significant Ingrients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Rice Fats and oils
Chocolate Flavorings
Cocoa Milk powder
Syrups Syrups Starches
Coconut Sugar
A simplified plant wastewater flow diagram is shown in
Figure A-14.
Sampling Procedure
An automatic sampler was used to collect six 24-hour com-
posite samples of the total raw effluent and two 24-hour
composite samples of the raw rice processing wastewater.
In addition, two grab sample composites of the rice
wastewater treatment plant effluent were taken. Sampling
locations are noted in Figure A-14.
Wastewater Characteristics
Total Plant Wastewater
(24 Hour Composites*)
Total Grease
COD BOD pH SS VSS P TKN and Oil
Avg. Cone.
(mg/1) 2,000 1,100 470 410 28 21 230
Range of
Cone. 1,800- 920- 5.9- 350- 340- 20- 14- 170-
(mg/1) 2,300 1,600 7.4 620 480 38 35 280
*Six samples
109
-------
RICE
OPERATION
RICE WASTEWATER
SAMPLING
STREAM A
STREAM
B
RICE
WASTEWATER
TREATMENT
PLANT
RICE WASTEWATER
TREATMENT PLANT
SAMPLING
WHIPPED
TOPPING
OPERATION
CHOCOLATE
OPERATION
DESERTS
OPERATION
SYRUP
OPERATION
TOTAL PLANT
EFFLUENT SAMPLING
COCONUT
OPERATION
FIGURE A-14
PLANT T
CHOCOLATE AND CANDY PLANT
SIMPLIFIED WASTEWATER FLOW DIAGRAM
-------
Raw Rice Processing Wastewater
(24 Hour Composites*)
Total Grease
COD BOD SS VSS P TKN and Oil
Avg. Cone.
(rag/1)
Range of
Cone.
(mg/1)
4,
3,
4,
000
600-
400
3,
2,
3,
000
400-
600
3,
2,
3,
100
900-
300
3
2
3
,000
,900-
,200
32
27-
38
29
26-
31
10
0.7-
20
*Two samples
pH ranges 6.6-6.8
Rice Wastewater Treatment Plant Effluent
(24 Hour Composites*)
COD
Avg. Cone.
(mg/1) 340
Range of
Cone. 260-
(mg/1) 420
*Two samples
Productivity
BOD pH
34.5
16- 5.7-
53 6.4
Factors
SS
320
210-
440
Total
VSS P
240 110
180- 100-
300 110
TKN
24
12-
35
Grease
and Oil
4.4
0.9-
7.9
Based on wastewater volume generated during sampling
periods, wastewater quality characteristics from the lab
analysis, and production data furnished by the plant,
the following productivity factors were calculated for
(1) the raw rice processing wastewater, (2) rice waste-
water treatment plant effluent, (3) all operations ex-
cept the rice, and (4) the. total plant effluent.
Pre-Treatment Facilities
Pre-treatment facilities consist of screening, settling,
and activated sludge for removal of BOD and solids. The
treatment plant effluent is discharged to the city sewer.
-------
Productivity Factors
Average k/kkg Finished Product
COD BOD SS VSS
Raw rice processing
wastewater 0.48 0.36 0.37 0.36
Rice wastewater
treatment plant
effluent 0.20 0.021 0.19 0.14
All process and
clean-up except
rice operation 4.7 2.6 0.74 0.60
Total plant efflu-
ent 5.4 3.0 1.3 1.1
Total
P
0.0038
0.067
0.0052
0.076
TKN
0.0035
0.014
0.040
0.057
Grease
and Oil
0.0012
0.0026
0.62
0.62
Waste-
water1
120
600
2,000
2,700
"-Wastewater generation in 1/kkg finished product
-------
JAMS AND JELLIES
Plant Code: U
Location: West
Category: 8
Products: Jams, jellies, preserves, apple butter, peach
butter, toppings, syrups
Significant Ingredients (used during processing period)
Processed at Plant Pre-Processed Elsewhere
None Strawberries Corn syrup
Oranges Carmel
Pineapples Butterscotch
Cherries Chocolate
Peaches Pectin
Plums Sugar
Grapes Acid
Blackberries Apricots
Red raspberries Blueberries
A simplified schematic diagram of plant operations is
shown in Figure A-15.
