Sludge Dewatering for Frozen Foods

A PLANT IN SOUTHERN CALIFORNIA produces frozen Tex-Mex-style cuisine. Their team aimed to reduce sludge hauling costs and associated emissions, which led to an evaluation of their wastewater treatment chemistry.

THE PROBLEM:‍

The plant’s influent had high solids and large swings in temperature and pH. Incumbent chemistry formed weak, inconsistent flocs that couldn’t be dewatered by the screw press, forcing disposal of wet, untreated sludge. Meanwhile, the client aimed to cut Scope 3 emissions and found sludge transport was a key contributor—making wastewater optimization a clear business case.

THE APPROACH:

We tested a range of products to optimize treatment performance, reliability, and sludge disposal costs and emissions:

• SimplePrime: Coagulant used prior to DAF system to destabilize colloids and improve effluent clarity, enhancing flocculation.
• SimpleFloc Gel: A no make-down product applied prior to DAF system to form stronger flocs, reducing TSS and improving water clarity.
• SimpleFloc Emulsion: Specifically chosen for screw press dewatering, this flocculant reduced sludge volume by 75%.

RESULTS:‍

The switch to SimplePrime and SimpleFloc had an immediate impact on the water, the P&L, and the plant’s scope 3 emissions:

• Sludge volume reduction: 75%
• Operational savings: $800,000 saved annually by reducing sludge haul-off costs.
• Enhanced operational efficiency: Reduced down-time and associated labor
• Reduced Scope 3 emissions: Transportation-related emissions from sludge haul-off

The CarboNet field team also recognized the challenge operators were facing with the screw press. Once the chemistry was in place to ensure the equipment could be used effectively, they worked with plant staff to ensure operators felt confident—providing a dosing & troubleshooting guide along with Standard Operating Procedure (SOP) documentation.

“The savings are impressive, but what really stood out with CarboNet was their attention to detail. They helped us tailor the chemistry to our unique challenges, delivering reliable performance at dramatically lower cost”

Plant Manager

Chemistry to compete

CarboNet’s NanoNet platform generates flocculants, coagulants, and targeting agents that that adjust in real time to changing wastewater conditions—cutting cost, dose rates, labor, and emissions.