Food Processing

Food production in New Zealand steadily increases each year with data suggesting there is capacity to grow even further. The seafood, produce and processed food sectors have seen tremendous growth in the last decade as New Zealand is solidified as a high quality global food exporter.

There are several types of food processing activities conducted in New Zealand, each of which are very different from one another. The production and processing of so many different products creates a truly unique water challenge, where no two treatment plants are the same. The Hydroflux team has installed hundreds of treatment plants for a range of different food manufacturing facilities.

Hydroflux has a comprehensive portfolio of wastewater treatment equipment and designs to suit any food processing facilities and will always consider the most appropriate solution based on CAPEX and OPEX. We will undertake complete design and construct contracts most of which utilise our own proprietary products such as HyDAF dissolved air flotation systems, chemical treatment, screens, sludge handling equipment and a full range of anaerobic and aerobic biological systems.

Hydroflux Industrial also has extensive experience in the design and construction of hygienic process water systems.

A wastewater treatment plant for a major food producer in QLD comprising HyDAF dissolved air flotation systems, chemical storage and handling, MBBR and sludge dewatering

Whether you are discharging to trade waste, the environment or wish to recycle wastewater for non-potable or potable reuse, you can be assured that Hydroflux will design and construct a wastewater treatment suited specifically to your needs.

• Bakeries

• Small goods

• Meat and poultry

• Rendering

• Edible oils and grains

• Plant based manufacturing

• Fruit and vegetables

• Potato and chips

• Beverages

• Prepared food

• Ingredients and spices

• Fish processing

Find out more

Trade waste plants in most food processing activities will typically incorporate screening followed by balancing, a form of chemical conditioning and a HyDAF system. This process will generally enable compliance with the local councils or water authorities trade waste discharge requirements.

Hydroflux will always consider each project on its own merits taking into account performance requirements, CAPEX and OPEX. We use process equipment and designs mostly sourced from our own proprietary range including the HyDAF system and will undertake turnkey design and construct contracts.

General process concept for treatment of wastewater discharging to sewer for food processing plants

The performance of a food processing trade waste plant is highly dependent on the chemical program applied upstream of the DAF systems. Hydroflux will always design the system with an appropriate chemical program to suit the desired degree of treatment taking into consideration the cost of chemcials, handling of chemicals, and sludge production.

Wastewater

Biological treatment

Sludge

Process water treatment

Advanced Water

Dissolved air flotation is the most common means of treating wastewater from food production facilities and Hydroflux has a comprehensive range of HyDAF systems to suit any food processing application.

All Hydroflux DAF systems are sized using a proven inhouse engineering tool that ensures that the DAF system selected is optimised based on flow and solids load. Hydroflux also has various designs that automatically remove settled solids from the base of the DAF system to minimise maintenance requirements.

A treatment plant comprising balancing and DAF at a food processing facility in Sydney

The capacity of the balancing facilities, the size and configuration of the DAF, and the chemical program applied to the wastewater will always depend on type of processing facility and the discharge water quality required, which varies considerably around the regions.

Hydroflux has a comprehensive range of dissolved air flotation models ranging in capacity from 10 kL/hr to 1000 kL/hr to suit any primary or further poultry processing application. The HyDAF dissolved air flotation units are configured with several options to accommodate automated removal of settled sludge and cleaning.

Treatable flow range(KL/Hr)*	Type
Treatable flow range(KL/Hr)*	HyDAF HD	HyDAF HD-V	FlooDAF
5 – 15	HD10
15 – 25	HD20
35 – 40	HD35
40 – 60	HD50	HD50V
65 – 140	HD75	HD75V
150 – 250	HD100	HD100V
275 – 325	HD200	HD200V
365 – 425			FlooDAF49
500 – 625			FlooDAF65
650 – 750			FlooDAF115
800 – 990			FlooDAF149

*typical capacities for industrial wastewaster. Consult Hydroflux Industrial for detailed sizing.

If the wastewater is being discharged to the environment, being reused, or the trade waste discharge limits are beyond the limitations of physical and chemical treatment, an aerobic biological process is required to remove organics and nutrients to suitable levels. Depending on the space available and required output, Hydroflux will design the most suitable solution from its portfolio including SBR, MBR, MBBR and activated sludge processes based on tank or pond structures.

Anaerobic treatment in the form of high rate or covered anaerobic ponds can also offer effective and sustainable solutions for large COD loads by converting COD into reusable biogas. Hydroflux has experience in the design and construction of anaerobic ponds and high-rate space saving anaerobic systems.

Hydroflux MBBR processes are highly effective in treating wastewater from food processing plant

Hydroflux has expertise in all aerobic and anaerobic biological processes and will design the most appropriate system in each case which typically depends on the required performance and available space.

Hydroflux will calculate the volume of sludge that is generated based on wastewater flow, solids load, and chemical program employed, and will evaluate sludge handling as a separate project on its own merit. In cases where sludge dewatering is viable, Hydroflux will select the most appropriate dewatering system from its extensive range of dewatering products including screw presses, centrifuges, filter presses and belt presses.

A screw press was selected for dewatering DAF sludge from a poultry facility which reduced the volume of sludge by more than 10-fold.

