Eagle Family Foods Wastewater Pretreatment System Upgrades Phase 1 and 2

This design-build project included construction of wastewater pretreatment facilities to meet the revised city water standards. GSE partnered with World Water Works (equipment supplier) and T-O Engineers to work with the client through preconstruction and deliver an exceptional solution. To meet the city’s aggressive discharge limit deadline and budgetary constraints, the project team proposed a two-phase approach. Phase 1 focused on the solids reduction and Phase 2 on biological treatment. The owner originally planned to perform partial treatment to their wastewater system with a DAF pretreatment facility (Phase 1). While in the middle of the project, the city engineer determined the pretreatment was insufficient. The owner came back to GSE with the need to create a secondary pretreatment system. GSE collaborated with the owner to determine which areas needed to be completed in Phase 1 and which could be completed in Phase 2. GSE worked with the suppliers and engineer to design the Phase 2 work. The changes required GSE to design and implement  both temporary piping and electrical systems. The solutions developed during this process reduced the capital expenditure while delivering a system that was compliant with all regulatory agency requirements.

Primary goals of the project were a low maintenance, relatively simple, and operator-friendly system capable of flow equalization, neutralization of pH swings, TSS reduction to <200 mg/L, BOD reduction to <200 mg/L, and FOG reduction to <50 mg/L. Design of Phase 2 began immediately after commencing Phase 1 construction and consisted of two lift stations, two 370,000-gallon MBBR tanks, blower building, chemical/electrical building, cooling tower, heat exchanger, and associated chemical/ electrical systems. Phase 2 also included migration of all chemical and electrical systems from their temporary Phase 1 locations to permanent locations in the chemical/electrical building. All work was designed to be phased and constructed with minimal impacts to the production facility and all tie-ins were completed during previously scheduled plant shutdowns. The project was a success due to the collaboration that the GSE team brought to the owner to ensure best value delivery.