Introduction
A large Midwest food processor was experiencing rising wastewater treatment costs, inconsistent clarifier performance, and increasing chemical demand while operating under strict discharge requirements.
While the existing ferric-based program had worked in the past, the system had become unstable. Effluent clarity declined, solids carryover increased, and maintaining compliance required more chemicals and operator attention.
The Challenge
The facility was experiencing instability in its activated sludge wastewater treatment system driven by variable influent loading from the production process. These issues became most visible in secondary clarification, where poor solids separation led to inconsistent effluent quality.
The treatment program was optimized for the lowest price per pound rather than total system performance, resulting in increasing chemical demand and operational inefficiencies.
The facility faced:
> Clarifier solids carryover
> Poor effluent clarity
> High phosphorus removal demand
> Increasing bleach, caustic, and bisulfite usage
> Inconsistent loading and system variability
The iron-based coagulant was not being fully removed and reacted with disinfection, driving excessive oxidant demand. Its acidic nature also increased caustic usage.
As conditions changed, the system became reactive, leading to rising chemical demand, reduced stability, and increased compliance risk.
The Haviland Approach
Haviland conducted a full wastewater treatment system evaluation, focusing on total process performance rather than individual chemical adjustments.
The solution included transitioning from ferric to a specialty coagulant program supported by bench-scale treatability testing for coagulant optimization and improved flocculation and polymer selection.
The program was designed to improve solids separation, enhance floc formation, and remove organics not fully treated in the activated sludge process. This reduced downstream chemical demand, improved clarifier performance, and stabilized overall system efficiency.
“I’ve spun jars with every major chemical company in the industry. Haviland was the most astute in the way they discussed the system and the approach with us.”
- Environmental Manager
What Changed
Following implementation, the system quickly stabilized and became easier to manage.
The facility saw:
> Improved phosphorus removal consistency
> Enhanced effluent clarity
> Elimination of clarifier solids carryover
> Significant reduction in bleach demand
> Complete elimination of caustic usage
> Reduced overall chemical variability
Results and Ongoing Impact
Within two months, the facility achieved:
> $125K reduction in total yearly wastewater treatment operating costs
> More stable and predictable system performance
> Reduced operator intervention
> Increased operating headroom within permitted discharge limits
The updated program reduced reliance on secondary chemicals while improving system consistency and control. Despite a higher cost per unit of coagulant, total system demand decreased, delivering measurable cost savings and stronger compliance performance.
$125,000 Reduction
In annual wastewater treatment operating costs after implementing Haviland specialty chemistry.
Why It Works
Haviland’s approach focuses on optimizing the entire wastewater treatment system rather than individual chemical inputs. By combining specialty and commodity chemistry with lab and field-supported testing, ongoing system evaluation, and reliable supply and logistics, facilities are able to reduce total wastewater treatment costs, improve performance, and maintain compliance with greater confidence.
Final Thoughts
Wastewater treatment doesn’t have to be a constant struggle.
When systems are evaluated holistically and supported with the right chemistry and expertise, facilities can improve performance, reduce cost, and operate with greater consistency.
“Trust Haviland to not just be a chemical sales company, but to be a chemical-focused problem solver.”
- Environmental Manager