Sampling Procedures
An automatic sampler was used to take eight 24-hour time
interval composite samples of the raw plant wastewater at
the final manhole before discharge to the city sewer.
Wastewater Characteristics
Combined Process and Clean-up Wastewaters
(24 Hour Composites*)
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
6
3
8
COD
,100
,600-
,400
3
2
4
BOD
,600
,200
,700
PH
4.8-
7.0
SS
340
170-
780
VSS
300
150-
700
Total
P
9
2
.6
.6-
26
TKN
15
6.4-
36
*Eight samples
113
-------
Fruit
(Preprocessed Elsewhere)
sugar
corn syrup
pectin
acid
Mixing
Vacuum
Cooking
Plant
Clean-up
Fillincr
Steam
Sterilization
Cooling
Labeling
Packaging
FIGURE A-15
PLANT U
JAMS AND JELLIES PLANT
SIMPLIFIED PROCESS DIAGRAM
(heavy arrow designates major
wastewater producing operations)
114
-------
Productivity Factors
Based upon average daily wastewater volumes, production
data supplied by the plant, and quality characteristics
of the wastewater, the following production factors were
calculated.
Productivity Factors
Combined Process and Clean-Up Wastewaters
Average kg/kkg
Constituent Finished Product
COD 12
BOD 7.2
SS 0.68
VSS 0.60
Total P 0.019
TKN 0.030
Wastewater Generation 2,000
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
There is no pre-treatment provided at the food plant.
Wastewater is discharged directly to the city sewer sys-
tem.
115
-------
CHINESE FOODS
Plant Code: V
Location: Midwest
Category: 9
Products: Chinese foods
Mixed vegetables/ chop suey vegetables, chow
mein, fried rice, bean sprouts, noodles,
water chestnuts, bamboo shoots, won ton soup,
egg drop soup, teriyaki sauce, Singapore
salad, brown gravy sauce.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Bean sprouts (sprouting, Vegetables (except bean
washing, blanching) sprouts, celery)
Rice (cooking or frying) Chicken, beef (initial
Noodles cleaning)
Chicken, beef, pork, Shrimp (peeling, cleaning)
shrimp (cutting cook- Spices Eggs
ing, frying) Seasonings Flour
Celery (washing, blanch-
ing)
A simplified schematic diagram of plant operations is
shown in Figure A-16.
Sampling Procedure
An automatic sampler was used to take nine 24-hour time
interval composite samples of the screened plant waste-
water at the outlet from the holding tank.
Wastewater Characteristics
Combined Process and Clean-Up Wastewater
(24 Hour Composites*)
Total Grease
COD BOD pH SS VSS P TKN & Oil
Avg. Cone.
(mg/1) 830 450 170 160 6.0 26 85
Range of Cone. 760- 380- 5.0- 140- 120- 4.2- 22- 17-
(mg/1) 920 590 5.9 210 200 7.4 29 230
*Nine samples
116
-------
Meat Line
Beef, Chicken, Shrimp, Lobster
(pre-processed elsewhere)
bean
sprouts
celery
Assembly Line
sauces
seasonings
Blanching
all other
vegetables
(pre-processed
elsewhere)
Starch Lines
rice
Cluster
Break-up
flour >
shortening-
Dough
Preparation
Mixing
egg
seasonings
FIGURE A-16
PLANT V
CHINESE SPECIALTIES PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(heavy arrows designate major
wastewater generating operations)
Plant
Clean-up
Combining
Packaging
1
Freezing
117
-------
Productivity Factors
Based upon average daily wastewater volume, wastewater
quality characteristics, and production data supplied by
the plant, the following productivity factors were cal-
culated.
Productivity Factors
Combined Process and Clean-Up Wastewaters
Average kg/kkg
Constituent Finished Product
COD 12
BOD 6.3
SS 2.4
VSS 2.2
Total P 0.084
TKN 0.36
Grease and Oil 1.2
Wastewater Generation 14,000
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
Pre-treatment consists merely of screening for solids
removal.
118
-------
CHINESE FOODS
Plant Code: W
Location: Midwest
Category: 9
Products: Chinese Foods
Prepared Dinners: beef chow mein, chicken chow mein,
shrimp chow mein, egg foo young.
Entrees: Shrimp eggrolls, chicken eggrolls, lobster egg-
rolls, meat eggrolls, fried rice with meat, chichen
chow mein, shrimp chow mein, beef chow mein, pork chow
mein, sweet and sour pork.
