Project overview
Client: Dessert Factory - Mellow
Location: Villers-le-Bouillet, Belgium
Industry: Food Production (Premium Cheesecakes)
Completion date: September 2025
Key results
Full environmental compliance achieved
Wastewater emissions now meet all regulatory thresholds.
Sustainable
operations
Automated system ensures consistent treatment quality.
Future-proof
solution
Scalable infrastructure supports business growth.
The challenge
Mellow, a thriving cheesecake manufacturer in Villers-le-Bouillet, faced a critical operational challenge: their wastewater exceeded the pollution thresholds specified in their environmental permit. As a food production facility, their effluent contained organic matter and other substances that required proper treatment before discharge.
The situation required:
Immediate compliance with environmental regulations
A solution that wouldn't disrupt daily production
A system that could handle the specific characteristics of food production wastewater
Our solution
Revalio designed and installed a comprehensive wastewater treatment system centered around a DAF (Dissolved Air Flotation) unit, which uses advanced coagulation-neutralization-flocculation-flottation processes to clean the effluent.
“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
System architecture
Primary components:
Conversion of existing 25 m³ (cuve divisée en deux compartiments : 5 m³ pour homogénéisation, 20 m³ pour stockage des boues) underground concrete tank into a two-chamber system
Automated pumping from the first chamber to the flotation unit
DAF unit housed in a compact container for easy maintenance
Sludge discharge system to the second chamber
The treatment process removes contaminants through:
Coagulation and neutralization of particles
Flocculation to bind contaminants
Flotation to separate clean water from waste solids
Figure1. Process Flow Infographic - Visual diagram showing wastewater journey from production floor through two-chamber system and DAF unit to compliant discharge
Implementation
Our team completed a comprehensive electrical integration to ensure all system components work seamlessly:
Equipment installed:
Feed pump
Dissolved air flotation unit (reaction and flotation chamber)
Flocculent preparation and maturation tank
Automated coagulant, neutralizer, and flocculant dosing systems
Sludge transfer tank
Odor control HVAC systems
Miscellaneous instrumentation
All connections were integrated into the existing electrical panel, minimizing infrastructure changes and installation time.
“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
Technical deep dive
For the Geeks
Tank configuration
The project began with the physical modification of Mellow's existing infrastructure. We partnered with Majinox to divide the 25 m³ (cuve divisée en deux compartiments : 5 m³ pour homogénéisation, 20 m³ pour stockage des boues) underground concrete tank into two separate chambers, creating an efficient pre-treatment and post-treatment system without the need for additional excavation or construction.
DAF technology
The Dissolved Air Flotation unit operates by saturating water with air under pressure. When released into the treatment chamber, microscopic bubbles attach to suspended particles and contaminants, causing them to float to the surface where they're skimmed off as sludge. This process is particularly effective for food industry wastewater, which contains fats, oils, and organic matter.
Electrical integration details
Each component was carefully specified for the demands of continuous industrial operation:
Feed pump: Maintains consistent flow rate through the treatment system
Thermal tracer: Prevents freezing in winter conditions, ensuring year-round operation
Heat pump: Optimizes treatment efficiency by maintaining ideal process temperatures
Ventilation: Manages odors and ensures safe working conditions
Sludge pump: Automatically transfers waste solids to the secondary chamber
The system was designed with failure safe to ensure continuous operation without manual intervention.
The treatment unit is entirely managed remotely by Revalio through the "Easyaccess" platform.
Containerized solution
Housing the DAF unit in a dedicated container provides several advantages:
Weather protection for sensitive equipment
Easy access for maintenance
Sound dampening for quieter operation
Future expandability if production increases
The impact
Mellow can now focus on what they do best: creating exceptional cheesecakes. They gained complete confidence that their environmental obligations are met automatically and consistently.
Benefits realized:
Regulatory compliance: Full adherence to environmental permit requirements
Operational continuity: No disruption to production during installation
Automated operation: Minimal staff intervention required
Scalability: The System can accommodate future production increases
Peace of mind: Real-time monitoring ensures consistent performance
Project metrics
System Type: DAF (Dissolved Air Flotation)
Treatment Capacity: 1 m³/hour for high-capacity FOG (Fats, Oils, and Grease) treatment
Commissioning: September 2025
Electrical Connections: 6 dedicated circuits
Facing Similar Challenges?
If your food production facility is dealing with wastewater compliance issues or environmental permit requirements, we're here to help. Revalio specializes in practical, efficient solutions that keep your operations running smoothly while meeting all regulatory standards. Get in touch with our team: