In the food and beverage manufacturing industry, water is an important resource. In a search for sustainable practices, water reclaim for product contact is a viable solution. This practice has historically been considered a bit taboo, given the psychological hurdle of using reclaimed water for product contact. However, when processed properly, this water quality can exceed typical incoming tap water. This blog explores how water reclaim for product contact works, the benefits, and a case study of reclaim in action.
Water Reclaim for Product Contact
In this context, reclaimed water is effluent from a wastewater treatment plant—what would normally be discharged back into the environment after treatment. This reclaimed wastewater is filtered and treated so it can be reused in the facility instead of discharged. This is not a new practice; for years, facilities have used reclaimed water for landscape irrigation, utilities, and other non-product contact uses.
For a manufacturing facility to expand its water reuse, it should include product contact. This is water for equipment and processes that may incidentally (or directly) contact the product. Reclaimed water for product contact requires a more intensive process to meet standards for reuse. This includes running wastewater through an ultrafilter (UF) to remove up to 90% of contaminants. Then the water is processed through a reverse osmosis (RO) filter to sterilize and remove contaminants down to the monovalent ion level. Finally, this clean water stream is treated with disinfection chemicals and an ultraviolet (UV) sterilizer. Further adjustments can be made for the end-use application. For example, adding food-grade salts or sodium hydroxide for pH adjustment can more closely match the water profile to tap water.
Quality is critical for product contact. The water must be tested and continually monitored. If it meets the requirements for product contact, it is pumped to the necessary locations in the plant for appropriate use. If it does not meet standards, water quality must be adjusted and any system failure corrected. Once the water is useable, it’s piped around the plant for use in systems like clean-in-place (CIP), line pushouts, and bottle rinsing. Used water then returns to the wastewater facility, starting the process over and achieving use reduction.
Benefits of Water Reclaim
- Environmental Impact: Reclaiming water significantly reduces the demand for fresh water. It also minimizes wastewater discharge, reducing the facility’s environmental footprint.
- Cost Savings: While the treatment system requires a high operation and maintenance (O&M) investment, depending on local water quality this can be similar to treatment needs and costs for raw water. Depending on local water rates, it could potentially lower the overall cost of plant water usage.
- Resiliency: In a world with less-than-predictable resource availability, reducing the reliance on raw materials can be important for business resilience.
- Regulatory Compliance: Many regions have heavy regulations on water usage and discharge, as well as fees associated with discharging. These regulations and costs can be avoided by reusing plant water.
Case Study
A large national brewery was looking to save water and meet its sustainability goals. Given the high water requirements and existing onsite wastewater treatment facilities, two plants were good candidates for reuse in product-contact applications. Previously, wastewater was treated and discharged directly into nearby rivers. During the design phase, Mead & Hunt identified significant reuse opportunities at the breweries. With the new water treatment equipment in place, the breweries now produce up to 400 gallons per minute of high-quality reclaimed water. The combined savings at the two sites total over 240 million gallons of annual water savings. Each site reuses the reclaimed water for various product contact purposes like washing bottles before they are filled and packaged.
Conclusion
Water reclaim for product contact in food manufacturing facilities can be a sustainable practice that offers many benefits. While using wastewater for product contact may not sound appealing at first, this practice is safe and can help your plant save finite environmental resources and money. By incorporating water reclaim into process improvements and sustainability goals, food manufacturers can contribute to a more sustainable and resilient future while maintaining high standards of product quality and safety.