Miscellaneous: Soy sauce, chow mein vegetables, bean
sprouts, noodles.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Bean sprouts (sprouting, Beef, pork, chicken (initial
washing) cleaning)
Rice (cooked) Shrimp, lobster (peeling,
Noodles cleaning, cutting)
Chicken, beef, pork, Eggs
shrimp (cutting, cook- Flour
ing or frying) Seasonings
Celery (washing, blanch-
ing)
A simplified schematic diagram of plant operations is
shown in Figure A-17.
Sampling Procedure
An automatic sampler was used to collect nine time inter-
val composite samples of the raw plant wastewater from a
sump just ahead of the pre-treatment facility.
Wastewater Characteristics
Combined Process and Clean-Up Wastewaters
(8 a.m. - 9 p.m.*)
Total Grease
COD BOD pH SS VSS P TKN and Oil
Avg. Cone.
(mg/1) 670 370 220 210 2.3 15 260
Range of Cone. 420- 230- 4.6- 110- 94- 0.04- 7.1- 53-
(mg/1) 1,200 600 10.2 490 450 5.1 22 920
*Nine samples
119
-------
MEAT LINE
BEEF, CHICKEN, SHRIMP, LOBSTER
(PRE-PROCESSED ELSEWHERE)
ASSEMBLY LINE
ALL OTHER VEGETABLES
( PRE-PROCESSED
ELSEWHERE )
FLOUR
SHORTENING
FIGURE A-17
PLANT W
CHINESE SPECIALTIES PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(heavy arrows designate major
wastewater generating operations)
120
-------
Productivity Factors
Based upon average daily wastewater volume, wastewater
quality characteristics, and production data supplied by
the plant, the following productivity factors were cal-
culated.
Productivity Factors
Combined Process and Clean-Up Wastewaters
Average kg/kkg
Constituent Finished Product
COD 12
BOD 6.7
SS 4.0
VSS 3.8
Total P 0.041
TKN 0.27
Grease and Oil 4.7
Wastewater Generation 18,000
(1/kkg finished
product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173
Pre-Treatment at the Food Plant
Pre-treatment consists of screening and dissolved air flo-
tation that is enhanced by alum coagulation. Caustic is
also added for pH control.
The treated effluent is discharged to the municipal sewer.
121
-------
MEXICAN FOODS
Plant Code: X
Location: West
Category: 9
Products: Mexican foods
Red taco sauce
Red taco sauce
Green taco sauce
Salsa brava
Salsa suprema
Salsa Victoria
Salsa ranchera
Chili chow chow
Red salsa jalapena
Green salsa jalapena
Guacamole dip mix
Tomatillo salsa
Hot chili mix
Cauliflower mix
Rajas de jalapenos
Jalapenos en esc.
Jalapenos en esc.
Jalapenos supremos
Yellow chilis mex. style
Pickled yellow chilis
Pickled yellow chilis
Pickled yellow chilis
Marinated cactus
Nopalitos tiernos
Nopalitos tiernos
Shredded shrimp, dry
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Beans
Cactus
Tomatoes
Beef
Shrimp
Spices
Chilis
A simplified schematic diagram, of plant operations is
shown in Figure A-18.
Sampling Procedure
An automatic sampler was used to take eight samples dur-
ing the processing shift, and two samples during the clean-
up shift. The samples were taken at the inlet of No. 1
clarifier of the plant treatment facility.
Wastewater Characteristics
122
-------
Plant
Clean-up
Final
Product
Cactus Line
Lye
Peeler
Vegetable Line
Inspection
Slicing &
Gratina
Bean Line
Cooking
Grindina
Material Preprocessed Elsewhere,
E.G. Tomato Base, Spices, Etc.
