Central WI Meat Processing Facility Sees Major Cost Savings by Switching to Dry Polymer
Background:
A meat processing facility in central WI was facing increasing operational costs due to their high usage of emulsion polyacrylamide flocculants for waste treatment. Although very effective, emulsion polymers required higher dosages to treat the slaughterhouse waste and presented storage, handling, and safety challenges. With tightening budgets and a mandate to improve operational efficiency, plant managers sought a more cost-effective solution.
Challenge:
The plant’s existing chemical program utilized the emulsion polymer for conditioning the process and slaughterhouse waste in dissolved air flotation clarifiers prior to their dewatering process. While the emulsion polymer delivered acceptable performance in the DAF’s, operators noticed high product consumption – up to 280 pounds of neat product per day. This high usage rate, coupled with rising chemical costs and additional costs related to handling and disposal of totes, prompted the search for alternatives.
Goals for the new solution included:
- Reducing overall polymer consumption
- Maintaining or improving DAF performance
- Lowering chemical and handling costs associated with polymer systems
- Ensuring ease of use and compatibility with existing process
Solution:
Midwest Chemical & Equipment proposed a high-efficiency dry polymer system for the facility to evaluate. After a thorough review of sludge characteristics, process equipment performance, and flow rates, the team selected a customized dry polymer product optimized for the plant’s operational profile. A dry makedown unit was brought in and performance indicators were tracked over the course of the trial to ensure all operational standards were met.
Results:
The facility’s switch to dry polymer revealed several compelling benefits:
- Reduced Polymer Usage: The dry polymer achieved equivalent or better performance at a significantly lower dose – around 80 – 90 pounds of dry product per day, representing approximately a 70% reduction compared to the emulsion polymer.
- Cost Savings: With a lower polymer dose required and no need for tote disposal, the plant saw cost savings of approximately $78,000 annually.
- Improved Logistics, Handling, and Safety: Midwest Chemical & Equipment’s dry polymer is shipped in pallets of triple lined bags. This removes any concern for shipping delays related to freezing and allows for better space utilization at the plant. Additionally, the facility saw improved housekeeping and safer chemical storage practices dealing with the dry product compared to the emulsion.
- Environmental Benefit: Reduced use of oil-based emulsion carriers and decreased chemical handling contributed to the plant’s sustainability goals.
Conclusion:
By converting from emulsion to dry polymer, the facility significantly lowered its chemical usage and operational costs without compromising performance. This switch not only improved the bottom line but also streamlined handling processes and aligned with environmental best practices.
Midwest Chemical & Equipment continues to support the facility with ongoing optimization and technical support, ensuring long-term success with the new dry polymer program.
Interested in reducing your plant’s chemical or operational costs?
Contact Midwest Chemical & Equipment today to schedule an on-site system evaluation.