Organic Wastewater Treatment
Meeting environmental compliance by treating wastewater for solids, organic load, fats, and grease.
Project overview
Client: Dessert Factory - Mellow
Location: Villers-le-Bouillet, Belgium
Industry: Food Production (Premium Cheesecakes)
Key results
Regulatory Compliance
Wastewater discharge parameters now strictly meet environmental permit thresholds.
Tax Reduction
Significant decrease in wastewater taxes due to a cleaner effluent discharge into the sewer.
Operational Reliability
Implementation of a self-cleaning filtration system protecting critical downstream equipment.
The challenge
Maintaining discharge parameters in compliance with environmental permits while reducing high pollution taxes.
Mellow, a producer of premium cheesecakes, faced a double challenge: their wastewater exceeded legal thresholds for organic load and grease, and their discharge taxes were rising. They needed a solution that could handle high-fat effluents without halting production. Furthermore, the existing infrastructure required a system that could protect sensitive pumps from organic fibres and plastic fragments inherent in the production environment.
What Revalio delivered
Revalio, in collaboration with Process Water Services (PWS), designed and installed a customised, high-performance treatment unit. The solution focused on circularity by repurposing existing assets:
Tank Conversion: An existing 25 m³ underground concrete tank was partitioned and upgraded with aerators to serve as a homogenization and sludge storage unit.
Self-Cleaning Filtration: To minimise daily maintenance, a second-hand, stainless steel automatic self-cleaning filter (HSB-J Series) was installed. This unit intercepts particles up to 3mm, protecting the recirculation pumps and the DAF unit.
Containerised DAF Unit: A compact Dissolved Air Flotation (DAF) unit was housed in a dedicated, frost-protected, and ventilated container.
Optimised Chemistry: A precise combination of coagulation, flocculation, and pH correction was implemented based on thorough effluent analysis.
“Revalio took the time to understand our production constraints and designed a solution perfectly tailored to our site. It wasn’t a standard installation, but a truly custom-built project.” — Virginie Marlière, QHSE Manager, Mellow
How the treatment works
The system utilises a multi-stage process designed for maximum grease and solid removal:
Primary Filtration: The automatic filter uses an integrated scraping system to continuously remove solids, which are then purged automatically to the sludge tank.
Chemical Pre-treatment: Automated dosing of coagulants and flocculants binds contaminants together, while lime milk adjusts the pH levels.
Dissolved Air Flotation (DAF): Microscopic air bubbles are injected into the effluent, attaching to the flocculated grease and solids. This carries them to the surface with 90% efficiency, where they are skimmed off as sludge.
Resource Integration: Existing dosing pumps and chemical stocks were integrated into the new control system to maximise previous investments and reduce waste.
*Figure1. Process Flow Infographic - Visual diagram showing wastewater journey from production floor through two-chamber system and DAF unit to compliant discharge
“This project perfectly illustrates what we love to do: listen, adapt, and deliver a reliable solution that makes our client’s life easier. We worked hand in hand with Mellow all the way through to commissioning.” — Arnaud de Lhoneux, COO, Revalio
Results
✓ Full environmental compliance, permit thresholds met
✓ Significant tax Ssvings
✓ 90% grease removal efficiency
✓ Minimal maintenance
✓ Zero production disruption
Facing Similar Challenges?
Whether you're facing a permit renewal, a compliance notice, or simply know your wastewater treatment isn't where it needs to be, Revalio can help you find the right solution without disrupting your operations. Get in touch with our team: