How Dual-Stage DAF Treatment Revolutionizes Wastewater Management in Bakeries
- 1 day ago
- 2 min read
A leading industrial bakery—producer of popular cookies and crackers found in homes across the country—faced a familiar challenge: although its operations generated relatively low volumes of wastewater, the organic ingredients present in washdown flows drove high levels of TSS, FOG, COD, and BOD. These constituents threatened compliance with discharge limits and increased disposal costs, prompting the facility to seek a more efficient and reliable treatment solution.
FRC Systems provided a robust, two‑stage dissolved air flotation (DAF) solution designed to maximize solids recovery, minimize sludge production, and confidently meet discharge permit requirements.
Process Flow:
A Two‑Stage Approach for High‑Strength Bakery Wastewater
The bakery’s production processes—particularly rinsing and sanitizing mixers, kettles, and work areas—introduce organic particulate and colloidal matter into the wastewater stream. While the daily flow rate remains modest at 36,000 GPD, influent concentrations present real challenges:
TSS: 1,200 mg/L
FOG: 1,200 mg/L
COD: 4,400 mg/L
BOD: 3,300 mg/L
pH: 6–9
To handle these high-strength characteristics, FRC Systems delivered a dual‑DAF configuration engineered for sequential solids removal.
Stage 1: Chemical‑Free Solids Recovery
The first DAF unit operates without chemical addition to capture heavier suspended organic materials. Removing these solids early reduces the organic loading on the second stage and dramatically lowers chemical consumption downstream.
This stage enables the facility to:
Recover valuable suspended organics
Reduce sludge generation volumes
Lower OPEX by limiting chemical usage in later treatment steps
Stage 2: Enhanced Clarification for Compliance
The second DAF system applies optimized chemical conditioning to target colloidal materials that are difficult to float without polymer or coagulant aid. This ensures the facility meets its discharge limits of <100 mg/L TSS and <100 mg/L FOG, supporting environmentally responsible and permit‑compliant operation.
System Components Delivered
FRC Systems supplied a complete, integrated treatment train, including:
(2) PCL‑3 DAF units
(2) F‑2 Flocculators
Chemical dosing panels
Pneumatic controls
Maintenance catwalk
Raw water tank, sludge handling, and recovered product pathways
This turnkey approach ensures efficient installation, streamlined operation, and long‑term reliability.
DAF Sizing & Performance Engineering
The design incorporates careful hydraulic and solids loading calculations to determine the appropriate flotation area. The case study outlines:
Hydraulic loading rate: Based on feed + recycle flows
Solids loading rate: Derived from influent TSS mass flow
Surface area requirements:
39 ft² for hydraulic loading
7 ft² for solids loading
These engineering guidelines ensure each DAF unit can manage peak loads while maintaining optimal flotation conditions.
A Complete Treatment Pathway
The bakery now benefits from a fully integrated process:
Raw water collection
Chemical dosing (as required in stage 2)
Flocculation for colloidal destabilization
DAF 1 – Primary solids recovery (no chemicals)
DAF 2 – Final polishing with chemical aid
Recovered product capture
Sludge dewatering
Discharge to sewer in compliance with permit limits
This engineered sequence minimizes waste, reduces disposal costs, and ensures dependable regulatory compliance.
Reliable, Scalable Treatment for the Food & Beverage Sector
For bakeries and other food manufacturers, wastewater streams often contain high-strength organic loads that can overwhelm traditional treatment processes. FRC’s dual‑stage DAF approach provides:
Superior solids and FOG removal
Reduced sludge volume
Lower chemical costs
Streamlined operations and maintenance
A proven path to permit compliance
This case study demonstrates how thoughtful engineering and the right combination of technologies can transform wastewater from a compliance challenge into a stable, predictable part of plant operations.
Comments