Brine or Water
Boilers
Cooling
! Steam
Retorting
Main
Assembly
Line
Blanchina
Mixing
Bottling or
Cannina
-FIGURE A-18
PLANT X
MEXICAN FOODS PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(heavy arrows designate significant
wastewater generating operations)
123
-------
Process Wastewater
(8 a.m. - 5 p.m.*)
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
COD
1,600
920-
2,500
BOD
1,100
690-
2,000
PH
4.9-
8.3
SS
260
72-
710
vss
170
48-
320
Total
P
22
0.60-
160
TKN
31
15-
71
*Eight samples
Clean-Up Wastewater
(5 p.m. - 11 p.m.*)
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
COD
340
260-
420
BOD
220
170-
280
PH
7.4-
8.3
SS
80
76-
84
VSS
63
58-
68
Total
P
60
23-
97
TKN
3.6
2.2-
5.0
*Two samples
Productivity Factors
Based upon average volume of wastewater generated during
processing and during clean-up operations, wastewater
quality characteristics from lab analysis, and production
figures provided by the plant, the following production
factors were calculated for the process shift, the clean-
up shift, and the total effluent.
Productivity Factors
kg/kkg Finished Product
Process
Clean-Up
Total
COD
11
0.78
12
BOD
7.3
0.51
7.8
SS
1.
0.
1.
7
18
9
VSS
1.
0.
1.
1
14
2
Total
P
0.15
0.14
0.29
Wastewater
Generation
TKN (1/kkg
0
0
0
.20
.0083
.21
6
2
8
product)
,600
,300
,900
1 gallon/ton = 4.173 1/kkg
1 Ib/ton =0.5 kg/kkg
124
-------
Pre-Treatment Facilities
Pre-treatment consists of 3 gravity clarifiers for re-
moval of suspended solids and floatables. The clarifiers
are manually cleaned as required. A large percentage of
the suspended solids and floatables are effectively re-
moved for disposal as solid waste.
125
-------
BREADED FROZEN PRODUCTS
. Plant Code: Y
Location: Midwest
Category: 10
. Products: Breaded onion rings, breaded mushrooms, breaded
perch.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
Onions (slicing and Perch
breading only) Flour
Mushrooms (slicing and Eggs
breading only) Seasoning
A simplified schematic diagram of plant operations is
shown in Figure A-19.
Sampling Procedure
An automatic sampler was used to collect eight 24 hour
time interval composite samples of the raw plant waste-
water, as well as two composite samples of just the
clean-up wastewater. The samples were collected from the
final effluent pipe.
Wastewater Characteristics
Combined Process and Clean-Up Wastewaters
(24 Hour Composites*)
Total Grease
COD BOD SS VSS P TKN & Oil
Avg. Cone.
(mg/1) 12,000 4,500 7,100 7,100 37 100 360
Range of
Cone. 6,100- 2,700- 2,900- 2,900- 15- 70- 130-
(mg/1) 19,000 5,600 9,900 9,800 55 120 760
*Eight samples
pH range/ 4.6 - 6.5
126
-------
Mushrooms
Onions
Perch
Washing
Slicing
Batter
Application
Breading
Application
Freezing
Plant
Clean-Up
FIGURE A-19
PLANT Y
BREADED ONION AND MUSHROOM PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(heavy arrows designate major wastewater
generating operations)
127
-------
Clean-Up Wastewaters
(12 midnite-3:00 a.m.*)
COD
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
11
10,
12
,000
600-
,000
BOD
3
3
3
,500
,400-
,600
8
7
8
SS
,000
,500-
,500
VSS
7,
7,
8,
800
400-
500
Total
P
63
63-
63
TKN
110
110-
110
Grease
& Oil
170
150-
190
*Two samples
pH range* 3.1 - 3.2
Productivity Factors
Based upon average daily wastewater volume, wastewater
quality characteristics, and raw ingredient consumption,
data supplied by the plant, the following productivity
factors were generated for the process shift, the clean-
up shift, and the total effluent.
Productivity Factors
(kg/kkg Raw Product)
Processing
Shifts
Clean-Up
Shift
Total
Plant
Operation
COD
19
21
40
BOD
8.4
6.6
15
SS
8.0
15
23
VSS
8.0
15
23
Total
P
0
0.12
0.12
TKN
0.12
0.21
0.33
Grease
& Oil
0.90
0.32
1.2
ww1
1,400
1,900
3,300
Wastewater Generation in 1/kkg raw product
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pre-Treatment Facilities
No treatment is provided before discharge to the city
sewer.
128
-------
BREADED FISH AND SHELLFISH
Plant Code: Z
Location: West
Category: 10
Products: Frozen fish and shellfish (with and without
breading).
Shrimp, scallops, oysters, sole, perch, had-
dock, cod.
