Arla Foods optimizes water treatment, achieving major savings

Introduction

In March 2021, Alumichem began a collaboration with Arla Foods in Hobro to optimize the company’s belt filter system for treating process water. The optimization project not only solved issues with the system’s load but also resulted in significant financial savings.

The Challenge

Changes in production at Arla Foods in Hobro led to an increased load on the belt filter system, resulting in reduced water quality and overloading of the local treatment plant. Mariagerfjord Vand, which receives wastewater from Arla, experienced periods of organic load up to 125,000 PE, even though
the facility is built to handle only 75,000 PE. This situation created the need for a comprehensive optimization to ensure both economic savings and sustainable operations.

Alumichem’s Solution

Alumichem stepped in in March 2021 and initiated a series of tests to improve the chemical treatment process of the wastewater. The existing belt filter system was upgraded by replacing hydrochloric acid with AluPAC as a coagulant and introducing a new type of polymer to optimize the flocculation process. This adjustment ensured more efficient removal of organic material from the process water and stabilized the treatment plant

Results

The results of the optimization were significant. Arla Foods in Hobro achieved an annual savings of approximately DKK 1,000,000 by avoiding the surcharge for overloading. Mariagerfjord Vand now receives more consistent and lower organic loads, which their plant has the capacity to handle. At the same time, the improved water quality and stability of the plant have reduced the need for further optimization measures, freeing up resources for other energy-saving initiatives. With over 40 years of experience in process optimization, Alumichem has provided Arla Foods with a sustainable solution that contributes positively to both the company’s economic and environmental future