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Projects

Meat Packaging Plant Wastewater Pretreatment Upgrade

Upgrades to achieve permit compliance and reduce city surcharge fees.
  • Wastewater pretreatment plant exterior–Gannett Fleming

    Gannett Fleming improved the client’s wastewater treatment system operational procedures for more consistent discharges and reduced costs.

  • Wastewater treatment system improvements–Gannett Fleming

    The upgraded system design addressed excessive FOG discharge and reduced high BOD levels.

Client
Confidential Client
Location
St. Joseph, Missouri
Our Role
Design-Build, Engineering Design, Construction Design, Design Support.
Data
Size:
550,000 gpd
Construction Cost:
$3.9 million
Completed:
2014
Type:
New Construction
Duration:
2 years
Outcomes
  • Managed high fats, oil, and grease (FOG) levels during facilities design
  • Saved hundreds of thousands of dollars by negotiating fees with the local municipality
  • Built the system to meet effluent requirements and reduce sewer discharge fees.

The client owns and operates a meat packaging plant that produces a variety of products. The facility generates several sources of process wastewater as a consequence of the production process, including Clean-In-Place (CIP) operations, waste residuals to floor drains, and general wash-downs. The wastewater contains high concentrations of FOG, biochemical oxygen demand (BOD), and total suspended solids (TSS). Our firm needed to design an upgraded wastewater treatment system (WWTS) that would address excessive FOG discharged to the city’s collection system from a compliance standpoint, as well as reduce the high levels of BOD that were causing the client to incur high surcharge fees.

To achieve the client’s goals, the upgraded system collects wastewater at a grinder lift station that receives wastewater from the Main Plant and North Plant via two separate sewers. Flow from the lift station is pumped to an elevated (mezzanine-level) rotary screen designed to remove solid materials from the flow before discharge to the equalization and physical-chemical (DAF) treatment system. Residuals are managed with two sludge storage tanks for disposal.

What We Did

Gannett Fleming Project Development Corporation, a subsidiary of Gannett Fleming Affiliates, developed a compliance plan in consultation with the client and the local municipality using a phased approach. Of immediate concern was excessive discharge of FOG, which needed to be captured prior to discharge to the city. Our firm implemented a fast-track design and mobilization to construct a temporary system to provide immediate relief to stakeholders. This interim measure allowed the project team to further evaluate and design the improvements and then, using design-build delivery, implement the phase 2 construction, start-up, and commissioning of the new WWTS upgrades.

Key Features

  • Improved WWTS operational procedures for more consistent discharges and reduced costs
  • Reduced BOD concentrations, thereby reducing surcharge fees to the client
  • Improved the client’s cost position with the city by challenging sampling and testing protocols and negotiating changes that resulted in more favorable results to the client
  • Resolved city-related discharge permit issues associated with FOG.

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