There are many factors that are used to determine the viability of onsite sludge dewatering including:

Wastewater flow,
Incoming solids load
Level of treatment applied
Chemical programs used

Dewatering equipment used
Achievable dry solids concentration and volumes
Costs and disposal routes of slurries and dewatered cake
Liquid and solids handling methods

New Zealand’s food industry have long been leaders in the sustainable management of water, pioneering the implementation of advanced water to the strictest of hygiene standards for reuse in direct contact with birds. The industry has also significantly reduced its water footprint, driving efficiencies to reduce water consumption. Hydroflux Group’s engineers and consultants who pioneered advanced water for the food industry over a decade ago are continuing to lead the efficiency drive of the food industry with advanced solutions tailored to minimise energy consumption and waste.

Hydroflux Solutions

Hydroflux have a range of proven, highly efficient process and advanced water solutions for the poultry industry, including:

Bore water treatment systems
Surface water treatment systems
Media Filtration & Activated carbon filtration
UV sterilisation

Ultrafiltration
Reverse Osmosis
Softening/Ion Exchange
Electrodeionization

Advanced Water Treatment is the treatment of wastewater for direct potable use. Hydroflux engineers pioneered Advanced Water Treatment in the poultry industry in the early 2000’s. Hydroflux continues to be at the forefront of Advanced Water Treatment and recycling technology and are investing in research into the treatment and recovery of salts so that in the future, and in particular, rural facilities and their communities will reap the benefits of Advanced Water Treatment.

Although an AWTP utilises a series of conventional wastewater and water treatment technologies such as Ultra Filtration , Reverse Osmosis and disinfection that can be applied down stream of a n aerobic biological plant, the main features of an AWTP are the implementation of 1), a multibarrier approach and 2), establishing a suitable and acceptable risk management plan.

The diagram below shows the relationship of framework elements for a recycled water management system that Hydroflux can provide including the design, construction and operation of the AWTP.

Source: NSW Guidance for Recycled Water Management systems – Department of Primary Industries Office of Water. May 2015

The processes required to embark on an AWTP project are not insignificant so working with a company that has a proven track record is essential. As well as having the experience and skills to design and construct an Advanced Water Treatment Plant, Hydroflux will also work with you to develop the risk management plan and obtain approvals from all stake holders prior to construction.

Hydroflux HyPURE RO systems are n integral components of an Advanced Water Treatment Plant

Design and construct solutions for Process and Advanced Water Treatment

As a specialist water treatment and wastewater specialist, our team are uniquely placed to offer complete support for all water services. We understand how process water management impacts on wastewater costs and vice versa. Procurement of water and wastewater projects through a single contractor offers customers significant benefits in terms of management of process risk, as well as cost savings in project delivery, through consolidated design, project management, site supervision and commissioning.

A 250kLD process water treatment plant constructed by Hydroflux incorporating a HyPURE MMF and RO systems

Hydroflux employs qualified civil, mechanical, chemical and electrical engineers plus a team of experienced project managers, site supervisors, commissioning engineers and service technicians based in offices in most capital cities providing a local presence throughout the duration of the project.

All projects are conducted under externally approved occupational health and safety, and environmental management systems.

Hydroflux is Australia’s first Water-tech company to achieve Climate Active certifications which means his means you are engaging with a carbon neutral organisation without increasing your carbon footprint and you are supporting positive and verified action on climate change.

Construction of a turnkey wastewater treatment plant at a new food production facility in SA.

Hydroflux can complete all the following works in-house which are typically required to construct a wastewater treatment plant.

Process design, development of PID’s and HAZOPS reviews
Establishment of the most suitable wastewater treatment plant layout
Equipment and component selection
Civil and building designs including preparation of documentation for council or other regulators
Electrical design and programming
Project management and site supervision
Environmental / Occupational health and safety plans and report
Quality assurance plans
Earthworks, civil works, building works, mechanical and electrical installation
Commissioning, training and documentation as required.

Stainless steel panel tanks are often used for aeration tanks.

Hydroflux Utilities provides virtually any form of wastewater management programs including:

Chemical optimisation

Hydroflux has a comprehensive range of coagulants, antiscalants, acids/alkalis, oxidizing/reducing agents and other chemicals suitable for conditioning process water feed prior to and after treatment. We also offer a range of proprietary cleaning and sanitizing agents. Our chemists work hand in hand with the project delivery team to develop the most appropriate chemical program tailored specifically to individual sites needs.

Preventative maintenance and service

Our engineers and technicians will discuss service and maintenance programs with you during construction of the treatment plant so that you can be assured that the system will perform consistently from day one. There are many types of programs available from routine preventative maintenance, periodic

service and overhauls, to complete plant operation. Our technicians are available 24/7 to attend to unforeseen breakdowns.

Biological plant modelling

Hydroflux designs, operates and maintains biological wastewater treatment plants and we are familiar with the many causes of failure and malfunction. Via routine site attendance or online remote monitoring of the biological operating parameters, Hydroflux engineers can predict potential process issues to minimise any impact on the performance of the plant or prevent even problems from happening.

Remote monitoring

Our proprietary HyCONNECT™ remote monitoring system is installed in all our process water plants as standard, enabling instant online technical support and troubleshooting. Specialty solutions are offered for remote locations with reduced cell coverage. No matter where you are, our team of specialists are never more than a phone call away.