Dairy processors utilize a tremendous amount of water, from intake through the creation of utility water, and the treatment of effluent prior to discharge or reuse.

Many processors are taking advantage of their own waste stream by generating their own biogas. Creating power to maintain on-site systems saves energy costs and contributes to sustainability goals.

Biogas is generated using anaerobic digestion. Xylem provides many variations of anaerobic digestion solutions which are designed specifically to the treatment goals of each customer. The generated biogas can either be used directly by the customer or can be upgraded to Renewable Natural Gas (RNG) and injected into the energy grid.

High-strength biological wastewater must be treated whether biogas is generated or not. Methodologies can include anaerobic digestion, aerobic treatment, or other types of treatment processes. Xylem provides solutions for all of these choices. Effluent is treated to meet stringent treatment goals in which the effluent will meet the local requirements for discharge.

Currently, Xylem is working with a municipal customer in the western U.S. who has seven local food processors, including dairy, all discharging their organic wastewater to a central treatment plant. This treatment plant is separate from the local plant treating residential wastewater, and was created for the purpose of generating biogas and renewable natural gas.

Xylem controls the water movement and treatment throughout the facility, and supplied the technologies that support the effort. Included in the design-build project are two 35M Bulk Volume Fermenter (BVF) reactors, aeration treatment, screening systems, boilers, pumps, control valves and a flare, all supplied by Xylem.

A cheese processor in the eastern U.S. is utilizing Xylem’s design-build capabilities for its wastewater treatment. Their system includes a 14 M BVF reactor as well as aeration treatment, chemical systems, and pumping. The effluent is treated to standards high enough to discharge directly into a local waterway.

Although biogas generation and RNG help customers meet their sustainability goals, Xylem can help meet those goals in other ways as well. Utilizing tertiary treatment such as ultrafiltration, nanofiltration, reverse osmosis, disinfection, and even membrane bioreactor technologies we help customers recycle and reuse water, reducing the demand of fresh water in the facility.

Xylem provides treatment solutions for every processing step starting with water intake. From self-cleaning screening systems treating raw water to carbon or resin systems that remove minerals or mitigate taste or odor issues. Water may then pass through softeners or continuous electrodeionization systems, also supplied and serviced by Xylem.

For ingredient-quality water and water for production a processor will need one or several types of treatment, possibly including chemical dosing systems. Chemical dosing isn’t just for disinfection – though it’s used for that, too – but for adding flavors, vitamins, extracts, and more. Ingredient water must be disinfected and is passed through an effective UV disinfection system. Water to be used in production must often be treated for particulates or total suspended solids of any size. For that a dairy processor would incorporate one of several systems for this purpose including microfiltration, nanofiltration, ultrafiltration, and potentially reverse osmosis to facilitate water reuse. Xylem can design, build, and operate a comprehensive treatment system for recycling and reuse. For facilities large enough to produce its own power it’s imperative to have plenty of deionized water on hand for boilers, cooling towers, and other mechanicals. Xylem’s reverse osmosis and deionization systems contribute to the pure water necessary to keep mechanicals running smoothly without scaling or buildup.

Many dairy or other types of food processors incorporate laboratories in their capabilities whether for testing or other types of research. Laboratory water must not only be treated differently but must also be delivered differently. To produce ultrapure water (Type I, Type II, Type III) Xylem supplies various countertop systems for ease of use in a lab setting. Research scientists can also use vessels loaded with application-specific media, connected to water right inside the lab. Xylem also provides many types of sensors and meters that measure water quality.

If these solutions sound complex relative to a dairy or other food processing facility that’s because these systems can become very complex and very specialized. Each system is designed specifically to a customer’s application and treatment goals. That’s why Xylem provides end-to-end services in support of these systems, including engineering and construction services when necessary. From initial system design to installation, commissioning, and ongoing service Xylem can focus on the water allowing the dairy processor to focus on the product. Ongoing service in support of a customer can include system uptime services such as water audits, system troubleshooting,g and deliveries such as deionized water, which can be delivered on-demand or on schedule, media changeouts, and onsite or offsite membrane cleaning.

Xylem provides effective solutions for water movement, measurement and treatment with an emphasis on sustainability through water reuse, biogas generation and potential upgrades to RNG.