Significant Ingredients (used during sampling period)
Processed at Plant Pre-Processed Elsewhere
i
Shrimp (shell removal, Flour Sole "j
cutting, breading) Batter Haddock ( lJ:JfaneT'
Fish (cutting, breading Scallops Cod J deboned)
only) Shrimp (heads removed)
Scallops (breading)
A simplified schematic diagram of plant operations is
shown in Figure A-20.
Sampling Procedure
An automatic sampler was used to take eleven daily, time
interval composite samples of the raw wastewater from the
surge tank just prior to screening.
Wastewater Characteristics
Combined Process and Clean-Up Wastewaters
(7 a.m. - 5 p.m.*)
Avg. Cone.
(mg/1)
Range of
Cone.
(mg/1)
COD
720
270-
1,300
BOD
400
180-
600
Ph
7.1-
8.4
SS
330
48-
730
VSS
320
44-
730
Total
P
6.3
0.50-
12
TKN
52
21-
36
*Eleven samples
129
-------
FROZEN FISH
OR SHELLFISH
THAWING
WASHING
CUTTING
WASHING
BATTER
APPLICATION
BREADING
PACKAGING
FROZEN
STORAGE
PLANT
CLEAN-UP
FIGURE A-20
PLANT Z
BREADED FISH AND SHELLFISH PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
(heavy arrows designate major wastewater
generating operations)
130
-------
Productivity Factors
Based upon total wastewater volume during the sampling
period, quality characteristics of the wastewater, and
raw ingredient consumption data supplied by the plant, the
following productivity factors were calculated.
Productivity Factors
Combined Process and Clean-Up Wastewaters
(7 a.m. - 5 p.m.)
kg/kkg Raw
Constituent Product
COD 66
BOD 37
SS 30
VSS 29
Total P 0.58
TKN 4.8
Wastewater Generation 92,000
(1/kkg raw product)
1 Ib/ton =0.5 kg/kkg
1 gallon/ton = 4.173 1/kkg
Pretreatment Facilities
Pre-treatment at this breaded fish and shellfish plant
consists of vibratory screening prior to discharge to the
sewer. However, the solids removed by the screen are
also discharged to the sewer following grinding.
131
-------
APPENDIX B
TYPICAL CALCULATIONS OF PLANT
WASTEWATER PRODUCTIVITY FACTORS
Three similar methods of calculating productivity factors
were used. They depended upon whether or not the plant pro-
vided daily figures on wastewater volumes and production
tonnages, and whether samples of clean-up wastewater only
were taken as well as samples of the total plant effluent.
Method I (used for plants A, D, E, F, K, P, Q, R, U, V, W, Z)
The most commonly used method of calculation was to correlate
the average wastewater characteristics with average waste-
water flow and production data for the sampling period. This
method was used when daily wastewater volume and/or daily
production data was not available. Samples taken were 24
hour composite samples of the total plant effluent.
Sample calculation:
Assume:
average daily wastewater flow = 100,000 gallons
average daily production = 200 tons
average COD concentration from
ten 24-hour composite samples= 5,000 mg/1
Calculation:
wastewater generation = (100,000 gal/200 tons) x 4.173*
= 2,086 (1/kkg product)
productivity factor = (5,000/106) x 2,086 1/kkg
= 10.4 (kg COD/kkg product)
Method II (used for plants J, N, X, Y)
This method is identical to Method I except that separate
samples of clean-up water were taken along with total plant
effluent or process shift samples. Average daily clean-up
wastewater volume and total effluent or process shift waste-
water volumes were available along with average daily pro-
duction data.
Sample calculation:
*1 gal/ton = 4.173 1/kkg
132
-------
Assume:
average daily clean-up wastewater flow = 25,000 gal
average daily process shift wastewater
flow = 50,000 gal
average daily production = 50 tons
average clean-up wastewater COD con-
centration = 3,000 mg/1
average process shift wastewater COD
concentration = 1,000 mg/1
Calculations:
clean-up wastewater generation = (25,000 gal/50 tons) x
4.173*
= 2,08b 1/kkg
process shift wastewater gen. = (50,000 gal/50 tons) x
4.173
= 4,173 1/kkg
total wastewater generation = 2,086 + 4,173 = 6,259
1/kkg
clean-up shift COD produc-
tivity factor = (3,000/106) x 2,086 1/kkg
= 6.3 kg/kkg product
process shift COD producti-
vity factor = (1,000/106) x 4,173 1/kkg
= 4.2 kg/kkg product
total COD productivity factor = 10.5 kg COD/kkg product
Method III (used for plants C, G, I, L, M, 0, S)
This method is based upon daily wastewater volume and pro-
duction information supplied by the plant. From this data,
specific productivity factors and wastewater generation
values for each sampling day can be calculated. Then, for
example, all the individual daily COD productivity factors
can be used to obtain an overall average and a range. Most
samples were 24 hour composite of the total plant effluent.
