CASE STUDY

Utilizing Particulate Scrubbers for the Complex Air Needs of Food Processing Applications Food manufacturers face unique challenges in treating particulate emissions at their facilities as cooking and frying processes generate byproducts, such as grease or fine dust, in the air stream. The byproducts often contaminate the air or leave residues, posing food safety and air permit compliance concerns if ineffective control technologies are used; for  example, bag houses or air filters, which will likely foul. These additional complexities in food manufacturing process streams make it more challenging to determine the proper abatement technology for your food plant without leveraging outside expertise.

Pollution Systems Inc. (PSI) not only offers a diverse product line of wet scrubbers and oxidizers but is fully committed to understanding every detail of the process requiring  treatment. Considering each customer’s technical, operational, and business needs, including sustainability, allows PSI to confidently recommend and design a comprehensive  air control solution that suits the specified application. In food production processes, food safety and plant optimization are additional considerations prioritized in the system  design.

The following are two examples of how Pollution Systems tailors its Wet Particulate Scrubbers to the varying needs of food production processes. 

Case 1: Venturi Scrubber and Meat Production Plant 

After the unsuccessful implementation of Electrostatic Precipitators (ESPs) and air filters to treat grease-laden particulate exhaust from a pork sausage cooking operation, a food manufacturer collaborated with Pollution Systems to design an effective emission control solution for their process. Through a comprehensive evaluation, Pollution Systems engineers recommended implementing a Venturi Scrubber with a heated sump to treat the dirty exhaust stream.

PSI Venturi Scrubbers feature:

• A smaller equipment footprint, allowing for ease of installation to preexisting lines. 
• Handles particulate-laden air streams with high temperatures or that contain moisture and grease, which can occur in cooking, smoking, and frying processes. 
• Offer low operating costs due to their solid-state construction.
• Continuously discharge a portion of the water in the sump (blowdown) which decreases the frequency of cleaning. Integrating an additional clean-in-place manifold system can further reduce maintenance needs.

The venturi scrubber pulls the smoke and grease-laden air into the upper portion of the scrubbing vessel and introduces the stream to high-velocity recirculated water. Fine water droplets form, entrenching the particulate matter. The droplets flow to the lower portion of the scrubber, where velocity is reduced and causes the particulate droplets to fall into the collection sump. After passing through the mist eliminator, the remaining water separates from the particulate. The blowdown of the scrubbing liquid inhibits plugging or severe buildup within the scrubber.

Subsequent emissions testing and operational trials proved the unit effective and offered low maintenance while outperforming the ESPs. The successful implementation of the 
Venturi Scrubber System on the first sausage cooker line led the company to purchase additional units for the separate production lines. Since commissioning this unit, the 
company has relocated the original scrubber to another facility and continues to offer exceptional results after 15+ years of operation.

Case 2: Multi-Vane Scrubber and Cereal Production Facility

This food client had an undesirable experience with the constant cleaning and maintenance of their previous scrubber equipment due to the buildup of sticky food residues and subsequent biological growth, which made them skeptical about purchasing another particulate scrubber.

Recognizing the need for a more effective and sustainable solution for this particular application, Pollution Systems recommended their Multi-Vane Particulate Scrubber (MVS) 
Unit and implementing a pilot study with the client’s drying line process to demonstrate its effectiveness. Specifically designed for air pollution control in unique manufacturing 
settings, this technology boasts several features tailored to address common pain points in the food industry, such as:

• High reliability is essential in commercial food production, where downtime can result in significant financial losses and safety hazards. The pilot system is capable of withstanding the demands of batch and continuous operations.
• Ease of maintenance and self-cleaning properties are essential for food manufacturing plants, where they must meet strict food safety regulations. The MVS pilot unit utilizes advanced mechanisms to handle the unique challenges present in food production processes.

After the pilot study demonstrated success, the customer agreed to install a larger Multi-Vane Scrubber on one dryer line of their process to further test its capabilities alongside a competing unit. The results showed that the Pollution Systems unit outperformed the competitor scrubber system. Particulate matter was reduced significantly, eliminating the  need for manually removing buildup on the unit and surrounding surfaces. Moreover, the biological growth accumulating on the rooftop disappeared, contributing to improved operational efficiency and a cleaner, safer working environment.

Impressed by the performance of the MVS technology on the single dryer line, the customer decided to invest in Pollution Systems Multi-Vane Scrubbers for the rest of their 
facility. 

With the decision to install multi-vane scrubbers across their facility, Pollution Systems worked closely with the customer to ensure seamless integration into their existing 
processes. The commissioning and training provided enabled optimal use of the new technology and minimized downtime during implementation. Pollution Systems also incorporated monitoring and maintenance strategies to maximize long-term efficiency and ensure continuous compliance with environmental regulations and good business 
standards.

Solutions Tailored to the Unique Demands of Your Process

The successful implementation of particulate scrubber technology within these manufacturing facilities offers valuable insights into options that meet the current industrial air pollution control needs. Customized solutions that adapt to the unique challenges of each application are crucial in improving operational efficiency and sustainability.  dditionally, leveraging pilot programs to test new processes before full-scale adoption can help minimize risk and maximize cost savings.

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