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Challenges of Permitting a Large Food Processing Company

Challenges of Permitting a Large Food Processing Company. Gene Bennett City of Everett, WA PNPC September 13, 2007. Company Profile. 1981 - Founded by Kevin Fortun in to supply local restaurants with fresh soups

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Challenges of Permitting a Large Food Processing Company

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  1. Challenges of Permitting a Large Food Processing Company Gene Bennett City of Everett, WA PNPC September 13, 2007

  2. Company Profile • 1981 - Founded by Kevin Fortun in to supply local restaurants with fresh soups • 1989 - Recognized by Inc Magazine as one of the 500 Fastest Growing Private Companies (306th) • 1998 - Purchased by Campbell Soup Company

  3. Company Profile • 2000 - Opened Woodinville facility • 2005 - Broke ground on $80 M Everett culinary campus, expanding production capacity by 50% • March 2007 - Started production at new facility • April 15, 2007 - Completed move to new facility

  4. Why the move? • Brightwater plant • Public perception • King County desired property • Chance to expand • Modernize facility

  5. Why stay in area? • $$$ • Maintain trained staff • Keep valued local suppliers

  6. Why Everett? • We had the room and capacity • 18 acres ready for development • Organic load and flow capacity • Excellent transportation access • Industry-friendly administration

  7. What’s in it for us? • Stable industry • $$$ • Estimated surcharge fees ~$1300/day • BOD $900 • TSS $250 • FOG $100 • Flow $50

  8. What were our challenges? • In short, nearly none • Failed to start sampling when they started production • pH control system

  9. Operation • Initial production rate 68,000,000 #/yr • Full capacity 90,000,000 #/yr • All produced by 320 production employees on 3 shift, 7 days per week schedule in 168,000 ft2 of production and storage space

  10. Wastewater Sources • Sanitary - separate system from production wastewater • Floor cleaning • All floor drains have strainers • CIP • Automated cooker cleaning system • Uses high/low pH chemicals, quaternary ammonia and chlorine base cleaners

  11. Wastewater Sources • Bulk load area • Dairy • Fuel oil • Spiral chillers

  12. Wastewater Characteristics

  13. Wastewater Limitations • Instantaneous Flow - 663 GPM • Daily Process Flow - 265,000 GPD • pH Minimum - 5.0 s.u. • pH Maximum - 11.0 s.u. • BOD5 - 250 mg/L1 • TSS - 250 mg/L1 • FOG(T) - 50 mg/L1 • 1 - surcharge level

  14. Waste Treatment • Lift station • 6000 gallon wetwell • 2 - 400 GPM pumps • Rotary screen • 0.020” slots • Continuous - 400 GPM • Intermittent - 800 GPM

  15. Waste Treatment • Grease Interceptor • 5400 gallon • pH control • 4800 gallon • Submersible propeller mixer • 2300 GPM capacity • NaOH and H2SO4 bulk tanks • Monitoring station • XL 60º Trapezoidal flume

  16. What Didn’t Work? • pH control system couldn’t keep up • CIP system caused large, rapid swings in pH • Most excursions on the high side

  17. Why Didn’t It Work? • Adequate H2SO4 pump capacity, but just barely • Inadequate mixing capacity

  18. pH Control Changes • Reconfigure tank inlet/outlet • Relocate pH probe in tank • Increase H2SO4 pump capacity • Change mixer • Top-mounted impeller style • 9000 GPM capacity • Better axial flow

  19. Compliance Schedule

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