Real-Time Effluent Monitoring Reduces Product Loss and COD Spikes for Dairy Processing Facility

Challenges Faced by Dairy Processing Plants

Like many dairy processing facilities, the customer faced significant challenges in minimizing product loss, especially during routine cleaning cycles and maintenance. Small changes in process conditions or human error could inadvertently send valuable products to the wastewater stream. This not only resulted in lost revenue but also increased the Chemical Oxygen Demand (COD) in the effluent, which could lead to compliance issues and higher charges from local municipalities for exceeding discharge limits.

A Real-Time Effluent Monitoring Solution

To address these challenges, facilities managers turned to innovative technology from BlueEdge™ by Badger Meter to monitor effluent quality in real time. The company implemented the spectro::lyser Industrial ATEX, a submersible UV-Vis spectrophotometer capable of measuring the absorption "fingerprint" of wastewater and converting it into real-time COD values. This enabled them to continuously monitor the contributions of various process streams (such as whole milk, skimmed milk, and cream) to the effluent, giving them valuable insights into where product loss occurred.

Additionally, they integrated the moni::tool event detection system, which uses advanced algorithms to automatically detect and alert operators to abnormal changes in the effluent composition. By analyzing data from different process streams, the system could differentiate between effluent types, helping to pinpoint the source of excess waste and optimize product retention.

Results & Impact

The implementation of the spectro::lyser and moni::tool systems delivered several key benefits including:

• Reduced Product Loss: By monitoring the effluent in real-time, the customer was able to identify and address waste streams quickly, reducing the volume of product lost to the wastewater treatment plant and increasing the amount of sellable product.
• Lowered Operating Costs: Continuous monitoring and event alerts facilitated immediate corrective action, reducing waste and minimizing costly fines related to COD non-compliance.
• Maintained Regulatory Compliance: The real-time data helped the processing facility stay within local discharge standards, avoiding penalties and improving environmental performance.
• Quick ROI: The advanced monitoring systems provided a rapid return on investment, proving their effectiveness in reducing costs and increasing operational efficiency.

Conclusion

Real-time effluent monitoring technology provides the insights needed to maintain operational efficiency and environmental compliance. With the spectro::lyser and moni::tool systems in place, the customer now has the data visibility to reduce product loss, minimize operating costs, and avoid costly fines, all while maintaining sustainable dairy processing practices. This technology empowers dairy producers to make informed decisions that drive both profitability and sustainability in their operations.