Gallon Per Day Lagoon
Johanna Foods is a state-of-the-art food manufacturer located in Flemington, NJ and one of the country’s largest producers and distributors of fruit juices, drinks and yogurt. They needed an innovative business partner to create a custom system to satisfy their needs as they grew.
Over the years, NSU has provided several planning and design services to Johanna Foods. In 2004, NSU was first retained to provide engineering services to address their pH concerns with the existing 200,000 gallon per day lagoon based biological treatment plant facility. An equalization tank was installed, in addition to automated systems for addition of lime and acid for pH, polymer for coagulation, urea for nitrogen and soda ash for alkalinity. Also, pump stations were added and existing ones were upgraded. A provision was made to distribute recycled activated sludge, raw wastewater and air evenly over lagoon allowing for CMAS or step aeration, along with the installation of a SCADA System. A few years later, Johanna Foods retained NSU to perform a sustainable water use audit report for submittal to New Jersey Board of Public Utilities. In 2012, NSU explored alternative wastewater treatment technologies to treat the wastewater at Johanna Foods who was under scrutiny with the NJDEP and the health department due to odors being generated at the wastewater treatment plant. The evaluation of the existing 200,000 gallon per day lagoon based biological treatment plant facility was precipitated by a major surge of concentrated fruit syrup disrupting plant operations and creating an odor problem. NSU investigated technology alternatives including MBBR and anaerobic digestion for beneficial reuse of biogas. NSU was selected to design the MBBR upgrades of the existing wastewater treatment plant. Johanna Foods selected the MBBR technology and NSU was selected to design these MBBR upgrades and is assisting the client with the site plan approval process. In addition, NSU designed an odor control system for the existing WWTP at JFI. This system will be reused in the new WWTP. NSU was able to deliver a solution to upgrade their existing wastewater treatment facility which resulted in the production of treated effluent that is in compliance with all New Jersey pre-treatment standards and eliminate odors outside the plant boundaries.