Sample calculation: (2 days only - most plant were sampled
8 to 10 days)
Assume:
10/9/74 10/10/74
wastewater flow = 30,000 gal wastewater flow = 25,000 gal
production = 15 tons production = 18 tons
COD concen. = 1,200 mg/1 COD concen. = 1,300 mg/1
*Note: 1 gal/ton = 4.173 1/kkg
133
-------
COD production factor
1,306 x 5,796 1/kkg
=7.5 kg/kkg
Average
8.7
7,070
Range
7.5-10.0
5,800-8,350
COD productivity factor =
1,200 x 8,346 1/kkg
100
=10.0 kg/kkg
Results
COD (kg/kkg product)
Wastewater Generation
(1/kkg product)
Miscellaneous
. Plant B
The technique used to calculate wastewater generation and
productivity factors was a combination of Methods II and
III. Daily information was available for both clean-up
and processing shifts. However, in this case significant
production occurred during the "clean-up" shift and
therefore this shift was treated as a second processing
shift. Productivity factors were calculated using ton-
nages produced during each processing shift only rather
than over the whole day as was done with the other plants.
Plant T
Method II was expanded to four different waste streams
rather than just "process" shift and "clean-up" shift.
Separate samples of the total plant effluent, rice opera-
tion wastewater, and rice treatment plant effluent were
taken as well as flow data for each stream. Productivity
factors for each of these streams were used to calculate
similar factors for the category "all plant operations
except the rice production."
134
-------
TECHNICAL REPORT DATA
(I'lcase read Instructions on the reverse before completing)
\. rupom NO.
EPA-660/2-7^-075_
4. TIT L t AN D SU B T I~T LE
2.
WASTEWATER CHARACTERIZATION FOR THE SPECIALTY FOOD
INDUSTRY
3. RECIPIENT'S ACCESSIOf»NO.
5. REPORT DATE
12-74 Date of issue
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Curtis J. Schmidt, Ernest V.
Engineers; John Farquhar
8. PERFORMING ORGANIZATION REPORT NO.
Clements III - SCS
9. PERFORMING ORG \NIZATION NAME AND ADDRESS
American Frozen Food Institute
919 18th Street, N.W.
Washington, D.C. 20006
10. PROGRAM ELEMENT NO.
1BB037
11. CONTRACT/GRANT NO.
R-801684
12. SPONSORING AGENCY NAME AND ADDRESS
Pacific NW Environmental Research Laboratory
National Environmental Research Center
Corvallis, OR 97330
13. TYPE OF REPORT AND PERIOD COVERED
Final report
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The specialty food industry generally falls within SIC Codes 2032, 2035 and 2037
and includes approximately 2,300 plants in the United States which produce a
wide variety of food products. For waste categorization purposes the specialty
food industry was divided into ten categories on the basis of ingredients used,
type of product, and liquid waste generation. Twenty-six nationally distributed
specialty food plants were investigated and 24 of these field sampled for ten
days each to determine raw wastewater characteristics and volume.
Related production and processing information was used to calculate the wastewater
generation per 1,000 kilograms of production in terms of: 5 day Biochemical
Oxygen Demand, Chemical Oxygen Demand, Suspended Solids, Volatile Suspended
Solids, Total Phosphorus, Total Kjeldahl Nitrogen, and Grease and Oil.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Industrial Wastes, Foods, Canneries,
Waste Identification, Waste Treatment
b.IDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Specialty Foods,
Waste Characterization
18. (JISTRIUUTION STATEMENT
Release Unlimited
19. SECURITY CLASS (ThisReport)
1. NO. OF PAGES
134
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22. PRICE
EPA Form 2220-1 (9-73)
V U.S. GOVERNMENT PRINTING OFFICE: 1975-697-£02/73 REGION io
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