Ice Cream Producer Minimizes Its Waste to Maximize Its Bottom Line

Being one of the most well-known producers of customer-labeled ice cream and novelty products in the United States may sound great, but along with this prestigious distinction comes the challenges related to running numerous production lines with multiple product changeovers driven by seasonal variations in demand. As you can guess, waste minimization and wastewater treatment are bottom-line issues that receive significant attention from plant personnel.

ATI first became involved with this organization through its predecessor company, when we evaluated its hybrid anaerobic treatment system that was not performing as designed. ATI also aided in the development of a waste minimization program. Out of this assignment came a recommendation to upgrade the existing dissolved air flotation pretreatment system and convert the existing hybrid anaerobic system to an upflow anaerobic sludge blanket (UASB) system. The new system was designed to utilize the existing welded steel reactor and a number of the existing pumping and piping systems, thus minimizing the capital expenditures for the project.

To make the project successful, ATI developed and released a turnkey anaerobic process bid package to prequalified suppliers of UASB technology. Construction was completed in April 2004. Since then, COD removals have averaged about 93%.  This has greatly reduced, or in some months eliminated, the company’s BOD surcharges to the City sewer. With its wastewater issues under control, the company can now concentrate on continuing its legacy as a leader in the ice cream and novelty products industry!